Shop Manual: PC400LC

CEBM016902
Shop
Manual
PC400LC-7E0
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC400LC-7E0 A87001 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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu

Printed in U.S.A.
Komatsu America Corp.
August 2007
FOREWORD CONTENTS
12
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 PC400LC-7E0
FOREWORD
The affected pages are indicated by using the following marks. It is Mark Indication Action
requested that necessary actions be taken to these pages accord-
ing to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 c 00-22 10-9 10-38
00-2 00-23 10-10 10-39
● 00-2-1 c 00-24 10-11 10-40
● 00-2-2 c 00-25 10-12 10-41
● 00-2-3 c 00-26 10-13 10-42
● 00-2-4 c 00-27 10-14 10-43
● 00-2-5 c 00-28 b 10-15 10-44
● 00-2-6 c 10-16 10-45
❍ 00-2-7 c 01-1 10-17 10-46
❍ 00-2-8 c 01-2 10-18 10-47
00-3 01-3 10-19 10-48
00-4 01-4 10-20 10-49
00-5 01-5 10-21 10-50
00-6 01-6 10-22 10-51
00-7 01-7 10-23 10-52
00-8 01-8 10-24 10-53
00-9 01-9 10-25 10-54
00-10 01-10 10-26 10-55
00-11 01-11 10-27 10-56
00-12 01-12 10-28 10-57
00-13 10-29 10-58
00-14 10-1 10-30 10-59
00-15 10-2 10-31 10-60
00-16 10-3 10-32 10-61
00-17 10-4 10-33 10-62
00-18 10-5 10-34 10-63
00-19 10-6 10-35 10-64
00-20 10-7 10-36 10-65
00-21 10-8 10-37 10-66
PC400LC-7E0 PC400LC-7E0 00-2-1 2

FOREWORD
10-67 10-100 10-133 10-166
10-68 10-101 10-134 10-167
10-69 10-102 10-135 10-168
10-70 10-103 10-136 10-169
10-71 10-104 10-137 10-170
10-72 10-105 10-138 10-171
10-73 10-106 10-139 10-172
10-74 10-107 10-140 10-173
10-75 10-108 10-141 10-174
10-76 10-109 10-142 10-175
10-77 10-110 10-143 10-176
10-78 10-111 10-144 10-177
10-79 10-112 10-145 10-178
10-80 10-113 10-146 10-179
10-81 10-114 10-147 10-180
10-82 10-115 10-148 10-181
10-83 10-116 10-149 10-182
10-84 10-117 10-150 10-183
10-85 10-118 10-151 10-184
10-86 10-119 10-152 10-185
10-87 10-120 10-153 10-186
10-88 10-121 10-154 10-187
10-89 10-122 10-155 10-188
10-90 10-123 10-156 10-189
10-91 10-124 10-157 10-190
10-92 10-125 10-158 10-191
10-93 10-126 10-159 10-192
10-94 10-127 ● 10-160 c 10-193
10-95 10-128 ● 10-161 c 10-194
10-96 10-129 ● 10-162 c 10-195
10-97 10-130 10-163 10-196
10-98 10-131 10-164 10-197
10-99 10-132 10-165 10-198
PC400LC-7E0 00-2-2 2
FOREWORD
10-199 10-232 20-117 b 20-150 b
10-200 10-233 20-118 b 20-151 b
10-201 10-234 20-119 b 20-152 b
10-202 10-235 20-120 b 20-153 b
10-203 10-236 20-121 b 20-154 b
10-204 20-122 b 20-155 b
10-205 20-1 b 20-123 b 20-156 b
10-206 20-2 b 20-124 b 20-157 b
10-207 20-3 b 20-125 b 20-158 b
10-208 ● 20-4 c 20-126 b 20-159 b
10-209 20-5 b 20-127 b 20-160 b
10-210 20-6 b 20-128 b 20-161 b
10-211 20-7 b 20-129 b 20-162 b
10-212 20-8 b 20-130 b 20-163 b
10-213 20-9 b 20-131 b 20-164 b
10-214 20-10 b 20-132 b 20-165 b
10-215 20-133 b 20-166 b
10-216 20-101 b 20-134 b 20-167 b
10-217 20-102 b 20-135 b 20-168 b
10-218 20-103 b 20-136 b 20-169 b
10-219 20-104 b 20-137 b 20-170 b
10-220 20-105 b 20-138 b 20-171 b
10-221 20-106 b 20-139 b 20-172 b
10-222 20-107 b 20-140 b 20-173 b
10-223 20-108 b 20-141 b 20-174 b
10-224 20-109 b 20-142 b 20-175 b
10-225 20-110 b 20-143 b 20-176 b
10-226 20-111 b 20-144 b 20-177 b
10-227 20-112 b 20-145 b 20-178 b
10-228 20-113 b 20-146 b 20-179 b
10-229 20-114 b 20-147 b ● 20-180 c
10-230 20-115 b 20-148 b 20-181 b
10-231 20-116 b 20-149 b 20-182 b
PC400LC-7E0 00-2-3 2
FOREWORD
● 20-183 c 20-229 b 20-305 b 20-338 b
20-184 b 20-230 b 20-306 b 20-339 b
● 20-185 c 20-231 b 20-307 b 20-340 b
● 20-186 c 20-232 b 20-308 b 20-341 b
20-233 b 20-309 b 20-342 b
20-201 b 20-234 b 20-310 b 20-343 b
20-202 b 20-235 b 20-311 b 20-344 b
20-203 b 20-236 b 20-312 b 20-345 b
20-204 b 20-237 b 20-313 b 20-346 b
20-205 b 20-238 b 20-314 b 20-347 b
20-206 b 20-239 b 20-315 b 20-348 b
20-207 b 20-240 b 20-316 b 20-349 b
20-208 b 20-241 b 20-317 b 20-350 b
20-209 b 20-242 b 20-318 b 20-351 b
20-210 b 20-243 b 20-319 b 20-352 b
20-211 b 20-244 b 20-320 b 20-353 b
20-212 b 20-245 b 20-321 b 20-354 b
20-213 b 20-246 b 20-322 b 20-355 b
20-214 b 20-247 b 20-323 b 20-356 b
20-215 b 20-248 b 20-324 b 20-357 b
20-216 b 20-249 b 20-325 b 20-358 b
20-217 b 20-250 b 20-326 b 20-359 b
20-218 b 20-251 b 20-327 b 20-360 b
20-219 b 20-252 b 20-328 b 20-361 b
20-220 b 20-253 b 20-329 b 20-362 b
20-221 b 20-254 b 20-330 b 20-363 b
20-222 b 20-255 b 20-331 b 20-364 b
20-223 b 20-256 b 20-332 b 20-365 b
20-224 b 20-333 b 20-366 b
20-225 b 20-301 b 20-334 b 20-367 b
20-226 b 20-302 b 20-335 b 20-368 b
20-227 b 20-303 b 20-336 b 20-369 b
20-228 b 20-304 b 20-337 b 20-370 b
PC400LC-7E0 00-2-4 2
FOREWORD
20-371 b 20-404 b 20-437 b 20-470 b
20-372 b 20-405 b 20-438 b 20-471 b
20-373 b 20-406 b 20-439 b 20-472 b
20-374 b 20-407 b 20-440 b 20-473 b
20-375 b 20-408 b 20-441 b 20-474 b
20-376 b 20-409 b 20-442 b 20-475 b
20-377 b 20-410 b 20-443 b 20-476 b
20-378 b 20-411 b 20-444 b 20-477 b
20-379 b 20-412 b 20-445 b 20-478 b
20-380 b 20-413 b 20-446 b
20-381 b 20-414 b 20-447 b 20-501 b
20-382 b 20-415 b 20-448 b 20-502 b
20-383 b 20-416 b 20-449 b 20-503 b
20-384 b 20-417 b 20-450 b 20-504 b
20-385 b 20-418 b 20-451 b 20-505 b
20-386 b 20-419 b 20-452 b 20-506 b
20-387 b 20-420 b 20-453 b 20-507 b
20-388 b 20-421 b 20-454 b 20-508 b
20-389 b 20-422 b 20-455 b 20-509 b
20-390 b 20-423 b 20-456 b 20-510 b
20-391 b 20-424 b 20-457 b 20-511 b
20-392 b 20-425 b 20-458 b 20-512 b
20-393 b 20-426 b 20-459 b 20-513 b
20-394 b 20-427 b 20-460 b 20-514 b
20-395 b 20-428 b 20-461 b 20-515 b
20-396 b 20-429 b 20-462 b 20-516 b
20-397 b 20-430 b 20-463 b 20-517 b
20-398 b 20-431 b 20-464 b 20-518 b
20-399 b 20-432 b 20-465 b 20-519 b
20-400 b 20-433 b 20-466 b 20-520 b
20-401 b 20-434 b 20-467 b 20-521 b
20-402 b 20-435 b 20-468 b 20-522 b
20-403 b 20-436 b 20-469 b 20-523 b
PC400LC-7E0 00-2-5 2
FOREWORD
20-524 b 20-602 b ❍ 30-8 c ❍ 30-41 c
20-525 b 20-603 b ❍ 30-9 c ❍ 30-42 c
20-526 b 20-604 b ❍ 30-10 c ❍ 30-43 c
20-527 b 20-605 b ❍ 30-11 c ❍ 30-44 c
20-528 b 20-606 b ❍ 30-12 c ❍ 30-45 c
20-529 b 20-607 b ❍ 30-13 c ❍ 30-46 c
20-530 b 20-608 b ❍ 30-14 c ❍ 30-47 c
20-531 b 20-609 b ❍ 30-15 c ❍ 30-48 c
20-532 b 20-610 b ❍ 30-16 c ❍ 30-49 c
20-533 b 20-611 b ❍ 30-17 c ❍ 30-50 c
20-534 b 20-612 b ❍ 30-18 c ❍ 30-51 c
20-535 b 20-613 b ❍ 30-19 c ❍ 30-52 c
20-536 b 20-614 b ❍ 30-20 c ❍ 30-53 c
20-537 b 20-615 b ❍ 30-21 c ❍ 30-54 c
20-538 b 20-616 b ❍ 30-22 c ❍ 30-55 c
20-539 b 20-617 b ❍ 30-23 c ❍ 30-56 c
20-540 b 20-618 b ❍ 30-24 c ❍ 30-57 c
20-541 b 20-619 b ❍ 30-25 c ❍ 30-58 c
20-542 b 20-620 b ❍ 30-26 c ❍ 30-59 c
20-543 b 20-621 b ❍ 30-27 c ❍ 30-60 c
20-544 b 20-622 b ❍ 30-28 c ❍ 30-61 c
20-545 b 20-623 b ❍ 30-29 c ❍ 30-62 c
20-546 b 20-624 b ❍ 30-30 c ❍ 30-63 c
20-547 b 20-625 b ❍ 30-31 c ❍ 30-64 c
20-548 b 20-626 b ❍ 30-32 c ❍ 30-65 c
20-549 b ❍ 30-33 c ❍ 30-66 c
20-550 b ❍ 30-1 c ❍ 30-34 c ❍ 30-67 c
20-551 b ❍ 30-2 c ❍ 30-35 c ❍ 30-68 c
20-552 b ❍ 30-3 c ❍ 30-36 c ❍ 30-69 c
20-553 b ❍ 30-4 c ❍ 30-37 c ❍ 30-70 c
20-554 b ❍ 30-5 c ❍ 30-38 c ❍ 30-71 c
❍ 30-6 c ❍ 30-39 c ❍ 30-72 c
20-601 b ❍ 30-7 c ❍ 30-40 c ❍ 30-73 c
PC400LC-7E0 00-2-6 2
FOREWORD
❍ 30-74 c ❍ 30-107 c 90-1 90-34
❍ 30-75 c ❍ 30-108 c 90-2 90-35
❍ 30-76 c ❍ 30-109 c 90-3 90-36
❍ 30-77 c ❍ 30-110 c 90-4 90-37
❍ 30-78 c ❍ 30-111 c 90-5 90-38
❍ 30-79 c ❍ 30-112 c 90-6 90-39
❍ 30-80 c ❍ 30-113 c 90-7 90-40
❍ 30-81 c ❍ 30-114 c 90-8 90-41
❍ 30-82 c ❍ 30-115 c 90-9 90-42
❍ 30-83 c ❍ 30-116 c 90-10 90-43
❍ 30-84 c ❍ 30-117 c 90-11 90-44
❍ 30-85 c ❍ 30-118 c 90-12 90-45
❍ 30-86 c ❍ 30-119 c 90-13 90-46
❍ 30-87 c ❍ 30-120 c 90-14 90-47
❍ 30-88 c ❍ 30-121 c 90-15 90-48
❍ 30-89 c ❍ 30-122 c 90-16 90-49
❍ 30-90 c ❍ 30-123 c 90-17 90-50
❍ 30-91 c ❍ 30-124 c 90-18 90-51 b
❍ 30-92 c ❍ 30-125 c 90-19 90-52 b
❍ 30-93 c ❍ 30-126 c 90-20 90-53 b
❍ 30-94 c ❍ 30-127 c 90-21 90-54 b
❍ 30-95 c ❍ 30-128 c 90-22 90-55 b
❍ 30-96 c ❍ 30-129 c 90-23 90-56 b
❍ 30-97 c ❍ 30-130 c 90-24 90-57 b
❍ 30-98 c ❍ 30-131 c 90-25 90-58 b
❍ 30-99 c ❍ 30-132 c 90-26 90-59 b
❍ 30-100 c ❍ 30-133 c 90-27 90-60 b
❍ 30-101 c ❍ 30-134 c 90-28 90-61 b
❍ 30-102 c ❍ 30-135 c 90-29 90-62 b
❍ 30-103 c ❍ 30-136 c 90-30 90-63 b
❍ 30-104 c ❍ 30-137 c 90-31 90-64 b
❍ 30-105 c ❍ 30-138 c 90-32 90-65 b
❍ 30-106 c 90-33 90-66 b
PC400LC-7E0 00-2-7 2
FOREWORD
90-67 b
90-68 b
PC400LC-7E0 00-2-8 2
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 PREPARATIONS FOR WORK 00
Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not
machine. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
• Always wear safety glasses when hitting parts with 3. When disassembling or assembling, support the
a hammer. machine with blocks, jacks or stands before starting
• Always wear safety glasses when grinding parts work.
with a grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or
before starting any step of the operation. Before starting hydraulic pressure measuring plugs, loosen them slowly
work, hang UNDER REPAIR signs on the controls in to prevent the oil from spurting out. Before
the operator's compartment. disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
5. Keep all tools in good condition and learn the correct the circuit.
way to use them.
2. The water and oil in the circuits are hot when the engine
6. Decide a place in the repair workshop to keep tools and is stopped, so be careful not to get burned. Wait for the
removed parts. Always keep the tools and parts in their oil and water to cool before carrying out any work on
correct places. Always keep the work area clean and the oil or water circuits.
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke 3. Before starting work, remove the leads from the battery.
while working. ALWAYS remove the lead from the negative (-)
terminal first.
PC400LC-7E0 00-3
FOREWORD SAFETY
12
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 immedi-
ately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean 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-7E0
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-7E0 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00
REVISIONS 00
Shop manuals are issued as a guide to carrying out repairs.

Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows:
between the title page and SAFETY page.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series SYMBOLS 00
Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models 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, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00
Special technical precautions or

Any additions, amendments or other changes will be sent to other precautions for preserving
★ Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
FILING METHOD 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Oil, water
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2
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-7E0
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
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.
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load
during hoisting, untwisting of
WIRE ROPES 00
the rope, or slipping of the

rope from its original winding
1. Use adequate ropes depending on the weight of parts to position on the load, which
be hoisted, referring to the table below: can result in a dangerous
Wire ropes accident
(Standard “Z” or “S” twist ropes without galvanizing)
4. Do not sling a heavy load with ropes forming a wide
Rope diameter Allowable load hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
mm kN tons
increase with the hanging angles. The table below
10 9.8 1.0 shows the variation of allowable load (kg) when hoist-
ing is made with two ropes, each of which is allowed to
11.2 13.7 1.4
sling up to 1000 kg vertically, at various hanging angles.
12.5 15.7 1.6 When two ropes sling a load vertically, up to 2000 kg of
total weight can be suspended. This weight becomes
14 21.6 2.2
1000 kg when two ropes make a 120° hanging angle. On
16 27.5 2.8 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
18 35.3 3.6
lifting angle of 150°.
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
★ 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-7E0 00-7
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.
WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected.
Accordingly, prepare an oil receiving
container.
TYPE 1 00
DISCONNECTION 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-8 PC400LC-7E0
TYPE 2 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the
right - clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
PC400LC-7E0 00-9
12
TYPE 3 00
DISCONNECTION 00
1. Hold the connector of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3)
contacts surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the connector of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of
the hexagonal portion at the male end to connect it.
00-10 PC400LC-7E0
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
EXPLANATION OF MAINTENANCE STANDARD TERMS 00
● The maintenance standard values necessary for judgment of

products and parts are described by the following terms.
1. Standard Size And Tolerance

• To be accurate, the finishing size of parts is a little different
from one to another.
• To specify a finishing size of a part, a temporary standard size
is set and an allowable difference from that size is indicated.
• The above size set temporarily is called the “standard size” and
the range of difference from the standard size is called the
“tolerance”.
• The tolerance with the symbols of + or – is indicated on the
right side of the standard size.
Example:
Standard size Tolerance
–0.022
120
–0.126
★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
• Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and
different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
• Indication of size of rotating shaft and hole and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
2. Standard Clearance And Standard Value

• The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range
from the minimum clearance to the maximum clearance.
• When some parts are repaired, the clearance is generally adjusted to the standard clearance.
• A value of performance and function of new products or equivalent is called the “standard value“, which is indicated
by a range or a target value.
• When some parts are repaired, the value of performance/function is set to the standard value.
3. Standard Interference
• When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference
between these sizes is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the shaft
to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard
interference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in
the standard range.
PC400LC-7E0 00-11
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
4. Repair Limit And Allowable Value
• The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the
“repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value below which the product can be used
without causing a problem is called the “allowable value”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated
from various tests or experiences in most cases, however, it must be judged after considering the operating condition
and customer's requirement.
5. Clearance Limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts
cannot be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference Limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called
the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
00-12 PC400LC-7E0
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
BOLTS AND NUTS 00
● Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench)
★ The following table corresponds to the bolts in Figure A.
Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
★ The following table corresponds to the bolts in Figure B.

Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52
Figure A Figure B
PC400LC-7E0 00-13
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm kgm
10 14 59 - 74 43.51 - 54.57
12 17 98 - 123 72.28 - 90.72
16 22 235 - 285 173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

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 ± 49 216.9 ± 36.1
00-14 PC400LC-7E0
12
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf ft})
Norminal No.
mm mm Range Target
02 14 35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
Varies depending on
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
type of connector.
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 1010 {550.22 - 744.93} 883 {651.26}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf lb})
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42}
10 10 17 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31}
12 12 19 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01}
14 14 22 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62}
16 16 24 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68}
18 18 27 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91}
20 20 30 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14}
24 24 32 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59}
30 30 32 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50}
33 33 _ 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {lbf ft}) Face seal type
type
Nominal Width Nominal thread
size of hose across flats Thread size size - Threads per Root diameter (mm)
Range Target
(mm) inch, Thread (Reference)
series
34 - 54 {25.0 - 39.8} 44 {32.4} - 9/16 - 18UN 14.3
02 19
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
22 54 - 93 {39.8 - 68.5} 74 {54.5} - 11/16 -16UN 17.5
03
24 59 - 98 {43.5 - 72.2} 78 57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
(12) 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
(14) 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -
PC400LC-7E0 00-15
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 num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 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
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow & Green &
Color — Red & Black Blue & Red
Black Yellow Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 PC400LC-7E0
12
HOW TO READ ELECTRIC WIRE CODE 00
★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational infor-
mation of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric
wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1. Type, Symbol, And Material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and
outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Type Symbol Material temperature Example of use
range °C (°F)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for AV appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
–30 to +60
Thin-cover Annealed copper for electric (-22 to +140)
Conductor
low-voltage appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold
low-voltage appliance –50 to +110
AEX district, wiring at high-temperature
wire for Heat-resistant crosslinked poly- (-58 to +230)
Insulator place
automobile ethylene
PC400LC-7E0 00-17
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conductor
Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cover D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cover D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
★ “f” of nominal No. denotes flexible”.
00-18 PC400LC-7E0
12
3. Color Codes Table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
● In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the
marking.
Example: “GW” means that the background is Green and marking is White.
★ Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC400LC-7E0 00-19
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 b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d 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.
c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
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
00-20 PC400LC-7E0
12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 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 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 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-7E0 00-21
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 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 1 2 3 4 5 6 7 8 9
0 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
00-22 PC400LC-7E0
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 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-7E0 00-23
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 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
00-24 PC400LC-7E0
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 °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
PC400LC-7E0 00-25
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber cushions
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 ● Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals, rubbers,
plastics and woods.
● Quick hardening type adhesive.
Aron-alpha Polyethylene ● Quick cure type (max. strength after 30 minutes).
790-129-9130 50 g
201 container ● Used mainly for adhesion of rubbers, plastics
and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tempera-
648-50 container
ture.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Gasket sealant
● Features: Resistance to heat

● Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent
LG-3 790-129-9070 1 kg Can seizure.
● Used as sealant for heat resistant gasket for at
high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-26 PC400LC-7E0
Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
● Used as sealant for mating surfaces of final drive
case, transmission case.
● Used as sealant for various threads, pipe joints,
Polyethylene con- flanges.
Gasket sealant
LG-5 790-129-9080 1 kg
tainer ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
● Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case, etc.
● Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube ● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond ● Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
● Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum
squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the thread

LM-P 09940-00040 200 g Tube when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load bearing
Grease
G2-CA SYG2-400CA-A Various Various

at places in contact with water or steam.
SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
PC400LC-7E0 00-27
12
00-28 PC400LC-7E0
01 GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
FIXED GAUGE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
VARIABLE GAUGE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WORKING RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
PC400LC-7E0 01-1
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
DIMENSIONS
WORKING RANGES
01-2 PC400LC-7E0
12
DIMENSIONS
FIXED GAUGE SPECIFICATION
Item Unit PC400LC-7E0

A Overall length mm 11,940
B Overall height mm 3,635
C Overall width mm 3,440
D Track shoe width mm 700
E Height of machine cab mm 3,265
F Tail swing radius mm 3,645
G Track overall length mm 5,355
H Length of track on ground mm 4,350
J Max. ground clearance mm 550
VARIABLE GAUGE SPECIFICATION
Item Unit PC400LC-7E0

A Overall length mm 11,940
B Overall height mm 3,635
C Overall width mm 3590
D Track shoe width mm 700
E Height of machine cab mm 3,265
F Tail swing radius mm 3,645
G Track overall length mm 5,355
H Length of track on ground mm 4,350
J Max. ground clearance mm 685
WORKING RANGES
Working range Unit PC400LC-7E0

A Max. digging reach mm 12,025
B Max. digging depth mm 7,820
C Max. digging height mm 10,915
D Max. vertical wall depth mm 6,870
E Max. dumping height mm 7,565
F Min. dumping height mm ó
G Max. reach at ground level mm 11,820
01-3 PC400LC-7E0
12
PC400LC-7E0
Machine model
Fixed gauge spec. Variable gauge spec.
Serial number A87001 and up
Bucket capacity m3 1.4
Weight of machine kg 42,200 43,500
Max. digging depth mm 7,820
Working ranges
Max. vertical wall depth mm 6,870

Max. digging reach mm 12,025
Max. reach at ground level mm 11,820
Working ranges Max. digging height mm 10,915
Performance
Max. dumping height mm 7,565

Max. digging force kN {kg} 256.0 {26,100}
Performance (using power max. function) kN {kg} (274.6 {28,000})
Swing speed rpm 9.1
Swing max. slope angle deg. 20
Travel speed km/h Lo: 3.0, Mi: 4.4, Hi: 5.5
Gradeability deg. 35
Ground pressure kPa {kg/cm2} 73.9 {0.75} 65.3 {0.67}
Overall length (for transport) mm 11,940 11,940
Overall width mm 3,440 3,590
Overall width of track mm 3,440 2,990
Overall width of track when extended mm --- 3,490
Overall height (for transport) mm 3,635 3,635
Overall height to top of machine mm 3,265 3,265
Dimensions
Ground clearance of upper structure mm 1,320 1,320

Min. ground clearance mm 555 685
Tail swing radius mm 3,645 3,645
Dimensions Min. swing radius of work equipment mm 4,735 4,735
Height of work equipment at min. swing radius mm 9,210 9,210
Length of track on ground mm 4,020 4,020
Track gauge mm 2,740 2,890
Height of machine cab mm 3,265 3,265
Width of standard shoe mm 700 700
01-4 PC400LC-7E0
12
MEMORANDUM
PC400LC-7E0 01-5
12
Machine model PC400LC-7E0

Serial number A87001 and up
Model SAA6D125E-5
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbocharger and aftercooler
No. of cylinders - bore x stroke mm 6-125x150
Piston displacement L {cc} 11.045 {11,045}

Performance
kW/rpm 257/1,900
Flywheel horsepower {HP/rpm} {345/1,900}
Engine
Nm/rpm 1,383/1,400
Max. torque {kgm/rpm} {141/1,400}
Max. speed at no load rpm 1,930
Min. speed at no load rpm 1,000
g/kWh
Min. fuel consumption 203 {147}
{g/HPh}
Starting motor 24V, 7.5 kW
Alternator 24V, 35A
Battery 12V, 110 Ah x 2
Radiator core type Alminum wave type, 4 rows
Carrier roller 2 on each side
Undercarriage
Track roller 8 on each side
Track shoe Assembly-type triple grouser, 49 on each side
Type x No. HPV190+190, variable displacement, piston type x 2

Hydraulic
Delivery L/min 345 x 2

pump
MPa
Set pressure 37.8 {380}
{kg/cm2}
Hydraulic system
Control
valve
Type x No. Control method 6-spool type + 1-spool type x 1 Hydraulic
Travel motor KMV200ADT-2, Variable displacement, piston type (with brake

valve, parking brake): x 2
Hydraulic
motor
Swing motor KMF230ABE-5, Fixed displacement piston type (with safety valve,
holding brake, reverse rotation preventive valve): x 1
Boom (*1) Arm (*1), (*2) Bucket

Double-acting Double-acting Double-acting
Hydraulic cylinder
Type piston piston piston

Inside diameter of cylinder mm 160 185 160
Hydraulic system
Diameter of piston rod mm 110 120 110

Stroke mm 1,570 1,820 1,270
Max. distance between pins mm 3,830 4,325 3,140
Min. distance between pins mm 2,260 2,505 1,870
Hydraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
01-6 PC400LC-7E0
*1: Cushion is provided on head side

*2: Cushion is provided on bottom side
PC400LC-7E0 01-7
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 1,500 (3,307)
l Engine 1,150 (2,535)
l Damper 14.7 (32)
l Hydraulic pump 210 (463)
Radiator, oil cooler assembly 213 (470)
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 (437)
Fuel tank (excluding fuel) 251 (554)
Revolving frame 3,297 (7,269)
Operator’s cab 279 (616)
Operator’s 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 40 (89)
Variable gauge
Fixed gauge specification
specification
Track frame assembly 10,965 (24,174) 11,934 (26,310)

Track frame 6,077 (13,398) 7,096 (15,644)
l Center frame --- 3,229 (7,119)
l Crawler frame --- 1,921 (4,235) x 2
Swing circle 605 (1,334) x 2

Idler 230 (507) x 2
Idler cushion 338 (745) x 2
Carrier roller 32 (71) x 4
Track roller 72 (159) x 16
Final drive (including travel motor) 722 (1,592) x 2
Track shoe assembly

l Standard triple grouser shoe (600 mm) 4,760 (10,494)
l Standard triple grouser shoe (700 mm) 5,210 (11,486)
l Wide triple grouser shoe (800 mm) 5,670 (12,500)
l Wide triple grouser shoe (900 mm)
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 510 (1,125)
01-8 PC400LC-7E0
GENERAL WEIGHT TABLE
Bucket cylinder assembly 297 (655)
Link assembly 258 (569)
Boom pin 92 (203) + 20 (45) x 2 + 73 (161) + 27 (60) + 54 (120)
Arm pin 17 (38) + 23 (51)
Bucket pin 38 (102) x 2
Link pin 34 (75) x 2
PC400LC-7E0 01-9
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.
Ambient Temperature
Recommended
Fluid
Reservoir -22 -4 14 32 50 68 86 140 122F° Komatsu
Type
Fluids
-30 -20 -10 0 10 20 30 40 50C°
Komatsu
SAE 0W30E0S and HTHS 3.5 min. (Note 1) EOS0W30
Komatsu
SAE 5W40EOS and HTHS 3.5 min. (Note 2) EOS5W40
Komatsu
EO10W30DH
Engine oil pan
Engine oil
API CH-4
SAE 10W30DH API CI-4
Komatsu
EO15W40DH
API CH-4
SAE 15W40DH API CI-4
Komatsu
SAE 30DH EO20DH
Swing machinery Power

Final drive case train oil TO 30 TO30
Damper case (Note 2)
Power
train oil TO 10 TO 10
Hydraulic system
Hydraulic
ill HO46-HM HO46-HM
Hyper
grease G2-TE
(Note 3) G2-TE
Grease
Lithium G2-L1
grease G2-L1
(Note 3)
50/50
Engine Cooling mix
system antifreeze ASTM D-4985 (Note 4) ASTM D-4985
(Note 4)
No. 2-D ASTM No. 2-D

Fuel tank Diesel fuel
No. 1-D ASTM No. 1-D
01-10 PC400LC-7E0
l API: American Petroleum Institute
l SAE: Society of Automotive Engineers
l ASTM: American Society of Testing and Material
Swing
Engine oil Final drive Damper Hydraulic Cooling
machinery Fuel tank
pan case (each) case system system
case
Specified liter 42 13.4 12 1.07 472 36 650
capacity US gal 11.10 3.54 3.17 0.28 124.70 9.51 171.73
Refill liter 38 13.4 12 - 248 - -
capacity US gal 10.04 3.54 3.17 - 65.2 - -
H Always Use Diesel Oil For The Fuel.

To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses
an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication,
so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly.
Note 1: SAE 0W30EOS and SAE 5W40EOS must be fully synthetic and HTHS (High-Temperature High-Shear Viscosity
150°C) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils. If these
oils are not available, contact your Komatsu distributor.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper white grease (G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-TE is recommended.
Note 4: For the engine cooling system use ASTM D-4985 50/50 mix rated antifreeze. Do not use Supercoolant (AF-NAC) or
other (AF-NAC) rated coolants.
PC400LC-7E0 01-11
12
MEMORANDUM
01-12 PC400LC-7E0
10 STRUCTURE AND FUNCTION
12
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
ENGINE RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
RADIATOR, OIL COOLER AND AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
TRIPLE GROUSER SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
HYDRAULIC PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
HYDRAULIC TANK AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
LS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
PC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
LS(PC)-EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
VARIABLE VOLUME VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
FUNCTIONS AND OPERATION BY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
UNLOAD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
LS BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
PRESSURE COMPENSATION VALVE INNER SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . 10-80
BOOM REGENERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
ARM REGENERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
MERGE-DIVIDER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
LS SELECT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
SELF PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
TRAVEL JUNCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
TRAVEL PPC SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
BOOM DRIFT PREVENTIVE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
ARM DRIFT PREVENTIVE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
LIFT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
2-STAGE SAFETY-SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
VARIABLE PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
ATTACHMENT CIRCUIT SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
VALVE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
PC400LC-7E0 10-1
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
SERVICE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
PPC ACCUMULATOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
RETURN OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
REVERSE PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
DIMENSIONS OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
DIMENSION OF ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
DIMENSION OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
ROTATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
AMBIENT PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
BOOST PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
BOOST TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
EGR VALVE STROKE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
ENGINE OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
ENGINE AND PUMP COMPOSITE CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
PUMP AND VALVE CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
POWER MAXIMIZING AND MACHINE PUSH-UP FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
AUTO-DECELERATION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
AUTO-WARM-UP AND OVERHEAT PREVENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
SWING CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
TRAVEL CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR FUNCTION . . . . . . . . . . . . . . . . . . . 10-202
SYSTEM COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-203
PUMP PRESSURE SENSOR (HIGH PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
MONITOR PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217
MAINTENANCE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
HYDRAULIC OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-231
10-2 PC400LC-7E0
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-231
KOMTRAX TERMINAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
KOMTRAX TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234
PC400LC-7E0 10-3
12
MEMORANDUM
10-4 PC400LC-7E0
STRUCTURE AND FUNCTION ENGINE AND COOLING SYSTEM
12
ENGINE AND COOLING SYSTEM
ENGINE RELATED PARTS
1. Damper assembly Outline

2. Drive plate A wet type damper assembly is used.
3. Torsion spring Oil capacity: 1.07 L (0.282 gal)
4. Stopper pin
5. Friction plate
6. Muffler
7. Rear engine mount
8. Front engine mount
PC400LC-7E0 10-5
STRUCTURE AND FUNCTION ENGINE AND COOLING SYSTEM
12
RADIATOR, OIL COOLER AND AFTERCOOLER
1. Oil cooler 6. Net

2. Radiator 7. Shroud
3. Radiator cap 8. Radiator outlet hose
4. Radiator inlet hose 9. Aftercooler
5. Reservoir tank 10. Condenser
Specifications
Radiator: Aluminum wave type, 4 rows
Oil cooler: CF40-1
10-6 PC400LC-7E0
STRUCTURE AND FUNCTION POWER TRAIN
12
POWER TRAIN
POWER TRAIN
1. 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 (SAA6D125E-5) 12. Swing circle
PC400LC-7E0 10-7
12
FINAL DRIVE
10-8 PC400LC-7E0
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
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
Backlash between No. 1 sun gear and No. 1 Standard clearance Clearance limit
14 planetary gear 0.15 - 0.54 1.10
Backlash between No. 1 planetary gear and ring
15 0.18 - 0.66 1.30
gear
Backlash between No. 2 planetary carrier and
16 0.06 - 0.24 ---
motor Replace
Backlash between No. 2 sun gear and No. 2
17 0.15 - 0.51 1.00
planetary gear
Backlash between No. 2 planetary gear and ring
18 gear 0.17 - 0.60 1.20
Backlash between No. 2 planetary carrier and

19 0.15 - 0.54 ---
No. 2 sun gear
20 Amount of wear on sprocket tooth Repair limit: 6
Standard size Repair limit Rebuild or replace
21 Width of sprocket tooth
90 87
Torque Nm Torque lbf ft
22 Bolt
59 - 78 44 - 57
23 Bolt 98 - 123 73 - 90
24 Bolt 59 - 74 44 - 54
25 Bolt 640 - 785 473 - 578
26 Bolt 490 - 608 362 - 448
PC400LC-7E0 10-9
12
SPROCKET
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip 355 343
2 Thickness of tooth root 20.8 14.8 Build-up welding for
rebuilding or replace
3 Width of tooth 90 87
Repair limit: 6 (measure with the full-size drawing of
4 Wear of tooth shape sprocket tooth shape)
10-10 PC400LC-7E0
12
FULL-SIZE DRAWING OF SPROCKET TOOTH SHAPE
★ The above drawing is reduced to 61%. Enlarge it to 164% to return it to the full scale and make a copy on an OHP sheet.
PC400LC-7E0 10-11
12
SWING MACHINERY
10-12 PC400LC-7E0
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
13. Drain plug
Specification
Reduction ratio:
[(19 +68)/19]x[(16+68)/16]=24.039
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14 No. 1 sun gear 0.18 - 0.28 ---
Backlash between No. 1 sun gear and No. 1
15 0.15 - 0.51 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.17 - 0.60 1.10
ring gear
Backlash between No. 1 planetary carrier
17 0.40 - 0.75 1.20
and No. 2 sun gear
Backlash between No. 2 sun gear and No. 2 Replace
18 0.16 - 0.55 1.00
planetary gear
Backlash between No. 2 planetary gear and
19 0.17 - 0.60 1.10
ring gear
Backlash between coupling and swing
20 0.08 - 0.25 ---
pinion
Backlash between swing pinion and swing
21 0.00 - 1.21 2.00
circle
22 Clearance between plate and coupling 0.57 - 1.09 ---
Standard size Repair limit Apply hard chrome
Wear of swing pinion surface contacting with plating, recondition, or
23 oil seal 150 0 --- replace
-0.100
24 Bolt
824 - 1030 608 - 759
25 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
PC400LC-7E0 10-13
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
Axial clearance of bearing (when mounted on Standard clearance Repair limit

4 Replace
chassis) 0.5 - 1.6 3.2
10-14 PC400LC-7E0
12
MEMORANDUM
PC400LC-7E0 10-15
STRUCTURE AND FUNCTION UNDERCARRIAGE AND FRAME
12
UNDERCARRIAGE AND FRAME
TRACK FRAME AND RECOIL SPRING
1. Idler
2. Track frame • The dimensions and the number of track rollers depend on the model, but the
basic structure is not different.
3. Carrier roller • Number of track rollers: 8
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Recoil spring
9. Front guard
10-16 PC400LC-7E0
12
Item Fixed gage
Shoe width 900 mm
Link pitch 228 mm
No. on track (one side) 49 (Pieces)
Unit: mm
Standard Tolerance Repair limit Rebuild or replace
size
10 Vertical width of idler guide +3
Track frame 148 ---
-1
Idler support 145 ±0.5 ---
+4
Track frame 302 ---
-1
11 Horizontal width of idler guide Idler support 297 --- ---
Free length Installation Installation Free length Installation Replace
x OD length load load
12 Recoil spring
239 kN
845 X 262 690 --- ---
{24,375 kg}
PC400LC-7E0 10-17
12
IDLER
10-18 PC400LC-7E0
12
Unit: mm
1 Outside diameter of protruding
704 ---
2 Outside diameter of tread 660 648
3 Depth of tread 22 28
4 Thickness of tread 21 15 Rebuild or
replace
5 Total width 202 ---
6 Width of tread 48.5 ---
Clearance between bushing and
7 support 0.46 - 0.86 ---
(Sum of clearance at both sides)
Tolerance Standard
Standard size
Shaft Hole clearance
8 Clearance between shaft and bushing
-0.120 +0.360
95 0.340-0.507
-0.207 +0.220 Replace
Tolerance bushing
Standard
Standard size
Shaft Hole interference
9 Interference between idler and bushing
+0.062 -0.037
102.6 0.064-0.149
+0.027 -0.089
10 Bolt
130 - 180 96 - 132
PC400LC-7E0 10-19
12
CARRIER ROLLER
Unit: mm
1 Outside diameter of flange
179 ---
3 Width of tread 50.3 ---
4 Thickness of tread 32 25
5 Width of flange 19 ---
Standard Tolerance Standard Interferenc Replace

size Shaft Hole interference e limit
6 Clearance between shaft and bushing
-0.250 +0.074
54 0.250 - 0.354 ---
-0.280 0
+0.117 +0.030 0.057 -
7 Clearance between roller and bushing 61 ---
+0.087 0 0.117
Standard clearance Clearance limit
8 Axial clearance of roller
0.5 - 0.7 ---
10-20 PC400LC-7E0
12
MEMORANDUM
PC400LC-7E0 10-21
12
TRACK ROLLER
10-22 PC400LC-7E0
12
Unit: mm
Outside diameter of outer Standard size Repair limit

1 flange 240 ---
3 Thickness of tread 56.2 48.0
Rebuild or
4 Overall width 278 --- replace
5 Width of tread Singe flange 54.6 ---
Width of outer Singe flange
6 32.6 ---
flange
7 Axial play 0.4 - 1.0 ---
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
8 bushing
-0.250 +0.174
80 0.279 -0.524 1.5 Replace
-0.350 +0.029 bushing
Standard Interference
Interference between roller and +0.108 -0.006 interference limit
9 87.6
bushing +0.008 -0.036
0.014-0.144 ---
10 Bolt
10 - 20 8 - 14
1st torque 200 ± 20 147 ± 14
11 Bolt
2nd torque 105 ± 5 77 ± 3
PC400LC-7E0 10-23
12
TRACK SHOE
★ P portion shows the link of bushing press-fitting end.
10-24 PC400LC-7E0
12
Unit: mm
1 Link pitch
228.9 231.9
Reverse or replace
Standard size When turned
2 Bushing outside diameter
71.5 66.5
3 Thickness of bushing metal 11.9 6.9 Adjust or replace
4 Link height
129 119 Repair or replace
Thickness of link metal (bushing 34.5 24.5
5 press-fitting portion)
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
9 Inside width 106
10 Link Overall width 51.6 Repair or replace
11 Tread width 44.8
12 Protrusion of pin 4.4
13 Protrusion of regular bushing 5.25
14 Overall length of pin 252 Adjust or replace
15 Overall length of bushing 164.5
16 Thickness of spacer ---
17 Bushing 118 - 304 kN {12 - 31 ton}
18 Press-fitting force Regular pin 176 - 451 kN {18 - 46 ton} ---
19* Master pin 137 - 284 kN {14 - 29 ton}
* : Dry type track link
PC400LC-7E0 10-25
12 Unit: mm
Tightening torque Additinal tightening angle
a. Regular (Nm {lbf ft}) (deg.)
link 393±39
Triple shoe 120±10
{289±28}
20 Shoe bolt Retighten
Tightening Additinal Lower limit torque
torque (Nm {lbf tightening angle (Nm {lbf ft})
b. Master link ft}) (deg.)
--- --- ---
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
21 and link
+0.494 +0.074
71 0.380 - 0.494
+0.454 0
Interference between regular +0.235 -0.218
22 47 0.303 - 0.515
pin and link +0.085 -0.280
Tolerance
Standard size Standard clearance
Clearance between regular pin Shaft Hole
23 and bushing
+0.235 +0.915 Adjust or
47 0.180 - 0.830
+0.085 +0.415 replace
Tolerance Standard
Standard size
Interference between master Shaft Hole interference
24* pin and bushing
+0.03 -0.218
47 0.218 - 0.310
0 -0.280
Tolerance
Standard size Standard clearance
Clearance between master pin Shaft Hole
25* and bushing
-0.2 +0.915
47 0.615 - 1.315
-0.4 +0.415
* : Dry type track link
10-26 PC400LC-7E0
12
TRIPLE GROUSER SHOE
Unit: mm
1 Height
37 22
2 Thickness 13
3 33
Length at of base
4 27 Build-up welding for
5 25.5 rebuilding or replace
6 Length at tip 17.5

7 23.5
8 Thickness
50 35
PC400LC-7E0 10-27
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
10-28 PC400LC-7E0
12
PC400LC-7E0 10-29
12
HYDRAULIC TANK AND FILTER
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)
10-30 PC400LC-7E0
12
MEMORANDUM
PC400LC-7E0 10-31
12
HYDRAULIC PUMP
Type: HPV160+160 (190)
10-32 PC400LC-7E0
12
Outline
• This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve and variable volume
valve.
BMP: Breather installation port PENR: Rear control pressure pickup port
IM: PC mode selector current PEPC: EPC basic pressure port
ISIG: LS set pressure selector current PEPB: EPC basic pressure pickup port
OCP: Oil level pickup port PFC: Front pump discharge pressure pickup port
PAF: Front pump discharge port PLSCR: LS set selector pressure pickup port
PAR: Rear pump discharge port PLSF: Front load pressure input port
PBF: Front pump pressure input port PLSFC: Front load pressure pickup port
PBR: Rear pump pressure input port PLSR: Rear load pressure input port
PD1F: Case drain port PLSRC: Rear load pressure pickup port
PD1R: Air bleeder PM: PC mode selector pressure pickup port
PD2F: Drain plug PRC: Rear pump discharge pressure pickup port
PD2R: Drain plug PS: Pump suction port
PENF: Front control pressure pickup port
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
7. Variable volume valve
Torque Nm Torque lbf ft Torque Nm Torque lbf ft
8 18.6 - 23.5 13.7 - 17.3 12 6.9 - 9.8 5.0 - 7.2
9 19.6 - 27.4 14.5 - 20.2 13 132 - 157 97.3 - 115.7
10 98.1 - 122.6 72.3 - 90.4 14 58.8 - 78 43.3 - 57.5
11 11.8 - 14.7 8.7 - 10.8
PC400LC-7E0 10-33
12
1. Front shaft 8. Valve plate

2. Cradle 9. End cap
3. Front case 10. Rear shaft
4. Rocker cam 11. Rear case
5. Shoe 12. Servo piston
6. Piston 13. PC valve
7. Cylinder block
Torque Nm Torque lbf ft Torque Nm Torque lbf ft
14 7.8 - 9.8 5.7 - 7.2 17 637 - 764.4 470 - 563.7
15 58.8 - 78 43.3 - 57.5 18 246.3 - 308.7 181.7 - 227.6
16 343 - 427 253 - 314 19 27 - 34 119.9 - 25.0
10-34 PC400LC-7E0
12
Function
• The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding 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 spline (14).

• Shaft (1) is supported by front and rear bearings (15).
• Tip of piston (6) is shaped as a concave ball and shoe (5) is crimped to it to form one unit.
• Piston (6) and shoe (5) constitute the 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) conducts high pressure oil to 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).
• Cylinder block (7) seals the pressurized 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 suctioned and discharged through valve plate (8).
PC400LC-7E0 10-35
12
Operation of pump
• 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 (a) between center line (X) of rocker cam (4) and the
axial direction of cylinder block (7) changes.
• (a) is named the swash plate angle.
• With center line (X) of rocker cam (4) at a swash plate angle (a) in
relation to the axial direction of cylinder block (7), flat surface (A)
acts 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).
• A single piston (6) sucks and discharges the oil by the amount
(F) – (E).
• As cylinder block (7) rotates and the volume of chamber (E) becomes
smaller, the pressurized oil is discharged.
• On the other hand, the volume of chamber (F) grows larger and, in this
process, the oil is suctioned.
• As center line (X) of rocker cam (4) matches the axial direction of
cylinder block (7) (swash plate angle (a) = 0), the difference between
volumes (E) and (F) inside cylinder block (7) becomes 0.
• Suction and discharge of pressurized oil is not carried out in this state.
Namely pumping action is not performed. (Actually, however, the
swash plate angle is not set to 0)
10-36 PC400LC-7E0
12
Control of pump delivery
• If the swash plate angle (a) becomes larger, the difference between
volumes (E) and (F) becomes larger and pump delivery (Q) increases.
• Servo piston (12) is used for changing swash plate angle (a).
• Servo piston (12) carries out linear reciprocal movement according to
the signal pressure from the PC and LS valves.
• This linear movement is transmitted to rocker cam (4) through slider
(13).
• Being supported by cradle (2) on the cylindrical surface, rocker cam
(4) slides on the surface while continuing revolving movement.
• Space of the pressure receiving area of servo piston (12) are not
identical on the left side and right side. Main pump discharge pressure
(self pressure) (PP) is always brought to the pressure chamber of the
small diameter piston side.
• Output pressure (PEN) of the LS valve is brought to the chamber
receiving the pressure at the large diameter piston end.
• The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter
piston 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-7E0 10-37
12
LS 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
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 to 27 kg/cm2 (170.6 ↔ 384.0 psi).
10-38 PC400LC-7E0
12
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-7E0 10-39
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.
10-40 PC400LC-7E0
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-7E0 10-41
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 (0 ↔ 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).
10-42 PC400LC-7E0
12
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
Function
• When the pump discharge pressure PP1 (self-pressure) and PP2 (other
pump pressure) are high, the PC valve controls the pump so that the
volume of oil beyond the discharge pressure-based specific flowrate
may not be conducted however you may increase the control valve
stroke. Namely it is intended at controlling the horse power for the
pumps so that it may not exceed the engine hose power.
• If the pump discharge pressure increases due to increased load during
operation, this valve decreases the pump delivery.
• And if the pump discharge pressure goes low, it increases the pump
delivery.
• In this case, relation between the mean discharge pressure of the front
and rear pumps [PP1 + PP2]/2 and the pump delivery Q will becomes
as shown in the diagram if the relation is represented as the parameter
the current value X to be given to PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed.
• If the engine speed goes below the specified value because of increased load, the controller sends a command current to
PC-EPC valve solenoid in order to reduce the slope angle in proportion to reduction in the engine speed.
PC400LC-7E0 10-43
12
Operation
1. 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 Front pump, it is the Rear pump pressure
For the Rear pump, it is the Front pump pressure
10-44 PC400LC-7E0
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.
PC400LC-7E0 10-45
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.
10-46 PC400LC-7E0
12 • 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.
PC400LC-7E0 10-47
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.
10-48 PC400LC-7E0
12
ii. 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-7E0 10-49
12
LS(PC)-EPC VALVE
1. Connector 5. Spool C: To LS (PC) valve

2. Coil 6. Rod P : From self pressure reducing valve
3. Body 7. Plunger T : To tank
4. Spring
Torque
Item
Nm lbf ft
8. 1-2 0.737 - 1.475
9. 9.8 - 12.7 7.228 - 9.367
10-50 PC400LC-7E0
12
Function
• The EPC valve consists of the proportional solenoid portion and the
hydraulic valve portion.
• When it receives signal current i from the controller, it generates the
EPC output pressure in proportion to the size of the signal, and outputs
it to the LS (PC) valve.
Operation
1. When signal current is 0 (coil is de-energized)

• When there is no signal current flowing from the controller to coil
(2), coil (2) is de-energized.
• Spool (5) is pushed to the left by spring (4).
• Port P closes and the pressurized oil from the self pressure
reducing valve does not flow to the LS (PC) valve.
• The pressurized oil from the LS (PC) valve is drained to the tank
through port C and port T.
PC400LC-7E0 10-51
12
2. When signal current is very small (coil is energized)
• When a very small signal current flows to coil (2), coil (2) is
energized, and a propulsion force is generated on the right side of
plunger (7).
• Rod (6) pushes spool (5) to the right, and pressurized oil flows
from port (P) to port (C).
• Pressures on port C increases and the force to act on spool (5)
surface and the spring load on spring (4) become larger than the
propulsion force of plunger (7).
• Spool (5) is pushed to the left, and port P is shut off from port C.
• Port C and port T are connected.
• Spool (5) moves so that the propulsion force of plunger (7) may
be balance with pressure of port C + spring load of spring (4).
• The circuit pressure between the EPC valve and the LS (PC)
valve is controlled in proportion to the size of the signal current.
3. When signal current is maximum (coil is energized)

• As the signal current flows to coil (2), coil (2) is energized.
• When this happens, the signal current is at its maximum, so the
propulsion force of plunger (7) is also at its maximum.
• Spool (5) is pushed toward right side by rod (6).
• The maximum volume of pressurized oil is conducted from port P
to port C, increasing the circuit pressure across EPC valve and LS
(PC) valve to the maximum level.
• Since port T is closed, pressurized oil does not flow to the tank.
10-52 PC400LC-7E0
12
VARIABLE VOLUME VALVE
1. Plug C: To PC valve
2. Block P: From self pressure reducing valve
3. Piston T: To tank
4. Spring
Torque
Item
Nm lbf ft
5. 44.1 - 53.9 32.52 - 39.75
Function
The variable volume valve stabilizes the EPC valve's output pressure.
Operation
• Output pressure from EPC valve is conducted to port C and as the

result propulsion force of piston (3) is increased by the load of spring
(4).
• Piston (3) is pushed to the left, and volume of port C is increased.
• The propulsion force of piston (3) becomes smaller than the load of
spring (4).
• Piston (3) is pushed toward right, and volume of port C is decreased.
PC400LC-7E0 10-53
12
CONTROL VALVE
Outline
• The control valve consists of a 7-spool valve (6-spool valve + boom Hi, arm Hi valve) and a set of service valves. A
merge-divider valve, a back pressure valve, a boom drift preventive 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 compact and easy to maintain.
• With one spool provided for one work equipment, this control valve is simple in construction.
A1: To bucket cylinder bottom P-5: From service 2 and PPC valves
A2: To L.H. travel motor P-6: From service 2 and PPC valves
A3: To boom cylinder bottom PLS1: To front pump control
A4: To swing motor PLS2: To rear pump control
A5: To R.H. travel motor PP1: From front pump
A6: To arm cylinder head PP2: From rear pump
A-1: To boom cylinder bottom PP1S: Pressure sensor mounting port
A-2: To attachment 1 PP2S: Pressure sensor mounting port
A-3: To attachment 2 PPS1: To front pump control
B1: To bucket cylinder head PPS2: To rear pump control
B2: To L.H. travel motor PR: To solenoid valve, PPC valve, and EPC valve
B3: PS: From merge-divide solenoid valve
B4: To swing motor PST: From travel junction valve solenoid valve
B5: To R.H. travel motor PX1: From 2-stage relief solenoid valve
B6: To arm cylinder bottom PX2: From 2-stage relief solenoid valve
B-1: To arm cylinder bottom T: To tank
B-2: To attachment 1 T1: To tank
B-3: To attachment 2 TS: To tank

BP1: Boom raising PPC output pressure TSW: To swing motor S-port (suction side)
BP5: From 2-stage safety valve solenoid valve
BP6: From attachment select solenoid valve 1. 6-spool valve
P1: From bucket PPC and EPC valves 2. Cover A
P2: From bucket PPC and EPC valves 3. Cover B
P3: From L.H. travel PPC valve 4. Boom Hi and arm Hi valve
P4: From L.H. travel PPC valve 5. Service valve 1
P5: From boom PPC and EPC valves 6. Service valve 2
P6: From boom PPC and EPC valves 7. Merge-divider valve
P7: From swing PPC and EPC valves 8. Boom drift preventive valve
P8: From swing PPC and EPC valves 9. Quick return valve
P9: From R.H. travel PPC valve 10. Boom Hi valve check valve
P10: From R.H. travel PPC valve Torque
P11: From arm PPC and EPC valves Nm lbf ft
P12: From arm PPC and EPC valves 11. Bolt 156.9-176.5 115.7-130.1
P-3: From service 1 and PPC valves 12. Bolt 27.5-34.3 20.2-25.2
P-4: From service 1 and PPC valves 13. Bolt 58.8-73.6 43.3-54.2
10-54 PC400LC-7E0
12
General view
PC400LC-7E0 10-55
12
Sectional view
(1/5)
10-56 PC400LC-7E0
12
1. Pressure compensation valve (Arm out) 16. Pressure compensation valve (Arm in)
2. Pressure compensation valve (R.H. travel reverse) 17. Main relief valve
3. Pressure compensation valve (Left swing) 18. Unload valve
4. Pressure compensation valve (Boom raise) 19. Unload valve
5. Pressure compensation valve (L.H. travel reverse) 20. Main relief valve
6. Pressure compensation valve (Bucket dump) 21. Spool (Service 2)
7. Pressure compensation valve (Boom Hi raise) 22. Spool (Service 1)
8. Variable pressure compensation valve (Service 1) 23. Spool (Boom Hi)
9. Variable pressure compensation valve (Service 2) 24. Spool (Bucket)
10. Pressure compensation valve (Arm Hi in) 25. Spool (L.H. travel)
11. Pressure compensation valve (Bucket curl) 26. Spool (Boom)
12. Pressure compensation valve (L.H. travel forward) 27. Spool (Swing)
13. Pressure compensation valve (Boom lower) 28. Spool (R.H. travel)
14. Pressure compensation valve (Right swing) 29. Spool (Arm)
15. Pressure compensation valve (R.H. travel forward) 30. Spool (Arm Hi)
Unit: mm
No Check item Criteria Remedy
Free length x Installed Installed Free Installed
Outside diameter length load length load
417 N 333 N
31 Spool return spring 54.2 x 34.8 51.2 {42.5 kg} - {34.0 kg}
393 N 315 N If damaged or
32 Spool return spring 54.5 x 34.8 51.2 -
{40.1 kg} {32.1 kg} deformed, replace
spring.
421 N 336 N
{42.9 kg} {34.3 kg}
251 N 201 N
{25.6 kg} {20.5 kg}
417 N 333 N
{42.5 kg} {34.0 kg}
Torque
Nm lbf ft
36 Valve 372.7 - 411.9 274.8 - 303.8
37 Plug 65.7 - 85.3 48.4 - 62.9
38 Plug 33.3 - 43.1 24.5 - 31.7
PC400LC-7E0 10-57
12
(2/5)
10-58 PC400LC-7E0
12
1. Safety-suction valve (Arm out) 13. Suction valve (Right travel forward)
2. Suction valve (Right travel reverse) 14. Safety-suction valve (Arm in)
3. Suction valve (Boom raise) 15. LS shuttle valve (Arm)
4. Suction valve (Left travel reverse) 16. LS shuttle valve (Right travel)
5. Suction valve (Boom Hi raise) 17. LS select valve
6. Safety-suction valve (Service 1) 18. LS shuttle valve (Boom)
7. Safety-suction valve (Service 2) 19. LS shuttle valve (Left travel)
8. 2-stage safety-suction valve (Service 1) 20. LS shuttle valve (Bucket)
9. Safety-suction valve (Arm Hi in) 21. LS shuttle valve (Service 1)
10. Safety-suction valve (Bucket curl) 22. LS shuttle valve (Service 2)
11. Suction valve (Left travel forward) 23. LS check valve
12. 2-stage safety-suction valve (Boom lower) 24. Pressure relief plug
Unit: mm
Outside diameter length load length load If damaged or
5.5 N 4.4 N deformed,
46.8 x 7.5 40.6 - replace spring.
25 Suction valve spring {0.56 kg} {0.45 kg}
1.5 N 1.2 N
26 Check valve spring 11.5 x 4.6 8.5 -
{0.15 kg} {0.12 kg}
Torque
Nm lbf ft
27 Valve 137.3 - 156.9 101.2 - 115.7
28 Valve 19.6 - 27.5 14.4 - 20.2
29 Valve 107.9 - 147.1 79.5 - 108.4
30 Plug 34 - 44 25.0 - 32.4
PC400LC-7E0 10-59
12
(3/5)
10-60 PC400LC-7E0
12
1. Unload valve R.H. travel valve
2. Safety valve (Boom raise)
12. LS shuttle valve
3. Main relief valve 13. Pressure compensation valve (Forward)
4. Lift check valve 14. Spool
15. Suction valve (Forward)
16. Suction valve (Reverse)
17. Pressure compensation valve (Reverse)
Arm valve Swing valve
5. LS shuttle valve 18. LS select valve

6. Pressure compensation valve (In) 19. Pressure compensation valve (R.H.)
7. Spool 20. Spool
8. Safety-suction valve (In) 21. Pressure compensation valve (L.H.)
9. Regeneration circuit check valve
10. Safety-suction valve (Out)
11. Pressure compensation valve (Out)
Unit: mm
Outside diameter length load length load If damaged or
19.6 N 15.7 N deformed, replace
50.0 x 14.4 42.0 - spring.
22 Spool return spring {2.0 kg} {1.6 kg}
5.9 N 4.71 N
{0.6 kg} {0.48 kg}
Torque
Nm lbf ft
24 Valve 137 - 157 101.0 - 115.7
25 Valve/Plug 147.1 - 186.3 108.4 - 137.4
26 Valve 49 - 58.8 36.1 - 43.3
PC400LC-7E0 10-61
12
(4/5)
10-62 PC400LC-7E0
12
1. Return spring L.H. travel valve
2. Merge-divide valve (for LS)
15. Merge-divider valve (travel junction valve)
3. Valve (Sequence valve) 16. Return spring
4. Spring (Sequence valve) 17. LS shuttle valve
5. Merge-divide valve (Main)
18. Pressure compensation valve (Forward)
6. Return spring 19. Spool
20. Suction valve (Forward)
21. Suction valve (Reverse)
22. Pressure compensation valve (Reverse)
Boom valve Bucket valve
7. Drift preventive valve 23. LS shuttle valve

8. LS shuttle valve 24. Pressure compensation valve (Curl)
9. Pressure compensation valve (Lower) 25. Spool
10. Spool 26. Safety-suction valve (Curl)
11. 2-stage safety-suction valve (Lower) 27. Safety-suction valve (Dump)
12. Regeneration circuit check valve 28. Pressure compensation valve (Dump)
13. Suction valve (Raise)
14. Pressure compensation valve (Raise)
Unit: mm
157 N 126 N
46.6 x 21.8 33.0 -
250 N 200 N
{25.5 kg} {20.4 kg}
{18.1 kg} {14.5 kg} deformed,
replace spring.
35.3 N 28.2 N
{3.6 kg} {2.88 kg}
13.7 N 11.0 N
{1.4 kg} {1.12 kg}
Check valve spring 5.9 N 4.71 N
34 31.5 x 10.3 19.5 -
{0.6 kg} {0.48 kg}
Piston return spring 50.0 N 40.0 N
35 30.7 x 20.5 23.0 -
{5.1 kg} {4.08 kg}
PC400LC-7E0 10-63
12
(5/5)
10-64 PC400LC-7E0
12
Boom Hi and arm Hi valve Service valve 1 Service valve 2
1. Boom Hi check valve 9. LS shuttle valve 14. LS shuttle valve

2. Quick return valve 10. Pressure compensation valve 15. Pressure compensation valve
3. Pressure compensation valve (Arm Hi in) 11. Spool 16. Spool
4. Arm Hi spool 12. 2-stage safety-suction valve 17. Safety-suction valve
5. Safety-suction valve (Arm Hi in) 13. Safety-suction valve 18. Unload valve
6. Boom Hi spool 19. Main relief valve
7. Suction valve (Boom Hi raise) 20. LS bypass plug
8. Pressure compensation valve (Boom Hi raise)
Torque
Nm lbf ft
21 End bolt 19.6 - 24.5 14.4 - 18.0
22 Plug 65.7 - 85.3 48.4 - 62.9
23 Plug 24.5 - 34.3 18.0 - 25.2
24 Valve 49 - 58.8 36.1 - 43.3
25 Valve 147.1 - 186.3 108.4 - 137.4
26 Valve 51.9 - 65.7 38.2 - 48.4
27 Valve 34.3 - 44.1 25.2 - 32.5
PC400LC-7E0 10-65
12
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)
Outline
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.
10-66 PC400LC-7E0
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-7E0 10-67
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.
10-68 PC400LC-7E0
12
3. System diagram
★ The illustration shows actuator (7) in the merge mode with stroke end at the time of relief.
1. Front pump 9. LS circuit

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit
PC400LC-7E0 10-69
12
FUNCTIONS AND OPERATION BY VALVE
Hydraulic circuit diagram and the name of valves
10-70 PC400LC-7E0
12
1. Arm valve 35. Main relief valve (bucket side)
2. R.H. travel valve Set pressure:
3. Swing valve 367.5±2.5 kg/cm2 (5227±35.5 psi) 112 L (29.5 gal) /min
4. Boom valve When digging force increased:
5. L.H. travel valve 389.5±2.5 kg/cm2 (5539.9±35.5 psi) 110 L (29.0 gal) /min
6. Bucket valve 36. Main relief valve (arm side)
7. Boom Hi valve Set pressure:
8. Arm Hi valve 367.5±2.5 kg/cm2 (5227±35.5 psi) 112 L (29.5 gal) /min
9. Service valve 1 When digging force increased:
10. Service valve 2 389.5±2.5 kg/cm2 (5539.9±35.5 psi) 110 L (29.0 gal) /min
11. Arm spool 37. Unload valve (bucket side)
12. R.H. travel spool Cracking pressure: 32 ± 5 kg/cm2 (455±71 psi)
13. Swing spool 38. Unload valve (arm side)
14. Boom spool Cracking pressure: 32 ± 5 kg/cm2 (455±71 psi)
15. L.H. travel spool 39. Safety-suction valve
16. Bucket spool Set pressure: 175 ± 5 kg/cm2 (2489±71 psi)
17. Boom Hi spool 40. Safety-suction valve
18. Arm Hi spool Set pressure: 390 ± 5 kg/cm2 (5547±71 psi)
19. Service spool 1 41. 2-stage safety-suction valve
20. Service spool 2 Set pressure: 1 stage: 205 ± 5 kg/cm2 (2915±71 psi)
21. Pressure compensation valve 2 stage: 175 ± 5 kg/cm2 (2489±71 psi)
22. Variable pressure compensation valve 42. 2-stage safety-suction valve
23. Suction valve Set pressure: 1 stage: 290 ± 5 kg/cm2 (4124±71 psi)
24. Check valve (for boom regeneration circuit) 2 stage:150 ± 5 kg/cm2 (2133±71 psi)
25. Check valve (for arm regeneration circuit) 43. Safety valve
26. LS shuttle valve Set pressure: 390 ± 5 kg/cm2 (5547±71 psi)
27. LS select valve
28. Merge-divider valve
29. Arm quick return valve
30. Self pressure reducing valve
31. Travel junction valve
32. Back pressure valve
33. Boom drift preventive valve
34. Boom Hi check valve
PC400LC-7E0 10-71
12
UNLOAD VALVE
1. When the unload valve is actuating
1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit
Function
• Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are in the holding.
• The pump pressure will correspond to a set load of spring (5) inside the valve (this pressure will be P1).
• Since LS pressure is drained from the LS bypass valve, LS pressure C tank pressure C 0 kg/cm2 (0 psi).
Operation
• Pressure of pump circuit (3) is received by the end of valve (2).

• Since the control valve is in neutral position, pressure of LS circuit (1) is 0 kg/cm2 (0 psi).
• Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
• When this pressure becomes larger than the force of spring (5), valve (2) moves to the left.
• Ports b and c are interconnected and the pump pressure flows to tank circuit (4).
• The pressurized oil of LS circuit (1) passes from orifice a through port c and is drained to the tank circuit (4).
• When actuated, LS pressure ≅ tank pressure.
• Since the pump discharge pressure – LS circuit pressure during unloading is larger than the pump LS control pressure, the
signal is output to minimize the pump swash plate angle.
10-72 PC400LC-7E0
12
• During operation (a work within a scope of discharge by a minimum
swash plate angle), the discharge pressure for the portion of minimum
pump swash plate angle is set to LS pressure + P1 pressure.
• LS control differential pressure EPLS of discharge for the portion of
minimum swash plate angle will be equal to P1 pressure.
2. Operation of relief valve

• When the cylinder reaches the stroke end, the main relief valve
opens.
• The pump delivery Q is relieved to the tank. (See the system
diagram)
• The pump discharge pressure PP and LS pressure PLS become
approximately the same as each has not flow at the upstream and
downstream of the spool, and LS differential pressure EPLS
becomes 0 kg/cm2 (0 psi).
• As LS differential pressure EPLS is lower than the LS set
pressure of LS valve, LS valve is actuated to maximize the pump
swash plate angle.
• Mechanically, operation of PC valve have the prevalence to that
of LS valve.
• The pump is held at a minimum swash plate angle by the cut-off function of PC valve.
PC400LC-7E0 10-73
12
Introduction of LS pressure
1. Hydraulic pump 5. Check valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve
Function
• Introduces the upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) and leads to
LS shuttle valve (7) as the LS pressure.
• Connected to actuator port B through valve (4), and makes LS pressure C actuator load pressure.
• Inlet port a inside main spool (2) has a small diameter concurrently serving as a throttle.
Operation
• When main spool (2) is operated, the pump pressure enters port c through inlet port a and is led to the LS circuit.
• When the pump pressures rises to reach the load pressure of port B, check valve (5) opens and the pressurized oil flows.
10-74 PC400LC-7E0
12
LS BYPASS VALVE
1. Hydraulic pump 4. LS shuttle valve

2. Main spool 5. LS bypass valve
3. Pressure compensation valve 6. LS circuit
Function
• Releases the residual pressure in LS pressure circuit (6) from orifices a and b.
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Bypass flow from LS bypass valve (5) causes a pressure loss to be generated due to the circuit resistance between throttle
c of main spool (2) and LS shuttle valve (4).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.
PC400LC-7E0 10-75
12
PRESSURE COMPENSATION VALVE
1. During independent operation and under maximum load pressure

(If the load pressure is higher than other work equipment during a combined operation)
1. Hydraulic pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function
• Pressure compensation valve works as the load check valve.

• If the pump pressure (LS pressure) is lower than the load at port c, shuttle valve (3) in pressure compensation valve piston
(4) interconnects spring chamber E and port C.
• The force of spring (5) operates piston (4) and valve (2) to the closing direction.
Integrated pressure compensation valve
• High stress may occur when valve (2) collides with valve chamber
seat portion C if a high peak pressure is generated in the actuator
circuit or repetitive peak pressure occurs continuously (example: when
using the breaker).
• To prevent this, a pressure compensation valve with integrated valve
(2) and piston (4) is used.
• With the present machine, this device is adopted for the bucket valve
(cylinder bottom) and the service valve.
• As principle, port C and spring chamber E are not interconnected in an
integrated pressure compensation valve.
• If high peak pressure is generated at port C, valve (7) does not collide
with the valve chamber.
• With a bucket valve, etc., port C and spring chamber E are designed to interconnect before valve (7) is seated.
10-76 PC400LC-7E0
12
2. When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function
• The pressure compensation valve closes under LS pressure of port D, and the spool meter-in downstream pressure of port
B becomes equivalent to the maximum pressure of other work equipment.
• Since the spool meter-in upstream pressure of port A is the pump pressure, the spool meter-in differential pressure
[upstream pressure port A pressure] – downstream pressure [port B pressure] becomes equivalent to all the spools in
operation.
• Pump flow is divided according to the ratio of the meter-in opening area.
Operation
• Spring chamber E is interconnected to port D.

• Piston (4) and valve (2) operate in the closing direction (to the right) under the LS circuit pressure from other work
equipment of port F.
• Valve upstream pressure (= spool meter-in downstream pressure) of port B is controlled with LS pressure.
PC400LC-7E0 10-77
12
3. Pressure compensation valve area ratio
Function
• The state of division changes according to the area ratio of pressure compensation portion A1 and A2.
Area ratio = A2/A1
• If area ratio = 1: the spool meter-in downstream pressure will be equal to the maximum load pressure, and the pressure
will be divided according to the opening area ratio.
• If area ratio = 1 or over: the spool meter-in downstream pressure will be greater than the maximum load pressure, and the
pressure will be divided smaller than the opening area ratio.
• If area ratio = 1 or under: the spool meter-in downstream pressure will be smaller than the maximum load pressure, and
the pressure will be divided greater than the opening area ratio.
10-78 PC400LC-7E0
12
PRESSURE COMPENSATION VALVE INNER SHUTTLE VALVE
1. If holding pressure at port A is larger than LS pressure in the springing chamber B
1. Hydraulic pump 3. Pressure compensation valve inner shuttle valve

2. Valve 4. Piston
Function
• Shuttle valve (3) is pushed to the right by port A pressure and cuts off interconnection between ports A and C.
• Holding pressure at port A is led to the spring chamber B to push piston (4) to the left so that piston (4) and valve (2) will
not be separated.
PC400LC-7E0 10-79
12
2. In the case of travel
Outline
• Since no holding pressure is generated at port A of the travel circuit, a pressure compensation valve without shuttle valve
(3) is adopted.
10-80 PC400LC-7E0
12
BOOM REGENERATION CIRCUIT
1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)
1. Hydraulic pump 5. Suction valve

2. Boom spool 6. Check valve
4. Safety-suction valve
Function
• Provides the regeneration circuit from the cylinder bottom to the cylinder head when the boom is lowered and increases
flow to the cylinder bottom.
Operation
• If the cylinder head pressure is lower than the bottom pressure, pressurized oil A from the cylinder bottom flows to drain
circuit B from the notch of boom spool (2).
• On the other hand, remaining oil flows to regeneration circuit C, opens check valve (6) and flows to the cylinder head
through circuit D.
• Flow from regeneration circuit C and pump (1) merges in circuit E.
PC400LC-7E0 10-81
12
2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
• Check valve (6) provided to regeneration circuit C closes to shut off the flow from the cylinder bottom to the head.
10-82 PC400LC-7E0
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ARM REGENERATION CIRCUIT
1. If the cylinder head pressure is higher than the bottom pressure
1. Hydraulic pump 5. Suction valve

2. Arm spool 6. Check valve
4. Safety-suction valve
Function
• During arm digging, regeneration circuit provided from the cylinder head to the bottom increases the cylinder speed as the
cylinder flow involves the pump delivery plus regenerated flow.
Operation
• If the cylinder head pressure is higher than the bottom pressure, pressurized oil A from the cylinder head flows to drain
circuit B from the notch of arm spool (2).
• On the other hand, remaining oil flows to regeneration circuit C, opens check valve (6) and flows to the cylinder bottom
through circuit D.
• Flow from regeneration circuit C and pump (1) merges in circuit E.
PC400LC-7E0 10-83
12
2. If the cylinder head pressure is lower than the bottom pressure
Function
• Check valve (6) provided to regeneration circuit C closes to shut off the flow from the cylinder bottom to the head.
10-84 PC400LC-7E0
12
MERGE-DIVIDER VALVE
1. When flows from the pumps merge [if pilot pressure PS is OFF]
1. Main spool 5. LS circuit (bucket side)

2. Spring 6. LS circuit (bucket side)
3. LS spool 7. LS circuit (arm side)
4. Spring 8. LS circuit (arm side)
Function
• Merges pressurized oil P1 and P2 discharged from the two pumps or divides (to respective control valve group).
• Merges and divides LS circuit pressure.
Operation
• Since pilot pressure PS is OFF, output pressure from PPC valve is 0 kg/cm2 (0 psi).
• Main spool (1) is pressed to the right by spring (2) and ports E and F are interconnected.
• Merges pressurized oil P1 and P2 discharged from the two pumps at ports E and F and sends to necessary control valve.
• Since pilot pressure PS is OFF for LS spool (3), it is pressed to the right by spring (4), and ports A – D and ports B – C are
interconnected.
• Forwards LS pressure led from respective control valve spools to LS circuits (5), (6), (7) and (8) to all the pressure
compensation valves.
PC400LC-7E0 10-85
12
2. When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation
• Pilot pressure PS turns ON, and output pressure from the PPC valve shifts main spool (1) to the left, and ports E and F are
divided.
• Pressurized oil discharged from the two pumps are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom
P2 pressure: To swing, R.H. travel, and arm
• In addition, LS spool (3) shifts to the left under the output pressure from the PPC valve, interconnects ports A and C and
divides other ports.
• Forwards LS pressure led from each control valve spool to LS circuits (5), (6), (7) and (8) to respective control valves.
10-86 PC400LC-7E0
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LS SELECT VALVE
Function
• Prevents high LS pressure from the swinging from entering the LS cir-
cuit of work valves while the swinging and work equipment are in
combined operation.
• Prevents high pressure generated during swing drive and improves
operability of work equipment.
★ The illustration shows the state of simultaneous operation of swinging
and R.H. travel. [BP pressure ON]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. LS shuttle valve
9. LS circuit
Operation
1. If pilot pressure BP is OFF

• Since pilot pressure BP is OFF, piston (3) is pressed to the left by
spring (2).
• When swing-operated, swing LS pressure P1 enters port A after
passing swing spool (5).
• Valve (1) is pressed to the left and ports A and B are
interconnected.
• Swing LS pressure P1 flows to LS shuttle valve (8).
2. If pilot pressure BP is ON
• If pilot pressure BP is ON, BP pressure contracts spring (2), and
piston (3) shifts to the right.
• Valve (1) is pressed to the right and interconnection between ports
A and B is closed.
• Swing LS pressure P1 stops flowing to LS shuttle valve (8).
• If swing LS pressure P1 rises, other LS circuits are not affected.
PC400LC-7E0 10-87
12
SELF PRESSURE REDUCING VALVE
Function
• Reduces the discharge pressure of the main pump and supplies it as

control pressure for the solenoid valves, EPC valves, etc.
Operation
1. While 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 TS.
• Valve (7) is pressed by spring (8) against the left side and port P2
is closed to A2.
10-88 PC400LC-7E0
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2. During neutral and when load pressure P2 is low.
★ When load pressure A2 is lower than self pressure reducing valve
output pressure PR.
• Valve (7) is pressed to the closing direction of circuit between
ports P2 and A2 by spring (8) and under pressure PR (which is
0 kg/cm2 (0 psi)).
• When pressurized oil flows in from port P2, a balance is reached
due to [(Ød area × P2 pressure) = force of spring (8) + (Ød area ×
PR pressure)].
• Adjusts valve (7) opening to keep pressure P2 at a constant level
over pressure PR.
• When pressure PR rises above the set pressure, poppet (11)
opens.
• Pressurized oil flows from port PR to orifice a in spool (14), then
flows to seal drain port TS from poppet (11) opening.
• Differential pressure is generated before and after orifice a in
spool (14) and then spool (14) moves to close the pass between
ports P2 and PR.
• Pressure P2 is reduced by the opening at this time and adjusted to
a constant pressure (the set pressure) and supplied as pressure PR.
3. When load pressure P2 is high.

• Load pressure A2 increases with the operation of digging, etc.,
and the pump discharge increases accordingly.
• Pressure P2 increases to [(Ød area × P2 pressure) = force of
spring (8) + (Ød area × PR pressure)], and valve (7) moves to the
right to the stroke end.
• As a result, opening between ports P2 and A2 increases, and the
pass resistance reduces, reducing the engine horsepower loss.
• When pressure PR rises above the set pressure, poppet (11)
opens.
• Pressurized oil flows from port PR to orifice a in spool (14), then
flows to seal drain port TS from poppet (11) opening.
• Differential pressure is generated before and after orifice a in
spool (14) and then spool (14) moves to close the pass between
ports P2 and PR.
• Pressure P2 is reduced by the opening at this time and adjusted to
a constant pressure (the set pressure) and supplied as pressure PR.
PC400LC-7E0 10-89
12
4. When abnormally high pressure is generated.
• If pressure PR of self pressure reducing valve becomes
abnormally high, ball (16) contracts spring (15) and becomes
separated from the seat.
• Allows the pressurized oil to TS from port PR and lowers
pressure PR.
• Protects PPC valve, solenoid valve and other devices from
abnormal pressure.
10-90 PC400LC-7E0
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TRAVEL JUNCTION VALVE
1. When pilot pressure is turned ON.
Function
• This valve connects the L.H. and R.H. travel circuits through travel junction valve so that the hydraulic oil will be
supplied evenly to both travel motors to improve machine's straight travel performance.
• When the machine is steered, outside pilot pressure PST closes the travel junction valve to improve steering
performance.
Operation
• Pilot pressure PST from the travel junction solenoid valve compresses spring (1), and travel junction spool (2) moves to
the left to the stroke end.
• Junction circuit between port PTL (L.H. travel circuit) and port PTR (R.H. travel circuit) is closed.
PC400LC-7E0 10-91
12
2. When pilot pressure is turned OFF.
Operation
• If pilot pressure PST from the solenoid valve is 0 kg/cm2 (0 psi), travel junction spool (2) is pressed to the right side by the
force of spring (1) and the passage between ports PTL and PTR is opened.
• If the oil flow rates to the L.H. and R.H. travel motors become different from each other, the oil flows through the route
between port PTL, travel junction spool (2), and port PTR so that the oil flow rates to both motors will be equalized
again.
10-92 PC400LC-7E0
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TRAVEL PPC SHUTTLE VALVE
1. When travel lever is in neutral.
Function
• Regulates flow to each cylinder by controlling the stroke of each spool of the boom, arm, and bucket using the pilot
pressure of travel PPC valve while climbing a steep grade, raising the boom, digging with arm, dumping, bucket-digging
or operating dump.
• When controlling the stroke of the boom, arm and/or bucket, pilot pressure of travel PPC valve passes through the circuit
inside the control valves to actuate the system.
Operation
• The oil in stroke regulation signal chamber a is drained through orifices (5) and (6) of pistons (3) and (4) in the travel
spring case and the travel PPC valve.
• When operated for boom raising (or arm digging, dumping, bucket digging, dumping), spool (1) moves to the left until it
makes contact with the end face of spring casing (2) st0.
PC400LC-7E0 10-93
12
2. When traveling.
Operation
• If the right travel lever is set in the reverse (or forward) direction, pilot pressure from the PPC valve presses spool (7) to
the left (or right).
• Spool (7) pushes piston (3) to close orifice (5) and shut off stroke regulation signal chamber a and the drain circuit of the
travel PPC valve.
• At this time, the right travel reverse (or forward) lever is set, pilot pressure from the PPC valve is applied through orifice
(6) of piston (4) to the left end of piston (8) to push piston (8) to the right.
• When operated for boom raising (or arm in, out, bucket curl, dump), spool (1) moves to the left.
• Maximum stroke of the spool is limited to st1 for the amount of movement st2 of piston (8) to the right.
10-94 PC400LC-7E0
12
BOOM DRIFT PREVENTIVE VALVE
1. When raising boom.
Function
• This valve prevents the oil in the boom cylinder bottom from leaking through spool (1) and the boom from lowering under
its weight while the boom lever is not operated.
Operation
• When the boom is raised, pressurized oil from the control valve works on the ring-shaped area S[= Ød1 area – Ød2 area]
caused by the difference between outside diameter d1 of poppet (5) and seat diameter d2 to move it to the left.
• Contracts spring (4) and poppet (5) moves to the left.
• As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the bottom end of
the boom cylinder.
PC400LC-7E0 10-95
12
2. When the boom is in neutral.
Operation
• Moves the lever to neutral with the boom raised.

• Pressurized oil flows inside poppet (5) from orifice a of poppet (5) is closed by pilot piston (2).
• Pressurized oil from the control valve and the holding pressure of the boom cylinder bottom are shut off.
• The holding pressure of boom cylinder bottom works on the ring-shaped area S caused by the difference between
outside diameter d1 of poppet (5) and seat diameter d2 to move it to the right.
• The sum of this force and the force of spring (4) closes poppet (5).
• Pressurized oil from the control valve and the holding pressure of the boom cylinder bottom are shut off.
10-96 PC400LC-7E0
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3. When lowering boom.
Operation
• When the boom is lowered, pilot pressure from the PPC valve presses pilot piston (2).
• Pressurized oil in chamber b inside the poppet is drained through orifice c.
• Pressurized oil of the boom bottom flows to orifice a → chamber b → orifice c → drain T, and the pressurized oil in
chamber b lowers.
• As the pressure of chamber b lowers under the pressure of port B, poppet (5) opens.
• Pressurized oil from port B is led to port A and then flows to the control valve.
PC400LC-7E0 10-97
12
ARM DRIFT PREVENTIVE VALVE
(if equipped)
1. When arm OUT.
Function
• This valve prevents the oil in the arm head from leaking through spool (1) and the boom from lowering under its weight
while the arm lever is not operated.
Operation
• When the arm OUT is operated, pressurized oil from the control valve works on the ring shaped area S [= Ød1 area – Ød2
area] caused by the difference between the outside diameter d1 of poppet (5) and the seat diameter d2 to move it to the
left.
• Contracts spring (4) and poppet (5) moves to the left.
• As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the arm cylinder
head.
10-98 PC400LC-7E0
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2. When the arm is in neutral.
Operation
• Moves the lever to neutral with the arm dumped.

• Pressurized oil flows inside poppet (5) from orifice a of poppet (5) is closed by pilot piston (2).
• Pressurized oil from the control valve and the holding pressure of the arm cylinder head are shut off.
• The holding pressure of arm cylinder head works on ring-shaped area S caused by the difference between outside
diameter d1 of poppet (5) and seat diameter d2 to move it to the right.
• The sum of this force and the force of spring (4) closes poppet (5).
• Pressurized oil from the control valve and the holding pressure of the arm cylinder head are shut off.
PC400LC-7E0 10-99
12
3. When arm IN.
Operation
• If arm is set to IN, pilot piston (2) is pushed by the pilot pressure from the PPC valve.
• Pressurized oil in chamber b inside the poppet is drained through orifice c.
• Pressurized oil of the arm head flows to orifice a → chamber b → orifice c → drain T, and the pressurized oil in
chamber b lowers.
• As the pressure of chamber b lowers under the pressure of port B, poppet (5) opens.
• Pressurized oil from port B is led to port A and then flows to the control valve.
10-100 PC400LC-7E0
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4. When abnormally high pressure is generated.
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port B pushes
check valve (6) open, then safety valve (3) operates.
• If arm drift preventive valve (If equipped) is installed to the arm cylinder head circuit, the boom cylinder bottom
circuit pressure force or arm cylinder head circuit pressure force, whichever having higher pressurized oil, pushes
check valve (6) or (6A) open to actuate safety valve (3).
PC400LC-7E0 10-101
12
QUICK RETURN VALVE
1. When arm OUT.
Function
• When arm is set to out, large volume of oil returns from the cylinder bottom.
• Reduces this pressure loss.
Operation
• When arm is set to out, pilot piston (1) is pushed by the pilot spool from the PPC valve.
• Pressurized oil in chamber b inside the valve is drained through orifice c.
• Pressurized oil of the arm bottom side flows to orifice a → chamber b → orifice c → drain T, and the pressure in
chamber b lowers.
• If the pressure of chamber b drops lower than that of port A, pressure receiving force of the pressure receiving portion
[Ød2 area S2 (seat diameter area)] on the side of port A increases by the sum of the pressure receiving force of
pressure receiving portion[Ød1 area S1] on the chamber b side of valve (2) and the spring force.
• Or (Ød2 pressure receiving force > Ød1 pressure receiving force + spring force).
• Valve (2) is pressed to the left and pressurized oil is led from port A to B.
• From port B, pressurized oil is drained directly to the tank.
10-102 PC400LC-7E0
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2. When the arm is in neutral.
Operation
• Returning the lever to neutral reduces the pilot pressure from the PPC valve to 0 kg/ cm2 (0 psi).
• The pressurized oil that has flowed and been drained through orifice a in valve (2) is closed by pilot piston (1).
• The holding pressure on the arm bottom side works on the difference between areas S2 and S1 of valve (2) to the right.
• Valve (2) is closed by the total of this force and the force of spring (3), so ports A and B are shut off.
PC400LC-7E0 10-103
12
LIFT CHECK VALVE
Function
• This valve applies back pressure to the drain circuit to prevent

generation of negative pressure on each actuator (motors, cylinders,
etc.).
Operation
1. While engine is stopped.

• Pressurized oil is not fed to the self pressure reducing valve from
the pump, and valve (1) is pressed to the right by the force of
spring (2).
• Drain circuit a of the control valve is connected with port T
through orifice b of valve (1).
2. While engine is running.

• Output pressure PR of the self pressure reducing valve is
conducted to through the control valve to spring chamber c of lift
check valve (3).
• Output pressure PR applied to spring chamber c is applied to the
left end of valve (1) (area of Ød) 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 Ød1) to push valve
(1) to the left.
• Valve (1) strikes balance to make the back pressure equal to PA in
the equation below.
PA = (Area of Ød) × PR + force of spring (2)
Area of Ød1
10-104 PC400LC-7E0
12
MAIN RELIEF VALVE
1. Spring
2. Poppet
Function
• Set pressure of the relief valve is in two stages.

• When power is needed, pilot pressure P is turned ON and the set pressure becomes higher.
Operation
• The set pressure of relief valve is determined by spring (1) installed load. (1st stage)
• Respective setting is not required for both the 1st and 2nd stages. Setting the 1st stage completes the setting of the 2nd
stage.
1. If pilot pressure P is OFF: Low-pressure setting.

Set pressure is determined by spring (1) installed load.
2. If pilot pressure P is ON: High-pressure setting.

Spring (1) installed load is added with pilot pressure P applied to the area of poppet (2) diameter d1, raising the set
pressure to higher level.
PC400LC-7E0 10-105
12
2-STAGE SAFETY-SUCTION VALVE
[Installed to port B on the boom cylinder head side and port B of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function
• Enables to provide the safety valve set pressure in two stages, and make the low-pressure setting smaller.
• Enables to relieve a load without lever operation if high load is applied to the cylinder.
• Improves work efficiency and reduces machine body vibration.
Operation
• The safety set pressure is determined by spring (1) installed load.
1. If pilot pressure is OFF (high-pressure setting)

• Since pilot pressure P is OFF, piston (2) is pressed to the left by
spring (3). [Spring (1) installed load < spring (3) installed load]
• Spring (1) installed load becomes maximum and the set pressure
rises.
• Passage B is interconnected to the drain circuit via passage C and
chamber D.
10-106 PC400LC-7E0
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2. If pilot pressure is ON (low-pressure setting).
• If the pilot pressure P is ON, the pilot pressure is led to section A
via passage B and works on the pressure-receiving bore section
(d2 – d1).
• This pilot pressure contracts spring (3), and piston (2) moves to
the right until making contact with holder (4).
• Spring (1) stretches, installed load is reduced, and the set pressure
lowers.
• Pressurized oil proportionate to the piston stroke is drained via
passage C and chamber D.
PC400LC-7E0 10-107
12
VARIABLE PRESSURE COMPENSATION VALVE
(Installed to the service valve)
A. Pump discharge pressure (P) (From service valve spool) 1. Valve 5. Spring
B. Cylinder port 2. Spring 6. Screw
C. Load pressure of other work equipment 3. Sleeve 7. Locknut
4. Poppet 8. Cap
Function
• Regulates flow distribution to the service valve when the service valve (attachment) and the work equipment valve (boom
raising, etc.) are operated together. (Equivalent surface area ratio variable).
• Pressurized oil from the service valve spool is applied to the left side of valve (1) and is led to chamber (g) via orifice a.
• LS pressure is led to chamber e through orifice d.
• Pressurized oil of cylinder port is led to chamber h through passage c and orifice f.
• The force of spring (2) acts on valve (1), and the force of spring (5) acts on poppet (4).
• The force of spring (5) can be adjusted with screw (6).
10-108 PC400LC-7E0
12
Operation when jointly operated with a high-load work equipment (such as the boom raising)
• Both of the pump discharge pressure P and LS pressures are

determined by other equipment's pressure, while cylinder port
pressure causes the attachment to operate.
• If the difference between the pump discharge pressure P and cylinder
pressure is smaller than the force of spring (5), the balance of forces
applying to valve (1) may be expressed with the following equation:
P × A1 = P × A2 + LS(A2 – 1) + F
A1: Area of Ød1
A2: Area of Ød2
F: Force of spring
P: Pump discharge oil pressure
• If the difference between the pump discharge pressure P and cylinder

port pressure B is larger than the force of spring (5), poppet (4) is
pressed to the right.
• Pump discharge pressure P flows to orifice a and chamber g and is
interconnected to cylinder port via passages b and c.
• Differential pressure is generated between the upstream and
downstream of orifice a, which reduces the pressure force in chamber
g.
• Force that presses valve (1) to the left is reduced.
• A state is reached where the area ratio has become smaller.
• Valve (1) moves to the right, and the flow increases from the pump to
the cylinder.
PC400LC-7E0 10-109
12
ATTACHMENT CIRCUIT SELECTOR VALVE
ACC: To accumulator T: To hydraulic oil tank 1. Spool

ATT: To attachment TS: To hydraulic oil tank 2. Spring
P1: From attachment selector solenoid valve V: To control valve
Unit: mm
If damaged
Free length x Installed Installed Installed or
Free length
Outside diameter length load load deformed,
replace
834 N 667 N spring.
132 x 29 114.5
Torque
Nm lbf ft
4 Bolt 59 - 74 43.5 - 54.5
10-110 PC400LC-7E0
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 pressed to the left by the force of spring (2).
• Ports ATT and V are interconnected and ports ATT and T are
shut off. Attachment is thus interconnected to the control valve.
2. When breaker is installed.

• Pilot pressure P1 from the attachment circuit selector solenoid
valve compresses spring (2), moving spool (1) rightward to the
stroke end.
• Ports ATT and V are shut off and ports ATT and T are
interconnected.
• Pressurized oil returning from the breaker returns directly to the
hydraulic tank via port T without passing through the control
valve.
PC400LC-7E0 10-111
12
VALVE CONTROL
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
10-112 PC400LC-7E0
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MEMORANDUM
PC400LC-7E0 10-113
12
PPC VALVE
Work equipment and swing PPC valve
P: From self pressure reducing valve

P1: L.H. PPC: Arm out/R.H. PPC: Boom lower
P2: L.H. PPC: Arm in/R.H. PPC: Boom raise
P3: L.H. PPC: Swing left/R.H. PPC: Bucket curl
P4: L.H. PPC: Swing right/R.H. PPC: Bucket dump
T: To tank
10-114 PC400LC-7E0
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1. Spool 4. Piston 7. Joint 10. Body

2. Metering spring 5. Disc 8. Plate 11. Filter
3. Centering spring 6. Nut (for lever connection) 9. Retainer
PC400LC-7E0 10-115
12
Unit: mm
Centering spring 17.7 N 13.7 N
42.5 x 15.5 34.0 If damaged or
12 (for ports P3 and P4) {1.80 kg} {1.40 kg}
deformed, replace
13 Centering spring 29.4 N 23.5 N spring.
44.5 x 15.5 34.0
(for ports P1 and P2) {3.0 kg} {2.40 kg}
14 Metering spring 16.7 N 13.7 N
26.5 x 8.15 24.9 {1.70 kg} {1.40 kg}
Torque
Nm lbf ft
15 Bolt 11.8 - 14.7 8.7 - 10.8
16 Nut 69 - 88 50.8 - 64.9
17 Nut 39 - 49 28.7 - 36.1
18 Plug 34 - 44 25.0 - 32.3
19 Plug 6 - 11 4.4 - 8.1
20 Plug 4-9 2.9 - 6.6
10-116 PC400LC-7E0
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Operation
1. When in neutral.
• Ports A and B of the control valve and ports P1 and P2 of the PPC
valve are connected to drain chamber D via fine control hole f in
spool (1).
2. During fine control.

(Neutral → fine control)
• When piston (4) is pushed by disc (5), retainer (9) is pushed,
spool (1) is also pushed by metering spring (2), and moves down.
• When fine control hole f is shut off from drain chamber D, it is
almost simultaneously interconnected to pump pressure chamber
PP.
• Pilot pressurized oil of the control pump is led to port A from port
P1 via fine control hole f.
• 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.
• As a result, spool (1) moves up and down until the force of
metering spool (2) is balanced with the pressure at port P1.
• The relationship of the position of spool (1) and body (10) [fine
control hole f is in the middle between drain chamber D and pump
pressure chamber PP] does not change until retainer (9) contacts
spool (1).
• Metering spring (2) contracts in proportion to the stroke of the control lever.
• Pressure at port P1 also rises in proportion to the stroke of the control lever.
• In this way, the control valve spool moves to a position where the pressure of chamber A (same as pressure at port
P1) and the force of the return spring of the control valve spool are balanced.
PC400LC-7E0 10-117
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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.
• Because of this, fine control hole f is connected to drain chamber
D, and the pressurized oil at port P1 is released.
• If the pressure of port P1 is lowered excessively, spool (1) is
pushed down by metering spring (2).
• Fine control hole f is shut off from drain chamber D, and it is
almost simultaneously interconnected to pump pressure chamber
PP.
• Pump pressure is supplied until the pressure at port P1 recovers to
the level equivalent to the lever position.
• When the spool of the control valve returns, the 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 replenish the chamber with pressurized oil.
4. At full stroke
• 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
interconnected to pump pressure chamber PP.
• Therefore, the pilot pressure oil from the self pressure reducing
valve passes through fine control hole f and flows to chamber A
from port P1 to push 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.
10-118 PC400LC-7E0
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TRAVEL PPC VALVE
P: From main pump P4: R.H. forward

P1: L.H. reverse P5: Travel signal
P2: L.H. forward P6: Steering signal
P3: R.H. reverse T: To tank
Torque
Nm lbf ft
1 Bolt 27 - 34 19.9 - 25.0
PC400LC-7E0 10-119
12
MEMORANDUM
10-120 PC400LC-7E0
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1. Plate 6. Metering spring

2. Body 7. Valve
3. Piston 8. Dumper
4. Collar 9. Steering signal spool
5. Centering spring 10. Steering signal spool spring
PC400LC-7E0 10-121
12
Unit: mm
108 N 86.3 N
48.6 x 15.5 32.5 - If damaged or deformed,
11 Centering spring {11.0 kg} {8.8 kg} replace spring.
16.7 N 13.7 N
12 Metering spring 26.5 x 8.15 24.9 -
{1.7 kg} {1.4 kg}
8.8 N 7.1 N
13 Steering signal spring 12.8 x 7.3 8.5 -
{0.9 kg} {0.72 kg}
Torque
Nm lbf ft
14 Bolt 25 - 31 18.4 - 22.8
15 Bolt 7.8 - 9.8 5.7 - 7.2
16 Cap 34 - 44 25.0 - 32.4
17 Plug 24.5 - 34.3 18.0 - 25.2
18 Plug 27 - 34 19.9 - 25.0
10-122 PC400LC-7E0
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1. Pressure reducing valve
Operation
A. When in neutral.
• Ports A and B of the control valve and ports P1 and P2 of the
PPC valve are connected to drain chamber D via fine control
hole f in spool (1).
B. During fine control.

(Neutral → fine control)
• When piston (4) is pushed by disc (5), retainer (9) is pushed,
spool (1) is also pushed by metering spring (2), and moves
down.
• When fine control hole f is shut off from drain chamber D, it
is almost simultaneously interconnected to pump pressure
chamber PP.
• Pilot pressurized oil of the control pump is led to port A from
port P1 via fine control hole f.
• 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.
• As a result, spool (1) moves up and down until the force of
metering spool (2) is balanced with the pressure at port P1.
• The relationship of the position of spool (1) and body (10)
[fine control hole f) is in the middle between drain chamber
D and pump pressure chamber PP] does not change until retainer (9) contacts spool (1).
• Metering spring (2) contracts in proportion to the stroke of the control lever.
• Pressure at port P1 also rises in proportion to the stroke of the control lever.
• In this way, the control valve spool moves to a position where the pressure of chamber A (same as pressure at
port P1) and the force of the return spring of the control valve spool are balanced.
PC400LC-7E0 10-123
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C. During fine control.
(When control lever is returned)
• When lever (5) starts to be returned, spool (1) is pushed up by
the force of centering spring (3) and pressure at port P1.
• Because of this, fine control hole f is connected to drain
chamber D, and the pressurized oil at port P1 is released.
• If the pressure of port P1 is lowered excessively, spool (1) is
pushed down by metering spring (2).
• Fine control hole f is shut off from drain chamber D, and it is
almost simultaneously interconnected to pump pressure
chamber PP.
• Pump pressure is supplied until the pressure at port P1
recovers to the level equivalent to the lever position.
• When the spool of the control valve returns, the 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 replenish the chamber with
pressurized oil.
D. At full stroke.
• Lever (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
interconnected to pump pressure chamber PP.
• Therefore, the pilot pressure oil from the self pressure
reducing valve passes through fine control hole f and flows to
chamber A from port P1 to push 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.
2. Travel signal/Steering function.

Travel signal
• Travel signal if either of the L.H. or R.H. travel levers is operated,
the higher PPC output pressure of both sides is output as the travel
signal.
• Accordingly, whether the machine is travelling 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 of 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, whether the machine is being steered is judged by the signal of port P6.
10-124 PC400LC-7E0
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Operation
A. When in neutral.
• No output is made from respective output ports [from port P1 to P4], travel signal [port P5] and steering signal
[port P)].
PC400LC-7E0 10-125
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B. During straight travel.
★ The Illustration shows the circuit for travelling straight forward.

• When operating L.H. motor forward [port P2 output] and R.H. motor forward [port P4 output], pressure of both
left spring chamber k and right spring chamber l rises high.
• Steering signal spool j remains at neutral position and does not output a steering signal to port P6.
10-126 PC400LC-7E0
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C. When steered or pivot-turned.
★ The Illustration 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.
• The pressure in left spring chamber k of steering signal spool j is P2.
• The pressure in right spring chamber l is P4.
• When the pressure state reaches [P4 – P2 × (Spool section) > Spring set load], the spool is switched to the
direction of the arrow.
• Port P4 pressure of the L.H. or R.H. PPC valves, whichever having a higher output pressure, is output to port P6
as the steering signal.
PC400LC-7E0 10-127
12
D. When counter-rotated.
★ The illustration shows the circuit for travelling left reverse and right forward.
• When operating L.H. motor reverse [port P1 output] and R.H. motor forward [port P4 output], pressure of the
right spring chamber l only rises high.
• Steering signal spool j strokes to the left to output the steering signal to port P6.
10-128 PC400LC-7E0
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SERVICE PPC VALVE
★ For the details of operation, see the paragraph of “Work equipment swing PPC valve.”
PC400LC-7E0 10-129
12
P: From self pressure reducing valve 1. Spool

P1: To service valve 2. Piston
P2: To service valve 3. Lever
T: To tank 4. Plate
5. Retainer
6. Body
Unit: mm
7 Outside diameter length load length load If damaged or
125 N 100 N deformed, replace
33.9 x 15.3 28.4 - spring.
Centering spring {12.7 kg} {10.2 kg}
16.7 N 13.3 N
8 Metering spring 22.7 x 8.10 22.0 -
{1.70 kg} {1.36 kg}
Torque
Nm lbf ft
9 Bolt 11.76 - 14.7 8.6 - 10.8
10-130 PC400LC-7E0
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SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up and travel junction solenoid valves
1. PPC lock solenoid valve T: To tank

2. Travel junction solenoid valve A1: To PPC valve
3. Merge-divider solenoid valve A2: To main valve (Travel junction valve)
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
7. 2-stage relief solenoid valve A6: To 2-stage safety valve at boom cylinder head
A8: To main valve (2-stage relief valve)
P1: From main pump
ACC: To accumulator
PC400LC-7E0 10-131
12
1. Connector 4. Spool
2. Moving core 5. Block
3. Coil 6. Spring
Operation
When solenoid is de-energized
• Since the signal current does not flow from the controller, solenoid (3)
is de-energized. For this reason, spool (4) is pushed to the left by
spring (6). By this operation, the pass from port P to port A is closed
and the pressurized 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 energized
• The signal current flows from the controller to solenoid (3), and the
latter is energized. Accordingly, spool (4) is pressed against to the
right side. By this operation, the pressurized oil from the main pump
flows through port P and spool (4) to port A, then flows into the
actuator. At the same time, port T closes and stops the oil from
flowing to the tank.
10-132 PC400LC-7E0
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PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Gas capacity: . . . . . . . . . . . . . . . . . . . . . 300 cc (for PPC)
PC400LC-7E0 10-133
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RETURN OIL FILTER
For breaker
1. Drain plug Specifications

2. Filter Rated pressure: 70 kg/cm2 (995 psi)
3. Case Flow: 200 L/min (52.8 gal/min)
4. Head cover Relief valve cracking pressure: 3.5 ± 0.5 kg/cm2 (49.7 ± 7 psi)
5. Relief valve Filter mesh size: 6 µm
Filtering area: 4,570 cm2 (708.35 inch2)
10-134 PC400LC-7E0
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CENTER SWIVEL JOINT
1. Cover A1: To L.H. travel motor port PB

2. Body A2: From control valve port A2
3. Slipper seal B1: To L.H. travel motor port PA
4. O-ring B2: From control valve port B2
5. Shaft C1: To R.H. travel motor port PA
C2: From control valve port A5
D1: To R.H. travel motor port PB
D2: From control valve port B5
E: To L.H. and R.H. travel motors port P
T1: From L.H. and R.H. travel motors port T
T2: To tank
PC400LC-7E0 10-135
12
Unit: mm
Standard size Standard clearance Clearance limit
Clearance between rotor Replace
6 and shaft 80 - -
10-136 PC400LC-7E0
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TRAVEL MOTOR
Type: KMV200ADT-2
PC400LC-7E0 10-137
12
PA: From control valve
PB: From control valve
PI: From travel speed solenoid valve
T: To tank
Specifications
Type: KMV200ADT-2
Theoretical displacement
(Min.): 130 cm3/rev (0.0343 gal/rev)
(Max.): 200 cm3/rev (0.0528 gal/rev)
Rated pressure: 380 kg/cm2 (5404.8 psi)
Rated speed
(Capacity min.): 2,650 rpm
(Capacity max.): 1,550 rpm
Brake release pressure: 10 kg/cm2 (142.2 psi)
Travel speed selector pressure
(differential pressure): 8 kg/cm2 (113.7 psi)
Torque
Nm lbf ft
1 Bolt 490 - 608 361.4 - 448.4
2 Nut 294 - 343 216.8 - 252.9
10-138 PC400LC-7E0
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PC400LC-7E0 10-139
12
1. Output shaft 11. Check valve spring
2. Motor case 12. Check valve
3. Piston 13. Counter balance valve spool
4. Cylinder block 14. Spool return spring
5. Valve plate 15. Safety valve
6. End cover 16. Regulator valve
7. Slow return valve 17. Spring
8. Regulator piston 18. Brake spring
9. Plate 19. Brake piston
10. Disk 20. Check valve
Unit: mm
62.5 x 32.0 42.0 -
21 Spool return spring {43.5 kg} {34.8 kg} deformed, replace
spring.
3.04 N 2.45 N
{0.31 kg} {0.25 kg}
23 Regulator piston 98.1 N 78.5 N

55.0 x 9.0 50.0 -
spring {10.0 kg} {8.0 kg}
Torque
Nm lbf ft
24 Plug 24.5 - 34.3 20 - 25
25 Plug 19.6 - 27.5 15 - 20
26 Bolt 65.7 - 82.4 48 - 61
27 Bolt 324 - 407 239 - 300
28 Plug 147.1 - 186.3 108 - 137
29 Plug 373 - 466 265 - 344
10-140 PC400LC-7E0
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Operation of motor
1. At slow speed (motor swash plate angle at maximum).
• As the solenoid valve is de-energized, the pilot pressurized oil from the self pressure reducing valve does not flow to
port P.
• Regulator valve (16) is being pushed down by spring (17).
• Pressurized oil conducted to end cover (6) by pressing check valve (20) is then conducted to chamber b via regulator
valve (16).
• Force is generated on regulator piston (8) that works in downward direction.
• Valve plate (5) and cylinder block (4) move in the maximum tilt and roll angle direction, increasing the motor
capacity to the maximum and thus turning on the low speed travel.
PC400LC-7E0 10-141
12
2. At high speed (motor swash plate angle at minimum).
• As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port P.
• Regulator valve (16) is pushed upward.
• Pressurized oil in chamber b is drained to the case and oil is conducted to chamber a through regulator valve (16).
• Force is generated on regulator piston (8) that works in upward direction.
• Valve plate (5) and cylinder block (4) move in the minimum tilt and rotation angle direction, decreasing the motor
capacity to the minimum and thus turning on the high speed travel.
10-142 PC400LC-7E0
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Operation of parking brake
1. When starting travel.
• As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (13), opening the
parking brake circuit.
• The pressurized oil is conducted to chamber e of brake piston (19) and compresses spring (18), pushing piston (19)
toward right.
• Since the pushing force to plate (9) and disc (10) disappears, plate (9) is separated from disc (10) and the brake is
released.
PC400LC-7E0 10-143
12
2. When travel is stopped.
• As the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and closing the
parking brake circuit.
• Pressurized oil in chamber e of brake piston (19) keeps flowing through the orifice of slow return valve (7) until
counter balance valve spool (13) is returned to the neutral.
• As counter balance valve spool (13) is returned to the neutral, pressurized oil is drained to the case through orifice f of
brake piston (19).
• Brake piston (19) is pushed to the left by spring (18).
• Plate (9) and disc (10) are pushed together, and the brake is applied.
• As brake piston (19) returns, flow of pressurized oil is reduced with slow return valve (7).
• The time delay will be set to activate the brake only after the machine has stopped.
10-144 PC400LC-7E0
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BRAKE VALVE
• The brake valve consists of check valves (1), counterbalance valve (2)
and safety valve (3).
• Functions and operations of respective components shall conform to
the following.
1. Counterbalance valve and check valve.

Function
• When traveling downhill, the machine travel speed tends to get faster
than the motor (engine) speed because of the downward force
generated from its own weight.
• If the machine travels with the engine at low speed, the motor may
rotate without load, causing the machine to run away, resulting in a
very dangerous situation.
• These valves are used to prevent above by controlling the machine to
travel according to the engine speed (pump delivery).
Operation when pressurized oil is supplied
• Operating the travel lever conducts the pressurized oil from the control
valve to port PA.
• The pressurized oil push-opens check valve (12A) and then flows to
motor outlet port MB via motor inlet port MA.
• The motor outlet side is closed by check valve (12B) and spool (13),
so the pressure at the supply side rises.
PC400LC-7E0 10-145
12
• The pressurized oil on the supply side flows to chamber S1 via orifice
E1 and orifice E2 of the spool (13).
• As the pressure in chamber S1 goes above the spool selector pressure,
spool (13) is pushed toward right.
• Port MB and port PB are connected, opening the motor outlet port
side and starting the motor rotating.
Operation of brake during travelling downhill
• If indication of the machine runaway is sensed while travelling

downhill, the motor will be caused to rotate without load to decrease
the inlet side oil pressure.
• Pressure in chamber S1 is released through orifices E1 and E2.
• As the pressure in chamber S1 goes below the spool selector pressure,
spool (13) is returned to the left by spring (14) and outlet port MB is
throttled.
• The pressure at the outlet port side rises, generating rotation resistance
on the motor to prevent the machine from running away.
• The spool moves to a position where the pressure on outlet port MB
can be balanced against the machine's own weight and the inlet port
pressure.
• Oil flow from the outlet circuit is reduced to ensure the travel speed
corresponded to the pump delivery.
10-146 PC400LC-7E0
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2. Safety valve
(bidirectional 2-stage set safety valve)
Function
• As long as the machine travel is stopped (or it is travelling downhill), the counterbalance valve closes the inlet and outlet
circuits of the motor.
• Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially
resulting in damages on the motor and piping.
• The safety valve releases this abnormal pressure to the inlet port side of the motor in order to prevent damages to the
equipment.
Bidirectional action
A. When pressure in chamber MB has become high (when rotating

clockwise)
• As long as the machine travel is stopped (or it is travelling
downhill), the check valve of counterbalance valve closes
chamber MB of the outlet port circuit.
• The motor tries to continue rotation resorting to inertial force,
thus pressure on the outlet port MB is increased.
• As the pressure goes above the set pressure, [Difference in

areas of circles D1 and D2 × Pressure] compresses spring (2).
• Poppet (1) is moved leftward and the pressurized oil flows
into chamber MA of the opposite circuit.
PC400LC-7E0 10-147
12
B. When pressure in chamber MA has become high (when rotating
counterclockwise).
• As long as the machine travel is stopped (or it is travelling
downhill), the check valve of counterbalance valve closes
chamber MA of the outlet port circuit.
• The motor tries to continue rotation resorting to inertial force,
thus pressure on the outlet port MA is increased.
• As the pressure goes above the set pressure, [Difference in

areas of circles D1 and D3 × Pressure] compresses spring (2).
• Poppet (1) is moved leftward and the pressurized oil flows
into chamber MB of the opposite circuit.
Operation of mechanism for varying set pressure
A. When starting travel (high-pressure setting).

• As the travel lever is operated, the pressurized oil from the
pump moves spool (19) toward right.
• Above opens the pilot circuit to the safety valve, conducting
the pressurized oil to chamber J through chamber G and
passage H.
• Piston (3) is pushed rightward, spring (2) is compressed and
the set load is increased.
• High pressure is turned on the safety valve, providing a large
tractional force to the valve.
10-148 PC400LC-7E0
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B. When travel is stopped (low-pressure setting).
• When the travel lever is placed in neutral, the pressure in
chamber PA drops and spool (24) returns to the neutral
position.
• When spool (24) is in the process of returning to the neutral
position, the pressurized oil in chamber J flows to chamber
PA through passage H and chamber G.
• Piston (3) moves to the left side, decreasing the set load.
• The safety valve is caused to the low pressure setting, thereby
attenuating the shocks when the speed is reduced.
Set pressure of safety valve
High pressure setting: 410 kg/cm2 (5831.5 psi)

(at start of travel and during travel)
Low pressure setting: 280 kg/cm2 (3982.5 psi)

(during stop)
PC400LC-7E0 10-149
12
MEMORANDUM
10-150 PC400LC-7E0
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SWING MOTOR
Type: KMF230ABE-5
PC400LC-7E0 10-151
12
B: From swing holding brake solenoid valve Specifications

MA: From control valve Type : KMF230ABE-5
MB :From control valve Theoretical displacement : 229.4 cm3/rev (0.0606 gal/rev)
S: From control valve Safety valve set pressure : 285 kg/cm2 (4053 psi)
T: To tank Rated speed : 1,413 rpm
Brake release pressure : 19 kg/cm2 (270.2 psi)
1. Reverse prevention valve
2. Safety valve
Torque
Nm lbf ft
3 27 - 34 20 - 25
4 98.1 - 122.6 72 - 90
5 294 - 392 217 - 289
10-152 PC400LC-7E0
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PC400LC-7E0 10-153
12
1. Brake spring 10. Cylinder block
2. Drive shaft 11. Valve plate
3. Spacer 12. Center shaft
4. Case 13. Center spring
5. Disc 14. Check valve
6. Plate 15. Check valve spring
7. Brake piston 16. Shuttle valve
8. Housing 17. Shuttle valve spring
9. Piston
Unit: mm
Basic dimensions Repair limit
Outside length load length load
diameter If damaged or deformed,
6.96 N 5.59 N replace spring.
66.5 x 25.6 45.0 -
18 Check valve spring {0.71 kg} {0.57 kg}
7.45 N 5.98 N
19 Shuttle valve spring 24.5 x 11.6 14.5 -
{0.76 kg} {0.61 kg}
Torque
Nm lbf ft
20 Cap 294 - 392 217 - 289
21 Cap 490.5 - 608.2 362 - 449
22 Cap 98.1 - 122.6 72 - 90
23 Cap 176.5 - 215.8 130 - 160
10-154 PC400LC-7E0
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Swing holding brake
1. When solenoid valve is de-energized.

Operation
• As the swing holding brake is de-energized, the pressurized oil from

the self pressure reducing valve is shut off.
• Port B is connected to tank circuit T.
• Brake piston (7) is pushed down by brake spring (1).
• Disc (5) and plate (6) are pushed together, and the brake is applied.
2. When solenoid valve is energized.

Operation
• As the swing brake solenoid valve is energized, the valve is switched.

• The pressurized oil from the self pressure reducing valve is conducted
brake chamber a via port B.
• After entering chamber a, the pressurized oil compresses brake spring
(1) and pushes brake piston (7) up.
• Disc (5) is separated from plate (6), releasing the brake.
PC400LC-7E0 10-155
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Relief valve portion
Outline
• The relief valve portion consists of check valves (2) and (3), shuttle
valves (4) and (5), and relief valve (1).
Function
• When the machine is in the swing holding mode, control valve (6)
closes the motor outlet circuit, but the motor rotation is continued by
inertial force.
• The motor output, therefore, is abnormally increased, resulting in
damaging the motor.
• In order to prevent the motor damages, the relief valve relieves the
abnormally high pressure to port S from the motor outlet side
(high-pressure side) of the motor.
Operation
1. When starting swing.

• When the swing control lever is operated to the right-swing, the
pressurized oil from the pump is supplied to port MA through
control valve (6).
• The pressure on port MA rises, the starting torque is generated in the motor, and the motor starts to rotate.
• The pressurized oil from the outlet port of the motor passes from port MB through the control valve (6) and returns to
the tank.
2. When swing is stopped.

• When the swing control lever is returned to neutral, the supply of
pressurized oil from the pump to port MA is stopped.
• The pressurized oil from the motor outlet can't return to the tank
since the returning circuit to the tank is closed from control valve
(6). Thus, pressure on port MB increases.
• Rotation resistance is generated on the motor and hence the brake
starts working.
• Shuttle valve (4) is pressed as pressure on port MB goes above
port MA.
• The pressure on chamber C is increased to the set pressure of
relief valve (1) and becomes the same as that of port MB.
• A high braking torque works on the motor, thereby stopping the
motor.
• When relief valve (1) is being actuated, the relieved pressurized
oil and the pressurized oil from port S are fed to port MA through
check valve (3).
• Above prevents cavitation on port MA.
10-156 PC400LC-7E0
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REVERSE PREVENTION VALVE
PC400LC-7E0 10-157
12
MA: From control valve 1. Valve body
MB: From control valve 2. Spool (MA side)
T1: To tank 3. Spring (MA side)
T2: To tank 4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
10-158 PC400LC-7E0
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Function
• This valve reduces the swing back generation 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.
• The valve contributes in preventing collapsing of load when the swing
is stopped and also contributes in reducing cycle time (enhances the
positioning performance, enabling you to proceed to the next work
quicker than ever).
Operation
1. When port MB brake pressure is generated.

• Pressure MB is conducted to chamber d via notch g.
• The pressure compresses spring (6) by use of the difference in
areas of circles (∅D1 > ∅D2) of spool (5) and moves spool (5) to
the left side.
• Port MB o chamber e will be interconnected.
• Since pressure MA is lower than the set pressure of spring (3),
spool (2) does not move and the pressurized oil is kept in. Thus
the braking force is ensured.
2. When motor is stopped temporarily.

• The motor rotation is reversed by the closing pressure generated
at port MB. (1st time: reverse rotation)
• Reversing pressure is generated on port MA. Pressure MA is
conducted to chamber a.
• The pressure compresses spring (3) by use of the difference in
areas of circles (∅D3 > ∅D4) of spool (2) and moves spool (2) to
the right side.
• Port MA → chamber b will be interconnected.
• Then ports b and f will be interconnected through the drilled hole
h on spool (5). This interconnection bypasses the reversing
pressure on port MA to port T, thereby preventing the reverse
rotation of the 2nd time.
PC400LC-7E0 10-159
12
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-160 2 PC400LC-7E0
12
Unit: mm

Cylinder size Shaft Hole clearance limit
-0.036 +0.261 0.083 -
Boom 110 0.412
Clearance between -0.090 +0.047 0.351
1 Replace bushing
piston rod and bushing
-0.036 +0.263 0.084 -
Arm 120 0.412
-0.090 +0.048 0.353
-0.036 +0.257 0.083 -
Bucket 110 0.447
-0.090 +0.047 0.347
-0.036 +0.169 0.136 -
Boom 110 -
-0.090 +0.100 0.259
Clearance between -0.036 +0.169 0.136 - Replace pin or
2 piston rod support pin Arm 110 -
-0.090 +0.100 0.259 bushing
and bushing
-0.036 +0.187 0.133 -
Bucket 100 -
-0.090 +0.097 0.277
-0.036 +0.190 0.106 -
Boom 100 -
-0.090 +0.070 0.280
Clearance between
cylinder -0.036 +0.195 0.135 -
3 Arm 110 -
bottom support pin and -0.090 +0.099 0.285
bushing
-0.036 +0.187 0.133 -
Bucket 100 -
-0.090 +0.097 0.277
Torque
Nm lbf ft
4 Bolt 530 ± 78.5 390 ± 57.8
5 Sleeve 294 ± 29.4 216.84 ± 21.6
6 Bolt 58.9 - 73.6 43.4 - 54.2
7 Bolt 892 ± 137 657.9 ± 101.0
PC400LC-7E0 10-161 2
12
MEMORANDUM
10-162 2 PC400LC-7E0
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
WORK EQUIPMENT
WORK EQUIPMENT
PC400LC-7E0 10-163
12
Unit: mm

size Shaft Hole clearance limit
Clearance between connecting
pin and bushing of revolving -0.036 +0.173
120 0.137 - 0.263 1.0
1 frame and boom -0.090 +0.101
Clearance between connecting -0.036 +0.180
2 pin and bushing of boom and 120 0.148 - 0.270 1.0
-0.090 +0.112
arm
3 100 0.117 - 0.262 1.0 Replace
pin and bushing of arm and link -0.090 +0.081
4 pin and bushing of arm and 100 0.113 - 0.228 1.0
-0.090 +0.077
bucket
5 pin and bushing of link and 100 0.117 - 0.262 1.0
-0.090 +0.081
bucket
6 100 0.133 - 0.280 1.0
pin and bushing of link and link -0.090 +0.097
7 Bucket clearance (a) 0.5 - 1.0
Adjust shims
8 Bucket clearance (b) 2.0
10-164 PC400LC-7E0
12
DIMENSIONS OF COMPONENTS
DIMENSION OF ARM
PC400LC-7E0 10-165
12
Unit: mm
Standard Tolerance
No. Measuring position size Shaft Hole
-0.036 +0.1
1 - φ 110 -0.090 0
+1.5
Arm side 129.3
2 0
Cylinder head side 126 ±1.2
+0.5
Boom side 355 0
3
-0.3
Arm side 351 -0.8
-0.036 +1.0
4 - φ 120 -0.090 0
5 - 514.8 -
6 - 195 -
7 - 1,038 -
8 - 3,375 -
9 - 2,977.5 -
10 - 502 -
11 - 720 -
12 - 719 -
13 - 537.1 -
14 - 1,850 -
-0.036 +0.1
15 - φ 100 -0.090 0
+1
Bucket side 371
16 0
Link side 370 ± 0.5
-0.036 +0.1
17 - φ 100 -0.090 0
0
Arm itself 355 -0.5
18
When press fitting bushing 370 -
Min. 1,870 -
19
Max. 3,140 -
10-166 PC400LC-7E0
12
DIMENSION OF BUCKET
PC400LC-7E0 10-167
12
Unit: mm
No Measuring position Standard size Tolerance
1 - 534.1 ±0.5
2 - 56.3 ±0.5
3 - 96°1' -
4 - 537.1 -
5 - 1,839 -
6 - 190 -
7 - - -
8 - 62°1' -
+0.1
A - φ 140.1 0
+0.063
9 B - φ 130 0
+0.1
C - φ 100 0
+0.1
10 - 371 0
A - 57 -
11
B - 72 -
12 - 144 -
+0.5
13 - 562.5 -2.5
14 - φ 26 -
A - φ 165 -
15
B - - -
16 - φ 230 -
17 - 146.1 -
18 - 137.6 -
19 - R115 -
20 - R85 -
21 - 410 ±1
22 - 64 -
10-168 PC400LC-7E0
STRUCTURE AND FUNCTION AIR CONDITIONER PIPING
12
AIR CONDITIONER PIPING
1. Receiver tank A: Fresh air

2. Condenser B: Recirculated air
3. Air conditioner compressor C: Hot/cool air
4. Refrigerant piping
5. Hot water pickup piping
6. Hot water return piping
7. Air conditioner unit
8. Duct
PC400LC-7E0 10-169
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM
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. Then, the starting motor
turns to start the engine.
When it happens, the engine controller checks the signal voltage 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 a signal voltage corresponding to the

rotation angle to the engine controller.
• The pump controller receives the fuel dial position information from
the engine controller through the network.
• The pump controller calculates the engine speed in accordance with
the working mode, the deceleration, and the like, and sends an
instruction to the engine controller.
• The engine controller determines the fuel injection quantity based on
the instruction received from the pump controller.
Stopping engine
• When detecting that the starting switch is set to the “STOP” position,
the engine controller cuts the fuel injection to stop the engine.
10-170 PC400LC-7E0
12
FUEL CONTROL DIAL
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
Function
• A potentiometer is installed under the knob. As the knob is turned, the

potentiometer shaft is turned.
• As the potentiometer shaft is turned, the resistance of the variable
resistor in potentiometer (5) changes and a throttle signal is sent to the
engine controller.
• The hatched area in the graph shown at right is the abnormality
detection area.
PC400LC-7E0 10-171
12
MEMORANDUM
10-172 PC400LC-7E0
12
ENGINE CONTROLLER
Meanings of signal classes in the terminal table shown below are as follows.
A: Power Supply C: Ground/Shield/Return E: Communication
B: Input D: Output
PC400LC-7E0 10-173
12
CN-CE01 CN-CE01
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
1 NC(*) - 28 NC(*) -
2 NC(*) - 29 NC(*) -
3 Atmosphere sensor D 30 Fuel temperature sensor D
4 Supply pump #1 (+) B 31 NC(*) -
5 Supply pump #1 (-) C 32 NC(*) -
5 V electric power supply for
6 CAN(+) C 33 A
sensor
7 NC(*) - 34 NC(*) -
8 CAN(+) B 35 NC(*) -
9 Supply pump #2 (+) B 36 NC(*) -
5 V electric power supply for
10 Supply pump #2 (-) C 37 A
sensor
11 EGR valve C 38 GND C
12 NC(*) - 39 NC(*) -
13 Engine oil pressure sensor D 40 NC(*) -
14 NC(*) - 41 NC(*) -
15 Coolant temperature sensor D 42 NC(*) -
5V electric power supply for
16 A 43 NC(*) -
sensor
17 NC(*) - 44 Boost pressure sensor D
18 NC(*) - 45 Injector #1 (+) B
19 EGR valve position sensor D 46 Injector #5 (+) B
20 NC(*) - 47 Sensor GND C
21 NC(*) - 48 Ne sensor (-) C
22 EGR valve (+) B 49 NC(*) -
23 Boost temperature sensor D 50 NC(*) -
24 NC(*) - 51 Injector #2 (-) C
25 Common rail pressure sensor D 52 Injector #3 (-) C
26 Buckup sensor D 53 Injector #1 (-) C
27 NE sensor (+) D 54 Injector #2 (+) B
*: Never connect to NC or malfunctions or failures will 55 Injector #3 (+) B
occur.
56 Injector #4 (+) B
57 Injector #6 (+) B
58 Injector #4 (-) C
*: Never connect to NC or malfunctions or failures will

occur.
10-174 PC400LC-7E0
12
PC400LC-7E0 10-175
12
CN-CE02 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
1 NC(*) B 26 NC(*) B
2 NC(*) B 27 NC(*) B
3 NC(*) B 28 NC(*) B
4 NC(*) B 29 NC(*) C
5 NC(*) B 30 NC(*) B
6 NC(*) B 31 NC(*) B
7 NC(*) B 32 NC(*) C
8 NC(*) B 33 GND C
9 Fuel control dial (+) B 34 NC(*) C
10 NC(*) E 35 NC(*) B
11 NC(*) B 36 NC(*) B
12 NC(*) B 37 NC(*) C
13 NC(*) B 38 NC(*) D
14 NC(*) B 39 Key switch (ACC) B
Electrical intake air heater relay
15 NC(*) B 40 D
drive
16 NC(*) B 41 NC(*) D
Electrical intake air heater relay
17 NC(*) B 42 C
return
18 NC(*) B 43 NC(*) D
19 NC(*) B 44 NC(*) D
20 NC(*) E 45 NC(*) -
21 NC(*) A 46 CAN(+) E
22 Fuel control dial (+5V) A 47 CAN(-) E
23 Fuel control dial (-) C 48 NC(*) D
PWM OUTPUT
24 NC(*) B 49 (Power train relay output) D
25 NC(*) B 50 NC(*) D
*: Never connect to NC or malfunctions or failures *: Never connect to NC or malfunctions or failures
will occur. will occur.
CN-CE03
Input/
Pin No. Signal name output
1 GND C
2 NC(*) C
Electric power supply
3 A
(+24V constantly)
4 NC(*) A
*: Never connect to NC or malfunctions or failures
will occur.
10-176 PC400LC-7E0
12
SENSORS
ROTATION SENSOR
1. Connector
2. Sensor
3. O-ring
OIL PRESSURE SWITCH
1. Connector
2. Sensor
3. O-ring
PC400LC-7E0 10-177
12
AMBIENT PRESSURE SENSOR
1. Connector
2. Pressure import port
BOOST PRESSURE SENSOR
1. O-ring
2. Sensor
3. Connector
10-178 PC400LC-7E0
12
BOOST TEMPERATURE SENSOR
1. Connector
2. Sensor
3. O-ring
COOLANT TEMPERATURE SENSOR

HYDRAULIC OIL TEMPERATURE SENSOR
1. Connector
2. Sensor
3. O-ring
PC400LC-7E0 10-179
12
EGR VALVE STROKE SENSOR
1. Core
2. O-ring
3. Sensor
4. Connector
10-180 PC400LC-7E0
12
ENGINE OIL LEVEL SENSOR
1. Connector
2. Bracket
3. Float
4. Switch
PC400LC-7E0 10-181
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
12
ELECTRONIC CONTROL SYSTEM
Control function
★ For the self-diagnosis function, see “Troubleshooting“.
10-182 PC400LC-7E0
12
Machine control system diagram
PC400LC-7E0 10-183
12
10-184 PC400LC-7E0
12
ENGINE AND PUMP COMPOSITE CONTROL FUNCTION
PC400LC-7E0 10-185
12
Function
• This function allows the operator to select proper engine torque and
pump absorption torque according to the type of work. Four modes are
provided: P, E, B and L. Using the work mode switch on the monitor
panel, the operator is required to select one of them.
• The pump controller detects the speed of the engine governor set with
the fuel control dial and the actual engine speed N 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.
10-186 PC400LC-7E0
12
1. Control method in each mode
P and E modes
• Matching point in P mode: Rated speed
Mode Matching point
246.3 kW/1,850 rpm
P {330 HP/1,850 rpm}
213.3 kW/1,720 rpm
E {286 HP/1,720 rpm}
• If the pump load increases and the pressure rises, engine speed N
lowers. At this time, the controller lowers the pump discharge so
that the engine speed will be near the maximum output point.
If the pressure lowers, the controller increases pump discharge Q

so that the engine speed will be near the maximum output point.
By repeating these operations, the controller constantly uses the
engine near the maximum output point.
PC400LC-7E0 10-187
12
B and L modes
Mode B mode L mode

Partial output point 82% 61%
Mode Matching point

194.9 kW/1,730 rpm
B
{261 HP/1,730 rpm}
150.8 kW/1,250 rpm
L {202 HP/1,250 rpm}
• In B or L mode, the controller controls the pump absorption torque

through the pump and engine compound control function to decrease
engine speed N while maintaining engine torque T constant along the
constant horsepower curve. This ensures reduced fuel consumption.
10-188 PC400LC-7E0
12
2. Function to control pump during travel.
• Traveling the machine in E or B mode leaves the working mode
unchanged, but raises the pump absorption torque and engine
speed N to values same as those in P mode.
• If the machine travels in L mode, the working mode and engine
speed N do not change, but the pump absorption torque is
increased.
3. Function to control when emergency pump drive switch is turned on.

• Even if any abnormality occurs in the controller or sensor, setting
emergency pump drive switch (10) to the “ON” position activates
the machine with an absorption torque approximately equivalent
to that in E mode.
In this case, a constant current flows from the battery to the EPC
valve for PC and therefore, the oil pressure is sensed by only the
EPC valve for PC.
PC400LC-7E0 10-189
12
PUMP AND VALVE 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.
10-190 PC400LC-7E0
12
1. LS control function.
• Depending on the operation condition of the actuator, this
function changes the pressure output from the LS-EPC valve to
LS valve to change the change point (LS set differential pressure
DLS) of the pump discharge in the LS valve.
• 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.
• This function increases PC-EPC current J to reduce the flow rate
in the relief state, improving fuel consumption.
Operating condition for turning on cut-off function

When the average value of the front and rear pressure sensors is
above 285 kg/cm2 (4053 psi) with the power maximizing function off.
The cut-off function does not work, however, while the machine is
travelling in P mode, swing lock switch is in the ìONî position.
3. 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 Relief pressure

• During travel
• When swing lock switch is turned to the ON position 355 kg/cm2 (5049 psi)
• When boom is lowered ↓
• When power maximizing function is turned on 380 kg/cm2 (5404 psi)
• When L mode is operated
PC400LC-7E0 10-191
12
POWER MAXIMIZING AND MACHINE PUSH-UP FUNCTION
Function
• The power maximizing function allows the operator to increase power for a certain time by operating the left knob switch.
• The machine push-up function allows the operator to increase the boom pushing force by operating the machine push-up
switch.
10-192 PC400LC-7E0
12
1. Power maximizing function.
• This function is used to increase digging force for a certain period of time (e.g., when digging up a large rock).
• If the left knob switch is pressed in P or E mode, the hydraulic force is increased about 7% to increase the digging
force.
Each function is set automatically as shown below.
Function Setting
Engine and pump control Matching at rated ouptut point
355 kg/cm2 (5049 psi)
2-stage relief function ↓
380 kg/cm2 (5404 psi)
Software cut-off function Cancel
• These settings are automatically reset after 8.5 seconds when the switch is pressed.
2. Machine push-up function.

• The machine push-up function allows the operator to increase the boom pushing force that is required for
ditching or mass excavation in hard ground by operating machine push-up switch (1).
Switch 2-stage safety valve function

OFF Setting of safety valve at boom cylinder head 150 kg/cm2 (2133 psi)
ON Setting of safety valve at boom cylinder head 290 kg/cm2 (4124 psi)
PC400LC-7E0 10-193
12
AUTO-DECELERATION FUNCTION
Function
• The auto-deceleration function automatically reduces the engine speed

to its medium speed range when the all control levers are set in
NEUTRAL while waiting for a dump truck or work to reduce the fuel
consumption and noise.
• If any lever is operated, the engine speed instantly returns to the speed
set with the fuel control dial.
Operation
When control levers are set in neutral.

• If all the control levers are kept to NEUTRAL for 4 sec. during
operation at a engine speed above a decelerator operation level
(approximately 1,300 rpm), this function lowers the engine speed to
the deceleration operation level (approximately 1,300 rpm) and keeps it until you operate any lever.
When any control lever is operated
• If you operate any control lever while the engine speed is kept at the deceleration operation level, the engine speed
instantly rises to the level set with the fuel control dial.
10-194 PC400LC-7E0
12
AUTO-WARM-UP AND OVERHEAT PREVENTION FUNCTION
Function
• The engine automatic warm-up function increases the engine speed to warm up the engine if coolant temperature is too
low after the engine starts.
• The overheat prevention function reduces the pump load when coolant or hydraulic oil temperature is too high during
operation to protect the engine from overheating.
PC400LC-7E0 10-195
12
1. Auto-warm-up function.
• After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm
up 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 protect
the engine from overheating.
• This function is turned on when the coolant temperature rises above 95°C (203°F).
10-196 PC400LC-7E0
12
SWING CONTROL FUNCTION
Function
The swing lock and swing holding brake function are provided as a swing control function.
PC400LC-7E0 10-197
12
1. Swing lock and swing holding brake function.
• 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.
• Operation of swing lock switch and swing lock/holding brake.
Lock switch Lock lamp Function Operation

If swing lever is set in neutral, swing brake operates in about 7 sec. If
OFF OFF Swing holding brake swing lever is operated, brake is released and machine can swing freely.
Swing lock operates and machine is locked from swinging. Even if swing
ON ON Swing lock lever is operated, swing lock is not reset and machine does not swing.
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.
• 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, only the hydraulic brake is applied by the safety valve. Note that if swinging is stopped on a
slope, the upper structure may swing by its gravity.
Swing holding brake release ON OFF

switch (when controller has trouble) (when controller is normaly)
Swing lock switch ON OFF ON OFF
Swing lock is turned Swing lock is Swing lock is Swing holding brake is turned
Swing brake on. can- celed. turned on. on.
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-off function is
cancelled and the relief pressure rises from 355 kg/cm2 (5049.2
psi) to 380 kg/cm2 (5404.8 psi). If the work equipment is relieved
under this condition, the hydraulic oil temperature rises quickly
and the warm-up time can be shortened.
10-198 PC400LC-7E0
12
TRAVEL CONTROL FUNCTION
Function
The machine is provided with a function that ensures travel performance best fit to the type of work and job site by controlling
pumps during travel or allowing operator to change travel speed automatically or manually.
PC400LC-7E0 10-199
12
1. Pump control function during travel.
• If the machine travels in a work mode other than P mode, the work mode and the engine speed are kept as they are
and the pump absorption torque is increased.
• For details, see “Engine and pump composite control function.”
2. Travel speed change function.
A. Manual change with travel speed switch.

If one of Lo, Mi and Hi is selected with the travel speed switch, the pump controller controls the pump capacity and
motor capacity at each gear speed as shown below to change the travel speed.
Travel speed switch Lo (Low speed) Mi (Midium speed) Hi (High speed)

Pump capacity (%) 90 80 100
Motor capacity Max. Max. Min.
Travel speed (km/h) 3.3 4.4 5.5
B. Automatic change by engine speed.

If the fuel control dial is used to set the engine speed to less than 1,200 rpm, the travel speed changes to Lo when the
machine is travelling in Mi or Hi. and the travel speed will not change to Mi or Hi.
C. Automatic change by pump discharge pressure.

When traveling with the travel speed switch set to Hi or Mi, if the
load increases, such as when travelling uphill, and the travel
pressure goes above 330 kg/cm2 (4693.7 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.)
If the load decreases, such as when travelling on level ground or
travelling downhill, and the travel pressure goes below 190 kg/
cm2 (2702.4 psi) for more than 0.5 sec., the travel motor capacity
will automatically change and will return to Hi or Mi.
10-200 PC400LC-7E0
12
ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR FUNCTION
(IF EQUIPPED)
Function
• This function is available only with the attachment specification.

• The function acts as follows according to the flow command and working mode from the monitor.
1. It throttles the attachment PPC pressure and controls the flow when the pedal is depressed fully.
2. In B mode and the other modes, it switches to attachment single acting B or double acting (other modes).
PC400LC-7E0 10-201
12
SYSTEM COMPONENT PARTS
1. PPC 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 (71.1 ± 14.2 psi)
Resetting (OFF) pressure: 3.0 ± 0.5 kg/cm2 (42.6 ± 7.1 psi)
Function
• The junction block has 6 PPC oil pressure switches.

• This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller.
10-202 PC400LC-7E0
12
2. Oil pressure sensor.
1. Sensor
2. Connector
Function
• The pump pressure sensor is installed to the input circuit of the control
valve.
• It converts the pump discharge pressure into a voltage and transmits it
to the pump controller.
Operation
• The oil pressure is applied to the diaphragm of the oil pressure sensor
from the pressure intake part, the diaphragm is deformed.
• The deformation in the diaphragm causes the resistance of the gauge
to change. This causes a change in the output voltage, which is
transmitted to the amplifier (voltage amplifier).
• The relationship between the pressure applied to sensors P and output
voltage E is shown in the figure below.
• The amplifier magnifies output voltage E and transmits it to the pump
controller.
PC400LC-7E0 10-203
12
PUMP PRESSURE SENSOR (HIGH PRESSURE)
1. Sensor
2. Connector
Operation
The relationship between the pressure applied to sensors P and output

voltage E is shown in the figure below.
10-204 PC400LC-7E0
12
PUMP CONTROLLER
PC400LC-7E0 10-205
12
CN- CN-
CP01 CP02
Pin No. Signal name Input/ Pin No. Signal name Input/
output output
1 NC(*) Input 1 NC(*) output
2 R pump pressure sensor Input 2 Emergency swing parking switch Input
3 NC(*) Input 3 NC(*) Input
4 NC(*) - 4 232C_RXD Input
7 NC(*) Input 7 Machine select 4 (ATT) Input
8 F pump pressure sensor Input 8 Service circuit SOL signal output
10 GND (SIG) - 10 NC(*) Input
11 Knob switch Input 11 NC(*) output
12 NC(*) Input 12 CAN_SH -
13 Bucket digging pressure sensor Input 13 Machine select 5 (ATT) Input
14 NC(*) Input 14 232C_TXD output
16 NC(*) output 16 Travel steering signal Input
17 Key switch (C-terminal) Input 17 Machine select 3 Input
19 Arm digging pressure sensor Input 19 NC(*) output
Input/
21 NC(*) - 21 NC(*)
output
Input/
22 POT-PWR output 22 CANO_L output
23 Key switch (ACC-terminal) Input 23 NC(*) Input/

output
24 NC(*) Input 24 FWE_switch Input
*: Never connect to NC or malfunctions or failures will 25 NC(*) Input
occur.
26 NC(*) Input
27 Machine select 2 Input
28 NC(*) Input
29 NC(*) -
30 NC(*) Input
31 NC(*) -
Input/
32 CANO_H
output
Input/
33 NC(*) output
34 GND (232C GND) -
35 Service pressure switch Input
36 NC(*) Input
37 Machine select 1 Input
38 Swing prorix switch Input
39 NC(*) -
40 NC(*) Input
occur.
10-206 PC400LC-7E0
CN-
CP03
Pin No. Signal name Input/

output
1 VB (Controller PWR) Input
2 VIS (Solenoid PWR) Input
3 SOL_COM (SOL. COM. GND) -
4 Battery relay drive signal output
5 NC(*) output
6 LS-EPC output
7 Travel junction solenoid output
8 NC(*) output
9 (Bucket digging pressure switch) Input
10 Boom rise pressure switch Input
11 VB (Controller PWR) Input
12 VIS (Solenoid PWR) Input
14 KEY_SIG Input
15 NC(*) output
16 PC-EPC output
17 Merge divider solenoid output
18 NC(*) output
19 Bucket dump pressure switch Input
20 Boom down pressure switch Input
21 GND (Controller GND) -
22 NC(*) Input
24 KEY_SIG Input
25 NC(*) output
26 ATT currented output
27 Travel speed solenoid output
28 2-stage relief solenoid output
29 Swing pressure switch Input
30 (Arm digging pressure switch) Input
34 NC(*) -
35 NC(*) output
36 NC(*) output
37 Swing parking brake solenoid output
38 NC(*) output
39 Travel pressure switch Input
40 Arm dump pressure switch Input
*: Never connect to NC or malfunctions or failures will occur.
PC400LC-7E0 10-207
STRUCTURE AND FUNCTION MONITOR SYSTEM
12
MONITOR SYSTEM
• The monitor system notifies the operator of machine status. It monitors the condition of the machine with sensors installed
on various parts of the machine, processes and immediately displays the obtained information on the panel. The informa-
tion that appears on the panel is roughly divided as follows.
A. Alarms that are issued when the machine has troubles.
B. Machine status, including coolant temperature, hydraulic oil temperature and fuel level.
• The machine monitor also has various mode selector switches and functions to operate the machine control system.
10-208 PC400LC-7E0
12
MACHINE MONITOR
Outline
• The machine monitor has the functions to display various items and the functions to select modes and electric parts.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
• The monitor display employs an LCD (Liquid Crystal Display). The switches are flat sheet switches.
PC400LC-7E0 10-209
12
Input and output signals
CN-1 CN-3
Pin No. Signal name Input/ Pin No. Signal name Input/
output output
1 Key ON Input 1 NC (*) Input
2 Key ON Input 2 NC (*) Input
3 Window washer motor output output 3 NC (*) Input
4 Starting signal Input 4 NC (*) Input
5 Limit switch (W) Input 5 NC (*) Input
6 GND - 6 NC (*) Input
7 GND - 7 RS230C CTS Input
8 VB+ Input 8 RS230C RXD Input
Input/
9 Wiper motor (+) output 9 RS230C RXD 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 -
CN-2 14 CAN (SHIELD) Input
Input/
Pin No. Signal name output 15 CAN (+) Input
1 Engine coolant temperature Input 16 CAN (-) Input

2 Fuel level Input occur.
3 Radiator coolant level Input
4 (Hydraulic oil level) Input
5 Air cleaner clogging Input
6 NC (*) Input
7 Engine oil pressure Input
8 Engine oil level Input
9 Network signal Input/

output
Input/
10 Network signal
output
11 Charge amount Input
Hydraulic oil temperature
12 Input
(analog)
13 GND (for analog signal) -
14 Buzzer drive Input
15 Limit switch (window) Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Light switch Input
20 Network GND -
occur.
10-210 PC400LC-7E0
12
MONITOR PORTION
1. Wiper monitor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power maximizing monitor
4. Engine coolant temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Engine oil pressure monitor
6. Engine coolant temperature gauge 16. Charge level monitor
7. Working mode monitor 17. Radiator coolant level monitor
8. Service monitor 18. Engine oil level monitor
9. Travel speed monitor 19. Air cleaner clogging monitor
10. Fuel gauge 20. Maintenance time warning monitor
PC400LC-7E0 10-211
Monitor items and display
Symbol Display item Display method

Swing holding brake
Swing lock switch Swing lock monitor
release switch
OFF OFF OFF
Swing lock ON OFF ON
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power max. switch status Power max. monitor status

Lights up but goes out after approx.
Power max. Being pressed 9 sec. when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic oil See gauge display on the next page
temperature
Fuel level
10-212 PC400LC-7E0
12
Gauge Range Temperature or volume Indicator Buzzer sound

A1 105 Red O
A2 102 Red
A3 100 Green
Engine coolant temperature (°C)
A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
B3 100 Green
Hydraulic oil temperature (°C)
B4 80 Green
B5 40 Green
B6 20 White
C1 467 Green
C2 381 Green
C3 295 Green
Fuel level (L)
C4 147.5 Green
C5 114 Green
C6 80.5 Red
PC400LC-7E0 10-213
12
Checks before starting (all symbols 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 disappear and the following symbols are displayed.
Check before When engine is When engine is

Symbol Display item starting item stopped running
When abnormal,
Engine oil pressure • - lights up and buzzer
sounds
Battery charge • - Lights up when abnormal
Radiator coolant Lights up when When abnormal, lights up and

•
level abnormal buzzer sounds
Lights up when
Engine oil level • -
abnormal
Air cleaner clogging • - Lights up when abnormal
Lights up when there is a warning. Lights up for only 30

Maintenance sec. after key is turned ON, then goes out.
Symbols appear in the order in which they occur from the upper left. When symbols are displayed, if the hydraulic oil
temperature is high or low, only its symbol is displayed.
Condition of hydraulic oil Color of symbol

Low temperature Black on
(Max. B6 or equivalent) white background
Normal (B6 - B2) No display
White on
High temperature (Min. B2) red background
10-214 PC400LC-7E0
12
Display category Symbol Display item Display range Display method
Wiper INT ON OFF Displays set condition
Working mode Displays set mode
Monitor
Travel speed Displays set speed
Auto- ON ⇔ OFF Displays actuation status

deceleration
Service meter Lights up when service

Service meter When service meter is working
indicator meter is working
PC400LC-7E0 10-215
12
SWITCHES
1. Working mode selector switch 6. Window washer switch

2. Selector switch 7. Wiper switch
3. Buzzer cancel switch 8. Maintenance switch
4. Display brightness, contrast adjustment switch 9. Travel speed selector switch
5. Control switch 10. Auto-deceleration switch
10-216 PC400LC-7E0
12
Working mode selector switch
Press one of the P, E, B and L switches to set the desired working mode. It is possible to check which mode is active with the
working mode monitor. The relationship between each working mode and the monitor display is shown in the table below.
Switch that is pressed Display Working mode status after setting
[P] P P mode (default)
[E] E E mode
[L] L L mode
[B] B B mode
Selector switch
This is used when making detailed settings in each working mode. For details, see “Attachment flow control function”.
Buzzer cancel switch
Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer. If a new abnormality is detected, the alarm
buzzer sounds.
Depending on the alarm buzzer type, it does not stop even if you press the buzzer cancel switch.
Maintenance switch
Check the condition of the maintenance items. For details, see “Maintenance function”.
Auto-deceleration switch
The auto-deceleration switch toggles the auto-deceleration function on and off. When the working mode is switched, it is auto-
matically set to ON.
When it is set to ON, the auto-deceleration monitor appears.
Travel speed selector switch
Each time the travel speed selector switch is pressed, the travel speed changes as shown below.
Lo → Mi → Hi → Lo →…..
The travel speed settings can be viewed on the monitor. The relationship between the speed setting and the monitor display is
shown in the table below.
Display Setting
Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Midium speed
Crawler symbol + Hi High speed
Wiper switch
Each time the wiper switch is pressed, the wiper setting changes as shown below.
OFF → INT → ON → OFF →…..
The wiper settings can be viewed on the wiper monitor. The relationship between the wiper setting and the monitor display is
Display Setting Wiper actuation status
None OFF Stowing stopped or now stowing
Wiper symbol + INT INT Intermittent actuation
Wiper symbol + ON ON Continuous actuation
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
This function is used to adjust the brightness and contrast of the display. For details, see each function.
PC400LC-7E0 10-217
Select mode function
1. Setting of oil flow.

• This is used when setting the flow in each working mode.
• It is available when genuine attachment piping is installed and
Attachment installed is selected with the initial value setting
function on the service menu.
• It is possible to check on the working mode monitor if this
function can be used.
Working mode Monitor display

P mode [P] + crusher symbol
E mode [E] + crusher symbol
B mode [B] + flow symbol
Method of use
★ Carry out the setting on the normal screen P mode, E mode.
A. Press select switch (1).
B. When the screen changed as below, select “01” by operating

switch (2), and press input confirmation switch (3).
C. 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
10-218 PC400LC-7E0
12
D. After completing the level selection, press input confirmation switch (3). The selection flow level is confirmed and
the screen moves to the normal screen. When input confirmation switch (3) is pressed, the attachment flow is
updated. The relationship between the flow level and the flow is shown in the table below.
Flow level Flow (L/min) Remarks

8 550 Default
7 476
6 401
5 327
4 253
3 179
2 104
1 30
★ Flow level is not changed until the input confirmation switch is pressed. It is, therefore, possible not to change
the flow level by pressing return switch (4) to return to the normal screen.
B mode
E. Press select switch (1).
F. When the screen changed as below, select “01” by operation

switch (2), and press input confirmation switch (3).
G. Select one of the three flow levels by moving the cursor with
operation switch (2) or entering the relevant number (01, 02 or
03) with the 10-key pad.
• The relationship between the flow level and the flow is
No. Flow (L/min) Remarks

01 230 Default
02 190
03 150
PC400LC-7E0 10-219
12
H. Pressing input confirmation switch (3) after selecting the flow
level finalizes the selection.
★ Flow level is not finalized until the input confirmation switch
is pressed. Returning to the normal screen by pressing return
switch (4) will leave the flow level setting unchanged.
I. After the flow level is confirmed, the screen changes to the screen
shown in the diagram below. With this screen, it is possible to
make fine adjustment to the flow.

right

left
J. Pressing input confirmation switch (3) after selecting the flow level finalizes the selection.
• The relationship between flow level and the flow is shown in the table below.
Flow level When flow is 100 L/ min. When flowis 140 L/ min. When flow is 180 L/ min. Remarks
7 200 280 360
6 180 260 340
5 160 240 320
4 140 220 300 Default
3 120 200 280
2 100 180 260
1 80 160 240
★ Flow level is not finalized until input confirmation switch (3) is pressed. Returning to the normal screen by press-
ing return switch (4) will leave the flow level setting unchanged.
K. Check the set value with the working mode monitor. The relationship between the display level and the set value is
Display level Set value (L/min.)

8 220 or 360
7 200 or 340
6 180 or 320
5 160 or 300
4 140 or 280
3 120 or 260
2 100 or 240
1 80
10-220 PC400LC-7E0
12
2. Adjusting E mode setting value
User can change a setting value on the E mode to adjust engine power
and enhance fuel mileage on the E mode.
A. Press select switch (1).
B. The screen shown below is displayed.

Operate operation switch (2) to select “02” and then press input
confirmation switch (3).
C. The setting value adjusting screen shown below is displayed.

Operate operation switch (2) to select the setting value.
Relationship between fuel mileage and work rate for each of the
setting values is as follows.
E0: Initial Setting Value
(highest priority is placed on work rate.)
E1: Economy Adjusting 1
(Priority is placed on work rate.)
(Priority is placed on fuel mileage.)
(highest priority is placed on fuel mileage.)
★ As the item goes lower, the fuel mileage is improved while, on the other hand, the work rate is decreased.
PC400LC-7E0 10-221
D. Press input confirmation switch (3) to confirm the setting value.
E. Press return switch (4) to return to the main screen.
10-222 PC400LC-7E0
12
MAINTENANCE FUNCTION
• This function alerts the operator when routine maintenance
(replacement, inspection or filling for the 11 maintenance items) is
due.
• When maintenance switch (1) is pressed, any maintenance item that is
due is displayed yellow or red for 30 seconds.
• The table below shows the maintenance items and replacement
intervals. The time remaining to maintenance is reduced as the
machine is operated.
No. Item Replacement interval

(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
41 Fuel prefilter 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
*: If equipped (To be determined)
• 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 back- There is one or more items with less than 30 hours remaining
ground) time for maintenance
Warning display (white symbol displayed on red background) There is one or more items with less than 0 hours remaining time
for maintenance
1. Method of checking maintenance items.

★ Carry out the setting on the normal screen.
A. Press maintenance switch (1) and switch to the maintenance list

display screen. The maintenance items are displayed as symbols
on the screen.
B. Select one of the maintenance items by moving the cursor with

control switch (2) or entering the relevant number (01 to 10) with
the 10-key pad.
★ If the remaining time is less than 30 hours, the item is dis-
played in yellow, and if it is less than 0 hours, it is displayed
in red.
PC400LC-7E0 10-223
12
2. Maintenance operation.
A. After completing the selection, press input confirmation switch

(3). The screen will change to the maintenance reset screen.
B. The maintenance reset screen shows the time remaining before

maintenance is due. To reset the remaining time, press input
confirmation switch (3). When input confirmation switch (3) is
pressed, the screen changes to the check screen. To return to the
maintenance list screen, press return switch (4).
C. The check screen shows the symbol for the selected maintenance
item and the set time in large letters.
D. To reset the remaining time, press input confirmation switch (3).

The remaining time is reset and the screen returns to the
maintenance list display screen. To return to the maintenance list
screen without resetting the remaining time, press return switch
(4).
E. On the maintenance list display screen, the background color of

the symbol for the item where the maintenance item was reset is
the same as the background of the screen.
10-224 PC400LC-7E0
12
Brightness, contrast adjustment function
This function is used to adjust the brightness and contrast of the display.
★ Carry out the setting on the normal screen.
1. Adjustment method.
A. Press display brightness/contrast adjustment switch (1) and

switch to the adjustment screen.
★ Relationship between menu symbol and content.
No. Symbol Content

00 Return mark Return
01 Contrast
02 Brightness
B. Press operation switch (2), or use the 10-key pad to input the
number (01 – 02) to select either contrast or brightness.
C. After completing the selection, press input confirmation switch

(3) to return to the adjustment screen. Pressing return switch (4)
without pressing input confirmation switch (3) or entering 00 with
the 10-key pad and then pressing input confirmation switch (3)
causes the screen to return to the normal screen.
D. Press operation switch (2) and adjust the brightness or contrast as

desired.

right

left
PC400LC-7E0 10-225
12
Service meter check function
• With the starting switch in the OFF position, pressing return switch (1)
while holding down operation switch (2) of the monitor for 3 to 5
seconds displays the service meter.
• When the 2 switches are released, the display goes out.
Display LCD check function
• On the normal screen, if monitor return switch (1) and working mode
switch “P” (2) are kept pressed at the same time, the whole screen will
become white. If any part of the display is black, the LCD is broken.
User code display function
• If there is any problem in operating the machine, the user code is

displayed on the monitor to advise the operator of the steps to take.
This code appears on the normal screen.
• On the normal screen, the user code is displayed on the portion for the
hydraulic oil temperature gauge in the center of the screen.
10-226 PC400LC-7E0
12
• If there are more than one user codes, they are displayed in turn every
2 seconds.
• While the user code is being displayed, if the input confirmation

switch is pressed, the service code and failure code can be displayed.
Both service code and failure code identify the cause of problem
corresponding to the displayed user code.
• If there are more than one service or failure codes, they are displayed
in turn every 2 seconds.
• Any service codes/failure codes that are not related to the displayed
user code is displayed with this function.
PC400LC-7E0 10-227
• If the telephone number has been set using the service menu, the
screen shows the service code/failure code as well as telephone
symbol and telephone number. For details of inputting the telephone
number, see “Special functions of monitor panel” in the “Testing and
adjusting” section.
10-228 PC400LC-7E0
12
SENSOR
• The signals from the sensors are input to the monitor panel directly.
• Either side of a sensor of contact type is always connected to the chassis ground.
Sensor name Type of sensor When normal When abnormal

Hydraulic oil level Contact ON (Closed) OFF (Open)
Hydraulic oil temperature Resistance - -
Coolant temperature Resistance - -
Fuel level Resistance - -
Air cleaner clogging Contact OFF (Closed) ON (Open)
HYDRAULIC OIL LEVEL SENSOR
1. Connector 3. Float
2. Bracket 4. Switch
HYDRAULIC OIL TEMPERATURE SENSOR

COOLANT TEMPERATURE SENSOR
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
PC400LC-7E0 10-229
12
FUEL LEVEL SENSOR
1. Float 3. Cover
2. Connector 4. Variable resistor
AIR CLEANER CLOGGING SENSOR
10-230 PC400LC-7E0
12
MEMORANDUM
PC400LC-7E0 10-231
12
KOMTRAX TERMINAL SYSTEM
• The KOMTRAX terminal system transmits various kinds of machine information wirelesses. Persons to operate the
KOMTRAX can refer to the information at office to provide various kinds of services for customers.
• Information transmittable from the KOMTRAX terminal system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
10-232 PC400LC-7E0
12
KOMTRAX TERMINAL
1. DRC connector connection (40 poles) • The KOMTRAX terminal obtains various kinds of machine information from
2. (Do not connect any cable) the network signals and input signals in the machine and transmits them via the
wireless communication antenna. It contains a CPU (Central Processing Unit)
3. GPS antenna connection and has wireless communication function and GPS function.
4. Film antenna connection • This terminal has an LED lamp unit and a 7-segment display lamp unit used for
inspection and troubleshooting. Input and output signals
PC400LC-7E0 10-233
12
Input and output signals
DRC connector DRC connector

Pin No. Signal name Input/output Pin No. Signal name Input/output
1 - - 26 - -
C-terminal input (Hi
2 - - 27 Input
side)
3 - - 28 R-terminal input Input
4 - - 29 - -
5 - - 30 - -
6 CAN shield GND - 31 - -
7 CAN signal (L) Input/output 32 - -
8 CAN signal (H) Input/output 33 - -
9 S-NET shield GND - 34 - -
10 S-NET signal Input/output 35 - -
11 - - 36 ACC input (analog) Input
12 - - 37 Power GND -
13 - - 38 Power GND -
14 - - 39 Regular power Input
15 - - 40 Regular power Input
*1: Never connect to NC or malfunctions or failures will
16 - - occur.
17 - -
18 - -
19 - -
20 Relay output output
21 Input for check Input
22 Input for check Input
23 - -
24 - -
25 - -
*1: Never connect to NC or malfunctions or failures will
occur.
10-234 PC400LC-7E0
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

ENGINE RELATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
CHASSIS RELATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
TROUBLESHOOTING
TROUBLESHOOTING GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND
FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED . . . . . . . . . . . . . . . . . . . 20-301
E-MODE = TROUBLESHOOTING ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
H-MODE = TROUBLESHOOTING HYDRAULIC, MECHANICAL SYSTEM . . . . . . . . . . . . . . . . . . . 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-7E0 20-1 1
TESTING AND ADJUSTING STANDARD VALUE TABLES
12
STANDARD VALUE TABLES
ENGINE RELATED
Applicable model PC400LC-7E0

Engine SAA6D125E-5
Permissible
Item Measurement conditions Unit Standard value value
High idle rpm 1,900 ± 50 1,900 ± 50
Engine speed Low idle rpm 1,000 ± 25 1,000 ± 25
Rated speed rpm 1,900 1,900
kPa Min. 133
Intake air pressure At rated output 107 {800}
{mmHg} {Min. 1,000}
Exhaust gas temperature All speed range (intake air temp: 20°C) °C Max. 700 700
%
At sudden acceleration (Low → High) {Bosch index} Max. 25 {Max. 2.5} -
Exhaust gas color At rated output Bosch index Max. 1.5 -
At high idle Bosch index Max. 1.0 -
Normal Intake valve mm 0.33 -

Valve clearance temperature Exhaust valve mm 0.71 -
Engine oil temperature: 40 - 60°C MPa
Compression pressure Min. 2.9 {Min. 30} 2.0 {200}
Engine speed: 200 - 250 rpm {kg/cm2}
At rated output kPa Min. 0.98 {Min.
Blow-by pressure 1.96 {200}
Engine coolant temperature: Min. 70°C {mmH2O} 100}
At rated output
Engine oil SAE0W30E0S, MPa 0.29 - 0.69 0.18 {1.8}
temperature: SAE5W40E0S, {kg/cm2} {3.0 - 7.0}
Min. 80°C SAE10W30DH,
Oil pressure
At low idle SAE15W40DH,
Engine oil SAE30DH MPa Min. 0.05
engine oil 0.03 {0.3}
temperature: {kg/cm2} {Min. 0.5}
Min. 80°C
Oil temperature All speed range (inside oil pan) °C 90 - 110 120
Fan belt, alternator belt Deflection when pressed with finger mm 13 - 16 13 - 16
tension force of approximately 98 N {10 kg}
20-2 1 PC400LC-7E0
TESTING AND ADJUSTING
12
CHASSIS RELATED
Standard Permissible
Cat. Item Measurement condition Unit
value value
• Engine coolant temperature:
Within operation range
• Hydraulic oil temperature: Within
2 pumps at relief 1,930 ± 100 1,930 ± 100
operation range
• Engine at high idling
• Arm in relief condition
• Engine coolant temperature:
Engine speed
Within operation range

rpm
At 2-pump relief + one touch power up operation range 1,830 ± 100 1,830 ± 100
• Arm relief + One-touch power
max. switch in ON condition
• Auto-deceleration switch in ON
Speed when auto-deceleration is
condition 1,300 ± 100 1,300 ± 100
operated
• All control levers in NEUTRAL
condition
Boom control valve
Spool stroke
Arm control valve

mm 9.5 ± 0.5 9.5 ± 0.5
Bucket control valve
(in) (0.4± 0.02) (0.4± 0.02)
Swing control valve
Travel control valve
85 ± 10 85 ± 10
Boom control lever
(3.3 ± 0.4) (3.3 ± 0.4)
85 ± 10 85 ± 10
Arm control lever
(3.3 ± 0.4) (3.3 ± 0.4)
Travel of control
• Engine stopped 85 ± 10 85 ± 10
Bucket control lever • At center of control lever grip (3.3 ± 0.4) (3.3 ± 0.4)
levers
mm
• Max. reading up to stroke end
(in) 85 ± 10 85 ± 10
Swing control lever (excepting lever play in
(3.3 ± 0.4) (3.3 ± 0.4)
NEUTRAL position)
115 ± 12 115 ± 12
Travel control lever
(5 ± 0.5) (5 ± 0.5)
Max. 10 Max. 15
Play of control lever
(Max. 0.4) (Max. 1.0)
15.7 ± 4.9 Max. 24.5
Boom control lever
(56 ± 18) (Max. 88)
15.7 ± 4.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within (56 ± 18) (Max. 88)
of control levers
Operating force
operation range 12.7 ± 2.9 Max. 21.6

Bucket control lever
• Engine at high idling (46 ± 10) (Max. 78)
N (ozf)
• At center of control lever grip 12.7 ± 2.9 Max. 21.6
Swing control lever
• At tip in case of pedal (46 ± 10) (Max. 78)
• Max. reading up to stroke end 24.5 ± 5.9 Max. 39.2
Lever
(88 ± 21) (Max. 141)
Travel control lever
74.5 ± 18.6 Max. 107.6
Pedal
(268 ± 68) (Max. 387)
PC400LC-7E0 20-3 1
12

Permissible
Cat. Item Measurement condition Unit Standard value
value
• Hydraulic oil temperature: Within operation range
42 ± 10 42 ± 10
Unload pressure • Working mode: P mode
(609 ± 145) (609 ± 145)
• Hydraulic pump output pressure with all control
levers in NEUTRAL position
355+15
-10 340 - 375
RAISE
(380+15 ) (365 - 400)
-10
LOWER - At
185 ± 10 170 - 200
Boom low-pressure
(2631 ± 142) (2416 - 2843)
• Hydraulic oil temperature: setting
Within operation range LOWER - At
320 ± 15 300 - 340
• Engine at high idling high-pressure
(4548 ± 213) (4235 - 4836)
• Working mode: P mode setting
• Hydraulic pump output pressure 355+15
-10
with all measurement circuits 340 -375
relieved [380+15
-10
] [365 - 400]
Arm & Bucket
Hydraulic pressure
• Values inside parenthesis: (5049+213 (4836 - 5333

Hydraulic oil pressure with -142
[5192 - 5689])
one-touch power max. switch in kg/cm2 [5404+213
-142
])
ON mode (reference only) (psi) 315+15
-25 285 - 335
Swing
(4480+213
-355
) (4053 - 4764)
380+30
-10 365 - 415
Travel +42)
(5404-142 (5192 - 5902)

Control circuit • Engine running at high idling 33 ± 2 29 - 35
source pressure • Self-reducing pressure valve output pressure with all (469 ± 28) (413 - 497)
control levers in NEUTRAL position
• Hydraulic oil temperature: Within When all control
operation range levers in 42 ± 10 40 ± 10
• Engine at high idling NEUTRAL (597 ± 142) (568 ± 142)
LS differential
• Working mode: P mode position
pressure • Traveling speed: Hi When traveling
• Hydraulic oil pump pressure - LS at half stroke 27 ± 1 27 ± 1
pressure (384 ± 14) (384 ± 14)
(without load)
• Hydraulic oil temperature: Within operation range 30+5.5 30+5.5
PPC valve output -1.5 -1.5
pressure (427+78 (427+78
• Control lever at full stroke -21 ) -21 )
Swing
Swing brake angle deg. Max. 120 Max. 150

• Engine running at high idling
• Working mode: P mode
• Swing circle misalignment amount when stopping
after one turn
20-4 2 PC400LC-7E0
12
Permissible
value
90° 3.7 ± 0.4 Max. 4.6
Time taken to start • Hydraulic oil temperature: Within sec.

swing operation range
• Working mode: P mode 180° 5.4 ± 0.5 Max. 6.4
• Time required for passing points
90 and 180 degrees from starting
point
Time taken to swing sec. 33.0 ± 3.3 Max. 38

Swing

• Time required for 5 more turns after making initial
one turn
Hydraulic drift of mm 0 0
swing • Hydraulic oil temperature: Within operation range (in) (0) (0)
• 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
Leakage from swing • Engine running at high idling L/m Max. 5.5 Max. 11
motor • Swing lock switch: ON (gpm) (Max. 1.5) (Max. 3.0)
• Leakage amount for one minute during swing relief
PC400LC-7E0 20-5 1
12
Permissible
value
Lo 67.3 ± 13.5 45.0 - 84.5
Travel speed
(idle travel) • Hydraulic oil temperature: Within Mi 48.1 ± 7.2 34.0 - 58.0
operation range
• Time required for track shoes to
make 5 turns after making one Hi 36.7 ± 3.6 32.0 - 44.0
initial idle turn
sec.
Lo 24.0 ± 4.8 18.9 - 31.0
Travel speed
(actual speed) • Hydraulic oil temperature: Within Mi 17.1 ± 2.6 14.4 - 21.0
operation range
Travel
• Working mode: P mode Hi

• Flat ground
• Time required for traveling 20 m 13.1 ± 1.3 11.7 - 15.1
after 10 m trial run

• Travel speed: Lo mm Max. 200 Max. 300
Travel deviation
• Solid and flat ground (in) (Max. 8.0) (Max. 12.0)
• Swerving amount while traveling 20 m (X) after
initial 10 m trial run
20-6 1 PC400LC-7E0
12
value value
mm 0 0
Hydraulic drift of travel
• Hydraulic oil temperature: Within (in) (0) (0)
operation range
Travel
• Engine stopped
• Parking machine on slope of 12
degrees with sprocket facing up the
slope
• Sliding distance for 5 minutes
operation range
• Engine at high idling L/m Max. 20 Max. 40
Leakage of travel motor
• Traveling with sprocket locked (gpm) (Max.5.3) (Max. 11)
• Oil leakage amount for one minute
with traveling in relief condition
Whole work equipment (tooth tip Max. 600 Max. 900
fall amount) (Max. 24) (Max. 35)
Boom cylinder (cylinder retraction Max. 25 Max. 38
amount) (Max. 1.0) (Max. 1.5)
Hydraulic drift of work equipment
Arm cylinder (cylinder extension Max. 85 Max. 128

amount) (Max. 3.3) (Max. 5.0)
Work equipment

operation range
mm
• Flat and level ground
(in)
• Work equipment in measurement
posture as illustrated above
Bucket cylinder (cylinder retraction • Bucket load: 3,060 kg (6,746 lb) Max. 30 Max. 45
amount) • Engine stopped (Max. 1.2) (Max. 2.0)
• Work equipment control lever in
NEUTRAL position
• Fall amount for 15 minutes as
measured every 5 minutes starting
immediately after initial setting
PC400LC-7E0 20-7 1
12
Permissible
value
RAISE
4.0 ± 0.4 Max. 4.8
Boom
• Hydraulic oil temperature: Within operation
range
LOWER
• Working mode: P mode 2.9 ± 0.3 Max. 3.4
• Time required from raise stroke end till bucket
touches ground
IN
4.3 ± 0.4 Max. 5.0
Work equipment speed
Arm
sec.
range
OUT
• Engine running at high idling 3.6 ± 0.4 Max. 4.3
Work equipment
• Time required from dumping stroke end to

digging stroke end
CURL
3.6 ± 0.4 Max. 4.3
Bucket
range
DUMP
• Engine running at high idling 2.9 ± 0.3 Max. 3.5

• Time required from dumping stroke end to
digging stroke end
Time lag
Boom sec. Max. 3.0 Max. 3.6

• Engine running at low idling
• Time required from raise stroke end till bucket
touches ground and pushes up machine front
20-8 1 PC400LC-7E0
12
Permissible
value
Arm Max. 3.0 Max. 3.6

• Time required from dumping stroke end till bucket
stops momentarily after control lever is tilted to
Time lag
digging and starts to move again

sec.
Work equipment
Bucket Max. 3.0 Max. 5.0

• Time required from dumping stroke end till bucket
stops momentarily after control lever is tilted to
digging and starts to move again
Internal leakage
• Hydraulic oil temperature: Within operation range 4.5 (0.3) 20 (1.2)

Cylinders
• Engine running at high idling cc/mm
Center swivel • Leakage amount for one minute with cylinder or (c/in)
10 (1.0) 50 (3.1)
joint travel to be measured in relief condition
❥ Hydraulic oil temperature: Within operation range

❥ Engine at high idling
Performance in compound operation
❥ Working mode: P mode

❥ Traveling speed: Lo
❥ Flat and level ground
Swerving amount in ❥ Swerving amount (X) when traveling 20 m after
simultaneous initial trial run of 10 m mm Max. 400 Max. 440
operation of work (in) (Max. 16) (Max. 17)
equipment and travel
hydraulic pump
Performance of
Hydraulic pump
See next page L/min. See next page
delivery
PC400LC-7E0 20-9 1
12
value value
Performance of hydraulic pump
❥ Pump speed: At 1,950 rpm, PC current 280 mA

Test pump Discharge pressure
Standard value for Judgement standard lower
discharge of other pump Average pressure
Check point discharge amount Q limit Q
pressure kg/cm2 (psi) kg/cm2 (psi)
2
L/min.(gal/min.) L/min.(gal/min.)
kg/cm (psi)
As desired P1 P2 P1 + P2- See graph See graph

-------------------
2
★ 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.
20-10 1 PC400LC-7E0
12
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
BLEEDING AIR FROM FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
HANDLING FUEL SYSTEM PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
RELEASING RESIDUAL FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
TESTING OF FUEL CIRCUIT FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR . 20-106
ADJUSTING ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
HANDLING CONTROLLER VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
INTAKE AIR PRESSURE (BOOST PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
NO-INJECTION CRANKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
REDUCED CYLINDER MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
TESTING AND ADJUSTING ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
FAN BELT AND ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
SWING CIRCLE BEARING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
TRACK SHOE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
CONTROL CIRCUIT - BASIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
PUMP PC CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118
PUMP LS CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
SOLENOID VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-127
PPC VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-132
SWING PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-132
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-133
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-135
MEASURING OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-136
BLEEDING AIR FROM VARIOUS PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-139
DIODE TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-142
MONITOR PANEL - SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-143
OPERATOR’S MENU (OUTLINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-145
FAILURE CODES TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
SERVICE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-154
LIST OF MONITORING ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-157
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171
PROCEDURE FOR TURNING ON KOMTRAX TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-172
PC400LC-7E0 20-101 1
TESTING AND ADJUSTING TABLE OF CONTENTS
ELECTRICAL EQUIPMENT SYSTEM - PREPARATION WORK FOR TROUBLESHOOTING . . . . . . . . 20-178
PM CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180
20-102 1 PC400LC-7E0
TESTING AND ADJUSTING SERVICE TOOLS
12
SERVICE TOOLS
Sym
Testing and adjusting item Part No. Part name Q'ty Remarks
-bol
Measuring intake air pressure 799-201-2202 Boost gauge kit 1 -101 - 200 kPa {-760 - 1,500 mmHg}
A
(boost pressure) 799-401-2220 Hose 1
Measuring exhaust temperature B 799-101-1502 Digital thermometer 1 -99.9 - 1,299°C
1 799-201-9000 Handy smoke check- Degree of contamination 0 - 70% (with

1
Measuring exhaust gas er the standard color)
C
color (Degree of contamination x 1/10
2 Commercially Smoke meter 1 approximately = Bosch index)
available
Commercially Filler gauge
Adjusting valve clearance D 1 (Intake: 35 mm, Exhaust: 57 mm)
available
1 795-502-1590 Compression gauge 1 0 - 6.9 MPa {0 - 70 kg/cm2}
Measuring compression pres- E 795-471-1420 Adapter 1
sure 2 For 125E-5 engine
6217-71-6112 Gasket 1
Measuring blow-by pressure F 799-201-1504 Blow-by checker 1
Pressure gauge: 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
Measuring engine oil pressure G 790-261-1204 Digital hydraulic
tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}

Pressure gauge: 2.5, 5.9, 39.2, 58.8
MPa {25, 60, 400, 600 kg/cm2}
1
790-261-1204 Digital hydraulic
tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Measuring fuel pressure H
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Adapter 1 8 x 1.25 mm → R1/8
3
07005-00812 O-ring 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Joint inside diameter: 10 mm
3 Commercially Hose 1 φ5 mm x 2 - 3 m
available
Measuring fuel return rate and J 4 Commercially Hose 1 φ15 mm x 2 - 3 m
leakage available
5 Commercially Measuring cylinder 1

available
6 Commercially Stopwatch 1
available
Measuring swing circle bearing Commercially Dial gauge
K 1 With magnet
clearance available
PC400LC-7E0 20-103 1
TESTING AND ADJUSTING SERVICE TOOLS
12
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
1 * Common with G1
Measuring and adjusting oil pressure 790-261-1204 Digital hydraulic tester 1
in work equipment, swing, and travel L
circuits 799-101-5220 Nipple 2
2 Size: 10 x 1.25 mm
07002-11023 O-ring 2
1 * Common with G1
Measuring and adjusting control cir- 790-261-1204 Digital hydraulic tester 1
M
cuit 799-101-5220 Nipple 2
2 * Common with K2
07002-11023 O-ring 2
1 * Common with G1
Measuring and adjusting oil pressure 790-261-1204 Digital hydraulic tester 1
N
in pump PC control circuit 799-101-5220 Nipple 4
2
07002-11023 O-ring 4
1 * Common with G1
790-261-1204 Digital hydraulic tester 1
Measuring and adjusting oil pressure O 799-101-5220 Nipple 4
in pump LS control circuit 2 * Common with M2
07002-11023 O-ring 4
3 799-401-2701 Differential pressure gauge 1
1 * Common with G1
Measuring solenoid valve output 790-261-1204 Digital hydraulic tester 1
P
pressure 799-401-3100 Adapter 1 Size: 02
2
799-401-3200 Adapter 1 Size: 03
Measuring PPC valve output pres- 1 * Common with G1
Q 790-261-1204 Digital hydraulic tester 1
sure
2 799-301-1740 Joint 1 Size: PF1/4 + PT1/4
Commercially Measuring cylinder
Measuring oil leakage R 1
available
Measuring wear on sprocket - 796-627-1120 Wear gauge 1
Measuring coolant temperature and - 799-101-1502 Digital thermometer 1 * Common with B
oil temperature
Measuring operating effort and de- 79A-264-0021 Push-pull scale 1 0 - 294 N {0 - 30 kg}
-
pressing force 79A-264-0091 Push-pull scale 1 0 - 490 N {0 - 50 kg}
Commercially Ruler
Measuring stroke and hydraulic drift - 1
available
Commercially Stopwatch
Measuring work equipment speed - 1
available
Commercially Circuit tester
Measuring voltage and resistance - 1
available
★ 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.
20-104 1 PC400LC-7E0
TESTING AND ADJUSTING ENGINE SPEED
12
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 P-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:
iii. Relieve the arm circuit by moving the arm in.
D. Measuring 2-pump relief + one-touch power maximizing speed (near rated speed):
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
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.
PC400LC-7E0 20-105 1
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-5 series engine, Section 30 (Testing and Adjusting), for the tool requirements and proper procedures.
FUEL
BLEEDING AIR FROM FUEL CIRCUIT
FUEL PRESSURE
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL FUEL SYSTEM PRESSURE
TESTING OF FUEL CIRCUIT FOR LEAKAGE
TESTING LEAKAGE FROM PRESSURE LIMITER AND RETURN RATE FROM INJECTOR
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING VALVE CLEARANCE
BLOW-BY PRESSURE
COMPRESSION PRESSURE
ENGINE OIL PRESSURE
ENGINE SPEED SENSOR
EXHAUST TEMPERATURE
HANDLING CONTROLLER VOLTAGE CIRCUIT
INTAKE AIR PRESSURE (BOOST PRESSURE)
NO-INJECTION CRANKING
REDUCED CYLINDER MODE OPERATION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
20-106 1 PC400LC-7E0
TESTING AND ADJUSTING EXHAUST GAS COLOR
12
EXHAUST GAS COLOR
WARNING! Be careful not to touch the highly heated parts, while removing and installing a
measurement tool.
★ If no compressed air or power is not available in the field, use Handy Smoke Checker C1. For recording official data, use
Smoke Meter C2.
1. Measurement with Handy Smoke Checker C1.
A. Fit a filtering paper to Handy Smoke Checker C1.
B. Insert the exhaust gas intake port to exhaust pipe (1).
C. Start the engine and keep it running until the engine coolant
temperature rises to the operating range.
D. Accelerate it suddenly or run it at high idle and then operate the

lever of smoke checker C1 in order to suction exhaust gas to the
filter paper.
E. Take out the filtering paper and compare it with the attached scale
for judgement.
F. Remove the measurement tool after the measurement, and make

sure that the machine is back to normal condition.
2. Measurement with Smoke Meter C2.
A. Insert probe [1] of smoke meter C2 to the outlet of exhaust pipe

(1) and fix it to the exhaust pipe with a clip.
B. Connect the probe hose, accelerator switch outlet and air hose to
the smoke meter C2.
★ Keep the pressure of the supplied compressed air at 1.5 MPa
{15 kg/cm2} or below.
C. Connect the power cable to an AC receptacle.

★ Confirm that the smoke meter power switch is in the OFF
position, before connecting the power cable to an outlet.
D. Loosen the cap nut of the suction pump and fit in the filter paper.
★ Fit the filtering paper securely so that air may not leak.
E. Move the Smoke Meter C2 power switch to the ON position.
F. Start the engine and keep it running until the engine coolant
temperature rises to the operating range.
G. Let the exhaust gas stay on the filtering paper by depressing the
accelerator pedal of Smoke Meter C2, when the engine speed is
suddenly accelerated or kept at high idle.
H. Put the polluted filtering paper on non-polluted filtering paper

(more than 10 sheets) in the filtering paper holder, and read the
indicated value.
I. Remove the measurement tool after the measurement, and make

sure that the machine is back to normal condition.
PC400LC-7E0 20-107 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. Open the inspection cover of the engine hood and remove the bracket
(1) and cover (2).
2. Loosen mounting bolt (3) and fixing bolt (4).
3. Loosen locknut (5).
4. Slide alternator (7) by rotating adjusting nut (6), adjust V belt (8)
tension and tighten locknut (5).
★ Nut (6):
● Tightening the locknut clockwise moves it to the
belt-loosening side.
● Tightening the locknut counterclockwise moves it to the
belt-tightening side.
★ Check the pulleys for breakage, V-groove for wear, V-belt for
wear and contact of the V-belt and V-groove for any trouble.
★ A belt must be replaced with a new one when it is elongated so as
to eliminate the adjustment allowance, or when cuts or cracks are
visible on it.
5. Tighten mounting bolt (3) and fixing bolt (4).
★ When a V-belt is replaced, adjust the tension again after operating

the machine for an hour.
20-108 1 PC400LC-7E0
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 - 16 mm
Adjusting
★ If the deflection is abnormal, adjust it according to the following

procedure.
1. Open the inspection cover of the engine hood and remove cover (1).
2. Loosen mounting bolt (2) and fixing bolt (3).
3. Slide compressor (6) by loosening locknut (4) and rotating adjusting

nut, adjust V-belt (7) tension and tighten locknut (5).
★ Check the pulleys for breakage, V-groove for wear, V-belt for
wear and contact of the V-belt and V-groove for any trouble.
★ A belt must be replaced with a new one when it is elongated so as
to eliminate the adjustment allowance, or when cuts or cracks are
visible on it.
4. Tighten mounting bolt (2) and fixing bolt (3).

★ When a V-belt is replaced, adjust the tension again after operating
the machine for an hour.
PC400LC-7E0 20-109 1
TESTING AND ADJUSTING SWING CIRCLE BEARING CLEARANCE
12
SWING CIRCLE BEARING CLEARANCE
Measuring swing circle bearing clearance.
WARNING! Be careful not to put a hand or foot under

the undercarriage, while taking
measurement.
1. Fix dial gauge K to outer lace (1) or inner lace (2) of the swing circle
and contact the probe against the end face of inner lace (2) or outer
lace (1) on the opposite side.
★ Set dial gauge K in the front side or rear side of the machine.
2. Keep the work equipment in the max. reach posture and keep the
height of the bucket teeth tip level with the lower height of the
revolving frame.
★ The upper structure is lowered at the front and raised at the rear at
that time.
3. Set dial gauge to the zero point.
4. Hold the arm nearly perpendicular to the ground, and lower the boom
until the track shoes will be lifted at the machine front.
★ The upper structure is raised at the front and lowered at the rear at
that time.
5. From this state, read the dial gauge K value.

★ The value indicated by dial gauge K is the clearance of the
bearing.
6. Return the machine to the condition of step 2 and check that dial gauge
K indicates zero point.
★ If zero value is not indicated, repeat the steps in Items 3 through
5.
20-110 1 PC400LC-7E0
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-7E0 20-111 1
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
12
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
★ 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 (14 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 L2 and connect it to oil pressure gauge [1] of

hydraulic tester L1.
★ 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.
20-112 1 PC400LC-7E0
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
attachment is installed to the service valve). Pump Actuator Valve relieved
(F unload valve) (F main relief valve)
3. Measuring unload pressure Service Safety valve for service
Boom Hi F main relief valve
A. Start the engine. Arm Hi
Front Bucket F main relief valve
B. Run the engine at high idling and set all the control levers in Left travel F main relief valve
neutral and measure the oil pressure.
RAISE: F main relief
★ The pressure measured when the unload valve is unloaded is valve
indicated. Boom LOWER: Safety-suction
valve
4. Measuring work equipment circuit relief pressure (Pump merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
A. Start the engine and move the cylinder to be measured to the Swing Swing motor safety valve
stroke end.
Rear Right travel R main relief valve
B. Run the engine at high idling and relieve the cylinder and measure Arm Lo R main relief valve
the oil pressure. (R unload valve) (R main relief valve)
★ The pressure measured when the main relief valve is relieved (Centralized safety valve) (Back pressure valve)
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-7E0 20-113 1
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. After finishing adjustment, check again that the pressure is normal according to the procedure for measurement
described above.
2. 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 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.
20-114 1 PC400LC-7E0

★ If the holder is
★ Quantity of adjustment per turn of holder: Approximately

258 kg/cm2 (3669 psi).

Locknut: 93 - 123 Nm (68.59 - 90.72 lbf ft)
E. Connect pilot hose.
described above.
★ If the high pressure setting side is adjusted, the low pressure setting side changes. Accordingly, adjust the low
pressure setting side.
3. 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.

★ If the holder is:
★ Quantity of adjustment per turn of holder: Approximately

258 kg/cm2 (3669 psi)

Locknut: 78 - 93 Nm (57.5 - 68.5 lbf ft)
E. Connect pilot hose.
described above.
PC400LC-7E0 20-115 1
12
4. 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:
★ Quantity of adjustment per turn of adjustment screw:

47.9 kg/cm2 (681 psi).
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.
20-116 1 PC400LC-7E0
TESTING AND ADJUSTING CONTROL CIRCUIT - BASIC PRESSURE
12
CONTROL CIRCUIT - BASIC PRESSURE
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 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)
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-7E0 20-117 1
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT
12
PUMP PC CONTROL CIRCUIT
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.
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).
● (3): Front PC valve output pressure pickup plug.
● (4): Rear PC 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.
● The figure shows the PC valve output pressure side.
20-118 1 PC400LC-7E0
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: P
● 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 Pressure ratio
Pump discharge pressure 1
PC valve output pressure 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-7E0 20-119 1
12
2. Measuring PC-EPC valve output pressure
A. Open the pump room cover and remove PC-EPC valve output
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 (853.4 psi).
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 Oil pressure
Low idling 30 kg/cm2
(426.7 psi)
Neutral
High idling 0 kg/cm2
(0 psi)
20-120 1 PC400LC-7E0
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-7E0 20-121 1
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT
12
PUMP LS CONTROL CIRCUIT
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.
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.
(1), (2), (3), and (4).
● (3): Front LS valve output pressure pickup plug.
● (4): Rear LS valve output pressure pickup plug.
B. Install nipple O2 and connect it to oil pressure gauge [1] of

hydraulic tester O1.
● The figure shows the LS valve output pressure side.
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.
20-122 1 PC400LC-7E0
12
pressure and LS valve output pressure (servo piston inlet
pressure) at the same time under the following condition.
● Working mode: P
● 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.
Pressure ratio
Measured pressure All levers Travel lever operated half-
in neutral way
Pump discharge pressure Almost 1
LS valve output pressure same Approximately 0.6 (3/5)
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.
(1), (2), (5), and (6).
● (5): Front LS valve output pressure pickup plug.

● (6): Rear LS valve output pressure pickup plug.
B. Install nipple O2 and connect it to differential pressure gauge O3

or the oil pressure gauge of hydraulic tester O1.
★ 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.
PC400LC-7E0 20-123 1
● The figure shows the LS valve output pressure side.
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.
pressure and LS pressure (actuator load pressure) at the same time
under the following condition.
● Working mode: P
● 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 LS differential pressure
Set all levers in neutral Unload pressure (See standard values table)
Operate travel lever halfway (Run track shoe idle) Specified LS differential pressure (See standard values table)
20-124 1 PC400LC-7E0
12
3. Measuring LS-EPC valve output pressure.
A. Open the pump room cover and remove LSEPC valve output
B. Install nipple O2 and connect it to oil pressure gauge [1] of

hydraulic tester O1.
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 Travel lever Oil pressure
Lo Neutral Approximately 30 kg/cm2 (427 psi)
Hi Fine operation (Remark) Approximately 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).
PC400LC-7E0 20-125 1
12
Adjusting
★ If the LS differential pressure is abnormal, adjust LS valves (8) and (9)

according to the following procedure.
● (8): Front pump LS valve.
● (9): Rear pump LS valve.
1. 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.
20-126 1 PC400LC-7E0
TESTING AND ADJUSTING SOLENOID VALVE - OUTPUT PRESSURE
12
SOLENOID VALVE - OUTPUT PRESSURE
★ Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal.
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 operator’s cab)
.
No. Solenoid valve to be measured
1 2-stage relief solenoid valve
2 Machine push-up solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed selector solenoid valve
5 Merge-divider solenoid valve
6 Travel junction solenoid valve
7 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-7E0 20-127 1
12
4. Run the engine and raise the engine oil temperature to the operating
range.
5. Run the engine at high idling, operate the control levers and switches
to turn the solenoid valve ON or OFF, and measure the oil pressure.
★ For the conditions for turning the solenoid valve ON and OFF, see
the operations table of each solenoid valve.
★ The operating condition of the solenoid valve can be checked
with the monitoring function of the monitor panel (For the operat-
ing method, see “Monitor Panel - Special Functions”).
★ If the output pressure is as follows, the solenoid valve is normal.

Solenoid valve Output pressure
OFF (Deenergized) 2
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

Overheating No. 1 setting is turned ON
OFF
All of work equipment, swing, and travel signals are turned OFF
Swing lock switch is turned ON
Travel signal is turned ON
L-mode is selected ON
Boom LOWER signal is turned ON
When signal other than swing single operation signal is turned
P or E-mode is When left knob switch is turned ON ON
selected
When swing single operation signal is turned ON
OFF
Other than above condition
Operation table of machine push-up solenoid valve

OFF ON
Machine push-up switch
ON OFF
Operation table of swing holding brake solenoid valve

Work equipment, When all are turned OFF OFF
swing, travel signal When one of them is turned ON ON
20-128 1 PC400LC-7E0
12
Operation table of travel speed shifting solenoid valve

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 F or R pump pressure is above 330 kg/
When travel speed switch is set to Mi or Hi cm2 (4693 psi)
When travel signal is turned ON
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 service signal is turned ON
When travel operation is performed singly
ON
When F or R pump pressure is above 200
kg/cm2 (2844 psi)
When not in L-mode
When travel signal is turned When work equipment, OFF
ON kg/cm2 (2133 psi)
switch, and service sig-
nals are turned ON When F or R pump pressure is above 170
ON
kg/cm2 (2418 psi)
When in L-mode
OFF
kg/cm2 (1707 psi)
When arm IN and bucket When 2F or R pump pressure is above 250 ON
When travel signal is turned When swing signal is CURL PPC pressures are kg/cm (3556 psi)
OFF turned OFF above 19.5 kg/cm2 (277 When F or R pump pressure is below 200
psi) kg/cm2 (2844 psi) OFF
When not under above condition
Operation table of travel junction solenoid valve

When travel steering signal is turned ON
When travel system is oper- When F or R pump pressure is above 350 ON
When travel steering signal is turned OFF ated singly kg/cm2 (4978 psi)
When not under above condition OFF
Operation table of PPC lock solenoid valve
Operating condition
Lock OFF
Safety lock lever
Free ON
PC400LC-7E0 20-129 1
TESTING AND ADJUSTING PPC VALVE - OUTPUT PRESSURE
12
PPC VALVE - OUTPUT PRESSURE
1. Remove the control valve top cover and operator’s 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. Circuit to be measured No. Circuit to be measured
1 Boom RAISE (S06) 7 Swing LEFT (S07)
2 Boom LOWER (S02) 8 Swing RIGHT (S03)
3 Arm IN (S04) 9 Travel (S30)
4 Arm OUT (S08) 10 Steering (S31)
5 Bucket CURL (S01)
6 Bucket DUMP (S05)
3. 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.
20-130 1 PC400LC-7E0
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 Output pressure
In neutral 2
0 kg/cm (0 psi)
Almost same as control basic pres-
Operated to stroke end sure (See standard values table)
6. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7E0 20-131 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 {boot} (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.
20-132 1 PC400LC-7E0
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-7E0 20-133 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 and 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).
20-134 1 PC400LC-7E0
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-7E0 20-135 1
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
12
MEASURING OIL LEAKAGE
1. 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 end.
★ 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. After finishing measurement, return the removed parts.
2. Measuring oil leakage from arm cylinder.
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).
side with a plate.
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”.

20-136 1 PC400LC-7E0
12
3. Measuring oil leakage from bucket cylinder.
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).
side with a plate.
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”.

4. Measuring oil leakage from swing motor.
B. Disconnect drain hose (4) and block the hose side with a plug.
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
★ After measuring 1 time, swing 180°, and then measure again.
E. After finishing measurement, return the removed parts.
PC400LC-7E0 20-137 1
12
5. Measuring oil leakage from travel motor.
A. Remove the travel motor cover.
B. Run the engine and raise the engine oil temperature to the
operating range, and then lock the travel system and stop the
engine.
WARNING! Put pin [1] between the sprocket and track
frame to lock the travel system securely.
C. Disconnect drain hose (5) of the travel motor and block the hose
side with a plug.
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
★ 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.
20-138 1 PC400LC-7E0
TESTING AND ADJUSTING BLEEDING AIR FROM VARIOUS PARTS
12
BLEEDING AIR FROM VARIOUS PARTS
Air bleeding procedure
1 2 3 4 5 6
Air bleeding item
Bleeding air Starting en- Bleeding air Bleeding air Bleeding air Check oil level and
from hydrau- from cylinder from swing from travel
gine starting work
Work lic pump motor motor
• •
Replacing hydraulic oil • • • •
(See Remark) (See Remark)
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
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 tight-
ening 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 coolant 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-7E0 20-139 1
12
3. Bleeding air from cylinder.
★ If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder
does not move to the lowering stroke end, if it is installed to the work equipment.
A. Run the engine at low idling for about 5 minutes.
B. Running the engine at low idling, raise and lower the boom 4 - 5 times.
★ Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil.
C. Running the engine at high idling, perform step B.
D. Running the engine at low idling, move the piston rod to the stroke end and relieve the oil.
E. Bleed air from the arm cylinder and bucket cylinder according to steps B - D.
4. 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.
20-140 1 PC400LC-7E0
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-7E0 20-141 1
TESTING AND ADJUSTING DIODE TESTING PROCEDURE
12
DIODE TESTING PROCEDURE
★ Test an assembled-type diode or a diode unit according to the
★ 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)
20-142 1 PC400LC-7E0
TESTING AND ADJUSTING MONITOR PANEL - SPECIAL FUNCTIONS
12
MONITOR PANEL - SPECIAL FUNCTIONS
[1] Figure input switch 1 [6] Figure input switch 6 [/ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [Δ ] Move-up switch
[3] Figure input switch 3 [8] Figure input switch 8 [∇ ] Move-down switch
[4] Figure input switch 4 [9] Figure input switch 9 [3 ] Input check switch
[5] Figure input switch 5 [0] Figure input switch 0
PC400LC-7E0 20-143 1
12
Ordinary 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.
Operator’s Menu Service Menu

1 Password input and setting function 16 Function of monitoring [01]
2 Screen to display KOMATSU logo
of abnor- Electrical system
3 Function of check before starting 17 Function
mality record [02] Mechanical system
4 Function of displaying maintenance items 18 Function of maintenance record [03]
5 Function of displaying caution items 19 Function of maintenance mode change [04]
Function of checking working mode and travel 20 Function of phone No. entry [05]
6 speed
Mode in which key is ON
7 Function of displaying ordinary screen
Function of adjusting brightness and contrast Function of initial Language
8 21 setting and default Unit
of display
[06]
E-mode adjustment and pump flow rate With/Without attachment
9 adjustment function when breaker or circuit
attachment is used Pump absorption torque
10 Function of checking maintenance information Function of adjust- Adjustment of flow for at-
22 ment [07]
11 Function of displaying service meter tachment during com-
pound operation
12 Function of checking display LCD
Function of cylinder cut out mode operation
13 Function of displaying cautions 23 [08]
14 Function of displaying action code 24 Function of no injection cranking [09]
15 Function of displaying failure code
20-144 1 PC400LC-7E0
12
OPERATOR’S MENU (OUTLINE)
★ This section introduces only the outline of the operator menu. For
details on the contents and operation steps of each menu, refer to the
operation and maintenance manual or the chapter of “Structure,
function and maintenance standard” in this shop manual.
1. Password input and setting function.

Displays the password input screen as the starting switch is turned
ON.
★ Above display is available only when the password function is
selected.
2. KOMATSU logo display screen.

KOMATSU logo is displayed for 2 seconds as a password is entered
(as a password is specified) or the starting switch is turned ON.
3. Check before starting function.

Check before starting screen is displayed for 2 seconds succeeding to
display of KOMATSU logo.
4. Maintenance display function.

Succeeding to display of the check before starting screen, a
maintenance mark appears for 30 seconds pointing the oil or filter
whose specified maintenance time has already expired or going to
expire soon.
★ Above display is available only when the maintenance function is
selected.
PC400LC-7E0 20-145 1
12
5. Caution items display function.
Succeeding display of the check before starting screen, an applicable
caution mark appears pointing a check before starting item on which a
problem was found.
6. Check of working mode and travel speed function.

Succeeding to display of the check before starting screen, symbol
marks of the working mode and travel speed appear sizably on the
screen to alert the operator attention to the setting.
7. Ordinary screen display function.

The ordinary display is turned on succeeding to display of the check of
working mode and travel speed screen.
★ If the currently set working mode or travel speed is changed or if
setting of the auto deceleration or wiper is enabled from the
ordinary screen, an applicable symbol mark is displayed large for
2 seconds.
★ The engine pre-heating monitor is displayed only when the
pre-heating operation is turned on.
8. Display's brightness and contrast adjusting function.

The screen adjustment switches allow adjusting the display brightness
and contrast.
20-146 1 PC400LC-7E0
12
9. E-mode adjustment, flow rate adjustment function when breaker or
attachment is used (for a machine equipped with breaker and
attachment).
The select switch allows adjusting E-mode and also adjusting the
pump flow rate when the breaker or attachment is used.
★ There are some differences between the symbol mark of the
breaker and attachment displayed on the screen as well as in the
messages displayed.
10. Check of maintenance information function.

The maintenance switch allows checking detailed information of the
maintenance items (specified maintenance time and elapsed time). It
also allows resetting after the maintenance.
★ Setting and resetting of the maintenance function as well as
setting of the maintenance time is done from the service menu.
11. Service meter display function.

Display of the service meter alone becomes available by operating the
following switches after the starting switch is turned OFF.
● Switch operation: [/] + [Δ] (Simultaneous operation)
PC400LC-7E0 20-147 1
12
12. Check of display LCD function.
Display of the display LCD can check by operating the following
switches from the password input screen or ordinary screen.
● Switch operation: [/] + [A] (Simultaneous operation)
★ The entire LCD should come on, turning the screen to white. The
display is, therefore, acceptable if it is free from any black spot.
★ Operating any switch from the checkup display restores the
immediately preceding screen.
13. Caution generation display function.

If a caution is warned for a caution item, applicable symbol mark is
displayed large for 2 seconds and then it remains on the screen in a
smaller size until the trouble is eliminated.
20-148 1 PC400LC-7E0
12
14. Action code display function.
If a trouble occurs on the machine, an applicable action code is
automatically displayed depending on the seriousness of the trouble in
order to alert the operator to take an appropriate action.
★ Operating any switch while an action code is on the screen, switch
the failure code display screen (see Item 15).
★ Action codes and instructions given to operator

Action code Failure mode Action
When the emergency pump drive switch is set in the upper (emergency) po-
E02 Error in pump control system sition, the machine can operate normally. Have the machine inspected im-
mediately.
Move the swing holding brake release switch in the upper (release) position
to release the brake. Apply the swing brake manually with the swing lock
E03 Error in swing brake system switch, if necessary. The brake may not be released, depending on the
cause of the failure. In any case, have the machine inspected immediately.
Error in engine controller power
supply or abnormality in engine
E10 controller drive system circuit (En- Have the machine inspected immediately.
gine stops)
Error in engine controller system Operate the machine to a safe posture and have the machine inspected im-
E11 (Output reduced to protect engine) mediately.
Operate the machine to a safe posture and have the machine inspected im-
E14 Error in throttle system mediately.
Error in engine sensor (water tem- Although the machine can operate normally, have the machine inspected im-
E15 perature, fuel temperature, or oil mediately.
pressure)
Operate the machine to a safe posture and have the machine inspected im-
E0E Error in network mediately.
PC400LC-7E0 20-149 1
12
15. Failure code display function.
Operating any switch while an action code is on the screen, sequentially displays the phone mark (if registered), phone
number (if registered) and failure code.
● Switching operation: (3) (keep the switch depressed)
★ The screen display sequentially changes as shown below as long as the switch is being depressed.
A. Telephone symbol mark.
B. Telephone number.
C. Failure code.
★ The telephone mark and telephone number are displayed only
when the telephone number is registered to the machine monitor.
Registration, correction or deletion of a telephone number is done
from the service menu.
★ For detailed information of failure codes, see the failure codes
table.
20-150 1 PC400LC-7E0
12
FAILURE CODES TABLE
Alarm buzz- Device in
Action code Failure code Trouble (Displayed on screen) Category of record
er charge
--- A000N1 Eng. Hi Out of Std MON Mechanical system
--- AA10NX Air cleaner Clogging MON Mechanical system
--- AB00KE Charge Voltage Low MON Mechanical system
--- B@BAZG Eng. Oil Press. Low MON Mechanical system
--- B@BAZK Eng. Oil Level Low MON Mechanical system
--- B@BCNS Eng. Water Overheat MON Mechanical system
--- B@BCZK Eng. Water Lvl Low MON Mechanical system
E02 B@HANS Hydr. Oil Overheat MON Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E11 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error l ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error l ENG Electrical system
E14 CA131 Throttle Sensor High Error l ENG Electrical system
E14 CA132 Throttle Sensor Low Error l ENG Electrical system
E15 CA135 Eng. Oil Press Sensor High Error l ENG Electrical system
E15 CA141 Eng. Oil Press Sensor Low Error l ENG Electrical system
E15 CA144 Coolant Temp Sens High Error l ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error l ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error l ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error l ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error l ENG Electrical system
E15 CA221 Ambient Press Sens High Error l ENG Electrical system
E15 CA222 Ambient Press Sens Low Error l ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error l ENG Electrical system
--- CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error l ENG Electrical system
E15 CA263 Fuel Temp Sensor High Error l ENG Electrical system
E15 CA265 Fuel Temp Sensor Low Error l ENG Electrical system
E11 CA271 IMV/PCV1 Short Error l ENG Electrical system
E11 CA272 IMV/PCV1 Open Error l ENG Electrical system
E11 CA273 PCV2 Short Error l ENG Electrical system
E11 CA274 PCV2 Open Error l ENG Electrical system
E11 CA322 Inj #1 (L#1) Open/Short Error l ENG Electrical system
E10 CA342 Calibration Code Incompatibility l ENG Electrical system
E10 CA351 Injectors Drive Circuit Error l ENG Electrical system
E10 CA441 Battery Voltage Low Error l ENG Electrical system
PC400LC-7E0 20-151 1
Alarm buzz- Device in

er charge
E10 CA442 Battery Voltage High Error l ENG Electrical system
E11 CA449 Rail Press Very High Error l ENG Electrical system
E11 CA451 Rail Press Sensor High Error l ENG Electrical system
E11 CA452 Rail Press Sensor Low Error l ENG Electrical system
E15 CA553 Rail Press High Error l ENG Electrical system
--- CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error l ENG Electrical system
E11 CA689 Ne Speed Sensor Error l ENG Electrical system
E11 CA731 Bkup Speed Sens Phase Error l ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Bkup Speed Sensor Error l ENG Electrical system
E15 CA1228 EGR Valve Servo Error 1 l ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error l ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error l ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error l ENG Electrical system
E11 CA2249 Rail Press Very Low Error l ENG Electrical system
E11 CA2271 EGR Valve Pos Sens High Error l ENG Electrical system
E11 CA2272 EGR Valve Pos Sens Low Error l ENG Electrical system
E11 CA2351 EGR Valve Sol Current High Error l ENG Electrical system
E11 CA2352 EGR Valve Sol Current Low Error l ENG Electrical system
E15 CA2555 Grid Htr Relay Volt Low Error l ENG Electrical system
E15 CA2556 Grid Htr Relay Volt High Error l ENG Electrical system
--- D110KB Battery Relay Drive S/C PUMP Electrical system
--- D196KA Service Return Relay Disc. PUMP Electrical system
--- D196KB Service Return Relay S/C PUMP Electrical system
E02 DA25KP Press. Sensor Power Abnormality l PUMP Electrical system
--- DA80MA Auto Lub Abnormal PUMP Electrical system
E0E DA2RMC Pump Comm. Abnormality l PUMP Electrical system
--- DA2SKQ Model Selection Abnormality l PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality l PUMP Electrical system
--- DHPAMA F Pump P. Sensor Abnormality PUMP Electrical system
--- DHPBMA R Pump P. Sensor Abnormality PUMP Electrical system
--- DHS3MA Arm Curl PPC Sen. Abnormality PUMP Electrical system
--- DHS4MA Bucket Curl PPC Sen. Abnormality PUMP Electrical system
--- DW43KA Travel Speed Sol. Disc. PUMP Electrical system
--- DW43KB Travel Speed Sol. S/C PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. l PUMP Electrical system
E03 DW45KB Swing Brake Sol. S/C l PUMP Electrical system
--- DW91KA Travel Junction Sol. Disc. PUMP Electrical system
--- DW91KB Travel Junction Sol. S/C PUMP Electrical system
--- DWJ0KA Merge-divider Sol. Disc PUMP Electrical system
--- DWJ0KB Merge-divider Sol. S/C PUMP Electrical system
--- DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system
20-152 1 PC400LC-7E0
Alarm Device in
buzzer charge
--- DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Disc. PUMP Electrical system
E02 DXA0KB PC-EPC Sol. S/C PUMP Electrical system
--- DXE0KA LS-EPC Sol. Disc. PUMP Electrical system
--- DXE0KB LS-EPC Sol. S/C PUMP Electrical system
--- DXE4KA Service Current EPC Disc. PUMP Electrical system
--- DXE4KB Service Current EPC S/C PUMP Electrical system
--- DY20KA Wiper Working Abnormality MON Electrical system
--- DY20MA Wiper Parking Abnormality MON Electrical system
--- DY2CKB Washer Drive S/C MON Electrical system
--- DY2DKB Wiper Drive (For) S/C MON Electrical system
--- DY2EKB Wiper Drive (Rev) S/C MON Electrical system
★ This table lists the failed sections in the order of the failure code.
★ Those failure codes to which the corresponding number is not indicated in the action code space are not displayed on the
ordinary screen if a failure is found. They are just recorded in the abnormality record (electrical system and mechanical
system) of the service menu.
★ The category of record is used for indicating to which of the electrical and mechanical system of the service menu's
abnormality record a given failure is classified.
★ E of at beginning the action code indicates the following state.
● With E: The failure still remains without being resolved.
● Without E: The failure is already resolved.
PC400LC-7E0 20-153 1
12
SERVICE MENU
Switching to service menu
★ When using the service menu, switch the screen through the following
special operation.
A. Confirmation of display.
Make sure that the conventional display is turned on.
★ Changing to Service Menu is usually available only from this
conventional display.
B. Switch operation.
Do the following switch operation.
★ Switch operation: [∇] + [1] → [2] → [3] (Enter the numbers while
holding ∇ down)
C. Displaying menu screen.

The display is changed to the initial display of Service Menu
program. Select an appropriate item from among the menu.
Number Service menu

00 Return (Ends the service menu)
01 Monitoring
02 Abnormality record
03 Maintenance record
04 Change of maintenance mode
05 Setting of telephone No.
06 Default
07 Adjustment
08 Cylinder cut out
09 No injection cranking
D. Ending the menu and function.

When ending the operation from the service menu screen or respective menu screens, select either of the following
operations.
● Press [/] switch (enables every screen).
● When “RETURN” switch is displayed, press the applicable switch.
● When “Return” menu is displayed, select the menu and press [3] switch.
20-154 1 PC400LC-7E0
12
16. Monitoring [01] function.
The machine monitor monitors signals from the switch sensor
actuators on various machine parts. It allows displaying and checking
the monitored information through following operations.
A. Menu selection.
Select “01 Monitoring” in the initial display of Service Menu and
depress [3] switch.
B. Setting a monitoring item.

Select and register an item to be monitored through the following
switch operation.
● [Δ] switch: Selection
● [∇] switch: Selection
● [3] switch: Registration
★ A monitoring item can be set from 1 to 4 at maximum
(Depending upon the selected item, the max. number can be
less than four)
★ In case of monitoring 1 to 3 items, move to the monitoring
information screen through any of the following switch
operations after the registration work has been completed.
● [Hold down [3] switch (for about 3 seconds).
● Select menu “99999” and press [3] switch.
★ When you have registered all the items that can be registered, the screen will be automatically switched to the
monitoring information screen.
★ Monitored information are transmitted via communication circuits.Thus the number of selected items can impact
the communication speed. If truly real time monitoring is required, reduce the selected items to the minimum.
★ For details on the monitoring items, display unit, etc., refer to the Table for Monitoring Items.
C. Operation for monitoring.

As the monitoring information screen is displayed, confirm the
monitored information operating the machine.
PC400LC-7E0 20-155 1
12
D. Monitored information holding function.
You can hold every monitored information by pressing [Δ] while
monitoring is continued.
If you press [∇] switch again in this condition, the currently held
information will be released.
E. Machine setup mode switching function.

If it becomes necessary to change settings of working mode,
select mode, travel speed and auto-decel while monitoring,
depress the corresponding switch, then the mode confirmation
display is shown.
★ Above figure shows the screen display in P-and E-mode (in
B-mode, part of the symbol mark shape is different from
above).
★ After confirming the setting, press [3] switch to return to the
monitoring screen.
★ If the setting was changed during monitoring, the new setting
is held even after the operator menu is restored from the
service menu after the monitoring is finished.
20-156 1 PC400LC-7E0
12
LIST OF MONITORING ITEMS
Unit (Default: ISO)
Code No. Monitoring item Remarks
ISO meter inch
00000 Return (Not display) End menu
99999 Display execution (Not display) Display execution menu
00200 Controller Model Select Numbers
00201 Machine ID Numbers
01002 Engine Speed r/min rpm rpm
01601 2nd Eng. Speed Command r/min rpm rpm
01100 F Pump Pressure MPa 2 psi
kg/cm
01101 R Pump Pressure MPa 2 psi
kg/cm
07200 Arm IN PPC Pressure MPa 2 psi
kg/cm
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi
04107 Coolant temperature °C °C °F
14200 Fuel temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
01300 PC-EPC Sol. Curr. mA mA mA
01500 LS-EPC Sol. Curr. mA mA mA
01700 Service Sol. Curr. mA mA mA
03200 Battery Voltage V V V
03203 Battery Power Supply V V V
04300 Battery Charge V V V
01006 Engine Speed r/min rpm rpm
37200 Engine oil pressure MPa 2 psi
kg/cm
36400 Common rail pressure MPa 2 psi
kg/cm
37400 Ambient Pressure kPa 2 psi
kg/cm
18400 Intake Temperature °C °C °F
18500 Charge Temperature °C °C °F
36500 Boost Pressure kPa kg/cm 2 psi
18000 EGR Inlet Pressure-A kPa kg/cm 2 psi
18100 EGR Valve Position mm mm in
36700 Engine Torque Ratio % % %
18700 Engine Output Torque Nm kgm lbft
03000 Fuel Dial Pos Sens Volt V V V
04200 Fuel Level Sensor Vol. V V V
04105 Eng. Water Temp. Vol. Lo V V V
04201 Fuel Temp. Sensor Vol. V V V
04402 Hydr. Temp. Sensor Vol. V V V
37201 Eng Oil Press Sens Volt V V V
37401 Ambient Press Sens Volt V V V
18401 Intake Temp Sens Volt V V V
18501 Charge Temp Sens Volt V V V
36501 Charge Press Sens Volt V V V
36401 Rail Pressure Sens Volt V V V
PC400LC-7E0 20-157 1
12
Code Unit (Default: ISO)
Monitoring item Remarks
No. ISO meter inch
18101 EGR Valve Pos Sens Volt V V V
17201 PCV Close Timing CA CA CA
17500 Engine Power Mode --- --- ---
31701 Throttle Position % % %
31706 Final Throttle Position % % %
3 3
18600 Inject Fueling Command mm /st mm /st mm3/st
36200 Rail Press Command MPa kg/cm2 psi
36300 Injection Timing Command CA CA CA
37300 Fuel Rate L/h L/h L/h
01602 2nd Eng. Speed Command % % %
13113 Main Pump Absorb Torque Nm kgm lbft
Swing ON/OFF
Travel ON/OFF
Boom Lower ON/OFF
01900 Pressure Switch 1
Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
01901 Pressure Switch 2
Service ON/OFF
Travel Steering ON/OFF
Travel Junction ON/OFF
Swing Brake Sw. ON/OFF
02300 Solenoid Valve 1 Merge-divider ON/OFF
2-Stage Relief ON/OFF
Travel Speed ON/OFF
02301 Solenoid Valve 2 Service Return ON/OFF
Lever Sw. ON/OFF
02200 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake SW. ON/OFF
Model Select 1 ON/OFF
02201 Switch Input 2
Low Viscosity Fuel Mode ON/OFF
02202 Switch Input 3 Key Switch (ACC) ON/OFF
03700 Controller Output 1 Battery Relay Output ON/OFF
Key Switch ON/OFF
Start ON/OFF
04500 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Rad. Level ON/OFF
20-158 1 PC400LC-7E0
Unit (Default: ISO)

Code No. Monitoring item Remarks
ISO meter inch
Air cleaner ON/OFF
Eng. Oil Level ON/OFF
04501 Monitor Input 2
Spare open ON/OFF
Battery Charge ON/OFF
Swing Brake Sw. ON/OFF
Bzzr Cancel Sw. ON/OFF
04502 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
20216 ECM Build Version --- --- ---
20217 ECM CAL Data Ver --- --- ---
18900 ECM Internal Temp °C °C °F
20400 ECM Serial No --- --- ---
20200 Monitor Prog. Version --- --- ---
20212 Pump Con. Prog. Version --- --- ---
PC400LC-7E0 20-159 1
12
17. Function of abnormality record [02].
The monitor panel records and classifies the past failure information
as into the electrical and mechanical failures. It allows displaying and
checking the information through the following operations.
A. Menu selection.
Select “02 Abnormality Record” in the initial display of Service
Menu and depress [3] switch.
B. Sub menu selection.

Select the sub menu from the abnormality record menu screen and
then press [3] switch.
Number Sub menu of abnormality record

00 Return (End of abnormality record)
01 Electrical systems
02 Mechanical systems
C. Contents of display of electrical system abnormality record

information screen.
(1): Occurrence order of abnormalities from latest one/Total
number of records
(2): Failure code (Equipment: 4 digits, Phenomena: 2 digits)
(3): Elapsed time on service meter from the first occurrence
(4): Contents of trouble
★ See the operator menu “Failure codes table”.
D. Contents of display of mechanical system abnormality record

information screen.
(1): Record number
(2): Contents of trouble
(3): Failure code (Equipment: 4 digits, Phenomena: 2 digits)
(4): Total number of occurrences
(5): Service meter reading at first occurrence
★ See the operator menu “Failure codes table”.
20-160 1 PC400LC-7E0
12
E. Resetting electrical systems.
★ Resetting abnormality record (deletion) is possible only with
the electrical system. The abnormality record in the
mechanical system cannot be reset.
★ When resetting individual or all information in the
abnormality record of the electrical systems, implement the
i. Following switch operation from the electrical system

abnormality record screen opens the reset screen.
● Switch operation: [Δ] + [1] → [2] → [3]
★ Above is the same as that done when switching to the

service menu.
ii. From the reset screen, do the switch operation according to

the screen instructions.
★ When a specific individual information alone is to be
reset, be sure to display the subject information on the
screen using [Δ] switch or [∇] switch.
★ When resetting all information, the information to be
displayed on the screen can be any.
18. Function of maintenance record [03].

The machine monitor records the maintenance information of the
filters, oils, etc., which the operator can display and check by the
following operations.
A. Menu selection.
Select “03 Maintenance Record” from the initial display of
Service Menu and then depress [3] switch.
PC400LC-7E0 20-161 1
B. Information to be displayed.
● Oil and filter names.
● Replacement time elapsed up to present.
● Time elapsed on service meter up to the last replacement.
19. Function of maintenance mode change [04].

Following procedure allows changing the currently set operating
conditions of the maintenance display function.
● Set function effective or ineffective
● Change set replacement interval
A. Menu selection.
Select “04 Maintenance Mode Change” from the Service Menu
and then depress [3] switch.
B. Selection of item to be changed.

Select the item to be changed from the Maintenance Mode
Change Selection Menu screen.
Number Items of the maintenance mode change

00 Return (End of change in the maintenance mode)
01 Maintenance mode on/off
02 Engine oil change int.
03 Engine oil filter change int.
04 Fuel main filter change int.
41 Fuel pre filter change int.
06 Hyd oil filter change int.
07 Hyd tank breather change int.
08 Corrosion resistor change int.
09 Damper case service int.
10 Final drive case oil change int.
11 Machinery case oil change int.
12 Hydraulic oil change int.
13 Initialize all items
★ 01 and 12 menus are provided for setting the whole maintenance mode, while those from 02 through 11 are for
setting individual items.
20-162 1 PC400LC-7E0
C. Contents of Maintenance Mode On/Off.
● Use (On): The maintenance display function of all oil and
filter-related items are turned effectual. (Irrespective of
whether “On” or “Off” set for individual items, this setting
prevails).
● Not use (Off): The maintenance display function of all oils
and filter related items is disabled (precedence is given to this
setting over the “On” or “Off” selected for an individual
items).
D. Description of individual setting items.
i. Default value: The maintenance time set in the monitor

(recommended by the manufacturer and cannot be changed).
ii. Set value: Denotes the maintenance time that can be freely
set. The maintenance mode operates based on this time (the
time can be increased or decreased in multiple of 50 hours by
use of [Δ] and [∇] switches).
iii. Use (On): Maintenance display function for this item is

enabled.
iv. Not use (Off): Maintenance display function for this item is
disabled.
★ The lower limit of this setting is 50 hours.
E. Description of “Initialize all items”.

Select this menu and then press [3] switch to restore the default value for the individually set information.
PC400LC-7E0 20-163 1
12
20. Function of phone number entry [05].
When the action code is displayed, following procedure allows
entering or correcting the phone numbers to be displayed alternately
with the failure code.
★ If a telephone number is not input, the phone number screen is not
displayed.
A. Menu selection.
Select “05 Phone Number Entry” menu from the Service Menu
initial screen and then depress [3] switch.
B. Changing the display.

Select “Entry” next to change the display to the Phone Number
Entry display.
★ Even if a Phone number is already inputted, it is deleted if
you switch the “Phone Number Entry” screen.
C. Entry and setting phone number.

Following the method explained below, enter a phone number in
the “Phone Number Entry” display. (Entry automatically begins
with a cursor at the left end)
i. Using the numerical keypad, enter the number starting with

the cursor position situated at the left end.
★ Numbers can be entered up to the max. 12 digits, but omit
unnecessary digits.
★ When entered a wrong number, depress [B] switch to
return the cursor by one digit.
ii. Depress [3] switch when all the numbers have been entered.
★ As the input is finished, the screen changes to entry
screen shown above. If the entered phone number is
shown on this display, the input is normal.
20-164 1 PC400LC-7E0
12
21. Function of default [06].
Following machine monitor- or machine related settings are
modifiable. Do necessary modifications as needed.
● Working mode as starting switch is turned ON.
● Language used in the service menu.
● Unit to be displayed in relation to the monitoring function.
● With/Without attachment.
A. Menu selection.
Select “06 Default” menu from the Service Menu initial screen
and then press [3] switch.
B. Selecting sub menu.

Select the target sub menu of setting change and then press [3]
switch.
C. Mode to be selected as key is turned on.

Following operation allows specifying the working mode to be
displayed on the machine monitor as the starting key is turned
ON.
● P-mode, E-mode, L-mode and B-mode: If any of above
modes is specified, that mode will be constantly turned ON
as the starting switch is pressed.
● The mode that had been selected as the starting key was
turned off in the last operation: This setting turns ON the last
used mode as the starting switch is pressed.
● Default: This setting turns ON the delivered default mode
(P-mode) as the starter switch is pressed.
★ If the engine is stopped from B-mode on a machine equipped
with the attachment, this mode will be invariably selected as
the starter switch is turned ON the next time independent of
above setting.
PC400LC-7E0 20-165 1
12
D. Language setting function.
Service Menu allows switching the language between Japanese
and English.
★ The default language of the machine monitor is English.
★ When using the machine monitor, which is a spare part, in the
Japanese- speaking sphere, switch this function from English
to Japanese.
E. Unit selection function.

You can select one from the three units to be used in the
monitoring function display of Service Menu.
★ SI unit system is the default setting of the machine monitor.
F. Function for selecting distinction of With/Without Service Cir.

It is possible in this function to set a distinction between with or
without attachment.
● With Service Circuit: When an attachment is installed.
● Without Service Circuit: When no attachment is installed.
★ When the attachment is installed, you must select “With
Service Circuit” from this screen. Otherwise, the selection
function (the function for sharing the attachment) won't be
available from the operator mode.
20-166 1 PC400LC-7E0
12
22. Function of adjustment [07].
The operator can adjust various items related to the machine with the
machine monitor.
A. Menu selection.
Select “07 Adjustment” menu from the Service Menu initial
screen and then depress [3] switch.
B. Sub menu selection.

Select the sub menu on which setting change is to be done and
then press [3] switch.
Number Adjustment of sub menu

00 Return (Ends the adjustment)
01 Pump absorption torque
02 Adjustment of flow to attachment in compound operation
C. Function for Pump Absorption Torque adjustment.

The pump absorption torque can be adjusted within the range
Torque ad- Torque ad-

Adjustment Adjustment
justment justment val-
value value
value ue
220 +4.0 kgm 225 -1.0 kgm
221 +3.0 kgm 226 -2.0 kgm
222 +2.0 kgm 227 -3.0 kgm
223 +1.0 kgm 228 -4.0 kgm
224 0.0 kgm
D. ATT flow rate adjustment function at compound operation.

In the compound operation of attachments, you can adjust the
flow rate allocation of the pump within the range shown in the
table below.
Adjustment value Flow rate allocation to ATT

370 0.5 times
371 0.7 times
372 1.0 times
373 0.4 times
PC400LC-7E0 20-167 1
12
23. Function of cylinder cut out operation [08].
The operator can perform the engine on cylinder cut out operation
with the machine monitor. “Cylinder Cut Out” 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 (combustion in it is
abnormal).
A. Selecting menu.
Select “08 Cylinder cut out” menu from the service menu initial
screen and press [3] switch.
B. Selecting cylinder to be disabled.

Press a switch corresponding to the cylinder No. to be disabled
from switches [1] to [6] of the machine monitor.
★ If pressing the switch changes the cylinder number on the
screen to a white letter enclosed in the white frame, the
cylinder is disabled (when a wrong number is selected, press
the correct switch again).
★ Number of cylinders to be reduced is any.
C. Resetting cut out cylinder.

Press the switch corresponding to the disabled cylinder's number
from switches [1] to [6] of the machine monitor to be reset.
★ If pressing the switch changes the cylinder number on the
screen to a black letter enclosed in the black frame, the
cylinder is reset.
20-168 1 PC400LC-7E0
12
D. Engine speed holding function.
Pressing [Δ] switch while the engine operation on cylinder cut out
screen is turned on holds the engine speed and its speed is newly
displayed in the lower space.
Pressing [∇] switch during holding cancels the holding function
and deletes the display in the lower space.
★ If the holding function is used, the held speed is displayed in
the lower space along with () and the upper space
continuously displays the current speed.
★ The holding function is usable independent of the currently
set mode – the cylinder cut out or not.
[Reference]: Using the holding function effectively.

The engine speed being displayed on the screen through the
holding function remains on it until the holding is cancelled. In
other words, enabling or disabling of the cylinder cut out mode
does not affect the display. Thus, when identifying a failed
cylinder quicker, following operation is effective.
i. Run the engine from the normal operation mode (no cylinder
cut-out) and then hold the speed of that time.
ii. Specify the cylinder to be diagnosed as the cut out.
iii. Run the engine under the same condition as that for (1). Then
compare the engine speed at that time and the held speed
being displayed to diagnose the cylinder.
iv. Reset a cut out cylinder independent of the fluctuations in the

engine speed.
v.Repeat above steps (2) to (4) and then compare the results
against that obtained from other cylinders.
★ If the diagnosis identified a cylinder on which there was no
decrease in the engine speed or the decrease was small, it can
be safely judged that there must be some abnormalities in its
fuel.
PC400LC-7E0 20-169 1
12
24. Function of no injection cranking [09].
No injection cranking of the engine is available from the machine
monitor.
No injection cranking denotes stopping injection of fuel from the
injector even if the engine is run from the starting motor. This mode is
used, for instance, for measurement of compressive pressure.
★ This setting must be done after stopping the engine.
A. Selecting menu.
Select “09 No Injection Cranking” from the service menu initial
screen and press [3] switch.
B. The initial screen for the no injection cranking will appear.

★ “Check Communication” will be displayed in red.
C. As the checkup is over, following screen appears.
D. Select “No Injection” and press [3] switch.

“Under Preparation” will be displayed on the screen.
★ The letters “Under Preparation” are displayed in red.
20-170 1 PC400LC-7E0
TESTING AND ADJUSTING HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
E. As the preparation for no injection cranking is completed, display
of “Under Preparation” i s replaced with “After No Injection”.
★ The letters “After No Injection” are displayed in green.
F. From this state, crank the engine using the starting motor.
★ Limit the cranking time to 20 seconds to protect the starting
motor.
G. After the no injection cranking is over, press [3] switch from the
previous screen and the letters “End” will be displayed for 3
seconds.
★ The letters “End” are displayed in green.
H. Press “Return” when ending the no injection cranking.
★ If the no injection cranking function is inadvertently selected

while the engine is running, “Engine Running” will appear as
No Injection in step D is selected. This “Engine Running”
display remains on the screen even after the engine is
stopped. Restoring the service menu screen alone deletes the
display.
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER

1. The starter switch must be turned OFF before disconnecting or connecting the connector across the engine controller and
engine.
2. It is prohibited to start the engine for diagnosis purpose when a T-adapter is inserted in or connected to the connector
across the engine controller and engine.
★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
PC400LC-7E0 20-171 1
TESTING AND ADJUSTING PROCEDURE FOR TURNING ON KOMTRAX TERMINAL
12
PROCEDURE FOR TURNING ON KOMTRAX TERMINAL
When the machine is delivered, KOMTRAX terminal is installed:
★ When the machine is delivered, KOMTRAX terminal is installed (machine with the standard equipment), implement the
1. Reporting of machine model, model number and serial number.

Report the machine model, model number and serial number to the person responsible to operation of KOMTRAX.
2. Registration of KOMTRAX terminal.

The person responsible to operation of KOMTRAX shall register the
subject terminal using the KOMTRAX client PC.
★ See “KOMTRAX administrator manual” for the procedure.
★ Above completes the necessary operations.
When installing KOMTRAX terminal after the machine is
delivered:
★ When installing KOMTRAX terminal after the machine is delivered

(machine with the retrospective equipment), implement the following
procedure.
1. Station opening inspection.

★ Referencing “Preparation work for troubleshooting of electrical
system”, confirm the position of KOMTRAX terminal and the
inspecting connector (the inspecting connector is provided at the
bottom of KOMTRAX terminal).
★ Finish the operations of steps D to G within 30 seconds.
A. Turn OFF the starting switch and then, after making sure 5
seconds have elapsed, proceed to the next step.
B. Make sure visually that the inspecting connectors 1 and 2 are

connected.
● Inspecting connector 1: G02 (female) and G03 (male)
● Inspecting connector 2: G04 (female) and G05 (male)
C. Disconnect the inspecting connector 1 and maintain that state for

5 seconds.
D. Turn ON the starting switch and maintain that state for 5 seconds.
E. Disconnect the inspecting connector 2 and maintain that state for

5 seconds.
F. Connect the inspecting connector 1 again and maintain that state

for 5 seconds.
G. Connect the inspecting connector 2 again and maintain that state

for 5 seconds.
H. Make sure that the KOMTRAX terminal 7- segment indicator lamps are normally turned on.
20-172 1 PC400LC-7E0
12 ★ As [Normal] is indicated, proceed to the next step.
★ If [Abnormal] is indicated, repeat the procedure from step A.
I. Set the starting switch to START position and maintain it in that

state for 5 seconds.
Make sure the engine is not started.
★ If the engine is started, repeat the procedure from step A.
J. Return the starting switch to ON position and maintain that state

for 5 seconds.
★ Don't return it to OFF position.
K. Set the starting switch to START position again and make sure the
engine is started.
L. Make sure that the KOMTRAX terminal 7-segment indicator

lamps are normally turned on.
Remark
The third number on the display can be “2” or “3” though “3” is
displayed in above figure (both for the normal state and when
trouble is present).
★ As [Normal] is confirmed, proceed to the next step (it will
take 90 seconds to 15 minutes until normal display is
restored).
★ If [GPS position data sensing error] were displayed, check
the GPS antenna and cable for external troubles. If any, repair
the trouble and repeat the procedure from step A.
★ If [Receiving error] were displayed, check the
communication antenna and cable for external troubles. If
any, repair the trouble and repeat the procedure from step A.
★ If [GPS position data sensing error and receiving error] were
displayed, check the GPS antenna and cable as well as the
communication antenna and cable for external troubles. If
any, repair the trouble and repeat the procedure from step A.
★ If [Network error] were displayed, check the indication of
[LED-C4] referencing “KOMTRAX terminal lamp
indications”. (When CAN is not recognized, check
KOMTRAX terminal CAN harness for troubles. If any,
repair the trouble and repeat the procedure from step A).
PC400LC-7E0 20-173 1
12
M. Turn the starting switch OFF.
N. Make sure that the 7-segment indicator lamp (a) comes on

normally in 10 seconds.
★ As [Normal] is displayed, the station opening inspection is
complete.
★ If [Abnormal] is displayed, the inspection is incomplete and
must be repeated from step A.
2. Application for start of use.

★ The application for start of use is allowed only after the terminal
station opening inspection has been successfully ended.
A. Concerning the machine body for which the station opening

inspection has been completed, report the following information
to the person responsible to operation of KOMTRAX.
i. Information of the machine body for which the station

opening inspection has been completed (machine model,
model number and serial number)
ii. Part number and serial number of KOMTRAX terminal
iii. The service meter reading when KOMTRAX terminal was

installed (in 0.1 h unit)
B. The person responsible to operation of KOMTRAX shall register

the machine body using the KOMTRAX client PC.
★ See “KOMTRAX administrator manual” for the procedure.
★ Above completes the necessary operations.
20-174 1 PC400LC-7E0
12
KOMTRAX terminal lamp indications
LED for communication module LED for CPU 7-segment and dot for CPU
LED-C1 (R signal and ACC sig- 12. 7-segment (Number of mails not transmit-
1. LED-A1 (Power lamp) 6. nal) ted yet)
2. LED-A2 (Within communication 7. LED-C2 (Initial output state) 13. Dot (GPS positioning state)
range lamp)
3. LED-A2 (Communication in LED-C3 (S-NET and C signal

8.
progress lamp) state)
4. LED-A2 (Internal transmitting 9. LED-C4 (CAN state)

lamp)
5. LED-A2 (Internal receiving lamp) 10. LED-C5 (Download writing state)
11. LED-C6 (Download writing state)
PC400LC-7E0 20-175 1
12
KOMTRAX system displays various information in the system as well as contents of information processing on the LED
display unit located at the top of KOMTRAX terminal. Thus, when a failure on the system is suspected, implement the
following checkups.
● Checking antennas.
● Checking terminal LED display.
Before using KOMTRAX, the application for start of use and the machine side station opening inspection must be completed.
When above is not completed, all LEDs for the communication module are turned off. It does not indicate the machine trouble.
Checking antennas
★ Before inspecting display of LED, check the communication antenna and its vicinity as well as GPS antenna and its
vicinity for any trouble.
● The communication antenna shall not be disconnected or damaged.
● The communication antenna cable shall not be broken and shall be appropriately connected to KOMTRAX terminal.
● GPS antenna shall not be disconnected or damaged.
● GPS antenna cable shall not broken and shall be appropriately connected to KOMTRAX terminal.
Checking terminal LED indication
1. Display contents of LED for communication module.

★ Turn ON the starting switch prior to inspection of LED display.
No. LED Name and function Display Contents of display

ON
1 LED-A1 Power lamp LED stays turned on as long as power is supplied normally
OFF
Within communication ON LED comes on as the machine body moves inside the communication
2 LED-A2 range lamp OFF range of KOMTRAX system.
Communication in ON LED stays turned on as long as KOMTRAX terminal is connected to

3 LED-A3 progress lamp OFF KOMTRAX server. (Connection is made only needed)
ON LED stays turned on as long as data transmission is continued from

Internal transmitting
4 LED-A4 CPU to the communication module. (Transmission is made only need-
lamp OFF ed)
ON LED stays turned on as long as the communication module is
5 LED-A5 Internal receiving lamp
OFF receiving data from CPU. (Receiving is made only needed)
20-176 1 PC400LC-7E0
12
2. Display contents of LED for CPU.
★ Turn ON, START the starting switch or the engine prior to inspection of LED display.
No. LED Name and function Display Contents of display

ON Starting switch ACC signal: ON, Alternator R signal: ON
Quick Starting switch ACC signal: ON, Alternator R signal: OFF
State of starting switch ACC flashing
6 LED-C1 signal, alternator R signal Slow Starting switch ACC signal: OFF, Alternator R signal: ON
flashing
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
State of engine control sig- ON Engine control signal: ON

7 LED-C2 nal OFF Engine control signal: OFF
ON S-NET: Connected, starting switch C signal: OFF
Quick Starting switch C signal: ON
State of S-NET connection flashing
8 LED-C3 and starting switch C signal Slow (Not used)
flashing
OFF S-NET: Disconnected, Starting switch C signal: OFF
ON CAN: Present (Fuel sensor: Absent)
Quick CAN: Present (Fuel sensor: Present)
flashing
9 LED-C4 State of CAN connection
Slow CAN: Absent (Fuel sensor: Present)
flashing
OFF CAN: Absent (Fuel sensor: Absent)
Single Download writing mode (Special function for system admin-
10 LED-C5 side ON istrator)
Download writing state Both
11 LED-C6 sides Normal working mode
OFF
* Types of flashing and flashing duration

Quick flashing: Flashing of approximately 1 second cycle
Slow flashing: Flashing of approximately 4 seconds cycle
3. Display contents of 7-segment and dots for CPU.

★ Turn ON the starting switch prior to inspection of LED display.
No. Display unit Name and function Display Contents of display

Number of mails not trans-
12 7-segment 0-9 Number of mails not transmitted yet
mitted yet
Positioning with GPS complete (Position is recognized
ON See * mark)
13 Dot State of positioning with GPS
Positioning with GPS incomplete (Position is not rec-
OFF ognized See * mark)
* In a outdoor location within radio waves penetration range, it sometimes takes more than a minute from turning on of the
starting switch to completion of the positioning.
Positioning is not available in a location where radio waves are extremely weak or unreachable.
PC400LC-7E0 20-177 1
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT SYSTEM - PREPARATION WORK
12
ELECTRICAL EQUIPMENT SYSTEM - PREPARATION WORK FOR
TROUBLESHOOTING
★ When troubleshooting the monitor panel, engine controller, pump
controller and KOMTRAX terminal-related electrical circuit, bare
applicable connectors according to the following procedure.
1. Machine monitor.
A. Take off cover (1).

★ The cover is fixed with two upper and lower clips. Pull it up
for the removal. If the sunlight sensor is equipped for an air
conditioner, disconnect P15 connector at the cover rear side.
B. Remove the 3 mounting screws to disconnect machine monitor

(2) from the mount.
★ Use care so that the screws may not fall into the console.
C. Insert or connect troubleshooting T-adapter for troubleshooting to

connectors P01, P02 and P70 of machine monitor.
2. Engine controller.
A. Open the engine hood cover on the control valve side.
B. Remove cover (1).
C. Insert or connect troubleshooting T-adapters in or to connectors

ENG, CE02, and CE03 of engine controller (2).
★ Connectors are fixed with screw. Loosen the screws before
disconnecting them.
★ When returning the connectors back to their position, tighten
them to the specified torque.
Screw: 2.82 Nm (2.07 lbf ft)
20-178 1 PC400LC-7E0
12
3. Pump controller.
The engine throttle and pump controller are installed in the cover
situated in the rear side of the operator seat.
A. Remove the 3 mounting bolts and cover (5).
B. Insert or connect troubleshooting T-adapter in or to connectors

CP01, CP02 and CP03 of pump controller (6).
Connectors are fixed with screw. Loosen the screws before
disconnecting them.
When returned the connectors to their original positions, fix
them by tightening the screws with the specified torque.
4. KOMTRAX terminal.
KOMTRAX terminal is installed in the cover situated in the rear
side of the operator seat.
A. Remove the 3 mounting bolts and cover (5).
B. Insert or connect troubleshooting T-adapter in or to connector

G01 KOMTRAX of terminal (7).
The connectors are fixed with screw. Loosen the screws
before disconnecting them.
When returning the connectors to their original positions, fix
them by tightening the screws with the specified torque.
Cable (8) is for the communication antenna.
When cable (8) is currently disconnected, be sure to connect
it again at this stage to the connector situated outside of the
terminal.
Care must be exercised in this operation since connecting the
cable to the opposite connector disables the communication.
Cable (9) is used for the GPS antenna.
PC400LC-7E0 20-179 1
12
PM CLINIC SERVICE
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
20-180 2 PC400LC-7E0
12
Positions to install measuring devices (Related to engine)
PC400LC-7E0 20-181 1
12
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
20-182 1 PC400LC-7E0
12
PC400LC-7E0 20-183 2
12
20-184 1 PC400LC-7E0
12
Visual check of welded structures
If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket
❑ Left ❑ Right ❑ Left ❑ Right ❑ Left ❑ Right
2. Arm foot 5. Boom cylinder bracket
❑ Left ❑ Right ❑ End plate ❑ Left ❑ Right Track frame
3. Arm top boss 6. Arm cylinder bracket 10. Circle bracket
❑ Left ❑ Right ❑ Left ❑ Right ❑ Front ❑ Rear
7. Boom lower plate ❑ Left ❑ Right
❑ Left ❑ Right
8. Boom foot
❑ Left ❑ Right
PC400LC-7E0 20-185 2
20-186 2 PC400LC-7E0
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
POSSIBLE PROBLEMS AND TROUBLESHOOTING NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-216
CONNECTOR ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
CAB & FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
KOMTRAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
BATTERY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
ENGINE ROOM & PUMP ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231
T-BOXES AND T-ADAPTERS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-253
PC400LC-7E0 20-201 b
TROUBLESHOOTING
12
MEMORANDUM
20-202 b PC400LC-7E0
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 investiga-
tion 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. Has the same kind of failure occurred before?
3. Check before troubleshooting
A. Is there any sign of irregularities of the machine?
B. Make checks before starting day's work.
PC400LC-7E0 20-203 b
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
C. Make checks of other items.
D. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. 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.
5. 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-7E0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC400LC-7E0 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 CONNEC-
TORS
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-7E0
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.
PC400LC-7E0 20-207 b
12
REMOVING, 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-7E0
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-7E0 20-209 b
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-7E0
12
HANDLING 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-7E0 20-211 b
12
POINTS 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-7E0
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-7E0 20-213 b
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel --- Add fuel
2. Check for impurities --- Clean, drain
3. Check hydraulic oil level --- Add oil
4. Check hydraulic strainer --- Clean, drain
Lubricating 5. Check swing machinery oil level --- Add oil
oil, coolant 6. Check engine oil level, type of oil --- Add oil
7. Check coolant level --- Add water
8. Check dust indicator for clogging --- Clean or replace
9. Check hydraulic filter --- Replace
10. Check final drive oil level --- Add oil
1. Check for looseness, corrosion of battery terminal, wiring --- Tighten or replace
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring --- Tighten or replace
equipment
3. Check for looseness, corrosion of starter motor terminal, wiring --- Tighten or replace
Hydraulic 1. Check for abnormal noise, smell --- Repair
mechanical 2. Check for oil leakage --- Repair
equipment 3. Carry out air bleeding --- Bleed air
1. Check battery voltage, engine stopped 20 to 30 V Replace
2. Check battery electrolyte level --- Add or replace
3. Check for discolored, burnt, exposed wires --- Replace
4. Check for missing wiring clamps, hanging wiring --- Repair
5. Check for water leaking on wiring (be particularly careful attention to water
Electric, elec- --- Disconnect and dry
leaking on connectors or terminals)
trical equip-
6. Check for blown, corroded fuses --- Replace
ment
After running
for several
7. Check alternator voltage, ½ throttle or above Replace
minutes:
27.5 to 29.5 V
8. Check operating sound of battery relay, when switch is turned ON/OFF --- Replace
20-214 b PC400LC-7E0
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
12
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION OF TROUBLESHOOTING
Mode Content
Code display Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL
STEPS FOR TROUBLESHOOTING

If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by performing the
following steps and proceed to the main body of troubleshooting.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
When action code is displayed on machine monitor, press [4] switch at panel switch section to display failure code.
Carry out the troubleshooting for the corresponding [Display of code] according to the displayed failure code.
2. Procedure for troubleshooting to be taken when failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check a failure code with the abnormality record function of the
machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the recorded code.
★ If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is
still detected.
★ An error code of the mechanical system cannot be deleted.
3. Procedure for troubleshooting to be taken when action code is not displayed and no failure code is recorded in
abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnormality record, a
trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical
system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of
“Phenomena looking like troubles and troubleshooting Nos.”, and then carry out troubleshooting corresponding to that
phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
PC400LC-7E0 20-215 b
12
POSSIBLE PROBLEMS AND TROUBLESHOOTING NO.
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL.
Troubleshooting
No. Phenomena looking like troubles
Display of code E-mode H-mode S-mode
Phenomena related to action code and failure code
1 An action code is displayed on machine monitor
When abnormality record is checked, failure code is displayed in
2 electrical system abnormality record According to
displayed code
3 When abnormality record is checked, failure code is displayed in
mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not start, Engine does not rotate E-1 S-2 (1)
6 Engine does not start, Engine rotates, but exhaust gas does not S-2 (2)
7 Engine does not start, Engine emits exhaust gas, but it does not S-2 (3)
start
8 Engine does not pick up smoothly (follow-up performance is poor) S-3
9 Engine stops during operations H-2 S-4
10 Engine rotation is unstable (it hunts) S-5
11 Engine lacks output or power H-1 S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive or exhaust smoke is blue S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in coolant, coolant spurts back or coolant level goes down S-11
17 Oil level rises (Entry of coolant or fuel) S-13
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
20 Auto-decelerator does not operate E-2 H-5
21 Automatic warm-up system does not operate E-3
22 Preheater does not operate E-4
Phenomena related to work equipment, swing and travel
23 Speed or power of whole work equipment, travel, and swing is low H-1 S-6
24 Engine speed lowers extremely or engine stalls H-2 S-4
25 Work equipment, swing, and travel mechanism do not move E-5 H-3
26 Abnormal sound comes out from around hydraulic pump H-4
27 Fine control performance or response is low H-6
Phenomena related to work equipment
28 Speed or power of boom is low E-18,19 H-7
29 Speed or power of arm is low E-20, 21 H-8
30 Speed or power of bucket is low E-22, 23 H-9
31 Boom, arm, or bucket does not move H-10
32 Hydraulic drift of work equipment is large H-11
20-216 b PC400LC-7E0
12
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
33 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts of work equip-
34 H-13
ment move
35 Power maximizing function does not work E-6, 18 - 23 H-14
Phenomena related to compound operation
36 In compound operation of work equipment, speed of part loaded more is H-15

low
When machine swings and raises boom simultaneously, boom rising
37 H-16
speed is low
When work equipment and travels simultaneously, travel speed lowers
38 largely H-17
Phenomena related to travel

39 Machine deviates during travel H-18
40 Travel speed is low E-25 H-19
41 Machine is not steered well or steering power is low E-25, 26 H-20
42 Travel speed does not change or travel speed is low or high E-25 H-21
43 Travel system does not move (only one side) H-22
Phenomena related to swing
44 Upper structure does not swing E-24 H-23
45 Swing acceleration or swing speed is low H-24
46 Upper structure overruns remarkably when it stops swinging H-25
47 Large shock is made when upper structure stops swinging H-26
48 Large sound is made when upper structure stops swinging H-27
49 Hydraulic drift of swing H-28
Phenomena related to machine monitor (Operator menu: ordinary screen)
50 Machine monitor does not display any items E-7
51 Machine monitor does not display some items E-8
Contents of display by machine monitor are different from applicable ma-
52 E-9
chine
53 Radiator coolant level monitor lights up in red during check before starting B@BCZK
54 Engine oil level monitor lights up in red during check before starting B@BAZK
55 Maintenance interval monitor lights up in red during check before starting See the Operation and Maintenance Manual.
56 Charge level monitor lights up in red while engine is running AB00KE
57 Fuel level monitor lights up in red while engine is running E-10
58 Air cleaner clogging monitor lights up in red while engine is running AA10NX
Engine coolant temperature monitor lights up in red while engine is run-
59 ning B@BCNS
60 Hydraulic oil temperature monitor lights up in red while engine is running B@HANS
61 Engine coolant temperature gauge does not indicate normally E-11
PC400LC-7E0 20-217 b
12
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
62 Hydraulic oil temperature gauge does not indicate normally E-12
63 Fuel level gauge does not indicate normally E-13
64 Swing lock monitor does not indicate normally E-14
Machine monitor display anything even when operated on monitor switch
65 section E-15
66 Windshield wiper does not operate E-16

67 Machine push-up function does not work normally E-17
Phenomena related to machine monitor (Service menu: special functions screen)
68 Monitoring function does not display "Boom RAISE" normally E-18
69 Monitoring function does not display "Boom LOWER" normally E-19
70 Monitoring function does not display "Arm IN" normally E-20
71 Monitoring function does not display "Arm OUT" normally E-21
72 Monitoring function does not display "Bucket CURL" normally E-22
73 Monitoring function does not display "Bucket DUMP" normally E-23
74 Monitoring function does not display "Swing" normally E-24
75 Monitoring function does not display "Travel" normally E-25
76 Monitoring function does not display "Travel Steering" normally E-26
77 Monitoring function does not display "Service" normally E-27
Phenomena related to KOMTRAX
78 KOMTRAX system does not operate normally E-28
Others
79 Air conditioner does not operate E-29
80 Travel alarm does not sound or does not stop sounding E-30
81 Horn does not sound E-31
20-218 b PC400LC-7E0
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
12
CONNECTOR ARRANGEMENT DIAGRAM
★ The address of each connector roughly shows the place of the connector in the connectors stereogram.
Number Address of ste-

Connector No. Model Component name
of pins reogram
A01 X 4 Intermediate connector V-1
A02 X 4 Intermediate connector W-1
A03 DT 12 Intermediate connector Q-1
A04 SWP 6 Intermediate connector R-1
A05 SWP 14 Intermediate connector W-1
A06 SWP 14 Intermediate connector Q-1
A07 SWP 16 Intermediate connector V-1
A09 SWP 8 Intermediate connector P-2
A13 DT 2 Intermediate connector (to boom working lamp) P-1
A22 DT 2 Rear working lamp H-9
CE02 DRC 50 Engine controller AK-5
CE03 DRC 4 Engine controller AK-6
CN1 DT 2 No. 1 fuel injector AK-9
CN2 DT 2 No. 2 fuel injector AK-9
CN3 DT 2 No. 3 fuel injector AL-9
CN4 DT 2 No. 4 fuel injector AN-7
CP01 DRC 24 Pump controller Y-9
CP02 OTP 40 Pump controller X-9
CP03 DRC 40 Pump controller X-9
D01 SWP 8 Concentrated diode AB-2
D02 SWP 8 Concentrated diode AB-2
D10 2 Diode AA-8
D11 2 Diode AA-8
EGR DT 2 EGR valve AJ-9
ENG DRC 60 Engine controller AK-6
F01 20 Fuse X-2
F02 M 2 Revolving warning lamp (if equipped) AB-9
F04 L 2 Fusible link (65A) B-6
F05 M 2 Fusible link (30A) E-2
G SUMITOMO 3 Engine G sensor AJ-6
G01 DRC 40 KOMTRAX Y-9
G02 M 1 (Male) for inspection Y-9
G03 M 1 (Female) for inspection Y-9
G04 M 1 (Male) for inspection Z-9
G05 M 1 (Female) for inspection Z-9
H06 090 20 Intermediate connector (to right console upper wiring harness) Q-8
H07 M 1 Chassis ground (Floor frame) W-2
H08 M 8 Intermediate connector (Speaker) AA-6
H09 S 8 Intermediate connector (Light) AA-5
PC400LC-7E0 20-219 b

of pins reogram
H10 S 16 Intermediate connector (Monitor panel) W-9
H11 S 16 Intermediate connector (Monitor panel) V-9
H12 S 12 Intermediate connector (Monitor panel) V-9
J01 20 Joint connector (Black) Y-2
J02 20 Joint connector (Black) Y-3
J03 20 Joint connector (Green) Y-3
J04 20 Joint connector (Green) Z-3
J05 20 Joint connector (Pink) Z-3
J06 20 Joint connector (Orange) Z-3
J07 20 Joint connector (Orange) Z-3
J1939 DT 3 CAN connector AM-9
JM01 9 Centralized terminals (Engine) AL-9
JM02 12 Centralized terminals (Engine) AL-9
JM03 10 Centralized terminals (Engine) AN-8
K01 M 2 Resistor (30z) Z-1
K02 D 3 CAN terminal resistance AJ-6
K31 D 3 CAN terminal resistance P-4
L01 4 Working lamp (Right front) E-9
L02 D 2 Working lamp (if equipped) C-2
L09 D 2 Working lamp (Boom) J-9
M01 PA 9 Radio W-2
M06 KES 2 Windshield washer motor L-4
M07 090 2 Horn (High tone) F-1
M08 090 2 Horn (Low tone) E-1
M09 M 2 Optional power supply AA-4
M10 M 2 Optional power supply AA-6
M11 M 3 DC/DC converter AA-6
M12 M 2 Service connector AA-7
M13 M 2 Speaker (Right) AG-8
M14 D 2 Travel alarm J-2
M17 D 2 Starting motor (S/R terminal circuit) AI-1
M18 Terminal 1 Alternator R terminal AK-1
M19 2 Cigarette lighter P-3
M20 Terminal 1 Starting motor B terminal AI-1
M21 Terminal 1 Alternator B terminal AL-1
M22 Terminal 1 Alternator E terminal AK-1
M23 Terminal 1 Intake air heater AK-9
M24 D 2 Fuel priming pump (if equipped)
M26 S 12 Air conditioner harness AA-4
M27 18 Air conditioner unit AA-5
M29 20 Air conditioner control unit X-2
M30 16 Air conditioner control unit X-2
M33 4 Air conditioner unit AA-5
M33 M 2 Optional power supply
20-220 b PC400LC-7E0

of pins reogram
M34 X 1 Air conditioner compressor electromagnetic clutch H-9
M40 M 2 Light switch AD-8
M41 M 2 Light switch (if equipped) AC-7
M45 DT 12 Network bus AA-7
M71 M 2 Room lamp AD-8
M72 M 4 DC/DC converter
M73 M 2 Speaker (Left) AH-8
M79 M 2 12V outlet Z-8
M81 X 2 Bucket quick coupler control box (if equipped)
M81 X 2 Bucket quick coupler solenoid (if equipped)
N01 M 4 Y-9
FRAM-
NE 3 Engine NE sensor AL-5
ATOME
P01 070 12 Monitor panel P-6
P01 AMP 3 Bucket CURL pressure sensor L-2
P02 X 2 Boom LOWER pressure switch L-2
P03 X 2 Swing RIGHT pressure switch L-2
P04 AMP 3 Arm IN pressure sensor L-2
P05 X 2 Bucket DUMP pressure switch L-1
P06 X 2 Boom RIGHT pressure switch L-1
P07 X 2 Swing LEFT pressure switch L-1
P08 X 2 Arm OUT pressure switch L-1
P09 X 2 Travel hydraulic pressure switch (Black) R-1
P10 X 2 Travel hydraulic pressure switch (Steering signal) (Red) R-1
P13 X 2 Intermediate connector K-3
P15 2 Air conditioner daylight sensor P-6
P17 2 Air conditioner high-pressure switch W-9
P20 M 3 Fuel control dial R-8
P21 X 1 Fuel level sensor D-9
P22 D 2 Hydraulic oil temperature sensor K-3
P23 D 2 Air cleaner clogging sensor G-9
P24 X 2 Radiator coolant level sensor AJ-1
P25 AMP 3 F pump oil pressure sensor L-4
P26 AMP 3 R pump oil pressure sensor K-3
P44 D 2 Engine oil level switch AK-5
FRAM-
PAMB 3 Atmospheric pressure sensor AM-9
ATOME
PFUEL AMP 3 Common rail pressure sensor AL-5
PIM CANNON 3 Boost pressure sensor AN-6
FRAM-
POIL 3 Engine oil pressure sensor AJ-6
ATOME
PV1 SUMITOMO 2 Fuel supply pump PCV1 AJ-6
PV2 SUMITOMO 2 Fuel supply pump PCV2 AJ-6
PC400LC-7E0 20-221 b
Number Address of
of pins stereogram
R01 Terminal 1 Battery relay (Terminal E) B-6
R02 Terminal 1 Battery relay (Terminal BR) B-7
R03A Terminal 1 Battery relay (Terminal M) D-6
R03B Terminal 1 Battery relay (Terminal M) D-6
R04 Terminal 1 Battery relay (Terminal B) D-7
R05 Relay 5 Light relay S-8
R06 Relay 5 Starting motor cutout relay (PPC lock) S-9
R07 Relay 5 Starting motor cutout relay (Personal code) T-9
R08 Relay 6 Horn relay AB-1
R15 Terminal 1 Intake air heater relay (Inlet) C-5
R16 Terminal 1 Intake air heater relay (Outlet) D-5
R17 Terminal 1 Intake air heater relay (Drive coil inlet) B-6
R18 Relay 5 Intake air heater relay (Drive relay) Z-2
R20 Relay 5 ATT circuit selector relay Z-2
R23 Relay 5 Engine power supply relay (1) Z-2
R24 Relay 5 Engine power supply relay (2) Z-1
R30 SUMITOMO 5 Air conditioner blower relay AA-4
R31 AMP 4 Air conditioner compressor relay AA-7
RES DT 2 Resistance (620z) AN-8
S01 Terminal 6 Starting switch R-8
S02 M 3 Light switch S-8
S04 M 4 Swing lock switch S-9
S05 M 2 Machine push-up switch T-9
S07 M 2 Revolving warning lamp switch X-2
S10 090 2 Horn switch R-8
S10 X 2 Pressure switch for service switch (Front) (if equipped) J-3
S11 090 2 Knob switch (Left) W-1
S11 X 2 Pressure switch for service switch (Rear) (if equipped) K-3
S14 M 2 PPC oil pressure lock switch V-1
S21 Terminal 6 Emergency pump drive switch U-9
S22 Terminal 6 Swing holding brake release switch T-9
S25 090 16 Intermediate connector (to right console emergency switch) U-9
S30 S 8 Model selection connector Z-2
S41 DT 2 Fuel priming pump (if equipped)
SEGR DT 4 EGR valve position sensor AJ-9
T01 Terminal 1 Floor frame ground Y-3
T03 Terminal 1 Radio body ground V-9
T04 Terminal 1 Revolving frame ground H-1
T05 Terminal 1 Revolving frame ground H-1
T06 Terminal 1 Revolving frame ground I-2
T08 Terminal 1 Revolving frame ground D-2
T10 Terminal 1 Revolving frame ground J-2
20-222 b PC400LC-7E0
Number Address of
of pins stereogram
T11 Terminal 1 CAB ground AH-3
T11 Terminal 1 Engine body ground AL-5
T12 Terminal 1 Alternator ground AJ-1
TFUEL PACKARD 2 Fuel temperature sensor AL-5
TIM PACKARD 2 Boost temperature sensor AM-9
TWTR PACKARD 3 Coolant temperature sensor AJ-1
V01 DT 2 PPC oil pressure lock solenoid valve M-5
V02 DT 2 Travel junction solenoid valve M-5
V03 DT 2 Merge-divider solenoid valve M-5
V04 DT 2 Travel speed solenoid valve (Hi/Lo) M-5
V05 DT 2 Swing holding brake solenoid valve M-4
V06 DT 2 Machine push-up solenoid valve M-4
V07 DT 2 ATT return selector solenoid valve M-3
V08 DT 2 2-stage relief solenoid valve M-4
V11 DT 2 PC-EPC solenoid valve L-6
V19 DT 2 LS-EPC solenoid valve L-7
V30 X 2 ATT flow adjustment EPC solenoid valve (if equipped) S-1
W03 M 2 Rear limit switch AF-9
W04 M 6 Wiper motor AC-4
PC400LC-7E0 20-223 b
12
CONNECTOR LOCATION STEREOGRAM
20-224 b PC400LC-7E0
12
PC400LC-7E0 20-225 b
12
20-226 b PC400LC-7E0
12
PC400LC-7E0 20-227 b
12
20-228 b PC400LC-7E0
12
PC400LC-7E0 20-229 b
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM
12
ELECTRICAL CIRCUIT DIAGRAM
BOOM
AIR CONDITIONER
CAB & FLOOR
KOMTRAX
BATTERY BOX
CHASSIS
ENGINE ROOM & PUMP ROOM

See Section 90 for diagrams.
PC400LC-7E0 20-230 b
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.
X type connector
No.of pins
Male (female housing) Female (male housing) T-adapter Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
Electric wire size: 0.85 Electric wire size: 0.85
--- ---
Grommet: Black Grommet: Black
Q’ty: 20 Q’ty: 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410
--- ---
Grommet: Red Grommet: Red
Q’ty: 20 Q’ty: 20
20-231 b PC400LC-7E0
12
SWP type connector

No.of
pins T-adapter
Male (female housing) Female (male housing) Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
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 Part No.: 08055-11491
PC400LC-7E0 20-232 b
12
SWP type connector

No.of pins T-adapter
Male (female housing) Female (male housing) Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
--- ---
Grommet: Black Grommet: Black
Q’ty: 20 Q’ty: 20
Terminal part No.: Terminal part No.:
--- ---
Grommet: Red Grommet: Red
Q’ty: 20 Q’ty: 20
20-233 b PC400LC-7E0
12
No.of M type connector
pins Male (female housing) Female (male housing) T-adapter Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
PC400LC-7E0 20-234 b
12
No.of S type connector
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10 799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12 799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16 799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-235 b PC400LC-7E0
12
No.of S type connector
10 ---
(Blue)
--- ---
12 799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16 799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC400LC-7E0 20-236 b
12
No.of MIC type connector
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) ---
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) ---
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-237 b PC400LC-7E0
12
No.of MIC type connector

17 799-601-2730
21 799-601-2740
Terminal part No.: 79A-222-2770 (Q’ty: 50) Terminal part No.: 79A-222-2760 (Q’ty: 50) ---
PC400LC-7E0 20-238 b
12
No.of AMP040 type connector
8 799-601-7180
--- Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220

★ Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-239 b PC400LC-7E0
12
No.of AMP070 type connector
10 799-601-7510
--- Part No.: 7821-92-7330
12 799-601-7520
--- Part No.: 7821-92-7340
14 799-601-7530
--- Part No.: 7821-92-7350
18 799-601-7540
--- Part No.: 7821-92-7360
20 799-601-7550
--- Part No.: 7821-92-7370
PC400LC-7E0 20-240 b
12
No.of L type connector
2 ---
--- ---
No.of Connector for PA

9 ---
--- ---
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing) No.
10 799-601-3460
--- ---
20-241 b PC400LC-7E0
12
No.of KES 1 (Automobile) connector
2 ---
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 ---
Part No.:08027-10310 Part No.:08027-10360
4 ---
08027-10420 (Black) 08027-10470 (Black)
6 ---
08027-10620 (Black) 08027-10670 (Black)
PC400LC-7E0 20-242 b
12
No.of KES 1 (Automobile) connector
8 ---
08027-10820 (Black) 08027-10870 (Black)
No.of Connector for relay (Socket type)

5 799-601-7360
--- ---
6 799-601-7370
--- ---
No.of F type connector

4 ---
--- ---
20-243 b PC400LC-7E0
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type HD30 Series connector

(shell
size Body (plug) Body (receptacle) T-adapter Part No.
code)
Pin (male terminal) Pin (female terminal)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

08191-11205, 08191-11206 08191-14105, 08191-14106
18-8 (1)
Pin (female terminal) Pin (male terminal)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin (male terminal)
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
PC400LC-7E0 20-244 b
12
Remark

(shell
code)
799-601-9230
Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

18-20 799-601-9230
(3)
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

18-21 799-601-9240
(4)
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
20-245 b PC400LC-7E0
12
Remark

(shell
code)
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
PC400LC-7E0 20-246 b
12
Remark

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
20-247 b PC400LC-7E0
12
Remark

(shell
code)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
PC400LC-7E0 20-248 b
12
Remark
DT Series connector
No.of
pins T-adapter
Body (plug) Body (receptacle) Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-249 b PC400LC-7E0
12
Remark
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12BR: 799-601-9140
PC400LC-7E0 20-250 b
12
Remark
DTM Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle) No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
No.of DTHD Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
2 ---
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-251 b PC400LC-7E0
12
Remark
DRC26 Series connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing) No.
24 799-601-9360
- Part No.:7821-93-3110
40 799-601-9350
(A)
- Part No.:7821-93-3120
40 799-601-9350
(B)
- Part No.:7821-93-3130
PC400LC-7E0 20-252 b
TROUBLESHOOTING T-BOXES AND T-ADAPTERS TABLE
12
T-BOXES AND T-ADAPTERS TABLE
★ The Nos. in the columns are the part Nos. of the T-boxes, T-adapters, and other parts. The Nos. in the lines are the kit Nos.
of the T-adapter kits.
20-253 b PC400LC-7E0
12
PC400LC-7E0 20-254 b
12
20-255 b PC400LC-7E0
12
MEMORANDUM
PC400LC-7E0 20-256 b
TROUBLESHOOTING ERROR CODES
AND FAILURE CODES
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-305

POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF . . . . . . . . . . . . 20-306
USER CODE MEMORY RETENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307
FAILURE CODES TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307
BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED . . . . . 20-310
INFORMATION IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-314
A000N1 - ENG. HI OUT OF STD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
AA10NX - AIR CLEANER CLOGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-317
AB00KE - CHARGE VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
B@BAZG - ENG OIL PRESS. LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
B@BAZK - ENG. OIL LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322
B@BCNS - ENG. WATER OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324
B@BCZK - ENG. WATER LVL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
B@HANS - HYD. OIL OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-327
CA111 - ECM CRITICAL INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
CA115 - ENG NE AND BKUP SPEED SENS ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-330
CA122 - CHG AIR PRESS SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
CA123 - CHG AIR PRESS SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
CA131 - THROTTLE SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336
CA132 - THROTTLE SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-337
CA135 - ENG OIL PRESS SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338
CA141 - ENG OIL PRESS SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-339
CA144 - COOLANT TEMP SENS HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
CA145 - COOLANT TEMP SENS LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-341
CA153 - CHG AIR TEMP SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342
CA154 - CHG AIR TEMP SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344
CA187 - SENS SUPPLY 2 VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-345
CA221 - AMBIENT PRESS SENS HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
CA222 - AMBIENT PRESS SENS LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348
CA227 - SENS SUPPLY 2 VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350
CA234 - ENG OVERSPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352
CA238 - NE SPEED SENS SUPPLY VOLT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354
CA263 - FUEL TEMP SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356
CA265 - FUEL TEMP SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
CA271 - IMV/PCV1 SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-359
CA272 - IMV/PCV1 OPEN ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
CA273 - PCV2 SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
CA274 - PCV2 OPEN ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-363
CA322 - INJ #1 (L#1) OPEN/SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
CA342 - CALIBRATION CODE INCOMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
CA351 - INJECTORS DRIVE CIRCUIT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
PC400LC-7E0 20-301 1
TROUBLESHOOTING TABLE OF CONTENTS
CA352 - SENS SUPPLY 1 VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-374
CA386 - SENS SUPPLY 1 VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376
CA441 - BATTERY VOLTAGE LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
CA442 - BATTERY VOLTAGE HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
CA449 - RAIL PRESS VERY HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
CA451 - RAIL PRESS SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
CA452 - RAIL PRESS SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
CA553 - RAIL PRESS HIGH ERROR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
CA554 - RAIL PRESS SENSOR IN RANGE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-385
CA559 - RAIL PRESS LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
CA689 - ENG NE SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390
CA731 - ENG BKUP SPEED SENS PHASE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
CA757 - ALL PERSISTENT DATA LOST ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-393
CA778 - ENG BKUP SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
CA1228 - EGR VALVE SERVO ERROR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
CA1625 - EGR VALVE SERVO ERROR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-397
CA1633 - KOMNET DATALINK TIMEOUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
CA2185 - THROT SENS SUP VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
CA2186 - THROT SENS SUP VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
CA2249 - RAIL PRESS VERY LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-403
CA2271 - EGR VALVE LIFT SENS HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
CA2272 - EGR VALVE LIFT SENS LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
CA2351 - EGR VALVE SOL CURRENT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
CA2352 - EGR VALVE SOL CURRENT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
CA2555 - GRID HTR RELAY VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411
CA2556 - GRID HTR RELAY VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
D110KB - BATTERY RELAY DRIVE S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
D196KA - SERVICE RETURN RELAY DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
D196KB - SERVICE RETURN RELAY S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
DA25KP - PRESS. SENSOR POWER ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
DA80MA - AUTO-LUBE ABNORMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
DA2RMC - PUMP COMM. ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
DA2SKQ - MODEL SELECTION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
DAFRMC - MONITOR COMM. ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
DHPAMA - F PUMP P. SENSOR ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
DHPBMA - R PUMP P. SENSOR ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
DHS3MA - ARM CURL PPC SEN. ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
DHS4MA - BUCKET CURL PPC SEN. ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
DW43KA - TRAVEL SPEED SOL. DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438
DW43KB - TRAVEL SPEED SOL. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
DW45KA - SWING BRAKE SOL. DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
DW45KB - SWING BRAKE SOL. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444
DW91KA - TRAVEL JUNCTION SOL. DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
DW91KB - TRAVEL JUNCTION SOL. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
DWJ0KA - MERGE-DIVIDER SOL. DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
DWJ0KB - MERGE-DIVIDER SOL. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
DWK0KA - 2-STAGE RELIEF SOL. DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
DWK0KB - 2-STAGE RELIEF SOL. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
DXA0KA - PC-EPC SOL. DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
DXA0KB - PC-EPC SOL. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-460
DXE0KA - LS-EPC SOL. DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-462
DXE0KB - LS-EPC SOL. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-464
DXE4KA - SERVICE CURRENT EPC DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
DXE4KB - SERVICE CURRENT EPC S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-467
DY20KA - WIPER WORKING ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-468
DY20MA - WIPER PARKING ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-470
DY2CKB - WASHER DRIVE S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-472
20-302 1 PC400LC-7E0
TROUBLESHOOTING TABLE OF CONTENTS
DY2DKB - WIPER DRIVE (FOR) S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474
DY2EKB - WIPER DRIVE (REV) S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-476
PC400LC-7E0 20-303 1
TROUBLESHOOTING
12
MEMORANDUM
20-304 1 PC400LC-7E0
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.
PC400LC-7E0 20-305 1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
12
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY
ITSELF
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.
20-306 1 PC400LC-7E0
TROUBLESHOOTING TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
12
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
FAILURE CODES TABLE
Action Alarm Device in
Failure code Trouble (Displayed on screen) Category of record
code buzzer charge
- A000N1 Eng. Hi Out of Std MON Mechanical system
- AA10NX Air cleaner Clogging MON Mechanical system
- AB00KE Charge Voltage Low MON Mechanical system
- B@BAZG Eng. Oil Press. Low MON Mechanical system
- B@BAZK Eng. Oil Level Low MON Mechanical system
- B@BCNS Eng. Water Overheat MON Mechanical system
- B@BCZK Eng. Water Lvl Low MON Mechanical system
E02 B@HANS Hyd. Oil Overheat MON Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E11 CA115 Eng Ne and Bkup Speed Sens Error l ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error l ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error l ENG Electrical system
E14 CA131 Throttle Sensor High Error l ENG Electrical system
E14 CA132 Throttle Sensor Low Error l ENG Electrical system
E15 CA135 Eng. Oil Press Sensor High Error l ENG Electrical system
E15 CA141 Eng. Oil Press Sensor Low Error l ENG Electrical system
E15 CA144 Coolant Temp Sens High Error l ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error l ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error l ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error l ENG Electrical system
E15 CA221 Ambient Press Sens High Error l ENG Electrical system
E15 CA222 Ambient Press Sens Low Error l ENG Electrical system
- CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error l ENG Electrical system
E15 CA263 Fuel Temp Sensor High Error l ENG Electrical system
E15 CA265 Fuel Temp Sensor Low Error l ENG Electrical system
E11 CA271 IMV/PCV1 Short Error l ENG Electrical system
E11 CA272 IMV/PCV1 Open Error l ENG Electrical system
E11 CA273 PCV2 Short Error l ENG Electrical system
E11 CA274 PCV2 Open Error l ENG Electrical system
E10 CA342 Calibration Code Incompatibility l ENG Electrical system
E10 CA351 Injectors Drive Circuit Error l ENG Electrical system
PC400LC-7E0 20-307 1

code buzzer charge
E10 CA441 Battery Voltage Low Error l ENG Electrical system
E10 CA442 Battery Voltage High Error l ENG Electrical system
E11 CA449 Rail Press Very High Error l ENG Electrical system
E11 CA451 Rail Press Sensor High Error l ENG Electrical system
E11 CA452 Rail Press Sensor Low Error l ENG Electrical system
E15 CA553 Rail Press High Error l ENG Electrical system
- CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error l ENG Electrical system
E11 CA689 Ne Speed Sensor Error l ENG Electrical system
E11 CA731 Bkup Speed Sens Phase Error l ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Bkup Speed Sensor Error l ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error l ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error l ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error l ENG Electrical system
E11 CA2249 Rail Press Very Low Error l ENG Electrical system
E11 CA2271 EGR Valve Pos Sens High Error l ENG Electrical system
E11 CA2272 EGR Valve Pos Sens Low Error l ENG Electrical system
E11 CA2351 EGR Valve Sol Current High Error l ENG Electrical system
E11 CA2352 EGR Valve Sol Current Low Error l ENG Electrical system
E15 CA2555 Grid Htr Relay Volt Low Error l ENG Electrical system
E15 CA2556 Grid Htr Relay Volt High Error l ENG Electrical system
- D110KB Battery Relay Drive S/C PUMP Electrical system
- D196KA Service Return Relay Disc. PUMP Electrical system
- D196KB Service Return Relay S/C PUMP Electrical system
E02 DA25KP Press. Sensor Power Abnormality l PUMP Electrical system
- DA80MA Auto Lub Abnormal PUMP Electrical system
E0E DA2RMC Pump Comm. Abnormality l PUMP Electrical system
- DA2SKQ Model Selection Abnormality l PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality l PUMP Electrical system
- DHPAMA F Pump P. Sensor Abnormality PUMP Electrical system
- DHPBMA R Pump P. Sensor Abnormality PUMP Electrical system
- DHS3MA Arm Curl PPC Sen. Abnormality PUMP Electrical system
- DHS4MA Bucket Curl PPC Sen. Abnormality PUMP Electrical system
- DW43KA Travel Speed Sol. Disc. PUMP Electrical system
- DW43KB Travel Speed Sol. S/C PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. l PUMP Electrical system
E03 DW45KB Swing Brake Sol. S/C l PUMP Electrical system
- DW91KA Travel Junction Sol. Disc. PUMP Electrical system
- DW91KB Travel Junction Sol. S/C PUMP Electrical system
- DWJ0KA Merge-divider Sol. Disc PUMP Electrical system
20-308 1 PC400LC-7E0

code buzzer charge
- DWJ0KB Merge-divider Sol. S/C PUMP Electrical system
- DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system
- DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Disc. PUMP Electrical system
E02 DXA0KB PC-EPC Sol. S/C PUMP Electrical system
- DXE0KA LS-EPC Sol. Disc. PUMP Electrical system
- DXE0KB LS-EPC Sol. S/C PUMP Electrical system
- DXE4KA Service Current EPC Disc. PUMP Electrical system
- DXE4KB Service Current EPC S/C PUMP Electrical system
- DY20KA Wiper Working Abnormality MON Electrical system
- DY20MA Wiper Parking Abnormality MON Electrical system
- DY2CKB Washer Drive S/C MON Electrical system
- DY2DKB Wiper Drive (For) S/C MON Electrical system
- DY2EKB Wiper Drive (Rev) S/C MON Electrical system
★ This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
PC400LC-7E0 20-309 1
12
BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS
DISPLAYED
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 in the ON position and a constant power supply is a
device which supplies power while the starting switch is in the OFF and ON positions).
★ When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if
the power is supplied normally.
Type of power sup- Fuse

Fusible link Fuse No. capacity Destination of power
ply
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
F04 3 20A Machine monitor
Switch power supply (65A) Wiper motor
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Intake air heater relay
7 10A Rotary lamp
F04 8 20A Right headlamp, working lamp (boom), working lamp (rear)
Switch power supply (65A) Radio
9 10A
Left-hand knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
F04
Switch power supply 13 20A Headlamp relay
(65A)
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Constant power sup- F05 17 10A Starting switch

ply (30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Switch power Starting switch 20 5A Engine controller (ACC signal)
supply ACC
20-310 1 PC400LC-7E0
12
Locations of fusible links
PC400LC-7E0 20-311 1
12
Troubles that occur when controller power supply of pump controller is defective
★ The controller power supply (F01-1) of the pump controller drives the controller system. Accordingly, if it is turned off,
the controller cannot control the system and the troubles shown below occur simultaneously (The following is an example
of the troubles).
• The working mode cannot be changed.
• The auto-decelerator does not work or is not reset.
• The travel speed does not change.
• The power maximizing function does not work.
• The swing holding brake cannot be reset automatically.
• The machine deviates during travel.
Troubles that occur when solenoid power supply of pump controller is defective
★ The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids and relays.
Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids or relays,
the power is not supplied to any of the solenoids and relays and all or some of the following failure codes are displayed
simultaneously.
• [DW43KA], [DW43KB]: Travel speed solenoid system
• [DW45KA], [DW45KB]: Swing holding brake solenoid system
• [DW4WKA], [DW4WKB]: Bucket dump prohibit solenoid system
• [DW91KA], [DW91KB]: Travel junction solenoid system
• [DWA2KA], [DWA2KB]: Service solenoid system
• [DWK0KA], [DWK0KB]: 2-stage relief solenoid system
• [DXA8KA], [DXA8KB]: PC-EPC (F) solenoid system
• [DXA9KA], [DXA9KB]: PC-EPC (R) solenoid system
• [DXE0KA], [DXE0KB]: LS-EPC solenoid system
• [DXE4KA], [DXE4KB]: Service current EPC system (if attachment is installed)
• [DXE5KA], [DXE5KB]: Merge-divider main solenoid system
• [DXE6KA], [DXE6KB]: Merge-divider LS solenoid system
★ If the above problems occur, check the related fuse (F01-2) and inlet voltage of the pump controller.
1. Disconnect connector CP03 of the controller and connect a T-adapter to the wiring harness side.
2. Turn the starting switch ON.
3. Measure the voltage between each of pins (2), and (12) and each of pins (27), (32), and (33).
★ Pins (2) and (12) are the power supply and pins (27), (32), and (33) are the chassis ground.
★ If the voltage is 20 – 30 V, it is normal.
20-312 1 PC400LC-7E0
12
Power supply connector (CP03) of pump controller
PC400LC-7E0 20-313 1
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
12
INFORMATION IN TROUBLESHOOTING TABLE
★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before
carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on machine Display on machine Trouble Trouble name displayed in abnormality record machine monitor
monitor monitor
Contents of trouble Contents of trouble detected by machine monitor or controller
Action of machine mon-
itor or controller Action taken by machine monitor or controller to protect system or devices when engine controller detects trouble
Problem that appears Problem that appears on machine as result of action taken by machine monitor or controller (shown above)
on machine
Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Ground fault
Possible causes and standard value in normal state
Wiring harness which is not connected to chassis ground circuit is in contact with chassis
ground circuit.
• Hot short
Wiring harness which is not connected to power source (24 V) circuit is in contact with power
2 source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each other abnormally.
Possible causes of trouble
(Given numbers are reference
numbers, which do not indicate
priority) <Precautions for troubleshooting>
1. Method of indicating connector No. and handling of T-adapter Insert or connect T-adapter as
explained below for troubleshooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female", disconnect connector and insert
T-adapters in both male side and female side.
• If connector No. has marks of "male" and "female", disconnect
connector and connect T-adapter to only male side or female side.
2. Entry order of pin Nos. and handling of tester leads Connect positive (+) lead and negative (-
) lead of tester as explained below for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or wiring harness entered on front side.
4 • Connect negative (-) lead to pin No. or harness entered on rear side.
20-314 1 PC400LC-7E0
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
12
Circuit Diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• “Connector No. and pin No.” from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• (⇐⇒): Roughly shows the location on the machine.
PC400LC-7E0 20-315 1
TROUBLESHOOTING A000N1 - ENG. HI OUT OF STD
12
A000N1 - ENG. HI OUT OF STD
Action code Failure code Eng. Hi Out of Std
Trouble (Mechanical system)
- A000N1
Contents of trouble • While the engine was running, engine speed exceeded 2,350 rpm for more than 10 seconds.
• None in particular.
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on • If machine is operated as it is, engine may be damaged.
machine
• Input from the engine speed sensor (engine speed) can be checked with monitoring function.
Related information
(Code 01002: Engine speed)

Defective engine mechanical sys- Check for any internal or external factor that might cause the excessive engine high
Possible causes and standard 1 tem idle speed for troubleshooting of engine mechanical system.
value in normal state
2 Defective engine controller Since trouble is in system, troubleshooting cannot be carried out. (If no visible error
appears on the machine, the controller can be continuously used as it is.)
20-316 1 PC400LC-7E0
TROUBLESHOOTING AA10NX - AIR CLEANER CLOGGING
12
AA10NX - AIR CLEANER CLOGGING
Action code Failure code Air cleaner Clogging
- AA10NX
Contents of trouble • While engine was running, signal circuit of air cleaner clogging switch was opened (disconnected with GND).
Action of machine moni-
tor • None in particular.

machine
• If an air cleaner clogging caution symbol appears on the machine monitor while the engine is running, this failure code will
be recorded.
Related information
Input from the air cleaner clogging switch (ON/OFF) can be checked with monitoring function.
(Code 04501: Monitor Input 2)

Clogging of air cleaner
★ Check the air cleaner for clogging and then clean or replace it if clogged.
1
(when system is normal)
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective air cleaner clogging P23 (male) Air cleaner Resistance
2 switch (internal disconnection)
Value in normal state Max. 1 Ω
Between (1) - (2)
Value when clogged Min. 1 MΩ
Disconnection in wiring harness
3 (Disconnection in wiring or defec- Wiring harness between P02 (female) (5) - P23 (female) (1) Resistance Max. 1 Ω
tive contact in connector)
Wiring harness between P23 (female) (2) - chassis ground Resistance Max. 1 Ω
P02 Air cleaner Voltage
4 Defective machine monitor
Value in normal state Max. 1 V
Between (5) - chassis ground
Value when clogged 20 - 30 V
Circuit diagram related to air cleaner clogging switch of machine monitor
PC400LC-7E0 20-317 1
TROUBLESHOOTING AB00KE - CHARGE VOLTAGE LOW
12
AB00KE - CHARGE VOLTAGE LOW
Action code Failure code Charge Voltage Low
- AB00KE
Contents of trouble • While engine is running, power generation signal from the alternator is not input.
Problem that appears on • If machine is operated as it is, battery may not be charged.
machine
• If a charge level caution symbol appears on the machine monitor while the engine is running, this failure code will be
recorded.
Related information
• Input from alternator (voltage) can be checked with monitoring function.
(Code 04300: Charge voltage)

Defective alternator
1 Alternator Engine speed Voltage
(Low power generation)
Between R terminal - chassis ground Medium or higher 27.5 - 29.5 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
Disconnection in wiring harness ON.
2 (Disconnection in wiring or defec-
tive contact in connector) Wiring harness between P02 (female) (11) - J02 - Resistance Max. 1 Ω
Alternator R terminal
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
3 Ground fault in wiring harness Wiring harness between P02 (female) (11) - J02 -
(Short circuit with GND circuit)
Alternator R terminal, - D01 (female) (6) - M17 Resistance Min. 1 MΩ
(female) (2)
4 Defective machine monitor P02 Engine speed Voltage
Between (11) - chassis ground Medium or higher 27.5 - 29.5 V
20-318 1 PC400LC-7E0
TROUBLESHOOTING AB00KE - CHARGE VOLTAGE LOW
12
Circuit diagram related to starting and charge of machine monitor
PC400LC-7E0 20-319 1
TROUBLESHOOTING B@BAZG - ENG OIL PRESS. LOW
12
B@BAZG - ENG OIL PRESS. LOW
Action code Failure code Eng Oil Press. Low
- B@BAZG
• While engine was running, signal circuit of engine oil pressure switch detected low engine oil pressure (sensor contact
Contents of trouble
opened).
• Displays engine oil pressure monitor on machine monitor.
If cause of failure disappears, system resets itself.
machine
• Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor.
Related information
• Method of reproducing failure code: Start engine.

Lowering of engine oil pressure
1
(when system is normal) ★ Determine the cause and check the damage to the engine and then modify it.
Defective engine oil pressure sensor POIL Engine Resistance
2
(Internal defect) When started Min. 1 MΩ
When stopped Max. 1 Ω
Disconnection in wiring harness ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female) (37) - POIL (fe-
tive contact in connector) male) (1) Resistance Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
4 (Short circuit with GND circuit) Wiring harness between ENG (female) (37) - POIL (fe-
Resistance Min. 1 MΩ
male) (1) and chassis ground (when engine is started)
ENG Engine Resistance
5 Defective engine controller
When started Min. 1 MΩ
When stopped Max. 1 Ω
20-320 1 PC400LC-7E0
TROUBLESHOOTING B@BAZG - ENG OIL PRESS. LOW
12
Circuit diagram related to engine oil pressure
PC400LC-7E0 20-321 1
TROUBLESHOOTING B@BAZK - ENG. OIL LEVEL LOW
12
B@BAZK - ENG. OIL LEVEL LOW
Action code Failure code Eng. Oil Level Low
Trouble (Machine monitor system)
- B@BAZK
• When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch detected low engine
Contents of trouble
oil level (sensor contact opened).
Action of machine moni- • Displays engine oil level monitor on machine monitor.
tor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on
• If machine is operated as it is, engine may be damaged.
machine
• Engine oil level switch signal can be checked with monitoring function.
Related information (Code 04501: Monitor Input 2)
• Method of reproducing failure code: Turn starting switch ON.
1
Lowering of engine oil level (when sys- ★ Check the engine oil level and add new oil.
tem is normal) (If this phenomenon frequently occurs, investigate the cause.)
ON.
2 Defective engine oil level switch (Internal P44 (male) Engine oil level Resistance
disconnection)
Value when coolant level is low Min. 1 MΩ
Disconnection in wiring harness (Discon- ON.
3 nection in wiring or defective contact in
connector) Wiring harness between P02 (female) (8) - P44 (female)
Resistance Max. 1 Ω
(1)
P02 Engine oil level Voltage
Value when coolant level is low 20 - 30 V
Circuit diagram related to engine oil level switch of machine monitor
20-322 1 PC400LC-7E0
TROUBLESHOOTING B@BAZK - ENG. OIL LEVEL LOW
12
MEMORANDUM
PC400LC-7E0 20-323 1
TROUBLESHOOTING B@BCNS - ENG. WATER OVERHEAT
12
B@BCNS - ENG. WATER OVERHEAT
Action code Failure code Eng. Water Overheat
Trouble (Engine controller system)
- B@BCNS
• While engine was running, signal circuit of engine coolant temperature sensor detected overheating of engine coolant
Contents of trouble
(above 102°C [215.6°F]).
Action of machine moni- • Displays engine coolant temperature monitor with red on machine monitor.
tor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• If machine is operated as it is, engine may be damaged.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor.
Related information • Engine coolant temperature can be checked with monitoring function (Code 04107: Engine coolant temperature)
• Method of reproducing failure code: Start engine.

Overheating of engine
1
(when system is normal) ★ Determine the cause and check the damage to the engine and then modify it.
ON.
2 Defective engine coolant temperature TWTR (male) Engine coolant temperature Resistance
sensor (Internal short circuit)
Between (2) - (1) 10 - 100°C 90 - 3.5 kΩ
Between (2) - chassis ground [50 - 212°F] Min. 1 MΩ
ON.
3
(Short circuit with GND circuit) Between wiring harness of ENG (fe-
male) (15) - TWTR (female) (A) and Resistance Min. 1 MΩ
chassis ground
ON.
4 Defective engine controller ENG (female) Engine coolant temperature Resistance
10 - 100°C
Between (15) - chassis ground [50 - 212°F] 90 - 3.5 kΩ
20-324 1 PC400LC-7E0
TROUBLESHOOTING B@BCNS - ENG. WATER OVERHEAT
12
Circuit diagram related to engine coolant temperature sensor of machine monitor
PC400LC-7E0 20-325 1
TROUBLESHOOTING B@BCZK - ENG. WATER LVL LOW
12
B@BCZK - ENG. WATER LVL LOW
Trouble Eng. Water Lvl Low (Mechanical system)
- B@BCZK
Contents of trouble • While engine was running, signal circuit of radiator coolant level switch was opened (disconnected with GND).
Problem that appears on • If machine is operated as it is, engine may overheat.

machine
• If radiator coolant level caution symbol appears on the machine monitor while the engine is running, this failure code will
be recorded.
Related information
• Input from the radiator coolant level switch (ON/OFF) can be checked with monitoring function.
1 Lowering of radiator coolant level ★ Check the coolant level and add coolant.
(when system is normal) (If this phenomenon frequently occurs, investigate the cause.)
ON.
Defective radiator coolant level switch P24 (male) Radiator coolant level Resistance
2
(internal disconnection)
Between (1) - (2) Value when coolant level is Min. 1 MΩ
low
ON.
Disconnection in wiring harness. (Dis-
3 connection in wiring or defective contact Wiring harness between P02 (female) (3) - P24 (fe- Resistance Max. 1 Ω
in connector) male) (1)
Wiring harness between P24 (female) (2) - chassis
ground
P02 Engine coolant temperature Voltage
Between (3) - chas-
sis ground Value when coolant level is
20 - 30 V
low
Circuit diagram related to radiator coolant level switch of machine monitor
20-326 1 PC400LC-7E0
TROUBLESHOOTING B@HANS - HYD. OIL OVERHEAT
12
B@HANS - HYD. OIL OVERHEAT
Action code Failure code Hydr. Oil Overheat
- B@HANS
Contents of trouble • While engine was running, signal of hydraulic oil temperature sensor input 102°C [215.6°F] or higher.
Problem that appears on • If machine is operated as it is, hydraulic components may be seized.
machine
• If hydraulic oil temperature gauge enters red range on the machine monitor while the engine is running, this failure code
will be recorded.
Related information
• Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function.
(Code 04402: Hydraulic oil temperature sensor voltage)

Hyd. Oil Overheat

1 (when system is normal) ★ Determine the cause and check the damage to the hydraulic components and then modify it.
P22 (male) Hydraulic oil temperature Resistance
2 Defective hydraulic oil temperature
sensor (Internal short circuit)
Between (1) - (2) 10 - 100°C 90 - 3.5 kΩ
3 (Short circuit with GND circuit) Wiring harness between P02 (female) (12) - P22 (female) (2) and Resistance
chassis ground Min. 1 MΩ
P02 (female) Hydraulic oil temperature Resistance
Between (12) - (13) 10 - 100°C 90 - 3.5 kΩ
Circuit diagram related to hydraulic oil temperature sensor of machine monitor
PC400LC-7E0 20-327 1
TROUBLESHOOTING CA111 - ECM CRITICAL INTERNAL FAILURE
12
CA111 - ECM CRITICAL INTERNAL FAILURE
Action code Failure code ECM Critical Internal Failure
E11 CA111
Contents of trouble • Incompatibility of data occurred in engine controller.
Action of controller • None in particular.
• Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related information

Fuse or circuit breaker on applicable machine side may be defective. Check it directly.
1 Defective fuse (If fuse is broken or circuit breaker is shut down, circuit probably has ground fault.)
2 (Disconnection in wiring or defec- Wiring harness between CE03 (female) (3) - battery (+) Resistance Max. 1 Ω
Wiring harness between CE03 (female) (1) - chassis ground Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between CE03 (female) (3) - battery (+) and
3 (Short circuit with GND circuit) Resistance Min. 1 MΩ
chassis ground
Wiring harness between CE03 (female) (1) - chassis ground Resistance Min. 1 MΩ
4 Defective engine controller CE03 Voltage
Between (3) - (1) 20 - 30 V
20-328 1 PC400LC-7E0
TROUBLESHOOTING CA111 - ECM CRITICAL INTERNAL FAILURE
12
Circuit diagram related to controller power supply
PC400LC-7E0 20-329 1
TROUBLESHOOTING CA115 - ENG NE AND BKUP SPEED SENS ERROR
12
CA115 - ENG NE AND BKUP SPEED SENS ERROR
Action code Failure code Eng Ne and Bkup Speed Sens Error
E10 CA115
Contents of trouble • Failure occurred simultaneously in engine Ne speed sensor and engine Bkup speed sensor.
• Engine cannot be started. (Engine is stopped.)
machine
Related information • Engine stops (during operations).

1 Defective Ne speed sensor system Carry out troubleshooting for failure code CA689.
Possible causes and standard
2 Defective Bkup speed sensor system Carry out troubleshooting for failure code CA778.
3 Defective installation of Ne speed sensor Ne speed sensor may be installed defectively. Check it directly.
(Defective installation of sensor itself, internal defect of flywheel, etc.)
Defective installation of Bkup speed sen- Bkup speed sensor may be installed defectively. Check it directly.
4
sor (Defective installation of sensor itself, internal defect of supply pump, etc.)
Defective connection of sensor connector Ne speed sensor and Bkup speed sensor may be connected defectively (or connected to wrong
5 (Wrong connection) parts). Check them directly.
6 Defective engine controller If causes 1 - 5 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
20-330 1 PC400LC-7E0
TROUBLESHOOTING CA115 - ENG NE AND BKUP SPEED SENS ERROR
12
MEMORANDUM
PC400LC-7E0 20-331 1
TROUBLESHOOTING CA122 - CHG AIR PRESS SENSOR HIGH ERROR
12
CA122 - CHG AIR PRESS SENSOR HIGH ERROR
Action code Failure code Chg Air Press Sensor High Error
E11 CA122
Contents of trouble • High pressure error occurred in charge air pressure sensor circuit.
Action of controller • Fixes charge pressure at 4.1 kg/cm2 (58.3 psi) and continues operation.
• Engine does not accelerate easily.
machine
Related information

Defective sensor power supply sys-
1 tem If failure code CA187 or CA227 is displayed, carry out troubleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting
in each case.
Defective charge air pressure sensor PIM Voltage

2
(Internal defect) Between (1) - (3) Power supply 4.75 - 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wir-
ing harness and controller, too, for another cause of trouble, and then judge.
Disconnection in wiring harness (Dis- Wiring harness between ENG (female) (37) - PIM (female) (1) Resistance Max. 1 Ω
3 connection in wiring or defective con-
tact in connector) Wiring harness between ENG (female) (44) - PIM (female) (2) Resistance Max. 1 Ω
Wiring harness between ENG (female) (47) - PIM (female) (3) Resistance Max. 1 Ω
Between wiring harness of ENG (female) (37) - PIM (female) (1) and
chassis ground
4 Ground fault in wiring harness (Short
circuit with GND circuit) Between wiring harness of ENG (female) (44) - PIM (female) (2) and
chassis ground Resistance Min. 1 MΩ
Between wiring harness of ENG (female) (47) - PIM (female) (3) and Resistance Min. 1 MΩ
chassis ground
Wiring harness between ENG (female) (37) - PIM (female) (1) and be-
tween ENG (female) (44) - PIM (female) (2) Resistance Min. 1 MΩ
Short circuit in wiring harness (with
5
another wiring harness) Wiring harness between ENG (female) (37) - PIM (female) (1) and be- Resistance Min. 1 MΩ
tween ENG (female) (47) - PIM (female) (3)
Wiring harness between ENG (female) (44) - PIM (female) (2) and be-
tween ENG (female) (47) - PIM (female) (3)
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out trouble-
shooting.
ENG Voltage
Between (37) - (47) Power supply 4.75 - 5.25 V
20-332 1 PC400LC-7E0
TROUBLESHOOTING CA122 - CHG AIR PRESS SENSOR HIGH ERROR
12
Circuit diagram related to charge pressure sensor
PC400LC-7E0 20-333 1
TROUBLESHOOTING CA123 - CHG AIR PRESS SENSOR LOW ERROR
12
CA123 - CHG AIR PRESS SENSOR LOW ERROR
Action code Failure code Chg Air Press Sensor Low Error
E11 CA123
Contents of trouble • Low pressure error occurred in charge air pressure sensor circuit.
Action of controller • Fixes charge pressure at 4.1 kg/cm2 (58.3 psi) and continues operation.
machine • Engine does not accelerate easily.
Related information
Possible causes and standard value Cause Standard value in normal state/Remarks on troubleshooting
in normal state Carry out troubleshooting for failure code CA122.
20-334 1 PC400LC-7E0
TROUBLESHOOTING CA123 - CHG AIR PRESS SENSOR LOW ERROR
12
MEMORANDUM
PC400LC-7E0 20-335 1
TROUBLESHOOTING CA131 - THROTTLE SENSOR HIGH ERROR
12
CA131 - THROTTLE SENSOR HIGH ERROR
Action code Failure code Throttle Sensor High Error
E14 CA131
Contents of trouble • High error occurred in throttle sensor circuit.
Action of controller • Use a signal other than throttle sensor to set the throttle position and continues operation.
machine
Related information

Defective sensor power supply sys-
1 tem If failure code CA2185 or CA2186 is displayed, carry out troubleshooting for it first.
P20 (male) Resistance
Defective fuel control dial (Internal
2 Between (1) - (3) 4.0 - 6.0 kΩ
defect)
Between (2) - (1) 0.25 - 5.0 kΩ
Between (2) - (3) 0.25 - 5.0 kΩ

Wiring harness between CE02 (female) (22) - P20 (fe-
Disconnection in wiring harness male) (1)
3 (Disconnection in wiring or defec- Wiring harness between CE02 (female) (9) - P20 (fe-
tive contact in connector) Resistance Max. 1 Ω
male) (2)
male) (3) Resistance Max. 1 Ω
Resistance Min. 1 Ω
male) (1) and chassis ground
4 Ground fault in wiring harness
(Short circuit with GND circuit) Wiring harness between CE02 (female) (9) - P20 (fe-
male) (2) and chassis ground Resistance Min. 1 Ω
Wiring harness between CE02 (female) (23) - P20 (fe- Resistance Min. 1 Ω
5 ★ Prepare with starting switch OFF, then turn starting ON and carry out troubleshooting.
CE02 Voltage
Defective engine controller
Between (22) - (23) Voltage 4.75 - 5.25 V
Between (9) - (23) Signal 0.5 - 4.5 V
20-336 1 PC400LC-7E0
TROUBLESHOOTING CA132 - THROTTLE SENSOR LOW ERROR
12
Circuit diagram related to fuel control dial throttle sensor
CA132 - THROTTLE SENSOR LOW ERROR

Action code Failure code Throttle Sensor Low Error
Trouble
E14 CA132 (Engine controller system)
Contents of trouble • Low error occurred in throttle sensor circuit.

Action of controller • Use a signal other than throttle sensor to set the throttle position for control.
Problem that appears on ma-
chine
Related information
Possible causes and standard Cause Standard value in normal state/Remarks on troubleshooting
value in normal state Carry out troubleshooting for failure code CA131.
PC400LC-7E0 20-337 1
TROUBLESHOOTING CA135 - ENG OIL PRESS SENSOR HIGH ERROR
12
CA135 - ENG OIL PRESS SENSOR HIGH ERROR
Trouble Eng Oil Press Sensor High Error (Engine controller system)
E15 CA135
Contents of trouble • High pressure error occurred in engine oil pressure sensor circuit.
Action of controller • Sets oil pressure to default (2.5 kg/cm2 [35.5 psi]) and continues operation.
machine
Related information
1 Defective sensor power supply sys- If failure code CA187 or CA227 is displayed, carry out troubleshooting for it first.
tem
Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting
in each case.
Defective oil pressure sensor (Inter- POIL Voltage

2 nal defect)
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring
harness and controller, too, for another cause of trouble, and then judge.
Disconnection in wiring harness Wiring harness between ENG (female) (37) - POIL (female) (1) Resistance Max. 1 Ω
tive contact in connector) Wiring harness between ENG (female) (47) - POIL (female) (2) Resistance Max. 1 Ω
Wiring harness between ENG (female) (13) - POIL (female) (3) Resistance Max. 1 Ω
Between wiring harness of ENG (female) (37) - POIL (female) (1) Resistance Min. 1 MΩ
and chassis ground
4 (Short circuit with GND circuit) Between wiring harness of ENG (female) (47) - POIL (female) (2)
and chassis ground
Between wiring harness of ENG (female) (13) - POIL (female) (3)
and chassis ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (37) - POIL (female) (1) and
between ENG (female) (47) - POIL (female) (2)
5 Short circuit in wiring harness (with
another wiring harness) Wiring harness between ENG (female) (37) - POIL (female) (1) and
between ENG (female) (13) - POIL (female) (3) Resistance Min. 1 MΩ
Wiring harness between ENG (female) (47) - POIL (female) (2) and
between ENG (female) (13) - POIL (female) (3) Resistance Min. 1 MΩ
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out
troubleshooting.
ENG Voltage
20-338 1 PC400LC-7E0
TROUBLESHOOTING CA141 - ENG OIL PRESS SENSOR LOW ERROR
12
Circuit diagram related to oil pressure sensor
CA141 - ENG OIL PRESS SENSOR LOW ERROR

Action code Failure code Eng Oil Press Sensor Low Error
Trouble
Contents of trouble • Low pressure error occurred in engine oil pressure sensor circuit.
Action of controller • Sets oil pressure to default (2.5 kg/cm2 [35.5 psi]) and continues operation.
machine
Related information
PC400LC-7E0 20-339 1
TROUBLESHOOTING CA144 - COOLANT TEMP SENS HIGH ERROR
12
CA144 - COOLANT TEMP SENS HIGH ERROR
Action code Failure code Coolant Temp Sens High Error
E15 CA144
Contents of trouble • High temperature error occurred in coolant temperature sensor circuit.
Action of controller • Fixes coolant temperature value (90°C [194°F]) and continues operation.
chine
Related information

Defective coolant temperature sen- TWTR (male) Coolant temperature Resistance

1 sor (Internal defect)
10 - 100°C
Between (A) - (B) [50 - 212°F] 0.6 - 20 kΩ
2 (Disconnection in wiring or defec- Wiring harness between ENG (female) (15) - TWTR (female) (A) Resistance Max. 1Ω
Wiring harness between ENG (female) (38) - TWTR (female) (B) Resistance Max. 1Ω
3
(Short circuit with GND circuit) Between wiring harness of ENG (female) (15) - TWTR (female)
(A) and chassis ground Resistance Min. 1Ω
4 Defective engine controller ENG (female) Coolant temperature Resistance
Between (15) - (38) 10 - 100°C 0.6 - 20 kΩ

[50 - 212°F]
20-340 1 PC400LC-7E0
TROUBLESHOOTING CA145 - COOLANT TEMP SENS LOW ERROR
12
Circuit diagram related to coolant temperature sensor
CA145 - COOLANT TEMP SENS LOW ERROR

Action code Failure code Coolant Temp Sens Low Error
Trouble
Contents of trouble • Low temperature error occurred in coolant temperature sensor circuit.
Action of controller • Fixes coolant temperature value (90°C [194°F]) and continues operation.
chine
Related information
PC400LC-7E0 20-341 1
TROUBLESHOOTING CA153 - CHG AIR TEMP SENSOR HIGH ERROR
12
CA153 - CHG AIR TEMP SENSOR HIGH ERROR
Action code Failure code Chg Air Temp Sensor High Error
E15 CA153
Contents of trouble • High temperature error occurred in charge air temperature sensor circuit.
Action of controller • Fixes charge air temperature (air intake temperature) at 70°C [158°F] and continues operation.
machine
Related information

ON.
Defective charge air temperature sensor TIM (male) Air intake temperature Resistance
1 (Internal defect)
Between (A) - (B) 10 - 100°C 0.5 - 20 kΩ
[50 - 212°F]
Between (A) - chassis ground Whole area Min. 1 MΩ
2 (Disconnection in wiring or
defective contact in connector) Wiring harness between ENG (female) (23) - TIM (female) (A) Resistance Max. 1 Ω
Wiring harness between ENG (female) (47) - TIM (female) (B) Resistance Max. 1 Ω
ON.
3 Ground fault in wiring harness (Short
circuit with GND circuit)
Between wiring harness of ENG (female) (23) - TIM (female)
(A) and chassis ground
ON.
4 Defective engine controller ENG (female) Air intake temperature Resistance
Between (23) - (47) 10 - 100°C 0.5 - 20 kΩ

[50 - 212°F]
20-342 1 PC400LC-7E0
TROUBLESHOOTING CA153 - CHG AIR TEMP SENSOR HIGH ERROR
12
Circuit diagram related to charge temperature sensor
PC400LC-7E0 20-343 1
TROUBLESHOOTING CA154 - CHG AIR TEMP SENSOR LOW ERROR
12
CA154 - CHG AIR TEMP SENSOR LOW ERROR
Action code Failure code Chg Air Temp Sensor Low Error
E15 CA154
Contents of trouble • Low temperature error occurred in charge air temperature sensor circuit.
Action of controller • Fixes charge air temperature (air intake temperature) at 70°C [158°F] and continues operation.
machine
Related information
20-344 1 PC400LC-7E0
TROUBLESHOOTING CA187 - SENS SUPPLY 2 VOLT LOW ERROR
12
CA187 - SENS SUPPLY 2 VOLT LOW ERROR
Action code Failure code Sens Supply 2 Volt Low Error
E15 CA187
Contents of trouble • Low voltage error occurred in sensor power supply 2 (5V) circuit.
• Engine Bkup speed sensor operates with signal from engine Ne speed sensor.
• Oil pressure sensor sets oil pressure to default (2.5 kg/cm2 [35.5 psi]) and continues operation.
• Ambient pressure sensor sets ambient pressure to default (0.5 kg/cm2 [7.11 psi]) and continues operation.
Action of controller • Charge air pressure sensor fixes charge pressure at 4.1 kg/cm2 [58.3 psi] and continues operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (1.0 kg/cm2 [14.22 psi]) and continues operation.
• EGR valve lift sensor limits output, and closes EGR and bypass valves.
• Bypass valve lift sensor limits output.
Problem that appears on • Engine output lowers.
machine
Related information
PC400LC-7E0 20-345 1
TROUBLESHOOTING CA221 - AMBIENT PRESS SENS HIGH ERROR
12
CA221 - AMBIENT PRESS SENS HIGH ERROR
Action code Failure code Ambient Press Sens High Error
E15 CA221
Contents of trouble • High pressure error occurred in ambient pressure sensor circuit.
Action of controller • Sets ambient pressure to default (0.52 kg/cm2 [7.39 psi]) and continues operation.
chine • Engine output lowers.
Related information

1 Defective sensor power supply system If failure code CA187 or CA227 is displayed, carry out troubleshooting for it first
PAMB Voltage
Defective ambient pressure sensor (Internal Between (1) - (3) Voltage 4.75 - 5.25 V
2
defect)
Between (2) - (3) Signal
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal,
check wiring harness and controller, too, for another cause of trouble, and then judge.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
switch ON.
Wiring harness between ENG (female) (37) - PAMB Resistance Max. 1 Ω
Disconnection in wiring harness (female) (1)
3 (Disconnection in wiring or defective
contact in connector) Wiring harness between ENG (female) (3) - PAMB (female)
(2)
Wiring harness between ENG (female) (38) - PAMB
(female) (3) Resistance Max. 1 Ω
switch ON.
Between wiring harness of ENG (female) (37) - PAMB
Ground fault in wiring harness (Short circuit (female) (1) and chassis ground
4 with GND circuit)
Between wiring harness of ENG (female) (3) - PAMB Resistance Min. 1 MΩ
(female) (2) and chassis ground
Between wiring harness of ENG (female) (38) - PAMB
switch ON.
(female) (1) and between ENG (female) (3) - PAMB Resistance Min. 1 MΩ
Short circuit in wiring harness (with another (female) (2)
5 wiring harness)
(female) (1) and between ENG (female) (38) - PAMB Resistance Min. 1 MΩ
(female) (3)
Wiring harness between ENG (female) (3) - PAMB (female) Resistance Min. 1 MΩ
(2) and between ENG (female) (38) - PAMB (female) (3)
troubleshooting.
6 Defective engine controller ENG Voltage
Between (37) - (38) 4.75 - 5.25 V
Between (3) - (38)
20-346 1 PC400LC-7E0
TROUBLESHOOTING CA221 - AMBIENT PRESS SENS HIGH ERROR
12
Circuit diagram related to atmospheric pressure sensor
PC400LC-7E0 20-347 1
TROUBLESHOOTING CA222 - AMBIENT PRESS SENS LOW ERROR
12
CA222 - AMBIENT PRESS SENS LOW ERROR
Action code Failure code Ambient Press Sens Low Error
E15 CA222
Contents of trouble • Low pressure error occurred in engine ambient pressure sensor circuit.
Action of controller • Sets ambient pressure to default (0.51 kg/cm2 [7.25 psi]) and continues operation.
machine • Engine output lowers.
Related information
Possible causes and standard value in Cause Standard value in normal state/Remarks on troubleshooting
normal state Carry out troubleshooting for failure code CA221.
20-348 1 PC400LC-7E0
TROUBLESHOOTING CA222 - AMBIENT PRESS SENS LOW ERROR
12
MEMORANDUM
PC400LC-7E0 20-349 1
TROUBLESHOOTING CA227 - SENS SUPPLY 2 VOLT HIGH ERROR
12
CA227 - SENS SUPPLY 2 VOLT HIGH ERROR
Action code Failure code Sens Supply 2 Volt High Error
E15 CA227
Contents of trouble • High voltage error occurred in sensor power supply 2 (5V) circuit.
• Engine Bkup speed sensor operates with signal from engine Ne speed sensor.
• Oil pressure sensor sets oil pressure to default (2.5 kg/cm2 [35 psi]) and continues operation.
• Ambient pressure sensor sets ambient pressure to default (0.51 kg/cm2 [7.25 psi]) and continues operation.
Action of controller • Charge air pressure sensor fixes charge pressure at 4.1 kg/cm2 [58.3 psi] and continues operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (1.0 kg/cm2 [14.2 psi]) and continues operation.
• EGR valve lift sensor limits output, and closes EGR and bypass valves.
• Bypass valve lift sensor limits output, and closes EGR and bypass valves.
Problem that appears on • Engine output lowers.
machine
Related information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
Bkup Speed Sensor G connector
Oil pressure sensor POIL connector
Defective sensor Ambient pressure sensor PAMB connector
2 Disconnect sensors at right in order.
(Internal defect) If no error code is displayed, that Charge air pressure sensor PIM connector
sensor is defective.
EGR inlet pressure sensor PEVA connector
EGR valve lift sensor SEGR connector
Bypass valve lift sensor SBP connector
3 (Disconnection in wiring or Wiring harness between ENG (female) (37) - each sensor (female Resistance Max. 1 Ω
defective contact in connector)
Wiring harness between ENG (female) (47) - each sensor (female) Resistance Max. 1 Ω
Wiring harness between ENG (female) (37) - each sensor (female) and
4 Ground fault in wiring harness chassis ground
Wiring harness between ENG (female) (47) - each sensor (female) and
chassis ground
Short circuit in wiring harness (with
5
another wiring harness) Wiring harness between ENG (female) (37) - each sensor (female) and Resistance Min. 1 MΩ
between ENG (female) (47) - each sensor (female)
Between (37) - (47) 4.75 - 5.25 V
20-350 1 PC400LC-7E0
12
Circuit diagram related to sensor power supply 2 (5 V)
PC400LC-7E0 20-351 1
TROUBLESHOOTING CA234 - ENG OVERSPEED
12
CA234 - ENG OVERSPEED
Action code Failure code Eng Overspeed
- CA234
Contents of trouble • Engine speed exceeded operating range.
Action of controller • Limits fuel injection rate until it lowers in operating range.
• Engine speed fluctuates.
machine
Related information

value in normal state 2 Improper use Machine may be used improperly. Teach operator proper using method.
3 Defective engine controller If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble
is in system, troubleshooting cannot be carried out.)
20-352 1 PC400LC-7E0
TROUBLESHOOTING CA234 - ENG OVERSPEED
12
MEMORANDUM
PC400LC-7E0 20-353 1
TROUBLESHOOTING CA238 - NE SPEED SENS SUPPLY VOLT ERROR
12
CA238 - NE SPEED SENS SUPPLY VOLT ERROR
Action code Failure code Ne Speed Sens Supply Volt Error
E15 CA238
Contents of trouble • High voltage error in engine Ne speed sensor power supply (5V) circuit.
Action of controller • Controls the engine with signal from engine Bkup speed sensor.
Problem that appears on • Engine stops during operations. (when engine Bkup speed sensor is also defective)
machine • Engine cannot be started during operations. (when engine Bkup speed sensor is also defective)
Related information

Defective Ne speed sensor (Internal
1
defect) Disconnect sensors at right in order. If no error code Ne speed sensor NE connector
is displayed, that sensor is defective.
Disconnection in wiring harness Wiring harness between ENG (female) (16) - NE (fe-
2 (Disconnection in wiring or defec- male) (1) Resistance Max. 1 Ω
Wiring harness between ENG (female) (48) - NE (fe- Resistance Max. 1 Ω
male) (2)
Ground fault in wiring harness Wiring harness between ENG (female) (16) - NE (fe-
3 Resistance Min. 1 MΩ
(Short circuit with GND circuit) male) (1) and chassis ground
Wiring harness between ENG (female) (48) - NE (fe-
male) (2) and chassis ground Resistance Min. 1 MΩ
4 Short circuit in wiring harness (with Wiring harness between ENG (female) (16) - NE (fe-
another wiring harness)
male) (1) and between ENG (female) (48) - NE (fe- Resistance Min. 1 MΩ
male) (2)
Between (16) - (48) 4.75 - 5.25 V
20-354 1 PC400LC-7E0
TROUBLESHOOTING CA238 - NE SPEED SENS SUPPLY VOLT ERROR
12
Circuit diagram related to Ne speed sensor power supply
PC400LC-7E0 20-355 1
TROUBLESHOOTING CA263 - FUEL TEMP SENSOR HIGH ERROR
12
CA263 - FUEL TEMP SENSOR HIGH ERROR
Action code Failure code Fuel Temp Sensor High Error
E11 CA263
Contents of trouble • High temperature error occurred in fuel temperature sensor circuit.
Action of controller • Fixes fuel temperature value at 90°C [194°F] and continues operation.
machine
Related information

Defective fuel temperature sensor TFUEL (male) Fuel temperature Resistance

1 (Internal defect)
10 - 100°C
Between (A) - (B) [50 - 212°F] 0.6 - 20 kΩ
Disconnection in wiring harness Wiring harness between ENG (female) (30) - TFU-
2 (Disconnection in wiring or defec- Resistance Max. 1 Ω
EL (female) (A)
Wiring harness between ENG (female) (47) - TFU-
EL (female) (B) Resistance Max. 1 Ω
3
(Short circuit with GND circuit) Wiring harness between ENG (female) (30) - TFU- Resistance Min. 1 MΩ
EL (female) (A) and chassis ground
4 Defective engine controller ENG (female) Fuel temperature Resistance
10 - 100°C
Between (30) - (47) 0.6 - 20 kΩ
[50 - 212°F]
20-356 1 PC400LC-7E0
TROUBLESHOOTING CA263 - FUEL TEMP SENSOR HIGH ERROR
12
Circuit diagram related to fuel temperature sensor
PC400LC-7E0 20-357 1
TROUBLESHOOTING CA265 - FUEL TEMP SENSOR LOW ERROR
12
CA265 - FUEL TEMP SENSOR LOW ERROR
Action code Failure code Fuel Temp Sensor Low Error
E15 CA265
Contents of trouble • Low temperature error occurred in fuel temperature sensor circuit.
Action of controller • Fixes fuel temperature value at 90°C [194°F]and continues operation.
machine
Related information
20-358 1 PC400LC-7E0
TROUBLESHOOTING CA271 - IMV/PCV1 SHORT ERROR
12
CA271 - IMV/PCV1 SHORT ERROR
Action code Failure code IMV/PCV1 Short Error
E11 CA271
Contents of trouble • Short circuit was detected in PCV1 circuit of supply pump.
Problem that appears on machine
Related information

PCV1 (male) Resistance
1 Defective supply pump PCV1
(Internal short circuit)
2.3 - 5.3 Ω
Between (1) - (2)

Between (1), (2) - chassis ground Min. 1 MΩ
Ground fault in wiring harness Wiring harness between ENG (female) (4) - PCV1 (female) (1) and chassis
2 (Short circuit with GND circuit) ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (5) - PCV1 (female) (2) and chassis Resistance Min. 1 MΩ
ground
Hot short in wiring harness Wiring harness between ENG (female) (4) - PCV1 (female) (1) and chassis
3 Voltage Max. 1 V
(Short circuit with 24V circuit) ground
Wiring harness between ENG (female) (5) - PCV1 (female) (2) and chassis
ground Voltage Max. 1 V
ENG (female) Resistance
Between (4) - (5) 2.3 - 5.3 Ω
Circuit diagram related to supply pump PCV1
PC400LC-7E0 20-359 1
TROUBLESHOOTING CA272 - IMV/PCV1 OPEN ERROR
12
CA272 - IMV/PCV1 OPEN ERROR
Action code Failure code IMV/PCV1 Open Error
E11 CA272
Contents of trouble • Open error was detected in PCV1 circuit of supply pump.
Related information

switch ON.
Defective supply pump PCV1 PCV1 (male) Resistance
1 (Internal disconnection)
2.3 - 5.3 Ω
Between (1) - (2)

switch ON.
2 Disconnection in wiring harness (Disconnection in
wiring or defective contact in connector) Wiring harness between ENG (female) (4) - PCV1 (female) (1) Resistance Max. 1 Ω
Wiring harness between ENG (female) (5) - PCV1 (female) (2) Resistance Max. 1 Ω
switch ON.
Ground fault in wiring harness (Short circuit with Between wiring harness of ENG (female) (4) - PCV1 (female) (1)
3 Resistance Max. 1 MΩ
GND circuit) and chassis ground and chassis ground
Between wiring harness of ENG (female) (5) - PCV1 (female) (2)
Resistance Max. 1 MΩ
and chassis ground and chassis ground
switch ON.
4 Defective engine controller ENG (female) Resistance
Between (4) - (5) 2.3 - 5.3 Ω
20-360 1 PC400LC-7E0
TROUBLESHOOTING CA272 - IMV/PCV1 OPEN ERROR
12
PC400LC-7E0 20-361 1
TROUBLESHOOTING CA273 - PCV2 SHORT ERROR
12
CA273 - PCV2 SHORT ERROR
Action code Failure code PCV2 Short Error
E11 CA273
Contents of trouble • Short circuit was detected in PCV2 circuit of supply pump.
Related information

switch ON.
Defective supply pump
1 PCV2 PCV2 (male) Resistance
Between (1) - (2) 2.3 - 5.3 Ω

switch ON.
Ground fault in wiring harness Wiring harness between ENG (female) (9) - PCV2 (female) (1) and
chassis ground
Wiring harness between ENG (female) (10) - PCV2 (female) (2) and
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Hot short in wiring harness Wiring harness between ENG (female) (9) - PCV2 (female) (1) and
3 (Short circuit with 24V circuit) Voltage Max. 1 V
chassis ground
Wiring harness between ENG (female) (10) - PCV2 (female) (2) and
chassis ground Voltage Max. 1 V
★ Prepare with starting switch OFF, then carry out trouble shooting without turning starting
switch ON.
Between (9) - (10) 2.3 - 5.3 Ω
20-362 1 PC400LC-7E0
TROUBLESHOOTING CA274 - PCV2 OPEN ERROR
12
CA274 - PCV2 OPEN ERROR
Action code Failure code PCV2 Open Error
E11 CA274
Contents of trouble • Open error was detected in PCV2 circuit of supply pump.
Related information

Defective supply pump
1 PCV2 PCV2 (male) Resistance

(Internal disconnection)
Between (1) - (2) 2.3 - 5.3 Ω
2 (Disconnection in wiring or Wiring harness between ENG (female) (9) - PCV2 (female) (1) Resistance Max. 1 Ω
Wiring harness between ENG (female) (10) - PCV2 (female) (2) Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between ENG (female) (9) - PCV2 (female) (1)
3 (Short circuit with GND circuit) and chassis ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (10) - PCV2 (female) (2)

Between (9) - (10) 2.3 - 5.3 Ω
PC400LC-7E0 20-363 1
TROUBLESHOOTING CA322 - INJ #1 (L#1) OPEN/SHORT ERROR
12
CA322 - INJ #1 (L#1) OPEN/SHORT ERROR
Action code Failure code Inj #1 (L#1) Open/Short Error
E11 CA322
Contents of trouble • Opening or short circuit was detected in injector #1 circuit.
• Engine output lowers.
• Speed is unstable.
Related information

ON.
Defective injector #1 CN1 (male) Resistance
1
(Internal defect)
0.4 - 1.1 Ω
Between (1) - (2)

Disconnection in wiring harness (Dis- ON.
2 connection in wiring or defective con-
tact in connector) Wiring harness between ENG (female) (45) - CN1 (female) (1) Resistance Max. 1 Ω
Wiring harness between ENG (female) (53) - CN1 (female) (2) Resistance Max. 1 Ω
ON.
3 Ground fault in wiring harness Wiring harness between ENG (female) (45) - CN1 (female) (1)
(Short circuit with GND circuit) and chassis ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (53) - CN1 (female) (2) Resistance Min. 1 MΩ
and chassis ground
ON.
Between (45) - (53) 0.4 - 1.1 Ω
Circuit diagram related to injector #1
20-364 1 PC400LC-7E0
12
E11 CA323
Problem that appears on machine • Engine output lowers.
Related information • Speed is unstable.

★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
1 (Internal defect)
0.4 - 1.1 Ω
Between (1) - (2)

Disconnection in wiring harness starting switch ON.
defective contact in connector) Wiring harness between ENG (female) (46) - CN5 (female) (1) Resistance Max. 1 Ω
starting switch ON.
Ground fault in wiring harness Wiring harness between ENG (female) (46) - CN5 (female) (1)
(Short circuit with GND circuit) and chassis ground
Wiring harness between ENG (female) (60) - CN5 (female) (2)
and chassis ground
starting switch ON.
Between (46) - (60) 0.4 - 1.1 Ω
PC400LC-7E0 20-365 1
12
E11 CA324

1
(Internal defect)
Between (1) - (2) 0.4 - 1.1 Ω
2 (Disconnection in wiring or Wiring harness between ENG (female) (55) - CN3 (female) (1) Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between ENG (female) (55) - CN3 (female) (1) and chassis
(Short circuit with GND circuit) ground
Wiring harness between ENG (female) (52) - CN3 (female) (2) and chassis
ground
Between (55) - (52) 0.4 - 1.1 Ω
20-366 1 PC400LC-7E0
12
E11 CA325

ON.
1 (Internal defect)
0.4 - 1.1 Ω
Between (1) - (2)

defective contact in connector) Wiring harness between ENG (female) (57) - CN6 (female) (1) Resistance Max. 1 Ω
ON.
Ground fault in wiring harness Wiring harness between ENG (female) (57) - CN6 (female) (1)
(Short circuit with GND circuit) and chassis ground
and chassis ground
ON.
Between (57) - (59) 0.4 - 1.1 Ω
PC400LC-7E0 20-367 1
12
E11 CA331

1
(Internal defect)
Between (1) - (2) 0.4 - 1.1 Ω
2 (Disconnection in wiring or Wiring harness between ENG (female) (54) - CN2 (female) (1) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between ENG (female) (51) - CN2 (female) (2)
Ground fault in wiring harness Wiring harness between ENG (female) (54) - CN2 (female) (1) and
3 chassis ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (51) - CN2 (female) (2) and Resistance Min. 1 MΩ
chassis ground
Between (54) - (51) 0.4 - 1.1 Ω
20-368 1 PC400LC-7E0
12
E11 CA332

1
(Internal defect)
Between (1) - (2) 0.4 - 1.1 Ω
2 (Disconnection in wiring or Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between ENG (female) (56) - CN4 (female) (1) and chassis
3 ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (58) - CN4 (female) (2) and chassis Resistance Min. 1 MΩ
ground
Between (56) - (58) 0.4 - 1.1 Ω
PC400LC-7E0 20-369 1
TROUBLESHOOTING CA342 - CALIBRATION CODE INCOMPATIBILITY
12
CA342 - CALIBRATION CODE INCOMPATIBILITY
Action code Failure code Calibration Code Incompatibility
E10 CA342
Contents of trouble • Incompatibility of data occurred in engine controller.
machine
Related information
20-370 1 PC400LC-7E0
TROUBLESHOOTING CA342 - CALIBRATION CODE INCOMPATIBILITY
12
MEMORANDUM
PC400LC-7E0 20-371 1
TROUBLESHOOTING CA351 - INJECTORS DRIVE CIRCUIT ERROR
12
CA351 - INJECTORS DRIVE CIRCUIT ERROR
Action code Failure code Injectors Drive Circuit Error
E10 CA351
Contents of trouble • There is error in injector drive circuit.
Action of controller • Limits output and continues operation (limits common rail pressure).
Related information

Check the code (injector system error code) that is displayed simultaneously. If another code is displayed,
1 Defect in related system

carry out troubleshooting for it.
Fuse may be defective. Check it directly.
2 Defective fuse No. 19
(If fuse is broken or circuit breaker is shut down, circuit probably has ground fault.)
3 (Disconnection in wiring or Wiring harness between CE03 (female) (3) - battery (+) Resistance Max. 1 Ω
Wiring harness between CE03 (female) (1) - chassis ground Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between CE03 (female) (3) - battery (+) and chassis
Wiring harness between CE03 (female) (1) - chassis ground Resistance Min. 1 MΩ
Between (3) - (1) 20 - 30 V
20-372 1 PC400LC-7E0
TROUBLESHOOTING CA351 - INJECTORS DRIVE CIRCUIT ERROR
12
Circuit diagram related to controller power supply.
PC400LC-7E0 20-373 1
12
CA352 - SENS SUPPLY 1 VOLT LOW ERROR
Action code Failure code Sens Supply 1 Volt Low Error
E15 CA352
Contents of trouble • Low voltage error occurred in sensor power supply 1 (5V) circuit.
Action of controller • Common rail pressure sensor limits output and continues operation (limits common rail pressure).
machine
Related information
20-374 1 PC400LC-7E0
12
MEMORANDUM
PC400LC-7E0 20-375 1
12
CA386 - SENS SUPPLY 1 VOLT HIGH ERROR
Action code Failure code Sens Supply 1 Volt High Error
E15 CA386
Contents of trouble • High voltage error occurred in sensor power supply 1 (5V) circuit.
Action of controller • Common rail pressure sensor limits output and continues operation (limits common rail pressure).
machine
Related information

2 Defective sensor
(Internal defect) Disconnect sensors at right in order. If no error code is displayed, Common rail pres-
that sensor is defective. sure sensor PFUEL connector
3 (Disconnection in wiring or Wiring harness between ENG (female) (33) - PFUEL (female) (1) Resistance Max. 1 Ω
Wiring harness between ENG (female) (47) - PFUEL (female) (3) Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between ENG (female) (33) - PFUEL (female) (1)
4 and chassis ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (47) - PFUEL (female) (3) Resistance Min. 1 MΩ
and chassis ground
5 Short circuit in wiring harness
(with another wiring harness) Wiring harness between ENG (female) (33) - PFUEL (female) (1)
and between ENG (female) (47) - PFUEL (female) (3) Resistance Min. 1 MΩ
Between (33) - (47) 4.75 - 5.25 V
20-376 1 PC400LC-7E0
12
Circuit diagram related to sensor power supply 1 (5 V)
PC400LC-7E0 20-377 1
TROUBLESHOOTING CA441 - BATTERY VOLTAGE LOW ERROR
12
CA441 - BATTERY VOLTAGE LOW ERROR
Action code Failure code Battery Voltage Low Error
E10 CA441
Contents of trouble • Low voltage error occurred in power supply circuit.
machine
Related information
normal state
Carry out troubleshooting for failure code CA111.
20-378 1 PC400LC-7E0
TROUBLESHOOTING CA442 - BATTERY VOLTAGE HIGH ERROR
12
CA442 - BATTERY VOLTAGE HIGH ERROR
Action code Failure code Battery Voltage High Error
Trouble
Contents of trouble • High voltage error occurred in power supply circuit.

Problem that appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related information
in normal state
Carry out troubleshooting for failure code CA111.
PC400LC-7E0 20-379 1
TROUBLESHOOTING CA449 - RAIL PRESS VERY HIGH ERROR
12
CA449 - RAIL PRESS VERY HIGH ERROR
Action code Failure code Rail Press Very High Error
E11 CA449
Contents of trouble • There is high pressure error (level 2) in common rail pressure sensor circuit.
machine
Related information
20-380 1 PC400LC-7E0
TROUBLESHOOTING CA449 - RAIL PRESS VERY HIGH ERROR
12
MEMORANDUM
PC400LC-7E0 20-381 1
TROUBLESHOOTING CA451 - RAIL PRESS SENSOR HIGH ERROR
12
CA451 - RAIL PRESS SENSOR HIGH ERROR
Action code Failure code Rail Press Sensor High Error
E11 CA451
Contents of trouble • High pressure error occurred in common rail pressure sensor circuit.
Related information
1 Defective sensor power supply sys- If failure code CA352 or CA386 is displayed, carry out troubleshooting for it first.
tem
troubleshooting.
PFUEL Voltage
Defective common rail pressure sen-
2 sor Between (1) - (3) Power supply 4.75 - 5.25 V
(Internal defect) Between (2) - (3) Signal 0.25 - 4.6 V
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble,
and then judge.
Disconnection in wiring harness Wiring harness between ENG (female) (33) - PFUEL (female) (1) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between ENG (female) (25) - PFUEL (female) (2) Resistance Max. 1 Ω
Wiring harness between ENG (female) (47) - PFUEL (female) (3) Resistance Max. 1 Ω
Wiring harness between ENG (female) (33) - PFUEL (female) (1) and
chassis ground
(Short circuit with GND circuit) Wiring harness between ENG (female) (25) - PFUEL (female) (2) and
Wiring harness between ENG (female) (47) - PFUEL (female) (3) and Resistance Min. 1 MΩ
chassis ground
Wiring harness between ENG (female) (33) - PFUEL (female) (1) and be-
tween ENG (female) (25) - PFUEL (female) (2) Resistance Min. 1 MΩ
Short circuit in wiring harness
5
(with another wiring harness) Wiring harness between ENG (female) (33) - PFUEL (female) (1) and be- Resistance Min. 1 MΩ
tween ENG (female) (47) - PFUEL (female) (3)
Wiring harness between ENG (female) (25) - PFUEL (female) (2) and be-
tween ENG (female) (47) - PFUEL (female) (3)
troubleshooting.
Between (33) - (47) 4.75 - 5.25V
Between (25) - (47) 0.25 - 4.6V
20-382 1 PC400LC-7E0
TROUBLESHOOTING CA451 - RAIL PRESS SENSOR HIGH ERROR
12
Circuit diagram related to common rail pressure sensor
PC400LC-7E0 20-383 1
TROUBLESHOOTING CA452 - RAIL PRESS SENSOR LOW ERROR
12
CA452 - RAIL PRESS SENSOR LOW ERROR
Action code Failure code Rail Press Sensor Low Error
E11 CA452
Contents of trouble Low pressure error occurred in common rail pressure sensor circuit.
Action of controller Limits output and continues operation (limits common rail pressure).
Problem that appears on machine Engine output lowers.
Related information
CA553 - RAIL PRESS HIGH ERROR 1

Action code Failure code Rail Press High Error 1
Trouble
Contents of trouble There is high pressure error (level 1) in common rail pressure sensor circuit.
Action of controller None in particular.
chine Engine output lowers.
Related information

Fuel used may be improper. Check it directly.
2 Use of improper fuel (Viscosity is high)
3 Defective electrical system of Electrical system of common rail pressure sensor may be defective.
Possible causes and stan- common rail pressure sensor Carry out troubleshooting for failure code CA451.
dard value in normal state Defective mechanical system of
4 Mechanical system of common rail pressure sensor may be defective. Check it directly.
common rail pressure sensor
Spring damage, seat wear, or ball fixing of overflow valve is suspected. Check it direct-
5 Defective overflow valve ly.
6 Clogged overflow piping Overflow piping may be clogged. Check it directly.
7 Defective pressure limiter Pressure limiter may be damaged mechanically. Check it directly.
20-384 1 PC400LC-7E0
TROUBLESHOOTING CA554 - RAIL PRESS SENSOR IN RANGE ERROR
12
CA554 - RAIL PRESS SENSOR IN RANGE ERROR
Action code Failure code Rail Press Sensor In Range Error
- CA554
Contents of trouble • In range error occurred in common rail pressure sensor circuit.
Related information
PC400LC-7E0 20-385 1
TROUBLESHOOTING CA559 - RAIL PRESS LOW ERROR
12
CA559 - RAIL PRESS LOW ERROR
Action code Failure code Rail Press Low Error
E15 CA559
Contents of trouble • There is rail press very low error (level 1).
Action of controller • Limits common rail pressure.
Related information

2 Use of improper fuel Fuel used may be improper. Check it directly.
★ For more information on troubleshooting, see Note 1 on the next page. For check of pressure
3 Defect in low pressure circuit parts in fuel low pressure circuit, see Testing and adjusting, Checking fuel pressure.
Min. 1.5 kg/cm2 [Min. 21 psi]

Pressure in fuel low-pressure circuit
4 Clogged fuel filter, strainer ★ For more information on troubleshooting, see Note 2 on the next page.
Defective electrical system of supply pump Electrical system of supply pump PCV may be defective. Carry out troubleshooting for failure code
5
PCV CA271, CA272, CA273, or CA274.
Mechanical system of common rail pressure sensor may be defective. Check whether wiring harness
6 Defective common rail pressure sensor is damaged.
For check of leakage through pressure limiter, see Testing and adjusting, Checking fuel return rate
7 Defective pressure limiter and leakage.
Leakage through pressure limiter Max. 10 cc/min [0.33 oz/min] (at 1,600 rpm)
★ For check of limit return rate (spill) from injector, see Testing and adjusting, Checking fuel
return rate and leakage.
Speed in rated operation Limited return (spill) rate from injector
1,600 rpm 960 cc/min [32.4 oz/min]
8 Defective injector
1,700 rpm 1,020 cc/min [34.4 oz/min]
1,800 rpm 1,080 cc/min [36.5 oz/min]
1,900 rpm 1,140 cc/min [38.5 oz/min]
2,000 rpm 1,200 cc/min [40.5 oz/min]
9 Defective supply pump If causes 1 - 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no pressure feed”.
20-386 1 PC400LC-7E0
12
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
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: Follow the procedure below to check, clean, and replace filter and strainer.
1) Gauze filter: Disassemble this filter for checking. If clogged, clean it
2) Gauze filter upstream strainer: Clean upstream strainer if gauze filter is clogged
3) Fuel filter: If failure is not remedied after steps 1) and 2) above were executed, replace fuel filter
PC400LC-7E0 20-387 1
12
20-388 1 PC400LC-7E0
12
*1 to *10: When using the monitoring function for checking, see Monitoring Code List.
Rating or equivalent: Relieve in

1) engine full,
2) P-mode, and
3) boom RAISE.
PC400LC-7E0 20-389 1
TROUBLESHOOTING CA689 - ENG NE SPEED SENSOR ERROR
12
CA689 - ENG NE SPEED SENSOR ERROR
Action code Failure code Eng Ne Speed Sensor Error
E11 CA689
Contents of trouble • There is error in engine Ne speed sensor circuit.
Action of controller • Operates the engine with signal from engine Bkup speed sensor.
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
Related information

1 Defective sensor power supply system If failure code CA238 is displayed, carry out troubleshooting for it first.
switch ON.
2 (Disconnection in wiring or Wiring harness between ENGINE (female) (16) - NE (female) (1) Resistance Max. 1 Ω
Wiring harness between ENGINE (female) (48) - NE (female) (2) Resistance Max. 1 Ω
Wiring harness between ENGINE (female) (27) - NE (female) (3) Resistance Max. 1 Ω
switch ON.
Wiring harness between ENG (female) (16) - NE (female) (1) and
Ground fault in wiring harness chassis ground
3
chassis ground
switch ON.
between ENG (female) (48) - NE (female) (2) Resistance Min. 1 MΩ
4 (with another wiring harness)
Wiring harness between ENG (female) (16) - NE (female) (1) and Resistance Min. 1 MΩ
between ENG (female) (27) - NE (female) (3)
between ENG (female) (27) - NE (female) (3)
Defective sensor installation or defective Ne speed sensor may be installed defectively (improper clearance), or rotation sensor parts (flywheel)
5 rotation sensor parts may be defective. Check them directly.
6 Defective engine Ne speed sensor If causes 1 - 5 are not detected, engine Ne speed sensor may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
If causes 1 - 5 are not detected, engine controller may be defective.
20-390 1 PC400LC-7E0
TROUBLESHOOTING CA689 - ENG NE SPEED SENSOR ERROR
12
Circuit diagram related to engine Ne speed sensor
PC400LC-7E0 20-391 1
TROUBLESHOOTING CA731 - ENG BKUP SPEED SENS PHASE ERROR
12
CA731 - ENG BKUP SPEED SENS PHASE ERROR
Action code Failure code Eng Bkup Speed Sens Phase Error
E11 CA731
Contents of trouble • There is phase error in engine Bkup speed sensor circuit.
Action of controller • Controls the engine with signal from engine Ne speed sensor.
• Engine stops during operations. (When engine Ne speed sensor is also defective)
Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
Related information

Defective engine Ne speed sensor Engine Ne speed sensor may be defective. Carry out troubleshooting for failure
Possible causes and standard 1
value in normal state system code CA689.
Defective engine Bkup speed sen- Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure
2 sor system code CA778.
20-392 1 PC400LC-7E0
TROUBLESHOOTING CA757 - ALL PERSISTENT DATA LOST ERROR
12
CA757 - ALL PERSISTENT DATA LOST ERROR
Action code Failure code All Persistent Data Lost Error
E10 CA757
Contents of trouble • All data in engine controller are lost.
Problem that appears on machine • Operations are continued, but engine may stop during operations or may not start in stopped state.
Related information
PC400LC-7E0 20-393 1
TROUBLESHOOTING CA778 - ENG BKUP SPEED SENSOR ERROR
12
CA778 - ENG BKUP SPEED SENSOR ERROR
Action code Failure code Engine Bkup speed sensor error
E11 CA778
Contents of trouble • There is error in engine Bkup speed sensor circuit.
Action of controller • Operates the engine with signal from engine Ne speed sensor.
• Engine stops during operations. (When engine Ne speed sensor is also defective)
Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
Related information

1 Defective sensor power supply system If failure code CA187 or CA227 is displayed, carry out troubleshooting for it first.
switch ON.
2 (Disconnection in wiring or defective contact in Wiring harness between ENG (female) (37) - G (female) (1) Resistance Max. 1 Ω
connector)
Wiring harness between ENG (female) (47) - G (female) (2) Resistance Max. 1 Ω
Wiring harness between ENG (female) (26) - G (female) (3) Resistance Max. 1 Ω
switch ON.
Wiring harness between ENG (female) (37) - G (female) (1) and
Ground fault in wiring harness chassis ground
3
chassis ground
switch ON.
between ENG (female) (47) - G (female) (2) Resistance Min. 1 MΩ
4 (with another wiring harness)
Wiring harness between ENG (female) (37) - G (female) (1) and Resistance Min. 1 MΩ
between ENG (female) (26) - G (female) (3)
between ENG (female) (26) - G (female) (3)
Defective sensor installation or defective Bkup speed sensor may be installed defectively (improper clearance), or rotation sensor parts (in
5 rotation sensor parts supply pump) may be defective. Check them directly.
6 Defective engine Bkup speed sensor If causes 1 - 5 are not detected, engine Bkup speed sensor may be defective. (Since trouble is in
system, troubleshooting cannot be carried out.)
20-394 1 PC400LC-7E0
TROUBLESHOOTING CA778 - ENG BKUP SPEED SENSOR ERROR
12
Circuit diagram related to engine Bkup speed sensor
PC400LC-7E0 20-395 1
TROUBLESHOOTING CA1228 - EGR VALVE SERVO ERROR 1
12
CA1228 - EGR VALVE SERVO ERROR 1
Action code Failure code EGR Valve Servo Error 1
E10 CA1228
Contents of trouble • There is EGR valve servo error (level 1).
Action of controller • Performs open control.
Related information

★ For check of engine oil pressure, see Testing and adjusting, Measuring engine oil
pressure.
Engine Engine oil pressure
2 Defective engine oil pressure system (main circuit) Low idle 0.8kg/cm2 [11.3 psi]
High idle 2.1kg/cm2 [29.8 psi]
If engine oil pressure is not normal, carry out troubleshooting for mechanical system.
(S-12 Oil pressure lowers.)
3 Defective EGR valve oil pump Oil pump or relief valve for EGR valve circuit may be defective. Check it directly.
4 Defective EGR valve oil pressure supply piping Oil pressure supply piping for EGR valve circuit may be defective. Check it directly.
5 Defective EGR valve oil pressure return piping Oil pressure return piping for EGR valve circuit may be defective. Check it directly.
6 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
7 Defective engine controller (Since trouble is in system, troubleshooting cannot be carried out.)
20-396 1 PC400LC-7E0
TROUBLESHOOTING CA1625 - EGR VALVE SERVO ERROR 2
12
CA1625 - EGR VALVE SERVO ERROR 2
Action code Failure code EGR Valve Servo Error 2
E11 CA1625
Contents of trouble • There is EGR valve servo error (level 2).
• Limits output and continues operation.
• Close EGR and bypass valves.
Related information
PC400LC-7E0 20-397 1
TROUBLESHOOTING CA1633 - KOMNET DATALINK TIMEOUT ERROR
12
CA1633 - KOMNET DATALINK TIMEOUT ERROR
Action code Failure code KOMNET Datalink Timeout Error
E0E CA1633
Contents of trouble • There is error in KOMNET communication circuit with machine monitor.
Action of controller • Operates in default mode or holds the state set when error occurred.
Related information

Disconnection in wiring harness Wiring harness between P70 (female) (16) - CE02 (female) (47), -
CP02 (female) (22)
Wiring harness between P70 (female) (15) - CE02 (female) (48), -

CP02 (female) (32) Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between P70 (female) (16) - CE02 (female) (47), -
(Short circuit with GND circuit) CP02 (female) (22), - other related circuit and chassis ground
CP02 (female) (32), - other related circuit and chassis ground Resistance Min. 1 MΩ
Hot short (Short circuit with Wiring harness between P70 (female) (16) - CE02 (female) (47), - Voltage Max. 1 V
3 CP02 (female) (22), - other related circuit and chassis ground
24V circuit) in wiring harness
Voltage Max. 1 V
CP02 (female) (32), - other related circuit and chassis ground
4 Defective CAN terminal resistance K02(male), K31(male) Resistance
Between (A) - (B) 40 - 80 z
Defective machine monitor, engine If causes 1 - 4 are not detected, machine monitor, engine controller, or pump controller may be defective.
5
controller, or pump controller (Since trouble is in system, troubleshooting cannot be carried out.)
20-398 1 PC400LC-7E0
TROUBLESHOOTING CA1633 - KOMNET DATALINK TIMEOUT ERROR
12
Circuit diagram related to CAN communication of pump controller
PC400LC-7E0 20-399 1
TROUBLESHOOTING CA2185 - THROT SENS SUP VOLT HIGH ERROR
12
CA2185 - THROT SENS SUP VOLT HIGH ERROR
Action code Failure code Throt Sens Sup Volt High Error
E14 CA2185
Contents of trouble • High voltage error occurred in throttle sensor power supply (5V) circuit.
Action of controller • Use a signal other than throttle sensor to set the throttle position for operations.
Related information

Defective fuel control dial
1 (Internal defect) Disconnect sensors at right in order. If no error code
Fuel control dial P20 connector
is displayed, that sensor is defective.
Disconnection in wiring harness Wiring harness between CE02 (female) (22) - P20
2 (Disconnection in wiring or defec- Resistance Max. 1Ω
(female) (1)
Wiring harness between CE02 (female) (23) - P20
Resistance Max. 1Ω
(female) (3)
Ground fault in wiring harness Wiring harness between CE02 (female) (22) - P20 Resistance Min. 1 MΩ
3 (female) (1) and chassis ground
Wiring harness between CE02 (female) (23) - P20 Resistance Min. 1 MΩ
4 Wiring harness between CE02 (female) (22) - P20
(with another wiring harness) (female) (1) and between CE02 (female) (23) - P20 Resistance Min. 1 MΩ
(female) (3)
Between (22) - (23) 4.75 - 5.25 V
20-400 1 PC400LC-7E0
TROUBLESHOOTING CA2185 - THROT SENS SUP VOLT HIGH ERROR
12
Circuit diagram related to fuel control dial throttle sensor
PC400LC-7E0 20-401 1
TROUBLESHOOTING CA2186 - THROT SENS SUP VOLT LOW ERROR
12
CA2186 - THROT SENS SUP VOLT LOW ERROR
Action code Failure code Throt Sens Sup Volt Low Error
E14 CA2186
Contents of trouble • Low voltage error occurred in throttle sensor power supply (5V) circuit.
Action of controller • Use a signal other than throttle sensor to set the throttle position for operations.
Related information
20-402 1 PC400LC-7E0
TROUBLESHOOTING CA2249 - RAIL PRESS VERY LOW ERROR
12
CA2249 - RAIL PRESS VERY LOW ERROR
Action code Failure code Rail Press Very Low Error
E11 CA2249
Contents of trouble There is rail press very low error (level 2).
Action of controller Limits common rail pressure.
Problem that appears on machine Engine output lowers.
Related information
PC400LC-7E0 20-403 1
TROUBLESHOOTING CA2271 - EGR VALVE LIFT SENS HIGH ERROR
12
CA2271 - EGR VALVE LIFT SENS HIGH ERROR
Action code Failure code EGR Valve Lift Sens High Error
E11 CA2271
Contents of trouble • High error occurred in EGR valve lift sensor circuit.
Related information

1 Defective sensor power supply system If failure code CA187 or CA227 is displayed, carry out troubleshooting for it first.
shooting.
SEGR Voltage
Defective EGR valve lift sensor
2 (Internal defect) Between (1) - (2) Power supply 4.75 - 5.25 V
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble,
and then judge.
★ Prepare with starting switch OFF, then carry out trouble shooting without turning starting switch
ON.
Wiring harness between ENG (female) (37) - SEGR
Disconnection in wiring harness (female) (1) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between ENG (female) (47) - SEGR Resistance Max. 1 Ω
female) (2)
(female) (3), (4)
ON.
Ground fault in wiring harness (female) (1) and chassis ground
4
(female) (2) and chassis ground Resistance Min. 1 MΩ
Wiring harness between ENG (female) (19) - SEGR Resistance Min. 1 MΩ

(female) (3), (4) and chassis ground
ON.
(female) (1) and between ENG (female) (47) - SEGR Resistance Min. 1 MΩ
(female) (2)
5 Short circuit in wiring harness
(with another wiring harness) Wiring harness between ENG (female) (37) - SEGR
(female) (3), (4)
(female) (3), (4)
shooting.
ENG Voltage
Between (37) - (47) 4.75 - 5.25 V
20-404 1 PC400LC-7E0
TROUBLESHOOTING CA2271 - EGR VALVE LIFT SENS HIGH ERROR
12
Circuit diagram related to EGR valve solenoid and lift sensor
PC400LC-7E0 20-405 1
TROUBLESHOOTING CA2272 - EGR VALVE LIFT SENS LOW ERROR
12
CA2272 - EGR VALVE LIFT SENS LOW ERROR
Action code Failure code EGR Valve Lift Sens Low Error
E11 CA2272
Contents of trouble • Low error occurred in EGR valve lift sensor circuit.
Related information
20-406 1 PC400LC-7E0
TROUBLESHOOTING CA2272 - EGR VALVE LIFT SENS LOW ERROR
12
MEMORANDUM
PC400LC-7E0 20-407 1
TROUBLESHOOTING CA2351 - EGR VALVE SOL CURRENT HIGH ERROR
12
CA2351 - EGR VALVE SOL CURRENT HIGH ERROR
Action code Failure code EGR Valve Sol Current High Error
E11 CA2351
Contents of trouble • High current error occurred in drive circuit of EGR valve solenoid.
Related information

Defective EGR valve solenoid
1 EGR (male) Resistance
(Internal defect)
Between (1) - (2) 10 - 21 Ω
2 (Disconnection in wiring or Wiring harness between ENG (female) (22) - EGR (female) (1) Resistance Max. 1 Ω
Wiring harness between ENG (female) (11) - EGR (female) (2) Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between ENG (female) (22) - EGR (female) (1) and chassis
Wiring harness between ENG (female) (11) - EGR (female) (2) and chassis
ground
Hot short in wiring harness Wiring harness between ENG (female) (22) - EGR (female) (1) and chassis Voltage Max. 1 V
4 ground
(Short circuit with 24V circuit)
Wiring harness between ENG (female) (11) - EGR (female) (2) and chassis
Voltage Max. 1 V
ground
Between (22) - (11) 10 - 21 Ω
20-408 1 PC400LC-7E0
TROUBLESHOOTING CA2351 - EGR VALVE SOL CURRENT HIGH ERROR
12
Circuit diagram related to EGR valve solenoid and lift sensor
PC400LC-7E0 20-409 1
TROUBLESHOOTING CA2352 - EGR VALVE SOL CURRENT LOW ERROR
12
CA2352 - EGR VALVE SOL CURRENT LOW ERROR
Action code Failure code EGR Valve Sol Current Low Error
E11 CA2352
Contents of trouble • Low current error occurred in drive circuit of EGR valve solenoid.
Related information
20-410 1 PC400LC-7E0
TROUBLESHOOTING CA2555 - GRID HTR RELAY VOLT LOW ERROR
12
CA2555 - GRID HTR RELAY VOLT LOW ERROR
Action code Failure code Grid Htr Relay Volt Low Error
E15 CA2555
Contents of trouble • Voltage low error was detected in grid heater relay circuit.
Problem that appears on machine • Engine does not start easily at low temperature.
Related information
PC400LC-7E0 20-411 1
TROUBLESHOOTING CA2556 - GRID HTR RELAY VOLT HIGH ERROR
12
CA2556 - GRID HTR RELAY VOLT HIGH ERROR
Action code Failure code Grid Htr Relay Volt High Error
E15 CA2556
Contents of trouble • Open error was detected in intake air heater relay circuit
Problem that appears on machine • Engine does not start easily at low temperature.
Related information • Heater relay drive conditions vary depending on applicable machine.

Defective grid heater relay ON.
1
(Internal defect) R18 (male) Resistance
Between (1) - (2) 200 - 400 Ω

contact in connector) Wiring harness between CE02 (female) (40) - R18 (female) (1) Resistance Max. 1 Ω
Wiring harness between CE02 (female) (42) - R18 (female) (2) Resistance Max. 1 Ω
ON.
Ground fault in wiring harness Wiring harness between CE02 (female) (40) - R18 (female) (1) and chassis
ground
Wiring harness between CE02 (female) (42) - R18 (female) (2) and chassis
ground Resistance Min. 1 MΩ
CE02 Heater relay Voltage
4 Defective engine controller Operating Max. 1 V
condition
Between (40) - (42)
Stop condi-
20 - 30 V
tion
20-412 1 PC400LC-7E0
TROUBLESHOOTING CA2556 - GRID HTR RELAY VOLT HIGH ERROR
12
Circuit diagram related to engine preheater
PC400LC-7E0 20-413 1
TROUBLESHOOTING D110KB - BATTERY RELAY DRIVE S/C
12
D110KB - BATTERY RELAY DRIVE S/C
Action code Failure code Battery Relay Drive S/C
Trouble (Pump controller system)
- D110KB
Contents of trouble • Abnormal current flowed at output to battery relay drive circuit.
• Turns output to battery relay drive circuit OFF.
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine • Engine does not start.
• Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
Related information
(Code 03700: Controller Output)

Defective battery relay Battery relay Resistance
1 (Internal short circuit)
Between R02 (terminal BR) - R01 (terminal E) There is continuity
Between R02 (terminal BR) - chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out trouble shooting without turning starting switch ON.
2 (Short circuit with GND circuit) Wiring harness between CP03 (female) (4) - D01 - J01 - A02 - R02
(terminal BR) and chassis ground
CP03 (female) Turn starting switch OFF. Voltage
3 Defective pump controller
20 - 30 V
Between (4) - chassis ground ON → OFF (4 - 7 sec.)
20-414 1 PC400LC-7E0
TROUBLESHOOTING D110KB - BATTERY RELAY DRIVE S/C
12
Circuit diagram related to battery relay drive
PC400LC-7E0 20-415 1
TROUBLESHOOTING D196KA - SERVICE RETURN RELAY DISC.
12
D196KA - SERVICE RETURN RELAY DISC.
Action code Failure code Service Return Relay Disc.
- D196KA
• When service return relay circuit was disconnected with GND (when output was turned OFF), 24V was not
Contents of trouble
generated.
• None in particular.
Problem that appears on machine • Hydraulic circuit for attachment does not change to single operation circuit.
• This code-related troubleshooting is done only when ATT is provided.
(Confirm settings on the machine monitor.)
★ This code detects only a trouble in the primary side (coil side) of service return relay. When service return
Related information solenoid may be in defective operation, check the power source, wiring harness, and solenoid in the secondary
side (contact side) of the relay.
• Operating condition of service return relay (ON/OFF) can be checked with monitoring function.
(Code 02301: Solenoid 2)

1 Defective fuse No.2 If fuse is burnt, circuit probably has ground fault.
Defective service return relay
2 (Internal disconnection) R20 (male) Resistance

Between (1) - (2) 100 - 500 Ω
3 (Disconnection in wiring or Wiring harness between CP02 (female) (8) - R20 (female) (2) Resistance Max. 1 Ω
Wiring harness between R20 (female) (1) - J03 - F01-2 outlet Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between CP02 (female) (8) - R20 (female) (2) and
(Short circuit with GND circuit) chassis ground
Wiring harness between R20 (female) (1) - J03 - F01-2 outlet and
CP02 Working mode Voltage
5 Defective pump controller When B-mode 20 - 30 V
is not selected
When B-mode
Max. 1 V
is selected
20-416 1 PC400LC-7E0
TROUBLESHOOTING D196KA - SERVICE RETURN RELAY DISC.
12
Circuit diagram related to service return relay and solenoid of pump controller
PC400LC-7E0 20-417 1
TROUBLESHOOTING D196KB - SERVICE RETURN RELAY S/C
12
D196KB - SERVICE RETURN RELAY S/C
Action code Failure code Service Return Relay S/C
- D196KB
Contents of trouble • When service return relay circuit was connected to GND (when output was turned ON), abnormal current flowed.
• Turns output to service return relay circuit OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine • Hydraulic circuit for attachment does not change to single operation circuit.
• This code-related troubleshooting is done only when ATT is provided. (Confirm settings on the machine monitor.)
★ This code detects only a trouble in the primary side (coil side) of service return relay.
When service return solenoid may be in defective operation, check the power source, wiring harness, and solenoid
Related information
in the secondary side (contact side) of the relay.
• Operating condition of service return relay (ON/OFF) can be checked with monitoring function.

Defective service return relay
1 R20 (male) Resistance
(internal short circuit)
Between (1) - (2) 100 - 500 Ω
2 Hot short (Short circuit with 24V
circuit) in wiring harness Wiring harness between CP02 (female) (8) - R20 (female) (2) and
Voltage Max. 1 V
chassis ground
3 Defective pump controller When B-mode is
not selected 20 - 30 V
When B-mode is selected Max. 1 V
20-418 1 PC400LC-7E0
TROUBLESHOOTING D196KB - SERVICE RETURN RELAY S/C
12
Circuit diagram related to service return relay and solenoid of pump controller
PC400LC-7E0 20-419 1
TROUBLESHOOTING DA25KP - PRESS. SENSOR POWER ABNORMALITY
12
DA25KP - PRESS. SENSOR POWER ABNORMALITY
Action code Failure code Press. Sensor Power Abnormality
- DA25KP
Contents of trouble • Abnormal current flowed in pressure sensor power supply (5V) circuit.
• Turns output to power supply (5V) circuit OFF.
• Even if phenomenon of failure disappears, system does not reset itself until starting switch is turned OFF.
• Signal of pressure sensor is not input normally.
• Pressure sensor failure code is displayed at the same time.
Related information

★ Disconnect connector with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
F pump pressure P25 connector
sensor
R pump pressure
P26 connector
Defective pressure sensor Disconnect sensors at right in order. If no error code is sensor
1
(Internal short circuit) displayed, that sensor is defective. Bucket CURL
press sensor P01 connector
Arm IN pressure P04 connector

sensor
Wiring harness between CP01 (female) (22) - A03 - P25
(female) (3) and chassis ground [F pump pressure sensor Resistance Min. 1 MΩ
system]
Ground fault in wiring harness (female) (3) and chassis ground [R pump pressure sensor Resistance Min. 1 MΩ
2 (Short circuit with GND circuit) system]
[Bucket CURL pressure sensor system]
(female) (3) and chassis ground [Arm IN pressure sensor
3 Defective pump controller CP01 Voltage
Between (22) - (10) 4.5 - 5.5 V
20-420 1 PC400LC-7E0
TROUBLESHOOTING DA25KP - PRESS. SENSOR POWER ABNORMALITY
12
Circuit diagram related to pressure sensor power supply of pump controller
PC400LC-7E0 20-421 1
TROUBLESHOOTING DA80MA - AUTO-LUBE ABNORMAL
12
DA80MA - AUTO-LUBE ABNORMAL
★ This failure code is displayed only when automatic lubrication equipment is installed.
20-422 1 PC400LC-7E0
TROUBLESHOOTING DA80MA - AUTO-LUBE ABNORMAL
12
MEMORANDUM
PC400LC-7E0 20-423 1
TROUBLESHOOTING DA2RMC - PUMP COMM. ABNORMALITY
12
DA2RMC - PUMP COMM. ABNORMALITY
Action code Failure code Pump Comm. Abnormality
E0E DA2RMC
• Pump controller detected communication error in CAN communication circuit between machine monitor and
Contents of trouble
engine controller.
• Fix engine output to E-mode, and limit pump absorption torque to about 80%.
• Output lowers. (Pump absorption torque decreases.)
As the working load increases, engine may stall.
Related information

Disconnection in wiring harness Wiring harness between P70 (female) (16) - CE02 (female) (47), - CP02
1 (Disconnection in wiring or (female) (22) Resistance Max. 1 Ω
Wiring harness between P70 (female) (15) - CE02 (female) (48), - CP02 Resistance Max. 1 Ω
(female) (32)
Ground fault in wiring harness Wiring harness between P70 (female) (16) - CE02 (female) (47), - CP02
2 (female) (22), - other related circuit and chassis ground Resistance Min. 1 MΩ
Wiring harness between P70 (female) (15) - CE02 (female) (48), - CP02 (
female) (32), - other related circuit and chassis ground Resistance Min. 1 MΩ
Hot short (Short circuit with 24V Wiring harness between P70 (female) (16) - CE02 (female) (47), - CP02 (
3 Voltage Max. 1 V
circuit) in wiring harness female) (22), - other related circuit and chassis ground
Wiring harness between P70 (female) (15) - CE02 (female) (48), - CP02 (
female) (32), - other related circuit and chassis ground Voltage Max. 1 V
4 Defective CAN terminal resistance K02 (male), K31 (male) Resistance
Between (A) - (B) 40 - 80 Ω
Defective machine monitor,
5 engine controller, or pump If causes 1 - 4 are not detected, machine monitor, engine controller, or pump controller may be defective.
controller
20-424 1 PC400LC-7E0
TROUBLESHOOTING DA2RMC - PUMP COMM. ABNORMALITY
12
Circuit diagram related to CAN communication of pump controller
PC400LC-7E0 20-425 1
TROUBLESHOOTING DA2SKQ - MODEL SELECTION ABNORMALITY
12
DA2SKQ - MODEL SELECTION ABNORMALITY
Action code Failure code Model Selection Abnormality
- DA2SKQ
Contents of trouble • Model code signal for model which is not registered in controller is input.
• Changes input model code to code of default model (PC400) and continues control.
Problem that appears on machine • None in particular.
• Controller-recognized model name (digits) can be checked with monitoring function. (Code: 00200)
Related information • Input of model selection signal (ON/OFF) can be checked with monitoring function.
(Code 02200: Switch Input 2)

Defective model selection connector S30 (female) Resistance
1 (Internal disconnection or short
circuit) Between (2), (3), (7) - (8) Max. 1 Ω
Between (1), (4), (5), (6) - (8) Min. 1 MΩ
Wiring harness between CP02 (female) (7) - S30 (male) (4) and chassis Resistance Max. 1 Ω
ground
2 (Disconnection in wiring or Wiring harness between CP02 (female) (17) - S30 (male) (3) Resistance Max. 1 Ω
Wiring harness between CP02 (female) (27) - S30 (male) (2) Resistance Max. 1 Ω
Wiring harness between CP02 (female) (13) - S30 (male) (7) Resistance Max. 1 Ω
Wiring harness between S30 (male) (8) - J05 - A01 - chassis ground Resistance Max. 1 Ω
Wiring harness between CP02 (female) (7) - S30 (male) (4) and chassis Resistance Min. 1 MΩ
ground
Ground fault in wiring harness Wiring harness between CP02 (female) (13) - S30 (male) (7) and chassis
Wiring harness between CP02 (female) (17) - S30 (male) (3) and chassis
Wiring harness between CP02 (female) (37) - S30 (male) (1) and chassis Resistance Min. 1 MΩ
ground
CP02 Voltage
Between (7), (37) - chassis ground 20 - 30 V
Between (13), (17), (27) - chassis ground Max. 1 V
20-426 1 PC400LC-7E0
TROUBLESHOOTING DA2SKQ - MODEL SELECTION ABNORMALITY
12
Circuit diagram related to model selection connector of pump controller
PC400LC-7E0 20-427 1
TROUBLESHOOTING DAFRMC - MONITOR COMM. ABNORMALITY
12
DAFRMC - MONITOR COMM. ABNORMALITY
Action code Failure code Monitor Comm. Abnormality
E0E DAFRMC
• Machine monitor detected communication error in CAN communication circuit between pump controller and
Contents of trouble
engine controller.
• Fix engine output to E-mode, and limit pump absorption torque to about 80%.
• Output lowers. (Pump absorption torque decreases.)
• As the working load increases, engine may stall.
Related information

Disconnection in wiring harness Wiring harness between P70 (female) (16) - CE02 (female) (47), -
CP02 (female) (22)
Wiring harnesses between P70 (female) (15) - CE02 (male)(48) and

- CP02 (females) (32)
Ground fault in wiring harness Wiring harness between P70 (female) (16) - CE02 (female) (47), - Resistance Min. 1 MΩ
2 CP02 (female) (22), - other related circuit and chassis ground
Wiring harness between P70 (female) (15) - CE02 (female) (48), - Resistance Min. 1 MΩ
Hot short (Short circuit with Wiring harness between P70 (female) (16) - CE02 (female) (47), -
3 CP02 (female) (22), - other related circuit and chassis ground Voltage Max. 1 V
Wiring harness between P70 (female) (15) - CE02 (female) (48), - Voltage Max. 1 V
4 Defective CAN terminal resistance K02(male), K31(male) Resistance
Between (A) - (B) 40 - 80 Ω
Defective machine monitor, If causes 1 - 4 are not detected, machine monitor, engine controller, or pump controller may be defective.
5 engine controller, or pump
controller (Since trouble is in system, troubleshooting cannot be carried out.)
20-428 1 PC400LC-7E0
TROUBLESHOOTING DAFRMC - MONITOR COMM. ABNORMALITY
12
Circuit diagram related to CAN communication of machine monitor
PC400LC-7E0 20-429 1
TROUBLESHOOTING DHPAMA - F PUMP P. SENSOR ABNORMALITY
12
DHPAMA - F PUMP P. SENSOR ABNORMALITY
F Pump P. Sensor Abnormality
Action code Failure code (Pump controller system)
Trouble
- DHPAMA
Contents of trouble • Signal voltage from F pump pressure sensor is below 0.3 V or above 4.42 V.
• Fixes F pump pressure at 0 kg/cm2 [0 psi] and continues control.

Problem that appears on machine • No automatic gear shifting
★ If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken.
Accordingly, take extreme care when checking.
Related information
• Input from F pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01112: F pump pressure)

Defective sensor power supply
1 system If error code DA25KP is also displayed, carry out troubleshooting for it first.
Defective F pump pressure sensor P25 Voltage
2
(Internal defect)
Between (3) - (1) 4.5 - 5.5V
Between (2) - (1) 0.5 - 4.5V
Wiring harness between CP01 (female) (22) - A03 - P25 (female)
(3) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between CP01 (female) (10) A06 - P25 (female) Resistance Max. 1 Ω
(1)
Wiring harness between CP01 (female) (8) - A06 - P25 (female)
(2)
4
(Short circuit with GND circuit) Wiring harness between CP01 (female) (8) - A06 - P25 (female) Resistance Min. 1 MΩ
(2) and chassis ground
Hot short (Short circuit with 24V Wiring harness between CP01 (female) (22) - A03 - P25 (female)
5 (3) and chassis ground Voltage Max. 1 V
circuit) in wiring harness
Wiring harness between CP01 (female) (8) - A06 - P25 (female) Voltage Max. 1 V
CP01 Voltage
Between (22) - (10) 4.5 - 5.5V
Between (8) - (10) 0.5 - 4.5V
20-430 1 PC400LC-7E0
TROUBLESHOOTING DHPAMA - F PUMP P. SENSOR ABNORMALITY
12
Circuit diagram related to F pump pressure sensor of pump controller
PC400LC-7E0 20-431 1
TROUBLESHOOTING DHPBMA - R PUMP P. SENSOR ABNORMALITY
12
DHPBMA - R PUMP P. SENSOR ABNORMALITY
Action code Failure code R Pump P. Sensor Abnormality
- DHPBMA
Contents of trouble • Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
• Fixes R pump pressure at 0 kg/cm2 [0 psi] and continues control.

Related information
• Input from R pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01113: R pump pressure
1 Defective sensor power supply If error code DA25KP is also displayed, carry out troubleshooting for it first.
system
Defective R pump pressure sensor P26 Voltage
2
(Internal defect) Between (3) - (1) 4.5 - 5.5V
Between (2) - (1) 0.5 - 4.5V

Disconnection in wiring harness Wiring harness between CP01 (female) (22) - A03 - P26 (female) (3) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between CP01 (female) (10) - A06 - P26 (female) (1) Resistance Max. 1 Ω
Wiring harness between CP01 (female) (2) - A06 - P26 (female) (2) Resistance Max. 1 Ω
4 (Short circuit with GND circuit) Wiring harness between CP01 (female) (2) - A06 - P25 (female) (2) and chassis
ground
Hot short (Short circuit with Wiring harness between CP01 (female) (22) - A03 - P25 (female) (3) and chassis Voltage Max. 1 V
5 ground
Wiring harness between CP01 (female) (2) - A06 - P26 (female) (2) and chassis
Voltage Max. 1 V
ground
CP01 Voltage
Between (22) - (10) 4.5 - 5.5V
Between (2) - (10) 0.5 - 4.5V
20-432 1 PC400LC-7E0
TROUBLESHOOTING DHPBMA - R PUMP P. SENSOR ABNORMALITY
12
Circuit diagram related to R pump pressure sensor of pump controller
PC400LC-7E0 20-433 1
TROUBLESHOOTING DHS3MA - ARM CURL PPC SEN. ABNORMALITY
12
DHS3MA - ARM CURL PPC SEN. ABNORMALITY
Action code Failure code Arm Curl PPC Sen. Abnormality
- DHS3MA
Contents of trouble • Signal voltage from arm curl PPC pressure sensor is below 0.3 V or above 4.72 V.
• Fixes arm IN PPC pressure at 0 kg/cm2 [0 psi] and continues control.

Related information
• Input from the pressure sensor (pressure) can be checked with monitoring function.
(Code 07200: Arm Curl PPC Pressure

1 Defective sensor power supply system If error code DA25KP is also displayed, carry out troubleshooting for it first.
Defective arm curl PPC pressure P01 Voltage
2 sensor (Internal defect)
Between (3) - (1) 4.5 - 5.5V
Between (2) - (1) 0.5 - 4.5V
ON.
3 (Disconnection in wiring or Wiring harness between CP01 (female) (22) - A06 - P01 (female) (3) Resistance Max. 1 Ω
Wiring harness between CP01 (female) (19) - P01 (female) (2) Resistance Max. 1 Ω
★ Prepare with starting switch OFF, then carry out trouble shooting without turning starting switch
Ground fault in wiring harness ON.
4
Wiring harness between CP01 (female) (19) - P01 (female) (2) and chassis Min. 1
Resistance
ground MΩ
Hot short (Short circuit with Wiring harness between CP01 (female) (22) - A03 - P01 (female) (3) and chas- Voltage Max. 1 V
5 sis ground
Wiring harness between CP01 (female) (19) - A09 - P04 (female) (2) and chas-
Voltage Max. 1 V
sis ground
CP01 Voltage
Between (22) - (10) 4.5 - 5.5V
Between (19) - (10) 0.5 - 4.5V
20-434 1 PC400LC-7E0
TROUBLESHOOTING DHS3MA - ARM CURL PPC SEN. ABNORMALITY
12
Circuit diagram related to arm curl PPC pressure sensor of pump controller
PC400LC-7E0 20-435 1
TROUBLESHOOTING DHS4MA - BUCKET CURL PPC SEN. ABNORMALITY
12
DHS4MA - BUCKET CURL PPC SEN. ABNORMALITY
Action code Failure code Bucket Curl PPC Sen. Abnormality
- DHS4MA
Contents of trouble • Signal voltage from bucket curl PPC pressure sensor is below 0.3 V or above 4.42 V.
• Fixes bucket curl PPC pressure at 0 kg/cm2 [0 psi] and continues control.
Related information
• Input from the pressure sensor (pressure) can be checked with monitoring function.
(Code 07300: Bucket Curl PPC Pressure)

1 Defective sensor power supply system If error code DA25KP is also displayed, carry out troubleshooting for it first.
Defective bucket curl PPC pressure P04 Voltage
2 sensor (Internal defect)
Between (3) - (1) 4.5 - 5.5V
Between (2) - (1) 0.5 - 4.5V
ON.
3 (Disconnection in wiring or defective Wiring harness between CP01 (female) (22) - A03 - P04 (female) (3) Resistance Max. 1 Ω
contact in connector)
Wiring harness between CP01 (female) (13) - P01 (female) (2) Resistance Max. 1 Ω
4
Wiring harness between CP01 (female) (13) - P01 (female) (2) and chassis
ground
Hot short (Short circuit with Wiring harness between CP01 (female) (22) - A03 - P04 (female) (3) and Voltage Max. 1 V
5 chassis ground
Wiring harness between CP01 (female) (13) - P01 (female) (2) and chassis
Voltage Max. 1 V
ground
Prepare with starting switch OFF, then start engine and carry out troubleshooting.
CP01 Voltage
Between (22) - (10) 4.5 - 5.5V
Between (13) - (10) 0.5 - 4.5V
20-436 1 PC400LC-7E0
TROUBLESHOOTING DHS4MA - BUCKET CURL PPC SEN. ABNORMALITY
12
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
PC400LC-7E0 20-437 1
TROUBLESHOOTING DW43KA - TRAVEL SPEED SOL. DISC.
12
DW43KA - TRAVEL SPEED SOL. DISC.
Action code Failure code Travel Speed Sol. Disc.
- DW43KA
Contents of trouble • No current flows travel speed solenoid circuit as power is turned on.
• None in particular. (Since no current flows, solenoid does not operate.)
Problem that appears on machine • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
• Operating condition of travel speed solenoid (ON/OFF) can be checked with the monitoring function.
Related information
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure to turn
output on. (For more information on how to turn output on/off, see troubleshooting for failure code DW43KB.)

Travel Speed Sol. Disc.
1 (Internal disconnection) V04 (male) Resistance
Between (1) - (2) 20 - 60 Ω
2 (Disconnection in wiring or Wiring harness between CP03 (female) (27) - A05 - V04 (female) (2) Resistance Max. 1 Ω
Wiring harness between V04 (female) (1) - chassis ground Resistance Max. 1 Ω
Hot short (Short circuit with
3 24V circuit) in wiring harness Wiring harness between CP03 (female) (27) - A05 - V04 (female) (2) and
Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective pump controller CP03 (female) Resistance
Between (27) - chassis ground 20 - 60 z
20-438 1 PC400LC-7E0
TROUBLESHOOTING DW43KA - TRAVEL SPEED SOL. DISC.
12
Circuit diagram related to travel speed solenoid of pump controller
PC400LC-7E0 20-439 1
TROUBLESHOOTING DW43KB - TRAVEL SPEED SOL. S/C
12
DW43KB - TRAVEL SPEED SOL. S/C
Action code Failure code Travel Speed Sol. S/C
- DW43KB
Contents of trouble • Abnormal current flowed at output to travel speed solenoid circuit.
• Turns output to travel speed solenoid circuit OFF.
Problem that appears on machine • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
• Operating condition of travel speed solenoid (ON/OFF) can be checked with the monitoring function.
Related information

Travel Speed Sol. Disc. V04 (male) Resistance
1 (Internal short circuit or ground
fault) Between (1) - (2) 20 - 60 Ω
Between (2) - chassis ground Min. 1 MΩ
(Short circuit with GND circuit) Wiring harness between CP03 (female) (27) - A05 - V04 (female)
(2) and chassis ground Resistance Min. 1 MΩ
Prepare with starting switch OFF, then start engine and carry out troubleshooting.
CP03 Travel speed Voltage
3 Defective pump controller Lo Max. 1 V
Between (27) - chassis ground Hi + Travel
operation 20 - 30 V
20-440 1 PC400LC-7E0
TROUBLESHOOTING DW43KB - TRAVEL SPEED SOL. S/C
12
Circuit diagram related to travel speed solenoid of pump controller
PC400LC-7E0 20-441 1
TROUBLESHOOTING DW45KA - SWING BRAKE SOL. DISC.
12
DW45KA - SWING BRAKE SOL. DISC.
Action code Failure code Swing Brake Sol. Disc.
E03 DW45KA
Contents of trouble • No current flows at output to swing brake solenoid circuit.
Problem that appears on machine • Machine cannot swing.
• Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function.
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake release
Related information switch in release position (Swing holding brake does not work, however, when machine stops).
• Turn both of swing lock and emergency swing release switches OFF during troubleshooting.
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure to turn
output on. (For more information on how to turn output on/off, see troubleshooting for failure code DW45KB.)

Defective swing holding brake
1 V05 (male) Resistance
solenoid (Internal disconnection)
Between (1) - (2) 20 - 60 Ω
Defective swing lock switch S04 (female) Switch Resistance
2
OFF Max. 1 Ω
Between (3) - (4)

LOCK Min. 1 MΩ
3 Defective assembled-type diode D01
(Internal disconnection) D01 (male) Digital circuit tester Continuity
Between (7) - (3) Diode mode There is continuity
Wiring harness between CP03 (female) (37) - D01 (female) (7) Resistance Max. 1 Ω
Disconnection in wiring harness Wiring harness between D01 (female) (3) - J02 - S04 (male) (3) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between S04 (female) (4) - A05 - V05 (female)
Wiring harness between V05 (female) (1) - CP03 (female) (3), Resistance Max. 1 Ω
(13), (23)
Hot short (Short circuit with Wiring harness between CP03 (female) (37) - D01 - H06 - S04
5 (male) (3) and chassis ground Voltage Max. 1 V
Wiring harness between V05 (female) (2) - A05 - H06 - S04 Voltage Max. 1 V
(male) (4) and chassis ground
Disconnect D01 and connect pins (3) and (7) on
Between (37) – chassis ground male side directly. 20 – 60 Ω
20-442 1 PC400LC-7E0
TROUBLESHOOTING DW45KA - SWING BRAKE SOL. DISC.
12
Circuit diagram related to swing holding brake solenoid of pump controller
PC400LC-7E0 20-443 1
TROUBLESHOOTING DW45KB - SWING BRAKE SOL. S/C
12
DW45KB - SWING BRAKE SOL. S/C
Action code Failure code Swing Brake Sol. S/C
E03 DW45KB
Contents of trouble • Abnormal current flowed at output to swing brake solenoid circuit.
• Turns output to swing brake solenoid circuit OFF.
Problem that appears on machine • Machine cannot swing.
• Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function.
Related information
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake release
switch to release position (Swing holding brake does not work, however, when machine stops).

Defective swing holding V05 (male) Resistance
1 brake solenoid (Internal short

circuit or ground fault) Between (1) - (2) 20 - 60 Ω
(Internal short circuit) D01 (male) Resistance
Between (3) - (7) Min. 1 MΩ
Ground fault in wiring harness Wiring harness between CP03 (female) (37) - D01 - J02 - H06 Resistance Min. 1 MΩ
3 - S04 (male) (3) and chassis ground
Wiring harness between V05 (female) (2) - A05 - H06 - S04
(male) (4) and chassis ground
CP03 Swing lever Voltage
When at neutral Max. 1 V
At swing 20 - 30 V
20-444 1 PC400LC-7E0
TROUBLESHOOTING DW45KB - SWING BRAKE SOL. S/C
12
Circuit diagram related to swing holding brake solenoid of pump controller
PC400LC-7E0 20-445 1
TROUBLESHOOTING DW91KA - TRAVEL JUNCTION SOL. DISC.
12
DW91KA - TRAVEL JUNCTION SOL. DISC.
Action code Failure code Travel Junction Sol. Disc.
- DW91KA
Contents of trouble • No current flows at output to travel junction valve solenoid circuit.
Problem that appears on machine • Turning from operating travel steering becomes difficult.
• Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Related information • Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure to
turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
DW91KB.)

1 Defective travel junction solenoid

(Internal disconnection) V02 (male) Resistance
Between (1) - (2) 20 - 60 Ω
defective contact in connector) Wiring harness between V02 (female) (1) - A05 - CP03 (female) (3), (13), (23) -
chassis ground Resistance Max. 1 Ω
Hot short (Short circuit with 24V
3 circuit) in wiring harness Wiring harness between CP03 (female) (7) - A05 - V02 (female) (2) and chassis
Voltage Max. 1 V
ground
Between (7) - (3), (13), (23) 20 - 60 Ω
20-446 1 PC400LC-7E0
TROUBLESHOOTING DW91KA - TRAVEL JUNCTION SOL. DISC.
12
Circuit diagram related to travel junction solenoid of pump controller
PC400LC-7E0 20-447 1
TROUBLESHOOTING DW91KB - TRAVEL JUNCTION SOL. S/C
12
DW91KB - TRAVEL JUNCTION SOL. S/C
Action code Failure code Travel Junction Sol. S/C
- DW91KB
Contents of trouble • Abnormal current flowed at output to travel junction solenoid circuit.
• Turns output to travel junction solenoid OFF.
Problem that appears on machine • Hard to turn when operating travel steering.
• Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Related information

Defective travel junction solenoid V02 (male) Resistance
fault) Between (1) - (2) 20 - 60 Ω
(Short circuit with GND circuit) Wiring harness between CP03 (female) (7) - A05 - V02 (female) (2) and
CP03 Travel lever Voltage
At straight
advance Max. 1 V
Between (7) - (3), (13), (23)
At steering 20 - 30 V
20-448 1 PC400LC-7E0
TROUBLESHOOTING DW91KB - TRAVEL JUNCTION SOL. S/C
12
Circuit diagram related to travel junction solenoid of pump controller
PC400LC-7E0 20-449 1
TROUBLESHOOTING DWJ0KA - MERGE-DIVIDER SOL. DISC.
12
DWJ0KA - MERGE-DIVIDER SOL. DISC.
Action code Failure code Merge-divider Sol. Disc.
- DWJ0KA
Contents of trouble • No current flows at output to merge-divider solenoid circuit.
Problem that appears on machine • Independent operation speed of work equipment and swing machinery is re high in lifting mode (L).
• Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
Related information
• Solenoid detects disconnection when output is turned on. To confirm the modification after repair, be sure to turn
output on. (For more information on how to turn output on/off, see troubleshooting for failure code DWJ0KB.)

Defective merge-divider solenoid

Between (1) - (2) 20 - 60Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.
Wiring harness between V03 (female) (1) - A05 - CP03 (female) (3), (13),
(23) - chassis ground Resistance Max. 1 Ω
3 24V circuit) in wiring harness Wiring harness between CP03 (female) (17) - A05 - V03 (female) (2) and
Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.
CP03 (female) Resistance
Between (17) - (3), (13), (23) 20 - 60 Ω
20-450 1 PC400LC-7E0
TROUBLESHOOTING DWJ0KA - MERGE-DIVIDER SOL. DISC.
12
Circuit diagram related to merge-divider solenoid of pump controller
PC400LC-7E0 20-451 1
TROUBLESHOOTING DWJ0KB - MERGE-DIVIDER SOL. S/C
DWJ0KB - MERGE-DIVIDER SOL. S/C

Action code Failure code Merge-Divider Sol. S/C
- DWJ0KB
Contents of trouble • Abnormal current flowed at output to merge-divider solenoid circuit.
• Turns output to merge-divider solenoid circuit OFF.
Problem that appears on machine • Single operation speed of work equipment and swing is re high in lifting mode (L).
• Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
Related information

Defective merge-divider solenoid V03 (male) Resistance

fault) Between (1) - (2) 20 - 60 Ω
When at
3 Defective pump controller neutral Max. 1 V
Between (17) - (3), (13), (23) When either
side is 20 - 30 V
operated
20-452 1 PC400LC-7E0
TROUBLESHOOTING DWJ0KB - MERGE-DIVIDER SOL. S/C
12
Circuit diagram related to merge-divider solenoid of pump controller
PC400LC-7E0 20-453 1
TROUBLESHOOTING DWK0KA - 2-STAGE RELIEF SOL. DISC.
12
DWK0KA - 2-STAGE RELIEF SOL. DISC.
Action code Failure code 2-stage Relief Sol. Disc.
- DWK0KA
Contents of trouble • No current flows at output to 2-stage relief solenoid circuit.
Problem that appears on machine • Power maximizing function does not work.
• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
Related information • Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure to
turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
DWK0KB.)

1 Defective 2-stage relief solenoid

(Internal disconnection) V08 (male) Resistance
Between (1) - (2) 20 - 60 Ω
defective contact in connector) Wiring harness between V08 (female) (1) - A05 - CP03 (female) (3), (13),
Hot short (short circuit with 24V
3 circuit) in wiring harness Wiring harness between CP03 (female) (28) - A05 - V08 (female) (2) and
Voltage Max. 1 V
chassis ground
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Between (28) - chassis ground 20 - 60 Ω
20-454 1 PC400LC-7E0
TROUBLESHOOTING DWK0KA - 2-STAGE RELIEF SOL. DISC.
12
Circuit diagram related to 2-stage relief solenoid of pump controller
PC400LC-7E0 20-455 1
TROUBLESHOOTING DWK0KB - 2-STAGE RELIEF SOL. S/C
12
DWK0KB - 2-STAGE RELIEF SOL. S/C
Action code Failure code 2-stage Relief Sol. S/C
- DWK0KB
Contents of trouble • Abnormal current flowed at output to 2-stage relief solenoid circuit.
• Turns output to 2-stage relief solenoid circuit OFF.
Problem that appears on machine • Power maximizing function does not work.
• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
Related information

Defective 2-stage relief solenoid V08 (male) Resistance
fault) Between (1) - (2) 20 - 60 Ω
When L-mode is not selected Max. 1 V
L-mode is selected 20 - 30 V
20-456 1 PC400LC-7E0
TROUBLESHOOTING DWK0KB - 2-STAGE RELIEF SOL. S/C
12
Circuit diagram related to 2-stage relief solenoid of pump controller
PC400LC-7E0 20-457 1
TROUBLESHOOTING DXA0KA - PC-EPC SOL. DISC.
12
DXA0KA - PC-EPC SOL. DISC.
Action code Failure code PC-EPC Sol. Disc.
E02 DXA0KA
Contents of trouble • No current flows at output to PC-EPC solenoid circuit.
Problem that appears on machine • If pump load increases, engine speed lowers largely and engine may stall.
• Output to PC-EPC solenoid can be checked with monitoring function.
(Code 01300: PC-EPC Sol. Curr.)
Related information
• If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can operate the
machine with output equivalent to E-mode. (Failure code DXA0KA is then displayed, but it is not defective.)

Defective PC-EPC solenoid
Between (1) - (2) 7 - 14 Ω
S21 Switch Resistance
Defective emergency pump OFF Max. 1 Ω

2 Between (2) - (3)
drive switch (Internal disconnection)
ON Min. 1 MΩ
OFF Max. 1 Ω
Between (5) - (6)
ON Min. 1 MΩ
Wiring harness between CP03 (female) (16) - S21 (3) Resistance Max. 1 Ω
3 (Disconnection in wiring or Wiring harness between S21 (2) - V11 (female) (1) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between CP03 (female) (21), (32), (33) - J05 - chassis
ground Resistance Max. 1 Ω
Wiring harness between S21 (2) - V11 (female) (2) Resistance Max. 1 Ω
Hot short (short circuit with Wiring harness between CP03 (female) (16) - S21 (3) and chassis
4 24V circuit) in wiring harness Voltage Max. 1 V
ground
Wiring harness between S21 (2) - V11 (female) (1) and chassis ground Voltage Max. 1 V
Between (16) - (21), (32), (33) 7 - 14 Ω
20-458 1 PC400LC-7E0
TROUBLESHOOTING DXA0KA - PC-EPC SOL. DISC.
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC400LC-7E0 20-459 1
TROUBLESHOOTING DXA0KB - PC-EPC SOL. S/C
12
DXA0KB - PC-EPC SOL. S/C
Action code Failure code PC-EPC Sol. S/C
E02 DXA0KB
Contents of trouble • Abnormal current flowed at output to PC-EPC solenoid circuit.
• Turns output to PC-EPC solenoid circuit OFF.
Problem that appears on machine • If pump load increases, engine speed lowers largely and engine may stall.
• Output to PC-EPC solenoid can be checked with monitoring function.
(Code 01300: PC-EPC Sol. Curr.)
Related information • If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can operate the
machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed, but it is not defective.)
★ Turn the emergency pump drive switch off as long as troubleshooting is continued.

starting switch ON.
Defective PC-EPC solenoid
1 (Internal short circuit or ground V11 (male) Resistance
fault)
Between (1) - (2) 7 - 14 Ω
Ground fault in wiring harness starting switch ON.
2 (Short circuit with GND circuit)
Wiring harness between CP03 (female) (16) - Resistance Min. 1 MΩ
S21 - V11 (female) (1) and chassis ground
Between (16) - (21), (32), (33) 7 - 14 Ω
20-460 1 PC400LC-7E0
TROUBLESHOOTING DXA0KB - PC-EPC SOL. S/C
12
PC400LC-7E0 20-461 1
TROUBLESHOOTING DXE0KA - LS-EPC SOL. DISC.
12
DXE0KA - LS-EPC SOL. DISC.
Action code Failure code LS-EPC Sol. Disc.
- DXE0KA
Contents of trouble • No current flows at output to LS-EPC solenoid circuit.
• Travel speed Mi or Lo is high.
• Work equipment speed and swing speed are high in lifting mode (L).
• Output to LS-EPC solenoid (current value) can be checked with monitoring function.
Related information
(Code 01500: LS-EPC Sol. Curr.)

Defective LS-EPC solenoid

1 V19 (male) Resistance
Between (1) - (2) 7 - 14 Ω
defective contact in connector) Wiring harness between CP03 (female) (21), (32), (33) - J05 - V19
(female) (2)
3 Hot short (Short circuit with
24V circuit) in wiring harness Wiring harness between CP03 (female) (6) - A04 - V19 (female) (1)
and chassis ground Voltage Max. 1 V
Between (6) - (21), (32), (33) 7 - 14 Ω
20-462 1 PC400LC-7E0
TROUBLESHOOTING DXE0KA - LS-EPC SOL. DISC.
12
PC400LC-7E0 20-463 1
TROUBLESHOOTING DXE0KB - LS-EPC SOL. S/C
12
DXE0KB - LS-EPC SOL. S/C
Action code Failure code LS-EPC Sol. S/C
- DXE0KB
Contents of trouble • Abnormal current flowed at output to LS-EPC solenoid circuit.
• Turns output to LS-EPC solenoid circuit OFF.
• Travel speed Mi or Lo is high.
• Work equipment speed and swing speed are high in lifting mode (L).
• Output to LS-EPC solenoid (current value) can be checked with monitoring function.
Related information
(Code 01500: LS-EPC Sol. Curr.)

Defective LS-EPC solenoid V19 (male) Resistance
fault) Between (1) - (2) 7 - 14 Ω
2 (Short circuit with GND circuit) Wiring harness between CP03 (female) (6) - A04 - V19 (female) (1) and chassis
ground
Between (6) - (21), (32), (33) 7 - 14 Ω
20-464 1 PC400LC-7E0
TROUBLESHOOTING DXE0KB - LS-EPC SOL. S/C
12
PC400LC-7E0 20-465 1
TROUBLESHOOTING DXE4KA - SERVICE CURRENT EPC DISC.
12
DXE4KA - SERVICE CURRENT EPC DISC.
Action code Failure code Service Current EPC Disc.
- DXE4KA
Contents of trouble • No current flows at output to service current EPC solenoid circuit.
Problem that appears on machine • Attachment does not move.
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related information • Output to service current EPC solenoid (current value) can be checked with monitoring function.
(Code 01700: Service Sol. Curr.)

Defective service current

1 EPC solenoid (Internal V30 (male) Resistance
disconnection)
Between (1) - (2) 7 - 14 Ω
2 (Disconnection in wiring or Wiring harness between CP03 (female) (26) - V30 (female) (1) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between CP03 (female) (3), (13), (23) - V30 (female)
(2)
24V circuit) in wiring harness Wiring harness between CP03 (female) (26) - V30 (female) (1) and
Between (26) - (3), (13), (23) 7 - 14Ω
Circuit diagram related to service current EPC solenoid of pump controller
20-466 1 PC400LC-7E0
TROUBLESHOOTING DXE4KB - SERVICE CURRENT EPC S/C
12
DXE4KB - SERVICE CURRENT EPC S/C
Action code Failure code Service Current EPC S/C
- DXE4KB
Contents of trouble • Abnormal current flowed at output to service current EPC solenoid circuit.
• Turns output to service current EPC solenoid circuit OFF.
Problem that appears on machine • Attachment does not move.
• This code-related troubleshooting is done only when ATT is provided. (Confirm settings on the machine monitor.)
Related information • Output to service current EPC solenoid (current value) can be checked with monitoring function.
(Code 01700: Service Sol. Curr.)

Defective service current V30 (male) Resistance
1 EPC solenoid (Internal short circuit
or ground fault) Between (1) - (2) 7 - 14 Ω
2 (Short circuit with GND circuit) Wiring harness between CP03 (female) (26) - V30 (female) (1) and chassis
ground
Between (26) - (3), (13), (23) 7 - 14 Ω
Circuit diagram related to service current EPC solenoid of pump controller
PC400LC-7E0 20-467 1
TROUBLESHOOTING DY20KA - WIPER WORKING ABNORMALITY
12
DY20KA - WIPER WORKING ABNORMALITY
Action code Failure code Wiper Working Abnormality
- DY20KA
Contents of trouble • When windshield wiper works, W signal of working ends is not input.
Action of monitor panel • Turns working output to wiper motor OFF.
Problem that appears on machine • Windshield wiper does not operate.
• Input of W signal in wiper working area (ON/OFF) can be checked with monitoring function.
Related information
(Code 04502 Monitor Input 3)

W04 (female) Wiper blade Resistance

Defective wiper motor
1 (Internal disconnection) Upper operating limit Max. 1 Ω
Between (6) - (5) Other than upper operating Min. 1 MΩ
limit
2 (Disconnection in wiring or Wiring harness between P01 (female) (5) - W04 (male) (6) Resistance Max. 1 Ω
Wiring harness between W04 (male) (5) - chassis ground Resistance Max. 1 Ω
P01 Wiper blade Voltage
Upper operating limit Max. 1 V
Between (5) - chassis ground Other than upper operating
20 - 30 V
limit
20-468 1 PC400LC-7E0
TROUBLESHOOTING DY20KA - WIPER WORKING ABNORMALITY
12
Circuit diagram related to wiper motor of machine monitor
PC400LC-7E0 20-469 1
TROUBLESHOOTING DY20MA - WIPER PARKING ABNORMALITY
12
DY20MA - WIPER PARKING ABNORMALITY
Action code Failure code Wiper Parking Abnormality
- DY20MA
Contents of trouble • When parking windshield wiper, P signal for storage area is not input.
Action of monitor panel • Turns parking output to wiper motor OFF.
Problem that appears on machine • Windshield wiper does not park.
• Input of P signal for wiper parking area (ON/OFF) can be checked with monitoring function.
Related information
(Code 04502 Monitor Input 3)

Defective wiper motor W04 (female) Wiper blade Resistance
1
(Internal disconnection) Storage area Max. 1 Ω
Between (4) - (5)
Working area Min. 1 MΩ
2 (Disconnection in wiring or Wiring harness between P01 (female) (12) - W04 (male) (4) Resistance Max. 1 Ω
Wiring harness between W04 (female) (5) - chassis ground Resistance Max. 1 Ω
P01 Wiper blade Voltage
Storage area Max. 1 V
Working area 20 - 30 V
20-470 1 PC400LC-7E0
TROUBLESHOOTING DY20MA - WIPER PARKING ABNORMALITY
12
PC400LC-7E0 20-471 1
TROUBLESHOOTING DY2CKB - WASHER DRIVE S/C
DY2CKB - WASHER DRIVE S/C

Action code Failure code Washer Drive S/C
- DY2CKB
Contents of trouble • When washer drive circuit was connected to GND (when output was turned ON), abnormal current flowed.
Action of monitor panel • Turns output to washer motor circuit OFF.
Problem that appears on machine • Window washer operation stops.
Related information

Defective washer motor
1 M06 (male) Resistance
Between (1) - (2) 5 - 20 Ω
24V circuit) in wiring harness Wiring harnesses between P01 (female) (3) - J04 - M06 (female) (2), -
D04(female) (8) and chassis ground Voltage Max. 1 V
P01 Washer switch Voltage
3 Defective machine monitor OFF 20 - 30 V
ON Max. 1 V
20-472 1 PC400LC-7E0
TROUBLESHOOTING DY2CKB - WASHER DRIVE S/C
12
Circuit diagram related to window washer motor of machine monitor
PC400LC-7E0 20-473 1
TROUBLESHOOTING DY2DKB - WIPER DRIVE (FOR) S/C
12
DY2DKB - WIPER DRIVE (FOR) S/C
Wiper Drive (For) S/C
Action code Failure code (Machine monitor system)
Trouble
- DY2DKB
Contents of trouble Abnormal current flowed at output to wiper motor drive (for) circuit.
Action of monitor panel Turns output to wiper motor drive (for) circuit OFF.
Problem that appears on machine Wiper operation stops.
Related information

Defective wiper motor W04 (female) Continuity/Resistance
fault) Between (3) - (1) There is continuity
2 (Short circuit with GND circuit) Wiring harness between P01 (female) (9) - W04 (male) (3) and
chassis ground
P01 Wiper switch Voltage
3 Defective machine monitor OFF Max. 3 V
Between (9) - chassis ground Max. 3 V ↔ 20 - 30 V
ON
(Constant cycle)
20-474 1 PC400LC-7E0
TROUBLESHOOTING DY2DKB - WIPER DRIVE (FOR) S/C
12
PC400LC-7E0 20-475 1
TROUBLESHOOTING DY2EKB - WIPER DRIVE (REV) S/C
12
DY2EKB - WIPER DRIVE (REV) S/C
Action code Failure code Wiper Drive (Rev) S/C
- DY2EKB
Contents of trouble Abnormal current flowed at output to wiper motor drive (rev.) circuit.
Action of monitor panel Turns output to wiper motor drive (rev.) circuit OFF.
Problem that appears on machine Wiper operation stops.
Related information

Defective wiper motor W04 (female) Continuity/Resistance
1 (Internal short circuit or
ground fault) Between (1) - (3) There is continuity
(Short circuit with GND circuit) Wiring harness between P01 (female) (10) - W04 (male) (1) and chassis
3 Defective machine monitor OFF Max. 3 V
Between (10) - chassis ground Max. 3 V ↔ 20 - 30 V

ON (Constant cycle)
20-476 1 PC400LC-7E0
12
PC400LC-7E0 20-477 1
12
MEMORANDUM
20-478 1 PC400LC-7E0
TROUBLESHOOTING OF ELECTRICAL
SYSTEM (E MODE)
12
BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . 20-502
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
E-1 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-505
E-2 AUTO-DECELERATOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-508
E-3 AUTOMATIC WARMING-UP DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-509
E-4 PREHEATER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE . . . . . . . . . . . . . 20-512
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
E-9 DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE . . . . . . . . 20-516
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING . . . . . . . . . . . . . . . 20-517
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY . . . . . . . . . . 20-518
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY . . . . . . . . . . . . 20-520
E-13 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING . . . . . . . . . . . . . . . 20-524
E-16 WINDSHIELD WIPER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-526
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . 20-530
E-18 MONITORING FUNCTION FAILS TO DISPLAY “BOOM RAISE” NORMALLY . . . . . . . . . . . . . . . 20-532
E-19 MONITORING FUNCTION FAILS TO DISPLAY “BOOM LOWER” NORMALLY . . . . . . . . . . . . . 20-533
E-20 MONITORING FUNCTION FAILS TO DISPLAY “ARM IN” NORMALLY . . . . . . . . . . . . . . . . . . . . 20-534
E-21 MONITORING FUNCTION FAILS TO DISPLAY “ARM OUT” NORMALLY . . . . . . . . . . . . . . . . . . 20-535
E-22 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET CURL” NORMALLY . . . . . . . . . . . . . 20-536
E-23 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET DUMP” NORMALLY . . . . . . . . . . . . . 20-537
E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NORMALLY . . . . . . . . . . . . . . . . . . . . 20-538
E-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NORMALLY . . . . . . . . . . . . . . . . . . . 20-540
E-26 MONITORING FAILS TO DISPLAY “TRAVEL DIFFERENTIAL PRESSURE” NORMALLY . . . . . 20-542
E-27 MONITORING FAILS TO DISPLAY “SERVICE” NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-544
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-546
E-29 AIR CONDITIONER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-548
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING . . . . . . . . . . . . . . . . . . . 20-550
E-31 HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552
PC400LC-7E0 20-501 1
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 in the ON position and a constant power supply is a
device which supplies power while the starting switch is in the OFF and ON positions).
★ When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if
the power is supplied normally.
Types of Fusible link Fuse No. Fuse capacity Destination of power

power supply
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
3 20A Machine monitor
Switch power supply F04 (65A)
Wiper drive
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Intake air heater
7 10A Rotary lamp
8 20A Right headlamp, working lamp (boom), working lamp (rear)
Switch power supply F04 (65A)
Radio
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
Switch power supply F04 (65A) 13 20A Headlamp
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Starting switch
Constant power supply F05 (30A) 17 10A
Machine monitor
18 10A (Spare)
19 30A Engine controller
Switch power supply Starting switch 20 5A Engine controller (ACC signal)

ACC
20-502 1 PC400LC-7E0
12
Locations of fusible links
20-503 1 PC400LC-7E0
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.
Trouble Phenomenon occurring on machine

Relative information Information on the failure occurred as well as the troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1 <Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Ground fault
Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground
circuit.
• Hot short
2 Wiring harness which is not connected to power source (24 V) circuit is in contact with power
source (24 V) circuit.
• Short circuit
Possible causes of trouble (Given Independent wiring harnesses are in contact with each other abnormally.
numbers are reference numbers,
which do not indicate priority)
<Precautions for troubleshooting>
3 1. Method of indicating connector No. and handling of T-adapter

Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
• If connector No. has no marks of "male" and "female", disconnect connector and insert T-
adapters in both male side and female side.
• If connector No. has marks of "male" and "female", disconnect connector and connect T-
adapter to only male side or female side.
4 2. Entry order of pin Nos. and handling of tester leads

Connect positive (+) lead and negative (-) lead of tester as explained below for troubleshooting,
unless otherwise specified.
• Connect positive (+) lead to pin No. or wiring harness entered on front side.
• Connect negative (-) lead to pin No. or harness entered on rear side.
Relative Electrical Circuit Diagram
PC400LC-7E0 20-504 1
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
E-1 ENGINE DOES NOT START
Trouble Engine does not start (Engine does not turn).
• Engine starting circuit has following 2 start lock mechanisms:
1) Start lock by the machine monitor password
Related information
2) Start lock by the safety lock lever
• In the case no error code for the engine controller mechanism is indicated

Battery voltage Specific gravity of battery
1 Low charge level of battery
Min. 24 V Min. 1.26
2 Defective fuse No. 3, No. 18 or fus- If fuse or fusible link is burnt out, the circuit probably has ground fault.
ible link F04 and F05 In the case the machine monitor does not light up, check the power circuit between the battery and the fuse.
Defective starting switch H06 (male) Position Resistance
3
(Internal disconnection) OFF Min. 1 MΩ
Between (1) - (4)
START Max. 1 Ω
Defective safety lock switch S14 (female) Lock lever Resistance

4 (internal short circuit)
Free Min. 1 MΩ
Between (1) - (3)
Lock Max. 1 Ω
R06 (female), R07 (female) Resistance
Defective starting motor cutout re-
5 lay R06 or R07 (internal disconnec- Between (1) - (2) 100 - 500 Ω
tion or short circuit)
Between (3) - (6) Max. 1 Ω
(If power supply and starting input and output are normal but starting motor does not turn, starting
motor is defective.)
Defective starting motor Starting motor Starting switch Voltage
6 (Internal disconnection or
breakage) Power supply: Between terminal B -
chassis ground 20 - 30 V
START
Starting input: Between terminal C -
20 - 30 V
chassis ground and chassis ground
shooting.
7 Defective alternator
(Internal short circuit) Alternator Voltage
Between terminal R - chassis ground Max. 1 V
20-505 1 PC400LC-7E0
12

Wiring harness between F01-18 outlet - H06 (female) (1) Resistance Max. 1 Ω
Wiring harness between H06 (female) (4) - J01 - R06 (female) (5) Resistance Max. 1 Ω
Disconnection in wiring harness Wiring harness between H06 (female) (3) - M17 (female) (1) Resistance Max. 1 Ω
tive contact in connector) Wiring harness between F01-3 outlet - S14 (female) (1) Resistance Max. 1 Ω
Wiring harness between H14 (female) (3) - R06 (female) (1) Resistance Max. 1 Ω
Wiring harness between R06 (female) (2) - R07 (female) (6) Resistance Max. 1 Ω
Wiring harness between R03 (female) (3) - J04 - chassis ground Resistance Max. 1 Ω
Wiring harness between battery relay terminal B (R04) - F05 - F01-18 inlet
Wiring harness between F01-18 outlet - H06 (female) (1) and chassis ground Resistance Min. 1 MΩ
Wiring harness between H06 (female) (4) - J01 - R06 (female) (5) and chassis
9
(Short circuit with GND circuit) Wiring harness between R06 (female) (3) - M17 (female) (1) and chassis Resistance Min. 1 MΩ
ground
Wiring harness between F01-3 outlet - S14 (female) (1) and chassis ground Resistance Min. 1 MΩ
Wiring harness between S14 (female) (3) - R06 (female) (1) and chassis Resistance Min. 1 MΩ
ground
Wiring harness between R07 (female) (2) - J05 - P02 (female) (14) and chas- Resistance Min. 1 MΩ
sis ground
10 Hot short (Short circuit with 24V
circuit) in wiring harness Wiring harness between P02 (female) (11) - J02 - M17 (female) (2), - D01
(female) (6), - alternator terminal R and chassis ground Voltage Max. 1 V
PC400LC-7E0 20-506 1
12
Circuit diagram related to engine start and battery charging
20-507 1 PC400LC-7E0
TROUBLESHOOTING E-2 AUTO-DECELERATOR DOES NOT OPERATE
12
E-2 AUTO-DECELERATOR DOES NOT OPERATE
Trouble • Auto-decelerator does not operate.
• Set speed of auto-decelerator is 1,400 rpm. Thus, the fuel control dial must be set above this speed when operating the
Related information auto-decelerator.
• Check all the monitoring indications after starting the engine.

In the case monitoring is not normally indicated, proceed to troubleshooting No. E-21.
1 Defective boom RAISE signal Monitoring code Item Normal display

Operation of lever: ON
01900 Boom RAISE Lever in neutral: OFF
Monitoring code Item Normal display

2 Defective boom LOWER signal
01900 Boom LOWER
Lever in neutral: OFF
3 Defective arm IN signal
01900 Arm IN Operation of lever: ON
4 Defective arm OUT signal
01900 Arm OUT
5 Defective bucket CURL signal
01901 Bucket CURL Operation of lever: ON
6 Defective bucket DUMP signal Monitoring code Item Normal display

01901 Bucket DUMP Lever in neutral: OFF
PC400LC-7E0 20-508 1
TROUBLESHOOTING E-3 AUTOMATIC WARMING-UP DOES NOT OPERATE
12

7 Defective swing signal Monitoring code Item Normal display

01900 Swing Lever in neutral: OFF
8 Defective travel signal
01900 Travel
9 Defective attachment signal
01901 Service Operation of lever: ON
Since trouble is in system, troubleshooting cannot be carried out. (If causes 1 - 9 above are not
detected, engine controller may be defective.)
E-3 AUTOMATIC WARMING-UP DOES NOT OPERATE

Trouble • Automatic warming-up system does not operate
• When engine coolant temperature is below 30°C [86°F], automatic warm-up system raises engine speed to 1,250 rpm.
Related information • If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned ON or after engine is
started, automatic warm-up system is turned OFF.

Defective engine coolant tempera- Monitoring code Item Normal display

1
ture signal
04102 Engine coolant temperature Compare with actual engine coolant
temperature
Since trouble is in system, troubleshooting cannot be carried out. (If causes stated above are not detected,
engine controller may be defective.)
20-509 1 PC400LC-7E0
TROUBLESHOOTING E-4 PREHEATER DOES NOT OPERATE
12
E-4 PREHEATER DOES NOT OPERATE
Trouble (1) • When starting switch is turned to HEAT position, preheating monitor does not light up.
• Input of preheating signal (ON/OFF) can be checked with monitoring function.
Related information

1 Defective starting switch system If preheating fails to operate (the heater does not warm up), refer to Trouble (2)

2 (Disconnection in wiring or defec- switch ON.
Wiring harness between P02 (female) (18) - J02 (male) (7) Resistance Max. 1 Ω
★ Prepare with starting switch OFF
P02 Starting switch Voltage
OFF Max. 1 V
HEAT 20 - 30 V
Trouble (2) When starting switch is turned to HEAT position, preheater does not warm up.
During low temperature (coolant temperature below 30°C [86°F]), pump controller drives the heater relay for 100 sec. after engine
Related information
start to automatically preheat.

★ Prepare with starting switch OFF
Defective starting switch H06 (male) Starting switch Resistance
OFF Min. 1 MΩ
Between (1) - (3)
HEAT Max. 1 Ω
switch ON.
Defective heater relay Heater relay Resistance

Coil terminal - chassis ground
Between contact terminals Min. 1 MΩ
Defective intake air heater switch ON.
3 (Internal disconnection).
Between heater terminals Normal if conductive
switch ON.
Wiring harness between H06 (female) (3) - J02 - Heater
relay terminal R17 Resistance Max. 1 Ω
Wiring harness between battery relay terminal M (R03) - Resistance Max. 1 Ω
Heater relay terminal R15
PC400LC-7E0 20-510 1
TROUBLESHOOTING E-4 PREHEATER DOES NOT OPERATE
12
Circuit diagram related to engine preheater
20-511 1 PC400LC-7E0
TROUBLESHOOTING E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM
12
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM
DO NOT MOVE
Trouble All travel, swing, and work equipment mechanism do not move.
Related information ---

1 Defective fuse No. 3 If fuse is burnt out, the circuit probably has ground fault.
switch ON.
Defective safety lock switch S14 (female) Lock lever Resistance
2
(internal disconnection)
Lock Min. 1 MΩ
Between (1) - (2)
Free Max. 1 Ω
switch ON.
Defective PPC lock solenoid
3 (Internal disconnection or short V01 (male) Resistance
circuit)
Between (1) - (2) 20 - 60 Ω

switch ON.
(Internal short circuit) D01 (male) Resistance
switch ON.
5 (Disconnection in wiring or Wiring harness between F01-3 outlet - J06 - S14 (male) (1) Resistance Max. 1 Ω
Wiring harness between S14 (male) (2) - J02 - V01 (male) (2) Resistance Max. 1 Ω
switch ON.
Ground fault in wiring harness Wiring harness between F01-3 outlet - J06 - S14 (male) (1) and
(Short circuit with GND circuit) chassis ground
Wiring harness between S14 (male) (2) - J02 - V01(female)
(2), - D01(female) (8) and chassis ground
PC400LC-7E0 20-512 1
TROUBLESHOOTING E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM
12
Circuit diagram related to PPC lock solenoid
20-513 1 PC400LC-7E0
TROUBLESHOOTING E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE
12
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE
Trouble • Power maximizing function does not work.
• Symbol mark is indicated on the machine monitor when the power maximizing switch is depressed during work equipment
operation while the engine is running in P- or E-mode.
Related information
• Input state of power maximizing switch (left knob switch) can be checked with monitoring function
(Code 02200: Switch Input 1)

ON.
Defective power maximizing switch
2 S11(male) Switch Resistance

Released Min. 1 MΩ
Between (1) - (2)
Pressed Max. 1 Ω
defective contact in connector) Wiring harness between F01-9 outlet - S11 (female) (1) Resistance Max. 1 Ω
Wiring harness between S11 (female) (2) - CP01 (female) (11) Resistance Max. 1 Ω
ON.
4 Wiring harness between F01-9 outlet - S11 (female) (1) and chassis ground Resistance Min. 1 MΩ
Wiring harness between S11 (female) (2) - CP01 (female) (11) and chassis Resistance Min. 1 MΩ
ground
CP01 Switch Voltage
Released Max. 1 V
Pressed 20 - 30 V
Circuit diagram related to power max. switch
PC400LC-7E0 20-514 1
TROUBLESHOOTING E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL
12
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL
Trouble • Machine monitor does not display at all when starting switch is turned ON

switch ON.
Wiring harness between P01(female) (1), (2) - J06 - F01-
2 (Disconnection in wiring or Max. 1 Ω
3 outlet Resistance
Wiring harness between P01 (female) (6), (7) - chassis Resistance Max. 1 Ω
ground
Ground fault in wiring harness switch ON.
Wiring harness between P01(female) (1), (2) - J06 - F01- Resistance Min. 1 MΩ
3 outlet and chassis ground
troubleshooting.
4 Defective machine monitor P01 (female) Voltage/Resistance
Between (1), (2) - chassis ground Voltage: 20 - 30 V
Between (6), (7) - chassis ground Resistance: Max. 1 Ω
Circuit diagram related to power source in monitor panel
20-515 1 PC400LC-7E0
TROUBLESHOOTING E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS
12
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS
Trouble • Machine monitor does not display some items when starting switch is turned ON

When following switches are operated, if all LCD panel is lighted up (all surface becomes
Possible causes and white), LCD panel is normal.
1 Defective machine monitor LCD
standard value in
normal state
• Switch operation: [ /] + [P] (Simultaneous operation)
2 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out. (If causes stated above are
not detected, engine controller may be defective.)
E-9 DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM

APPLICABLE MACHINE
Trouble Contents of display by machine monitor are different from applicable machine.

In the case monitoring display is not normal, proceed to failure code
code [DA2SKQ].
Possible causes and 1 Defective model code signal Monitoring code Item Normal display
standard value in (Internal defect)
normal state 00200 Controller model code 300
00201 Select model
Since trouble is in system, troubleshooting cannot be carried out. (If causes stated above are
not detected, engine controller may be defective.)
PC400LC-7E0 20-516 1
TROUBLESHOOTINGE-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE
12
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE
ENGINE RUNNING
Trouble • Fuel level monitor was lighted in red while the engine running
• If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Related information • Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
(Code 04200: Fuel Level Sensor Vol.)
1 Low fuel level ★ Add fuel

(When system is normal)
switch ON.
2 Defective fuel level sensor P21 (male) Fuel level Resistance
Possible FULL (Upper limit) Approximately 12 Ω
causes and Between (1) - chassis ground
EMPTY (Lower limit) 85 - 110 Ω
standard
value in
Disconnection in wiring harness ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
normal
state 3 (Disconnection in wiring or switch ON.
Wiring harness between P02 (female) (2) - P21 (female) (1) Resistance Max. 1 Ω
switch ON.
4 Defective machine monitor P02 (female) Fuel level Resistance
FULL (Upper limit) Approximately 12 Ω
Circuit diagram related to fuel level sensor
20-517 1 PC400LC-7E0
TROUBLESHOOTING E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDI-
12
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDI-
CATE NORMALLY
• While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
• While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
• Input from the engine coolant temperature sensor (temperature) can be checked with monitoring function.
(Code 04105: Engine coolant temperature)
Related information
• Check if failure code for abnormal communication (machine monitor) system DAFRMC is indicated
(if yes, diagnose that failure first).

Defective engine coolant tempera- TWTR (male) Engine coolant temperature Resistance
1 ture sensor (Internal disconnection
or short circuit) Between (B) - (A) 10 - 100°C 90 - 3.5 kΩ

Between (B) - chassis ground (50 - 212°F) Min. 1 MΩ
2 (Disconnection in wiring or defec- Wiring harness between ENG (female) (15) - G5 (female) (2) Resistance Max. 1 Ω
Wiring harness between TWTR (female) (1) - chassis ground Resistance Max. 1 Ω
3 (Short circuit with GND circuit) Wiring harness between ENG (female) (15) - TWTR (female) (2) and chassis
ground
24V circuit) in wiring harness Wiring harness between ENG (female) (15) - TWTR (female) (2) and chassis
5 Defective engine controller ENG (female) Engine coolant temperature Resistance
Between (15) - chassis ground 10 - 100°C 90 - 3.5 kΩ

(50 - 212°F)
PC400LC-7E0 20-518 1
TROUBLESHOOTING E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDI-
12
Circuit diagram related to engine coolant temperature sensor
20-519 1 PC400LC-7E0
TROUBLESHOOTING E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDI-
12
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDI-
CATE NORMALLY
• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
• Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function.
Related information
(Code 04402: Hydraulic oil temperature)

Defective hydraulic oil temperature P22 Engine coolant temperature Resistance
1 sensor (Internal disconnection or
short circuit) Between (1) - (2) 90 - 3.5 kΩ

10 - 100°C (50 - 212°F)
2 (Disconnection in wiring or Wiring harness between P02 (female) (12) - P22 (female) (2) Resistance Max. 1 Ω
Wiring harness between P02 (female) (13) - P22 (female) (1) Resistance Max. 1 Ω
3 (Short circuit with GND circuit) Wiring harness between P02 (female) (12) - P22 (female) (2) and chassis
ground
24 V circuit) in wiring harness Wiring harness between P02 (female) (12) - P22 (female) (2) and chassis
P02 Engine coolant temperature Resistance
Between (12) - (13) 90 - 3.5 kΩ
10 - 100°C (50 - 212°F)
Circuit diagram related to hydraulic oil temperature sensor
PC400LC-7E0 20-520 1
TROUBLESHOOTING E-13 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY
12
E-13 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY
• While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
• While fuel level is low, fuel level gauge does not lower from green range (F).
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
Related information
(Code 04200: Fuel level sensor voltage)

Defective fuel level sensor (Internal P21 (male) Fuel level Resistance
1
disconnection or short circuit) FULL (Upper limit) Approximately 12 Ω

Disconnection in wiring harness ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
defective contact in connector) Wiring harness between P02 (female) (2) - P21 (female) (1) Resistance Max. 1 Ω
3
(Short circuit with GND circuit) Wiring harness between P02 (female) (2) - P21 (female) (1) and chassis Resistance Min. 1 MΩ
ground
Hot short (Short circuit with 24 V
4
circuit) in wiring harness ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Wiring harness between P02 (female) (2) - P21 (female) (1) and chassis
P02 Fuel level Resistance
FULL (Upper limit) Approximately 12 Ω
Circuit diagram related to fuel level sensor
20-521 1 PC400LC-7E0
TROUBLESHOOTING E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY
12
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY
• When swing lock switch is turned ON, swing lock monitor does not light up.
Trouble
• When swing lock switch is turned ON, swing lock monitor lights up.
• Input from swing lock switch (ON/OFF) can be checked with monitoring function.
Related information

ON.
1 Defective swing lock switch (Internal S04 (female) Swing lock switch Resistance
disconnection or short circuit)
OFF Min. 1 MΩ
Between (1) - (2)

ON Max. 1 Ω
contact in connector) Wiring harness between P02 (female) (17) - J02 - S04 (male) (1) Resistance Max. 1 Ω
Wiring harness between S04 (male) (2) - J05 - chassis ground Resistance Max. 1 Ω
Ground fault in wiring harness (Short ON.
3
circuit with GND circuit)
Wiring harness between P02 (female) (17) - J02 - S04 (male) (1) and chassis
4
circuit) in wiring harness Wiring harness between P02 (female) (17) - J02 - S04 (male) (1) and chassis Voltage Max. 1 V
ground
P02 Swing lock switch Voltage
OFF 20 - 30 V
ON Max. 1 V
PC400LC-7E0 20-522 1
TROUBLESHOOTING E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY
12
Circuit diagram related to swing lock switch
20-523 1 PC400LC-7E0
TROUBLESHOOTINGE-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS
12
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DIS-
PLAYS NOTHING
Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
value in normal state 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
Trouble (2) • When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related information ★ If auto-decelerator fails to operate, proceed with troubleshooting No. E-2.
Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related information If travel speed selection fails, proceed with troubleshooting No. H-21.
Trouble (4) • When wiper switch is operated, wiper monitor is not displayed.
Related information ★ If wiper fails to operate, proceed with troubleshooting No. E-16.
• When LCD monitor adjust switch is operated, adjust screen is not displayed.
Trouble (5) • When select switch is operated, adjust screen is not displayed.
• When maintenance switch is operated, maintenance item screen is not displayed.
PC400LC-7E0 20-524 1
TROUBLESHOOTINGE-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS
12
MEMORANDUM
20-525 1 PC400LC-7E0
TROUBLESHOOTING E-16 WINDSHIELD WIPER DOES NOT OPERATE
12
E-16 WINDSHIELD WIPER DOES NOT OPERATE
Trouble • Windshield wiper and window washer do not operate (1) Windshield wiper does not operate.
• Input from window limit switch (ON/OFF) can be checked with monitoring function.
Related information

ON.
Defective window rear limit switch W03 (male) Front window Resistance
1
(Internal disconnection or short circuit)
When installed to front Min. 1 MΩ
Between (1) - (2)
When retracted to rear Max. 1 Ω
ON.
2 Defective wiper motor (Internal W04 (male) Resistance

Between (3) - (1)
contact in connector) Wiring harness between P01 (female) (9) - W04 (female) (3) Resistance Max. 1 Ω
Wiring harness between P01 (female) (10) - W04 (female) (1) Resistance Max. 1 Ω
4
Wiring harness between P02 (female) (15) - W03 (male) (1) and
chassis ground
Defective machine monitor P02 Front window Voltage
(Window limiter switch system)
Between (15) - chassis When installed to front 20 - 30 V
ground When retracted to rear Max. 1 V
5
Defective machine monitor
(Wiper motor system) Between (9) - chassis ground OFF Max. 3 V
Between (10) - chassis Max. 3 V ↔ 20 - 30 V
ground ON (Constant cycle)
PC400LC-7E0 20-526 1
12
Circuit diagram related to windshield wiper motor
20-527 1 PC400LC-7E0
12
Trouble • Windshield wiper and window washer do not operate (2) Window washer does not operate.
Related information

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault (See cause 4).
Defective washer motor (Internal M06 (male) Resistance

2
Between (1) - (2) 5 - 20 Ω
3 (Disconnection in wiring or Wiring harness between F01-4 - J03 - J06 - M06 (female) (1) Resistance Max. 1 Ω
Wiring harness between M06 (female) (2) - J04 - P01 (female) (3) Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between F01-4 - J03 - J06 - M06 (female) (1), - D04
(Short circuit with GND circuit) (female) (4), - other harnesses between related circuits and chassis ground
Wiring harness between M06 (female) (2) - J04 - P01 (female) (3), - D04
Defective machine monitor P01 Window washer switch Voltage
5
(Window limiter switch system)
OFF 20 - 30 V
ON Max. 1 V
PC400LC-7E0 20-528 1
12
Circuit diagram related to window washer motor of machine monitor
PC400LC-7E0 20-529 1
TROUBLESHOOTING E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NOR-
12
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NOR-
MALLY
• Machine push-up function does not operate
Trouble (1) Machine push-up function does not operate.
normally
Related information • When machine push-up function is set to high pressure, solenoid is de-energized.

1 Defective fuse No.2 If fuse is broken, circuit probably has ground fault. (See Cause 6)
Defective machine push-up S05 (female) Machine push-up switch Resistance
2
switch (Internal disconnection)
Low pressure set Max. 1 Ω
Between (1) - (2)
High pressure set Min. 1 MΩ

Defective machine push-up solenoid V06 (male) Resistance
3 (Internal disconnection or short
circuit or ground fault) Between (1) - (2) 20 - 60 Ω
Defective assembled-type diode D04
4 D02 (male) Resistance (Continuity)
Between (3) - (7) Min. 1 MΩ (without continuity)
Disconnection in wiring harness Wiring harness between F01-2 outlet - S05 (male) (1) Resistance Max. 1 Ω
defective contact in connector) Wiring harness between S05 (male) (2) - J07 - V06 (female) (2) Resistance Max. 1 Ω
Ground fault in wiring harness Wiring harness between F01-2 outlet - S05 (male) (1), - other harnesses between
6 related circuits and chassis ground Resistance Min. 1 MΩ
Wiring harness between S05 (male) (2) - J07 - V06 (female) (2), - D02 (female) Resistance Min. 1 MΩ
20-530 1 PC400LC-7E0
TROUBLESHOOTING E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NOR-
12
• Machine push-up function does not operate
Trouble (2) Machine push-up function does not release.
normally
Related information • When machine push-up function is set to low pressure, solenoid is energized.

Defective machine push-up switch S05 (female) Machine push-up switch Resistance
1 (Internal short circuit)
Low-pressure set Max. 1 Ω
Between (1) - (2)
High-pressure set Min. 1 MΩ

2 circuit) in wiring harness Wiring harness between S05 (female) (2) - J07 - V06 (female) (2), - D02 (female)
Voltage Max. 1 V
Circuit diagram related to machine push-up solenoid
PC400LC-7E0 20-531 1
TROUBLESHOOTING E-18 MONITORING FUNCTION FAILS TO DISPLAY “BOOM RAISE”
12
E-18 MONITORING FUNCTION FAILS TO DISPLAY “BOOM RAISE”
NORMALLY
Trouble • Boom Raise operation is not displayed normally by machine monitoring function (Special functions)
Related information • Monitoring code: 01900 (Pressure Switch 1)

Defective boom RAISE PPC oil P06 (male) Boom lever Resistance
1 pressure switch (Internal
disconnection or short circuit) Neutral Min. 1 MΩ

Between (1) - (2)
Boom RAISE Max. 1 Ω
2 (Disconnection in wiring or Wiring harness between CP03 (female) (10) - P06 (female) (2) Resistance Max. 1 Ω
3 (Short circuit with GND circuit) Wiring harness between CP03 (female) (10) - P06 (female) (2)
and chassis ground
4
circuit) in wiring harness Wiring harness between CP03 (female) (10) - P06 (female) (2) Voltage Max. 1 V
and chassis ground
CP03 Boom lever Voltage
Neutral 20 - 30 V
Boom RAISE Max. 1 V
Circuit diagram related to boom RAISE PPC oil pressure switch
20-532 1 PC400LC-7E0
TROUBLESHOOTINGE-19 MONITORING FUNCTION FAILS TO DISPLAY “BOOM LOWER”
12
E-19 MONITORING FUNCTION FAILS TO DISPLAY “BOOM
LOWER” NORMALLY
Trouble • Boom LOWER operation is not displayed normally by machine monitoring function (Special functions)
Related information • Monitoring code: 01900 (Output Switch 1)

Defective boom LOWER PPC oil pressure P02 (male) Boom lever Resistance
1 switch (Internal disconnection or short
circuit) Neutral Min. 1 MΩ
Between (1) - (2)
LOWER Max. 1 Ω
Disconnection in wiring harness switch ON.
2 (Disconnection in wiring or defective contact
in connector) Wiring harness between CP03 (female) (20) - P02 (female) (2) Resistance Max. 1 Ω
Ground fault in wiring harness (Short circuit switch ON.
3 with GND circuit)
Wiring harness between CP03 (female) (20) - P02 (female) (2) and Resistance Min. 1 MΩ
chassis ground
4 24V circuit) in wiring harness Wiring harness between CP03 (female) (20) - P02 (female) (2) and
Voltage Max. 1 V
chassis ground
CP03 Boom lever Voltage
Neutral 20 - 30 V
LOWER Max. 1 V
Circuit diagram related to boom LOWER PPC oil pressure switch
PC400LC-7E0 20-533 1
TROUBLESHOOTING E-20 MONITORING FUNCTION FAILS TO DISPLAY “ARM IN” NOR-
12
E-20 MONITORING FUNCTION FAILS TO DISPLAY “ARM IN” NOR-
MALLY
Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions)

Defective arm IN pressure sensor P04 (male) Voltage
1
(Internal disconnection or short circuit)
Between (3) - (1) 4.5 - 5.5 V
Between (2) - (1) 0.5 - 4.5 V

contact in connector) Wiring harness between CP01 (female) (19) - P04 (female) (2) Resistance Max. 1 Ω
Wiring harness between CP01 (female) (19) - P04 (female) (2) and chassis Resistance Min. 1 MΩ
ground
Hot short (Short circuit with 24 V circuit)
4 in wiring harness Wiring harness between CP01 (female) (19) - P04 (female) (2) and chassis
Voltage Max. 1 V
ground
CP01 Voltage
Between (22) - (10) 4.5 - 5.5 V
Between (19) - (10) 0.5 - 4.5 V
Circuit diagram related to arm IN PPC oil pressure witch
20-534 1 PC400LC-7E0
TROUBLESHOOTING E-21 MONITORING FUNCTION FAILS TO DISPLAY “ARM OUT”
12
E-21 MONITORING FUNCTION FAILS TO DISPLAY “ARM OUT”
NORMALLY
Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions)

Defective arm OUT PPC oil pressure P08 (male) Arm lever Resistance
1 switch (Internal disconnection or
short circuit) Neutral Min. 1 MΩ

Between (1) - (2)
OUT Max. 1 Ω
3 (Short circuit with GND circuit) Wiring harness between CP03 (female) (40) - P08 (female) (2) and chassis
ground
4
circuit) in wiring harness Wiring harness between CP03 (female) (40) - P08 (female) (2) and chassis Voltage Max. 1 V
ground
CP03 Arm lever Voltage
Neutral 20 - 30 V
OUT Max. 1 V
Circuit diagram related to arm OUT PPC oil pressure switch
PC400LC-7E0 20-535 1
TROUBLESHOOTINGE-22 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET CURL”
12
E-22 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET
CURL” NORMALLY
Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions)

Defective bucket CURL pressure P01 (male) Bucket lever Voltage
1 sensor (internal disconnection or
short circuit) Between (3) - (1) Neutral 4.5 - 5.5 V

Between (2) - (1) CURL 0.5 - 5.5 V
ground
4 Hot short (Short circuit with 24 V Wiring harness between CP01 (female) (13) - P01 (female) (2) and chassis Voltage Max. 1 V
circuit) in wiring harness ground
CP01 Voltage
5 Defective pump controller Between (22) - (10) 4.5 - 5.5 V
Between (13) - (10) 0.5 - 5.5 V
Circuit diagram related to bucket CURL PPC oil pressure switch
20-536 1 PC400LC-7E0
TROUBLESHOOTING E-23 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET
12
E-23 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET
DUMP” NORMALLY
Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)

Defective bucket DUMP PPC oil P05 (male) Bucket lever Resistance
1 pressure switch (Internal disconnec-
tion or short circuit) Neutral Min. 1 MΩ

Between (1) - (2)
Dump Max. 1 Ω
2 (Disconnection in wiring or defec- Wiring harness between CP03 (female) (19) - P05 (female) (2) Resistance Max. 1 Ω
ground
4
circuit) in wiring harness Wiring harness between CP03 (female) (19) - P05 (female) (2) and chassis Voltage Max. 1 V
ground
CP03 Bucket lever Voltage
Neutral 20 - 30 V
Dump Max. 1 V
Circuit diagram related to bucket DUMP PPC oil pressure witch
PC400LC-7E0 20-537 1
TROUBLESHOOTING E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NOR-
12
E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NOR-
MALLY
Trouble • Swing is not displayed normally by machine monitoring function (Special function)

Defective swing left PPC oil pres- P07 (male) Swing lever Resistance
1 sure switch (Internal disconnection
or short circuit) Neutral Min. 1 MΩ
Between (1) - (2)
Left Max. 1 Ω
Defective swing right PPC oil pres- P03 (male) Swing lever Resistance
2 sure switch (Internal disconnection
or short circuit) Neutral Min. 1 MΩ
Between (1) - (2)
Right Max. 1 Ω
Disconnection in wiring harness Wiring harness between CP03 (female) (29) - P03 (female) (2), - P07 (female) Resistance Max. 1 Ω
3 (Disconnection in wiring or (2)
defective contact in connector) Wiring harness between P03 (female) (1) - chassis ground Resistance Max. 1 Ω
(Short circuit with GND circuit) Wiring harness between CP03 (female) (29) - P03 (female) (2), - P07 (female)
(2) and chassis ground Resistance Min. 1 MΩ
5 24V circuit) in wiring harness Wiring harness between CP03 (female) (29) - P03 (female) (2), - P07 (female)
Voltage Max. 1 V
CP03 Bucket lever Voltage
Neutral 20 - 30 V
Left or Right Max. 1 V
20-538 1 PC400LC-7E0
TROUBLESHOOTING E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NOR-
12
Circuit diagram related to right and left swing PPC oil pressure witches
PC400LC-7E0 20-539 1
TROUBLESHOOTINGE-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NOR-
12
E-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NOR-
MALLY
Trouble ★ Travel is not displayed normally by machine monitoring function (Special functions)
Related information ★ Monitoring code: 01900 (Output Switch 1)

Defective travel PPC pressure P09 (male) Travel lever Resistance
1 switch (Internal disconnection or
short circuit) Neutral Min. 1 MΩ

Between (1) - (2)
Front or rear Max. 1 Ω
2 (Disconnection in wiring or Wiring harness between CP03 (female) (39) - J01 - P09 (female) (2) Resistance Max. 1 Ω
Wiring harness between P09 (female) (1) - J05 - chassis ground Resistance Max. 1 Ω
(Short circuit with GND circuit) Wiring harness between CP03 (female) (39) - J01 - P09 (female) (2), - A14
4 24V circuit) in wiring harness Wiring harness between CP03 (female) (39) - J01 - P09 (female) (2), - A14
Voltage Max. 1 V
Neutral 20 - 30 V
Front or rear Max. 1 V
20-540 1 PC400LC-7E0
TROUBLESHOOTINGE-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NOR-
12
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400LC-7E0 20-541 1
TROUBLESHOOTING E-26 MONITORING FAILS TO DISPLAY “TRAVEL DIFFERENTIAL
12
E-26 MONITORING FAILS TO DISPLAY “TRAVEL DIFFERENTIAL
PRESSURE” NORMALLY
Trouble • Travel differential pressure is not displayed normally by machine monitoring function (Special functions)
• Travel differential pressure is turned on as a pressure difference occurred between the right and left travel PPC circuits
Related information (during steering).
• Monitoring code: 01901 (Output Switch 2)

Defective travel steering PPC oil P10 (male) Travel lever Resistance
1 pressure switch (Internal
disconnection or short circuit) Neutral Min. 1 MΩ

Between (1) - (2)
Left or Right only Max. 1 Ω
Wiring harness between P10 (female) (1) - J05 - chassis ground Resistance Max. 1 Ω
3 (Short circuit with GND circuit) Wiring harness between CP02 (female) (16) - P10 (female) (2) and
chassis ground
4 Hot short (Short circuit with 24 V
circuit) in wiring harness Wiring harness between CP02 (female) (16) - P10 (female) (2) and
Neutral 20 - 30 V
Left or Right only Max. 1 V
20-542 1 PC400LC-7E0
TROUBLESHOOTING E-26 MONITORING FAILS TO DISPLAY “TRAVEL DIFFERENTIAL
12
Circuit diagram related to travel steering PPC oil pressure switch
PC400LC-7E0 20-543 1
TROUBLESHOOTING E-27 MONITORING FAILS TO DISPLAY “SERVICE” NORMALLY
12
E-27 MONITORING FAILS TO DISPLAY “SERVICE” NORMALLY
Trouble • Service is not displayed normally by machine monitoring function (Special functions)

Defective (front) PPC oil pressure S10 (male) Service pedal Resistance
circuit) Neutral Min. 1 MΩ
Between (1) - (2)
Front Max. 1 Ω
Defective (rear) PPC oil pressure S11(male) Service pedal Resistance

circuit) Neutral Min. 1 Mz
Between (1) - (2)
Rear Max. 1 z
Wiring harness between CP02 (female) (35) - S10 (female) (2), - S11 (fe-
Disconnection in wiring harness Resistance Max. 1 Ω
3 (Disconnection in wiring or male) (2)
Wiring harness between S10 (female) (1) - chassis ground Resistance Max. 1 Ω
Wiring harness between S10 (female) (1) - chassis ground Resistance Max. 1 Ω
4
(Short circuit with GND circuit) Wiring harness between CP02 (female) (35) - S10 (female) (2), - S11 (fe- Resistance Min. 1 MΩ
24V circuit) in wiring harness Wiring harness between CP02 (female) (35) - S10 (female) (2), – S11
(female) (2) and chassis ground Voltage Max. 1 V
CP02 Service pedal Voltage
Neutral 20 - 30 V
Front or rear Max. 1 V
20-544 1 PC400LC-7E0
TROUBLESHOOTING E-27 MONITORING FAILS TO DISPLAY “SERVICE” NORMALLY
12
Circuit diagram related to service PPC oil pressure switch
PC400LC-7E0 20-545 1
TROUBLESHOOTING E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
12
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
Trouble • KOMTRAX system does not operate normally.
• If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry out following
Related information troubleshooting.
• Even if KOMTRAX system has trouble, it does not particularly appear on machine.

★ Turn starting switch OFF, then carry out troubleshooting.
LED (1) Normal state
LED-A1 ON
1 Defective power supply
G01 Signal Voltage
(39), (40) - Constant 20 - 30 V
Between (37) - (38) power supply
★ Turn starting switch ON and carry out troubleshooting.
2 Defective GPS LED (2) Normal state
LED-A2 ON
★ Start engine and carry out troubleshooting.
LED-C1 ON
Defective starting switch ACC sig-
3
nal and alternator R signal ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting.
G01 Signal Voltage

Between (36) - (37), (38) Starting switch ACC 20 - 30 V
Between (28) - (37), (38) Alternator R 20 - 30 V
LED-C3 ON
Defective S-NET connection and
4
starting switch C signal ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
G01 Signal Voltage
Between (10) - (9) S-NET 6-9V
Between (27) - (37), (38) Starting switch C Max. 1 V
LED-C4 ON
5 State of CAN connection
★ Prepare with starting switch OFF and carry out troubleshooting.
G01 Signal Resistance
Between (7) - (8) CAN 40 - 80 z
6 Number of mails not transmitted yet LED (12) Normal state
7-segment 0-9
★ Turn starting switch ON and carry out troubleshooting (See *)
Dot ON
7 State of positioning with GPS
* In an outdoor location within radio waves' penetration range, it sometimes takes more than a minute from
turning on of the starting switch to completion of the positioning.
20-546 1 PC400LC-7E0
TROUBLESHOOTING E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
12
LED display unit
G01 connector
PC400LC-7E0 20-547 1
TROUBLESHOOTING E-29 AIR CONDITIONER DOES NOT OPERATE
12
E-29 AIR CONDITIONER DOES NOT OPERATE
Trouble • Air conditioner does not start.
• For electrical circuit inside the air conditioner unit, refer to the structure, function and maintenance standard, "Air
Related information
conditioner system".

1 Defective fuse No. 11 If fuse is burnt, circuit probably has ground fault.
Defective A/C Hi/Lo pressure switch switch ON.
2 (Internal disconnection or defective
contact) P17 (Male) Resistance
Between (1) - (2) Max. 1 Ω

switch ON.
Disconnection in wiring harness Wiring harness between F01-11 outlet - M26 (male) (5) Resistance Max. 1 Ω
3 (Disconnection in wiring or defective contact in
connector) Wiring harness between M26 (male) (12) - P17 (female) (1) Resistance Max. 1 Ω
Wiring harness between M26 (male) (8) - chassis ground Resistance Max. 1 Ω
Wiring harness between P17 (female) (2) - J04 - A07 - chassis ground Resistance Max. 1 Ω
switch ON.
(Short circuit with GND circuit) Wiring harness between F01-11 outlet - M26 (male) (5) and chassis Resistance Min. 1 MΩ
ground
Wiring harness between M26 (male) (12) - P17 (female) (1) Resistance Min. 1 MΩ
troubleshooting.
5 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
M26 Voltage
Between (5) - (8) 20 - 30 V
20-548 1 PC400LC-7E0
TROUBLESHOOTING E-29 AIR CONDITIONER DOES NOT OPERATE
12
Circuit diagram related to air conditioner
PC400LC-7E0 20-549 1
TROUBLESHOOTING E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP
12
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP
SOUNDING
• Alarm does not sound during travel.
Trouble
• Alarm sounds in stopped state.

2 Defective travel signal Operation of lever: ON

019 Travel
When the monitoring display is not correct, proceed to diagnosis for "Travel is not normally indicated in the
monitoring function".
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting (insert T-adapter).
A14 Travel lever Voltage
3 Defective travel alarm (Internal
disconnection or short circuit) Neutral Max. 1 V
Between (1) - (2)
Operated 20 - 30 V
If above voltage is normal and travel alarm does not sound, travel alarm is defective.
4 (Disconnection in wiring or Wiring harness between F01-15 outlet - J03 - A07 - A14 (female) (1) Resistance Max. 1 Ω
Wiring harness between A14 (female) (2) - J01 (19) Resistance Max. 1 Ω
5 (Short circuit with GND circuit) Wiring harness between F01-15 outlet - J03 - A07 - A14 (female) (1)
and chassis ground
Since trouble is in system, troubleshooting cannot be carried out. (If causes 1 - 5 above are not detected,
6 Defective pump controller travel alarm may be defective.)
20-550 1 PC400LC-7E0
TROUBLESHOOTING E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP
12
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400LC-7E0 20-551 1
TROUBLESHOOTING E-31 HORN DOES NOT SOUND
12
E-31 HORN DOES NOT SOUND
Trouble • Horn does not sound

1 Defective fuse F01-(5) If fuse is broken, circuit probably has ground fault. (See Cause 6)
2 Defective horn relay If the horn sounds after replacing the relay, the relay was defective
Between M07 (2) - chassis ground (with horn switch turned ON) Voltage 20 - 30 V
3 Defective high tone horn ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Between M07 (female) (1) - chassis ground Resistance Max. 1Ω
If above is normal, the horn is defective

Between M08 (2) - chassis ground (with horn switch turned ON) Voltage 20 - 30 V
4 Defective low tone horn ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Between M08 (female) (1) – chassis ground Resistance Max. 1 Ω
If above is normal, the horn is defective
Wiring harness between F01 (5) - S10 (female) - R08 (female) (3) Resistance Max. 1 Ω
Disconnection in wiring harness Wiring harness between S10 (female) (2) - R08 (female) - A07 -
5 (Disconnection in wiring or M07 (female) (2) Resistance Max. 1 Ω
Wiring harness between R08 (female) (5) - A07 - M08 (female) (2) Resistance Max. 1 Ω
Wiring harness between R08 (female) (2) - J04 (male) (18) - A07 -
chassis ground Resistance Max. 1 Ω
Wiring harness between F01 (5) - S10 (female) - R08 (female) (3)
and chassis ground
(Short circuit with GND circuit) Wiring harness between S10 (female) (2) - R08 (female) – A07 –
M07 (female) (2) and chassis ground Resistance Min. 1 MΩ
Wiring harness between R08 (female) (5) – A07 – M08 (female) (2) Resistance Min. 1 MΩ
and chassis ground
20-552 1 PC400LC-7E0
12
Circuit diagram related to horn
PC400LC-7E0 20-553 1
12
MEMORANDUM
20-554 1 PC400LC-7E0
PC400LC-7E0 20-555 1
20-556 1 PC400LC-7E0
PC400LC-7E0 20-557 1
20-558 1 PC400LC-7E0
PC400LC-7E0 20-559 1
20-560 1 PC400LC-7E0
PC400LC-7E0 20-561 1
20-562 1 PC400LC-7E0
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE)
12
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-602
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-604
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW . . . . . 20-605
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . 20-607
H-5 AUTO-DECELERATOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
H-6 FINE CONTROL MODE DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
H-7 BOOM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H-8 ARM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
H-9 BUCKET MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION . . . . . . . . . . . . . . . . . . . . . . 20-611
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
H-12 WORK EQUIPMENT HAS BIG TIME LAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT . . . . . . . . . . . . . . . . 20-613
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY . 20-614
H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . 20-615
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
H-19 MACHINE SWERVES IN TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
H-20 MACHINE TRAVELS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-22 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED. . . 20-619
H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-24 MACHINE DOES NOT SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-28 LARGE SOUND CAUSED WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-29 SWING NATURAL DRIFT IS TOO LARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . 20-625
PC400LC-7E0 20-601 1
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND ME-
12
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
PC400LC-7E0 20-602 1
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND ME-
12
H 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.
20-603 1 PC400LC-7E0
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLE-
12
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
H 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
Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value
Cause for presumed failure (The <Contents>

3 attached No. for filing and refer- • The standard values in normalcy by which to judge "good" or "no good" about presumed causes.
ence purpose only. It does not
stand for any priority) • References for making judgement of "good" or "no good".
4
PC400LC-7E0 20-604 1
TROUBLESHOOTING H-1 ALL WORK EQUIPMENT LACK POWER,
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 P mode for troubleshooting.

H Stop engine for preparations. Start troubleshooting at engine high idling.
1 Malfunctioning of unload valve Control lever Unload pressure
All control levers in NEUTRAL 42±10 kgf/cm2 (597±142 psi)
Control lever Main relief pressure
Improper adjustment or mal-
2
functioning of main relief valve Arm, DIGGING 340 - 375kgf/cm2 (4836 - 5333 psi)
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.
3 Malfunctioning of self pressure Control lever Control circuit source pressure

Presumed cause and standard value in normalcy
decompression valve
All control levers in NEUTRAL 29 - 35kgf/cm2
(412 - 497 psi)
Oil pressure to be measured Measurement condition Oil pressure ratio
Improper adjustment or mal- Pump delivery pressure 1
4 functioning of PC valve Swing lock: ON
PC valve output pressure Arm: Digging relief Approximately 0.6 (Approximately 3/5)
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.
Malfunctioning of LS-EPC Travel speed Travel control lever LS-EPC output pressure
5 valve Lo NEUTRAL Approximately 14 kgf/cm2 (199 psi)
Hi OPERATED 0 kgf/cm2 (0 psi)
Oil pressure ratio
Oil pressure to be measured All control levers in NEU- Travel without load (control lever held at half
Improper adjustment or mal- TRAL stroke)
6
functioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approximately 0.6 (Approximately 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of LS valve or its internal
7 Malfunctioning of servo piston Malfunctioning of servo piston is suspected. Check the piston itself.
If none of the above listed causes is detected, the piston pump is suspected of deteriorated performance, malfunc-
8 Piston pump defective tioning or internal failure.
20-605 1 PC400LC-7E0
TROUBLESHOOTING H-2 ENGINE SPEED SHARPLY DROPS OR
12
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS
Failure information The engine speed sharply drops or the engine stalls.
Relative information Set the working mode in P-mode before start.

Improper adjustment or mal- Control lever Main relief pressure

1 functioning of main relief
valve
Arm, DIGGING 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.

Oil pressure to be measured Measurement condition Oil pressure ratio
Improper adjustment or mal- Pump delivery pressure 1
2 Swing lock: ON
functioning of PC valve Arm: Digging relief
PC valve output pressure Approximately 0.6 (Approximately 3/5)
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.
Oil pressure ratio
Oil pressure to be measured All control levers in NEU- Travel without load
Improper adjustment or mal- TRAL (control lever held at half stroke)
3
functioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approximately 0.6 (Approximately 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its in-
ternal failure is suspected. In that case, check the valve itself.
4 Orifice or filter in servo equip- The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself.
ment clogged
Malfunction of servo
5 The servo piston is suspected of malfunction. Check the piston itself.
piston
PC400LC-7E0 20-606 1
TROUBLESHOOTING H-3 NO WORK EQUIPMENT, TRAVEL OR
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 P mode for the troubleshooting.

Malfunctioning of PPC lock Safety lock lever Solenoid output pressure

1 solenoid valve Locked 0 kgf/cm2 (0 psi)
Released 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of self pres-
2 sure decompression valve Control lever Control circuit source pressure
All control levers in NEUTRAL position 29 - 35 kgf/cm2 (412 - 497 psi)
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the following manner.
3 Piston pump defective • Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal
condition.
It is presumed that the pump shaft does not rotate due to some internal failure of the damper. Check the damper
4 Damper defective itself.
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC

PUMP
Failure information An abnormal noise is heard from around the hydraulic pump.
Relative information ---

Presumed cause and standard
1 Hydraulic oil level lowered Make a visual check.

value in normalcy
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
3 Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside
clogged the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction
4
clogged circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
20-607 1 PC400LC-7E0
TROUBLESHOOTING H-5 AUTO-DECELERATOR DOES NOT
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 P mode for the troubleshooting.

standard value in normalcy
Presumed cause and

Travel control lever PPC valve output pressure
1 Malfunctioning of travel PPC NEUTRAL 0 kgf/cm2 (0 psi)

valve (shuttle valve)
Operation Above 28 kgf/cm2 (Above 398 psi)
H-6 FINE CONTROL MODE DOES NOT FUNCTION

Failure information The fine control mode poorly functions or its response is slow.

Travel speed Travel control lever LS-EPC valve output pressure
Malfunctioning of LS- EPC

1 valve Approximately 14 kgf/cm2
Lo NEUTRAL
(Approximately 199 psi)
Hi OPERATED 0 kgf/cm2 (0 psi)
2 Orifice in LS circuit clogged The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
Oil pressure ratio
Oil pressure to be measured All control levers in NEU- Travel without load
TRAL (control lever held at half stroke)
Improper adjustment or
3 malfunctioning of LS valve Pump delivery pressure 1
Nearly equal oil pressure
PC valve output pressure Approximately 0.6 (Approximately 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal
Malfunctioning of servo
4 piston Malfunctioning of the servo piston is suspected. Check the piston itself.
PC400LC-7E0 20-608 1
TROUBLESHOOTING H-7 BOOM MOVES SLOWLY OR LACKS
12
H-7 BOOM MOVES SLOWLY OR LACKS POWER
Failure information The boom moves slowly or lacks power

R.H. work equipment control lever PPC valve output pressure
1 Malfunctioning of right PPC
valve (in boom circuit) NEUTRAL 0 kgf/cm2 (0 psi)
Boom RAISE
Boom LOWER Above 28 kgf/cm2 (Above 398 psi)
Malfunction of merge-divide Travel lever Solenoid output pressure

2 solenoid valve Neutral 0 kgf/cm2 (0 psi)
Operated (Note) 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of merge/di-
3 vide valve (main and LS The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself.
valves)
4 Malfunctioning of boom con- The spool in the boom control valve (Lo/Hi) is presumed to malfunction. Check the valve itself.
trol valve (spool)
Malfunctioning of boom con-
The pressure compensation valve in the boom control valve (Lo/Hi) is presumed to malfunction. Check the valve
5 trol valve (pressure compensa- itself.
tion valve)
6 Malfunctioning of boom con- The regeneration valve in the boom control valve (Lo) or the seal is presumed to malfunction. Check the valve
trol valve (regeneration valve) itself.
7 The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the valve itself.
trol valve (lock valve)
Malfunction of boom control
8 valve (check valve) The check valve in the boom control valve (Hi) is presumed to malfunction. Check the valve itself.
9 Malfunctioning of safety valve The safety valve for the lock valve is presumed to malfunction, or the seal is suspected to be defective. Check
for lock valve or seal defective the valve itself.
The suction valve (bottom side) in the boom control valve (Lo) is presumed to malfunction, or the seal is sus-
10 trol valve (suction valve) or seal pected to be defective.
defective
The safety and suction valves (head side) in the boom control valve (Lo) are presumed to malfunction, or the seal
11 trol valve (safety-suction is suspected to be defective. Check those valves themselves.
valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the left travel control valve, bucket control valve and service control valve are presumed to
12 valve (left travel, bucket and malfunction. Check those valves themselves.
service valves)
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.
20-609 1 PC400LC-7E0
TROUBLESHOOTING H-8 ARM MOVES SLOWLY OR LACKS POW-
12
H-8 ARM MOVES SLOWLY OR LACKS POWER
Failure information The arm moves slowly, or lacks power.

L.H. work equipment control lever PPC valve output pressure
1 Malfunctioning of left PPC
valve (arm circuit) NEUTRAL 0 kgf/cm2 (0 psi)
Arm DIGGING
Arm DUMPING Above 28 kgf/cm2 (Above 398 psi)
Malfunctioning of merge/di- Travel lever Solenoid output pressure

2 vide solenoid valve
Neutral 0 kgf/cm2 (0 psi)

Operated (Note) 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of merge/ di-
3 vide valve (main and LS The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself.
valves)
4 Malfunctioning of arm control The spool in the arm control valve (Lo/Hi) is presumed to malfunction. Check the valve itself.
valve (spool)
Malfunctioning of arm control
The pressure compensation valve in the arm control valve (Lo/Hi) is presumed to malfunction. Check the valve
5 valve (pressure compensation itself.
valve)
6 Malfunctioning of arm control The generation valve in the arm control valve (Lo) is presumed to malfunction, or the seal is suspected to be de-
valve (regeneration valve) fective. Check the valve itself.
Malfunctioning of arm control
The safety and suction valves in the arm control valve (Lo/Hi) are presumed to malfunction, or the seal is sus-
7 valve (safety and suction pected of defect. Check those valves themselves.
valves) or seal defective
Malfunction of arm control
8 The quick return valve in the arm control valve (Hi) is presumed to malfunction. Check the valve itself.
valve (quick return valve)
valve (right travel, boom, left LS shuttle valves in the right travel control valve, boom control valve, left travel control valve, bucket control
9
travel, bucket and service valve and service valve are presumed to malfunction. Check those valves themselves.
valves)
10 Arm cylinder defective 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-7E0 20-610 1
TROUBLESHOOTING H-9 BUCKET MOVES SLOWLY OR LACKS
12
H-9 BUCKET MOVES SLOWLY OR LACKS POWER
Failure information The bucket moves slowly, or lacks power.

R.H. work equipment control lever PPC valve output pressure
1 Malfunctioning of right PPC valve

(bucket circuit) NEUTRAL 0 kgf/cm2 (0 psi)
Bucket DIGGING Above 28 kgf/cm2
Bucket DUMPING (Above 398 psi)
Malfunctioning of bucket control
2 valve (spool) The spool in the bucket control valve is presumed to malfunction. Check the valve itself.
3 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
The safety/suction valves in the bucket control valve are presumed to malfunction, or the seal is suspected
4 valve (safety/suction valves) or seal to be defective. Check those valves themselves.
defective
Malfunction of LS shuttle valve (ser-
5 The LS shuttle valve in the service control valve is presumed to malfunction. Check the valve itself.
vice valve)
6 Bucket cylinder defective Bucket cylinder Amount oil leakage from cylinder
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPER-

ATION
Work equipment does not move in its single operation
(1) The boom does not move when operated independently.
Failure information (2) The arm does not move when operated independently.
(3) The bucket does not move when operated independently.


value in normalcy
Work equipment control lever PPC valve output pressure

1 Malfunctioning of PPC valve
NEUTRAL 0 kgf/cm2 (0 psi)
Operated Above 28 kgf/cm2 (Above 398 psi)
Malfunctioning of work equip-

2 ment control valve (spool) The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
20-611 1 PC400LC-7E0
TROUBLESHOOTING H-11 WORK EQUIPMENT HAS A BIT TOO
12
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT
Work equipment has a bit too fast hydraulic drift
Failure information (1) Hydraulic drift of the boom is a bit too fast.


value in normalcy
1 Boom cylinder defective Boom cylinder Amount oil leakage from cylinder
Raise relief 20 cc/min
2 Boom control lever (lock valve) The seal at lock valve in the boom control lever is suspected to be defective. Check the valve itself.
seal defective
Seal at safety valve for lock valve
3 The seal at the safety valve in the lock valve (Lo) is suspected to be defective. Check the valve itself.
defective

Failure information (2) Hydraulic drift of the arm is a bit too fast.


1 Arm cylinder defective Arm cylinder Amount oil leakage from cylinder
The seal for safety and suction valves (bottom side) in the arm control valve (Lo/Hi) is suspected to be de-
2 Arm control valve (safety/suction fective. Check the valve itself.
valves) seal defective
(Whether the seal is defective or not may well be determined by changing for other safety/suction valves.)
Arm control valve (spool) seal de-
3 fective The seal for spool in the arm control valve (Lo/Hi) is suspected to be defective. Check the seal itself.
Arm control valve (pressure com-

The seal for pressure compensation valve (bottom side) in the arm control valve
4 pensation (Lo/Hi) is suspected to be defective. Check the seal itself.
valve) seal defective

Failure information (3) Hydraulic drift of the bucket is a bit too fast.


1 Bucket cylinder defective Bucket cylinder Amount oil leakage from cylinder
Bucket control valve (safety/suction The seal for the safety and suction valves (bottom side) in the bucket control lever is suspected to be defec-
2 tive. Check the seal itself.
valves) seal defective (Whether the seal is defective or not may well be determined by changing for other safety/suction valves.)
3 Bucket control valve (spool) seal The seal for spool in the bucket control valve is suspected to be defective. Check the seal itself.
defective
Bucket control valve

4 (pressure compensation valve) seal The seal for pressure compensation valve (bottom side) in the bucket control valve is suspected to be defec-
tive. Check the seal itself.
defective
PC400LC-7E0 20-612 1
TROUBLESHOOTING H-12 WORK EQUIPMENT HAS BIG TIME LAG
12
H-12 WORK EQUIPMENT HAS BIG TIME LAG
Failure information The work equipment has a big time lag.

Malfunctioning of LS-EPC Travel speed Travel control lever LS-EPC valve output pressure
1 valve Lo NEUTRAL 14 kgf/cm2 (199 psi)
Hi Operation 0 kgf/cm2 (0 psi)
Malfunctioning of control valve
2 (regeneration valve) - with The regeneration valve in the control valve is presumed to malfunction. Check the valve itself.
boom and arm only
Malfunctioning of control The safety/suction valves (boom: head side, arm and bucket: bottom side) of the control valve are presumed to
3 malfunction. Check those valves themselves directly.
valves (safety & suction valve) (Whether they are defective or not may well be determined by changing them for other safety/suction valves.)
4 Malfunctioning of control valve The pressure compensation valve of the control valve is presumed to malfunction. Check the valve itself directly.
(pressure compensation valve)
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SIN-

GLE CIRCUIT
Failure information Other work equipment moves when relieving the single circuit of specific work equipment.

value in normalcy
1 Control valve (pressure compensa- The seal for pressure compression valve in the control valve is suspected to be defective. Check the seal it-
tion valve) seal defective self.
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK

Failure information One-touch power max. function does not work.


value in normalcy
Malfunctioning of 2-stage Swing lock switch Solenoid valve output pressure

1 solenoid valve OFF 0 kgf/cm2 (0 psi)
ON 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of main relief

2 The main relief valve of control valve is presumed to malfunction. Check the valve itself.
valve
20-613 1 PC400LC-7E0
TROUBLESHOOTING H-15 MACHINE PUSH-UP FUNCTION DOES
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 P-mode.

H Prepare with starting switch OFF, then run engine at high idling and carry out troubleshooting.
value in normalcy
Malfunction of machine push-up Machine push-up switch Solenoid outlet pressure

1 solenoid valve OFF Min. 28 kgf/cm2 (Min. 398 psi)
ON 0 kgf/cm2 (0 psi)
Malfunction of boom 2 control The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting side on the head
2
valve (safety-suction valve) side) may be malfunctioning. Check it directly.
H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH

LARGER LOAD MOVES SLOWLY
Failure information In a compound operation, work equipment with larger load tends to move slowly.
Relative information ---

The pressure compensation valve for the work equipment with larger load is presumed to malfunction.
Check the valve itself.
Combination of compound operation Work equipment with larger load Work equipment with
smaller load
Boom RAISE +
Boom Arm
arm DIGGING
Malfunctioning of pressure compensa-
Boom RAISE +
1 tion valve for work equipment with arm DUMPING Arm Boom
larger load
Boom RAISE + Boom Bucket
bucket DIGGING
Arm DUMPING +
Arm Bucket
bucket DIGGING
Boom LOWER +
arm DUMPING Arm Boom
PC400LC-7E0 20-614 1
TROUBLESHOOTING H-17 IN SWING + BOOM RAISE OPERATION,
12
H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES
SLOWLY
Failure information 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.

value in normalcy
Malfunctioning of LS select valve The LS select valve of control valve is presumed to malfunction, or the seal is suspected to be defective.
1
or seal defective Check the valve and seal themselves.
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY

Failure information 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.

value in normalcy
Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing control valve is presumed to malfunction.
1 valve (left travel and swing) Check both of them directly.
20-615 1 PC400LC-7E0
TROUBLESHOOTING H-19 MACHINE SWERVES IN TRAVEL
12
H-19 MACHINE SWERVES IN TRAVEL
Failure information The machine tends to swerve while traveling.

Malfunctioning of travel PPC
1 Operated to Forward
valve
Operated to Reverse Above 28 kgf/cm2 (Above 398 psi)
Differential output between right and

left sides 4 kgf/cm2 (56 psi)

Malfunctioning of self-pres-
2 Control lever Control circuit source pressure
sure decompression valve
All control levers in NEUTRAL 29 - 35 kgf/cm2 (412 - 497 psi)

Oil Pressure ratio
Oil pressure to be measured All control levers in NEU- Travel without load (control lever held
Improper adjustment or mal-
3 TRAL at half stroke)
functioning of LS valve
Pump delivery pressure 1
Nearly equal pressure Approximately 0.6
LS valve output pressure
(Approximately 3/5)
Malfunctioning of travel inter- Travel control lever PPC valve output pressure
4
locking solenoid valve NEUTRAL 0 kgf/cm2 (0 psi)
When either side operated 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of travel inter-
5 locking valve The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
6 Malfunctioning of travel con- The spool in the travel interlocking valve is presumed to malfunction. Check the spool itself.
trol valve (spool)
7 Malfunction of travel motor 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.
8 Final drive defective (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-7E0 20-616 1
TROUBLESHOOTING H-20 MACHINE TRAVELS SLOWLY
12
H-20 MACHINE TRAVELS SLOWLY
Failure information The machine's travel speed is slow.

Malfunctioning of travel PPC
1 Operated to Forward
valve Operated to Reverse Above 28 kgf/cm2 (Above 398 psi)
Output differential between right

and left or front and rear Below 4 kgf/cm2 (56 psi)

Malfunctioning of
2 self-pressure decompression Control lever Control circuit source pressure

valve
All control levers in NEUTRAL 29 - 35 kgf/cm2 (412 - 497 psi)
3 Malfunctioning of LS-EPC
valve Lo NEUTRAL Approximately 14 kgf/cm2 (0.0199 psi)
Hi Operated 0 kgf/cm2 (0 psi)
Malfunction of travel control
4 The spool in the travel control valve is presumed to malfunction. Check the spool itself.
valve (spool)
Malfunctioning of travel
5 control valve (pressure The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
compensation valve)
Malfunctioning of travel
6 The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
control valve (suction valve)
7 valve (bucket) The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.

7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
8 Final drive defective (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 PC400LC-7E0
TROUBLESHOOTING H-21 MACHINE CANNOT BE EASILY
12
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER
Failure information The machine cannot be easily steered.

Malfunctioning of travel PPC valve Travel control lever PPC valve output pressure (steering)
1 (steering spool) NEUTRAL on both sides 0 kgf/cm2 (0 psi)
When either side operated Above 28 kgf/cm2 (Above 398 psi)
Malfunctioning of travel junction Travel control lever Solenoid valve output pressure
2
solenoid valve NEUTRAL 0 kgf/cm2 (0 psi)
When either side operated 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of travel junction

3 The travel junction valve of control valve is presumed to malfunction. Check the valve itself.
valve
Malfunctioning of merge/divide Travel control lever Solenoid valve output pressure

4 solenoid valve NEUTRAL 0 kgf/cm2 (0 psi)
OPERATED 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of merge/divide
5 valve The merge/divide valve of control valve is presumed to malfunction. Check the valve itself.
6 Malfunction of travel control valve The spool in the travel control valve is presumed to malfunction. Check the spool itself.
(spool)
Malfunctioning of travel control The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve
7
valve (pressure compensation valve) itself.
Malfunctioning of travel control
8 valve (suction valve) The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
9 Malfunctioning of LS shuttle valve The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
(bucket)
Check valve seal defective at LS oil The seal in the check valve of LS oil pressure pick-up port is suspected to be defective. Check the seal
10
pressure pick-up port itself.
The seal in the check valve of the travel motor is suspected to be defective. Check the seal itself.
11 Malfunctioning of travel motor (Whether the seal is defective or not may well be determined by swapping the motors between forward
(safety valve)
and reverse, or right and left.)
The seal in the check valve of the travel motor is suspected of defect. Check the seal itself.
12 Malfunctioning of travel motor (Whether the seal is defective or not may well be determined by swapping the motors between forward
(check valve)
and reverse, or right and left.)
PC400LC-7E0 20-618 1
TROUBLESHOOTING H-22 TRAVEL SPEED DOES NOT SHIFT, OR
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.

Travel speed Travel control lever Monitoring [01500]
Lo 690mA
Fine control (to the extent that the
Mi decelerator is released) 740mA
Hi 0 mA
1 Malfunctioning of LS-EPC valve

Approximately
Lo NEUTRAL
14 kgf/cm2 (0.0199 psi)
Hi Operation 0 kgf/cm2 (0 psi)
Malfunctioning of travel Travel speed Travel control lever Solenoid output pressure
2
speed solenoid valve Lo NEUTRAL 0 kgf/cm2 (0 psi)
Hi Operation 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of travel motor
3 The travel motor is presumed to malfunction when shifting speed. Check the speed shifting portion directly.
(speed shifting)
H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)
Failure information A track shoe does not turn (only on one side).

1 Travel control valve (suction valve) seat de- The suction valve seat in the travel control valve is suspected of defect. Check the seat itself.
fective
2 Travel motor (safety valve) seat defective The safety valve seat in the travel motor is suspected of defect. Check the seat itself.
3 Travel motor (check valve) seat defective The check valve seat in the travel motor is suspected of defect. Check the seat itself.
4 Travel Motor speed Travel control lever Amount of oil leakage from travel motor
5 Final drive defective (A failure inside the final drive may well be determined by an abnormal noise from within, abnor-
mal heat generated or metal dust or chips contained in the drained oil.)
20-619 1 PC400LC-7E0
TROUBLESHOOTING H-24 MACHINE DOES NOT SWING
12
H-24 MACHINE DOES NOT SWING
Machine does not swing
Failure information (1) The machine swings neither to the right nor to the left.

Malfunctioning of swing R.H. work equipment control lever Solenoid valve output pressure
1
holding brake solenoid valve
NEUTRAL 0 kgf/cm2 (0 psi)

Swing operated 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
2 (holding brake) Check it directly.
L.H. work equipment
Improper adjustment or Swing lock switch Swing relief pressure
control lever
3 malfunctioning of swing motor
(safety valve) ON Swing relief 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 mal-
function, or suspected of an internal failure. Check the valve itself.
4 Swing motor defective L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Max. 11 L/min (2.9 gal/min)
The swing machinery is suspected of an internal failure. Check the inside of the swing machinery directly.
5 Swing machinery defective (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.)
Failure information Machine does not swing

(2) The machine does not swing in one direction.

Malfunctioning of swing PPC L.H. work equipment control lever PPC valve output pressure
1 valve NEUTRAL 0 kgf/cm2 (0 psi)
Swing operated Above 28 kgf/cm2 (Above 398 psi)
2 Malfunctioning of swing The spool in the swing control valve is presumed to malfunction. Check the spool itself.
control valve (spool)
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
Swing motor (suction valve)
3 seal defective (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
4 defective (Whether the seal is defective or not may well be determined by swapping the right and left check valves and
watching the result.)
PC400LC-7E0 20-620 1
TROUBLESHOOTING H-25 SWING ACCELERATION IS POOR, OR
12
H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS
SLOW
Swing acceleration is poor, or swing speed is slow
Failure information
(1) Swing acceleration is poor, or swing speed is slow.
1 Malfunctioning of LS shuttle valve The LS shuttle valves for all the control valves are presumed to malfunction. Check them directly.
(all LS shuttles)
2 Malfunctioning of swing The swing holding brake portion of the swing motor is presumed to malfunction.
L.H. work equipment
Improper adjustment or malfunc- Swing lock switch Swing relief pressure
control lever
3 tioning of swing motor (safety
valve) ON Swing relief 285 - 335 kgf/cm2 (4,053 - 4,764 psi)
4 Swing motor defective L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Max. 11 L/min (2.9 gal/min)
Inside of the swing machinery is presumed to malfunction. Check itself.
5 Swing machinery defective (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.

2 Malfunctioning of swing The spool in the swing control valve is presumed to malfunction. Check the valve itself.
control valve (spool)
Malfunctioning of swing
The pressure compensation valve in the swing motor is presumed to malfunction.
3 control valve (pressure Check the valve itself.
compensation valve)
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
4 seal defective (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
Swing motor (check valve) seal
5 defective (Whether the seal is defective or not may well be determined by swapping the right and left check valves and
20-621 1 PC400LC-7E0
TROUBLESHOOTING H-26 EXCESSIVE OVERRUN WHEN STOP-
12
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING
Excessive overrun when stopping swing.
Failure information (1) The work equipment overruns excessively when stopping swing.


L.H. work equipment
Improper adjustment or Swing lock switch control lever Swing relief pressure
1 malfunctioning of swing motor
(safety valve) ON Swing relief 285 - 335 kgf/cm2 (4,053 - 4,764 psi)
L.H. work equipment control
Amount of oil leakage from swing motor
lever
2 Swing motor defective
Swing relief H Max. 11 L/min (2.9 gal/min)
Excessive overrun when stopping swing

Failure information (2) Swing acceleration is poor only on one side, or swing speed is slow.

1
valve NEUTRAL 0 kgf/cm2 (0 psi)
The PPC slow return valve is suspected of clogging. Check the valve itself.
2 Swing PPC slow return valve (Whether the valve is clogged or not may well be determined by swapping the right and left valves and watching
clogged
the result.)
Malfunctioning of swing con-
3 trol valve (spool) The spool in the swing control valve is resumed to malfunction. Check the valve itself.
Swing motor (suction valve) The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
4 (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
seal defective watching the result.)
Swing motor (check valve) seal The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
5 (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-7E0 20-622 1
TROUBLESHOOTING H-27 THERE IS BIG SHOCK WHEN STOP-
12
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING
Failure information There is a big shock caused when stopping a swing motion.

Malfunctioning of swing PPC The swing PPC slow return valve is presumed to malfunction. Check the valve itself.
2 (Whether the valve malfunctions or not may well be determined by swapping the right and left valves and watch-
slow return valve ing the result.)
3 Malfunctioning of swing motor The swing motor shockless valve is presumed to malfunction. Check the valve itself.
(shockless valve)
H-28 LARGE SOUND CAUSED WHEN STOPPING SWING

Failure information There is a big abnormal noise caused when stopping a swing motion.

Malfunctioning of back pres-

1 The back pressure valve is presumed to malfunction. Check the valve itself.
sure valve
Malfunction of swing motor
2 (safety valve) The safety valve in the swing motor is presumed to malfunction. Check the valve itself.
Malfunction of swing motor The seal in suction valve of the swing motor is suspected of defect. Check the seal itself.
3 (Whether the seal is defective or not may well be determined by swapping the right and left valves and watching the
(suction valve) result.)
The swing machinery is suspected of an internal failure. Check the inside of the machinery itself.
4 Swing machinery defective (A failure inside the swing machinery may well be determined by monitoring abnormal noise, abnormal heat gen-
erated or metal dust or chips contained in the drained oil.)
20-623 1 PC400LC-7E0
TROUBLESHOOTING H-29 SWING NATURAL DRIFT IS TOO
12
H-29 SWING NATURAL DRIFT IS TOO LARGE
Swing natural drift is too big.
Failure information (1) When the swing holding brake is activated.
• When the swing lock switch is ON position, or the swing holding brake release switch is in the normal position, the
Relative information swing brake is activated and the swing is fixed with a disc brake.
• Set the working mode in P mode for troubleshooting.


value in normalcy
Swing and holding brake solenoid R.H. work equipment control lever Solenoid valve output pressure
1
valve malfunctioned NEUTRAL 0 kgf/cm2 (0 psi)
Swing operated 29 - 35 kgf/cm2 (412 - 497 psi)
2 Swing motor (parking brake portion) The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that
malfunctioned portion directly.
Swing natural drift is too big.

Failure information (2) When the swing holding brake is released.
• When the swing holding brake release switch is in the emergency condition, the swing brake is released and the
Relative information swing is retained only hydraulically.
• Set the working mode in P mode for troubleshooting.

1 Swing control valve (spool) The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly.
malfunctioned
Swing control valve (pressure
The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself
2 compensation valve) malfunc- directly.
tioned
Swing motor (safety valve) de-
3 The safety valve seal in the swing motor is suspected of defect. Check the valve itself directly.
fective
4 defective The suction valve seal in the swing motor is suspected of defect. Check the valve itself directly.
5 Swing motor (check valve) de- The check valve seal in the swing motor is suspected of defect. Check the valve itself directly.
fective
Swing motor (shockless valve) The shockless valve in the swing motor is suspected of malfunction or the seal is suspected of defect. Check the
6
malfunctioned or seal defective valve or seal itself directly.
PC400LC-7E0 20-624 1
TROUBLESHOOTING H-30 ATTACHMENT CIRCUIT DOES NOT
12
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE
When attachment is installed
Failure information The return circuit of the attachment circuit does not change.
On a machine equipped with attachment, service circuit is changed as follows according to selected working mode.
1. When P- or E-mode is selected: Double acting circuit is selected, setting safety valve to low-pressure set.
Relative information
2. When B-mode is selected: Single acting circuit is selected, setting safety valve to high-pressure setting.
H B port alone allows changing the set of safety valve. The valve remains constantly at low-pressure set on A
port side.

H
Keep the engine stopped for the preparations, and keep it running at high idling during the
troubleshooting.
value in normalcy
Malfunction of attachment return se- Working mode Solenoid valve output pressure
1 lector solenoid valve
Mode E or P 0 kgf/cm2 (0 psi)
Mode B 29 - 35 kgf/cm2 (412 - 497 psi)
Malfunction of service attachment re-
2 turn selector valve The service attachment return selector valve may have a malfunction. Check it directly.
3 Malfunction of service 3 control valve The safety valve of the service control valve (on port B side) may have a malfunction. Check it directly.
(safety valve)
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE

ADJUSTED
When attachment is installed
Failure information Flow rate in attachment circuit cannot be adjusted.

• If an attachment is installed, the flow rate in the service circuit changes according to the selected working mode.
Relative information • How to adjust the flow rate in modes P and E is different from that in mode B. For details, see OPERATION
MANUAL.

Malfunction of attachment flow

1 The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly.
value in normalcy
rate adjustment EPC valve

H Keep the engine stopped for the preparations, and keep it running at high idling during the
troubleshooting.
2 Malfunction of service PPC valve Wiring harness connector Service pedal PPC valve output pressure
Disconnect connector V30 of at- In NEUTRAL 0 kgf/cm2 (0 psi)
tachment flow rate adjustment
EPC valve. Operated Above 28 kgf/cm2 (Above 398 psi)
20-625 1 PC400LC-7E0
TROUBLESHOOTING H-31 FLOW RATE IN ATTACHMENT CIRCUIT
12
MEMORANDUM
PC400LC-7E0 20-626 1
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

REMOVAL AND INSTALLATION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
HYDRAULIC OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
AFTERCOOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
ENGINE AND HYDRAULIC OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
PC400LC-7E0 30-1 C
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
SWING MOTOR AND SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
SWING MOTOR AND SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
SWING CIRCLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
TRACK ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-67
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-67
IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
RECOIL SPRING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
TRACK SHOE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
EXPANSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
REVOLVING FRAME ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
COUNTERWEIGHT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
CENTER SWIVEL JOINT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
HYDRAULIC TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL . . . . . . . . . . 30-89
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
HYDRAULIC PUMP INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
WORK EQUIPMENT PPC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
TRAVEL PPC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
30-2 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
HYDRAULIC CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
WORK EQUIPMENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
CAB GLASS (STUCK GLASS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
WINDOW ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
AIR CONDITIONER UNIT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134
KOMTRAX TERMINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
MONITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
PC400LC-7E0 30-3 C
DISASSEMBLY AND ASSEMBLY
12
MEMORANDUM
30-4 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF PARTS

SPECIAL TOOLS
● Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their
part names, part numbers and quantities are described in the special tool list.
● Also the following information is described in the special tool list.
1. Necessity
t Special tools that cannot be substituted and should always be used.
q Special tools that are useful if available and can be substituted with commercially available tools.
2. Distinction of new and existing special tools

N: Tools newly developed for this model have a new part number.
R: Tools with upgraded part numbers are remodeled from already available tools for other models.
Blank: Tools already available for other models can be used without any modification.
3. Circle mark in sketch column:

● The sketch of the special tool is presented in the section of "Sketches of special tools."
● Part No. of special tools starting with 79* T-***-***; means that they can not be supplied from Komatsu in Japan
(i.e. locally made parts).
★ General tools that are necessary for removal or installation are described as [1], [2]•••etc. and their part names, part
numbers and quantities are not described.
REMOVAL
● The Removal Section contains procedures and precautions for implementing the work, know how and the amount of
oil or coolant to be drained.
● Various symbols used in the Removal Section are explained and listed below.
WARNING! This mark indicates safety-related precautions that must be followed when implementing the
work.
★ Know-how or precautions for work.

[*1] This mark shows that there are instructions or precautions for installing parts.
This mark shows the amount of oil or coolant to be drained.
Weight of part or component.
PC400LC-7E0 30-5 C
12
INSTALLATION
● Except where otherwise instructed, installation of parts is done in 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! Precautions related to safety in execution of work.
★ This mark gives guidance or precautions when doing the procedure.
Type of coating material.
Torque
Quantity of oil or coolant to be added.
SKETCHES OF SPECIAL TOOLS
● Various special tools are illustrated for the convenience of local manufacture.
30-6 C PC400LC-7E0
12
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS
● Special tools which are deemed necessary for disassembly or assembly of parts are described as A1,•••X1 etc. and
their part names, part numbers and quantities are described in the special tool list.
● Also the following information is described in the special tool list.
1. Necessity
t Special tools that cannot be substituted and should always be used.
q Special tools that are useful if available and can be substituted with commercially available tools.
2. Distinction of new and existing special tools

N: Tools newly developed for this model have a new part number.
R: Tools with upgraded part numbers are remodeled from already available tools for other models.
Blank: Tools already available for other models can be used without any modification.
3. Circle mark in sketch column:

● The sketch of the special tool is presented in the section of "Sketches of special tools."
● Part No. of special tools starting with 79* T-***-***; means that they can not be supplied from Komatsu in Japan
(i.e. locally made parts).
★ General tools that are necessary for disassembly or assembly are described as [1], [2]•••etc. and their part names, part
numbers and quantities are not described.
DISASSEMBLY
● In Disassembly Section, the work procedures, precautions and know-how for carrying out those procedures, and
quantity of the oil and coolant drained are described.
● The meanings of the symbols used in the Disassembly Section are as follows.
WARNING! This mark indicates safety-related precautions that must be followed when implementing the
work.
★ Know-how or precautions for work.
Quantity of oil or coolant to be drained.
PC400LC-7E0 30-7 C
12
ASSEMBLY
● In the Assembly Section, the work procedures, precautions and know-how for carrying out those procedures, and
quantity of the oil and coolant added are described.
● The meanings of the symbols used in the Assembly Section are as follows..
WARNING! Precautions related to safety in execution of work.
★ This mark gives guidance or precautions when doing the procedure.
Type of coating material.
Torque
Quantity of oil or coolant to be added.
● Various special tools are illustrated for the convenience of local manufacture.
30-8 C PC400LC-7E0
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
Nominal Sleeve nut (elbow end) Use the two items

Plug (nut end)
number below as a set
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)
2. Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
PC400LC-7E0 30-9 C
12
3. If the part is not under hydraulic pressure, the following corks can be
used:
Dimensions
Nominal
Part Number
number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 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.
30-10 C PC400LC-7E0
12
PRECAUTIONS 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-7E0 30-11 C
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

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 are remodeled from items already available for
other models
Blank:... Tools already available for other model can be 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)..
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
1 795-630-5500 Standard puller t 1

Fuel supply pump 2 01010-81080 Bolt t 2 Removal of fuel supply pump
3 01643-31032 Washer t 2
4 795-931-1100 Seal puller assembly q Removal of rear oil seal
5 795-931-1210 Sleeve jig tool t 1
Rear oil seal A 6 795-931-1220 Sleeve jig tool t 1
Press fitting of rear oil seal
7 01050-31645 Bolt t 3
8 01050-31625 Bolt t 3
Angle tightening of
9 790-331-1110 Wrench q 1
bolt
Engine valve Adjustment of engine valve
10 795-125-1360 Clearance gauge q 1
clearance clearance
Removal, installation of engine
Engine and B 796T-601-1110 Stopper t 1 N Q
mounting bolt
hydraulic pump
796-460-1210 Oil stopper q 1
assembly C Stopping of oil
796-770-1320 Adapter q 1
1 796T-627-1630 Push tool q 1 Q Removal of shaft
2 790-201-2350 Push tool t 1 Removal of bearing
3 790-201-2510 Push tool t 1 Press fitting of bearing
790-101-5401 Push tool kit t 1
Swing motor and • 790-101-5531 • Plate 1
swing machinery D 4 Press fitting of oil seal
assembly • 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
5 790-201-2870 Push tool t 1 Press fitting of bearing inner race
6 790-201-2770 Push tool t 1 Press fitting of bearing inner race
7 796T-626-1110 Push tool t 1 Q Press fitting of bearing
30-12 C PC400LC-7E0
New/remodel
Necessity
Symbol
Sketch
Q'ty
796-627-1210 Wrench assembly t 1

• 796-627-1220 • Wrench 1
1 Removal, installation of round nut
• 796-427-1140 • Pin 3
• 01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
Final drive 791-122-1130 Plate q 1
E
assembly 790-101-2550 Leg q 2
2 790-101-2740 Adapter q 2 Pressing of bearing inner race
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (294 kN {30 t}) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1 Installation of floating seal
Carrier roller 791-430-3230 Installer t 1
F
assembly 791-601-1000 Oil pump t 1
Track roller 791-630-1780 Installer t 1
G Supply of oil
assembly 791-601-1000 Oil pump t 1
791-575-1520 Installer t 1
Idler assembly H
791-601-1000 Oil pump t 1
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
Disassembly, assembly of recoil
1 Cylinder
790-101-1600 t 1 spring assembly
(686 kN {70 t})
Recoil spring 790-101-1102 Pump t 1
J
assembly
• 790-201-1660 • Plate 1
2 Installation of dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
791-650-3000 Remover and installer t 1
Track shoe Cylinder
K 790-101-1300 t 1 Pulling out of master pin
assembly (980 kN {100 t})
790-101-1102 Pump t 1
PC400LC-7E0 30-13 C
New/remodel
Necessity
Symbol
Sketch
Q'ty
796-946-1310 Guide Ø21.8

1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide Ø20.9
1 1
(For 723-46-44100)
796-946-2210 Guide Ø20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide Ø21.6
1
(For 723-46-42800)
2
Control valve 796-946-2120 Guide Replacement of pressure
L 1
assembly (For 723-46-44100) compensation valve seal
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500)
796-946-1330 Sleeve
1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve
1
(For 723-46-42800)
3
796-946-2130 Sleeve
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
790-101-2501 Push puller t 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Center swivel joint Disassembly, assembly of center
M • 790-101-2540 • Washer 1
assembly swivel joint assembly
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
30-14 C PC400LC-7E0
New/remodel
Necessity
Symbol
Sketch
Q'ty
Disassembly, assembly of hydraulic

1 790-502-1003 Cylinder repair stand t 1
cylinder assembly
790-102-4300 Wrench assembly t 1 Removal, installation of piston
2
790-102-4310 Pin t 2 assembly
3 790-720-1000 Expander q 1
Ring (For boom and
796-720-1680 q 1
bucket)
Clamp (For boom and Installation of piston ring
4 07281-01589 q 1
bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
• Push tool
Hydraulic cylinder • 790-201-1851 1
N (For bucket)
assembly
• Push tool
• 790-201-1861 1
5 (For boom) Press fitting of bushing
• Push tool (For arm)
• 790-201-1871 1
Ø120
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
6 • Plate Press fitting of dust seal
• 790-201-1660 1
(For bucket)
• 790-201-1670 • Plate (For boom) 1
• 790-201-1680 • Plate (For arm) 1
796-670-1100 Remover q 1
• 796-670-1110 • Sleeve 1
• 796-670-1120 • Plate 1
• 796-670-1130 • Screw 1
Work equipment • 796-870-1110 • Adapter 1
P Removal of foot pin
assembly • 01643-33080 • Washer 1
• 01803-13034 • Nut 1
Puller (490 kN {50t},
790-101-4000 q 1
long)
790-101-1102 Pump (294 kN {30t}) q 1
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100V) t 1
Air conditioner unit Filling with air conditioner
Q 799-703-1110 Vacuum pump (220V) t 1
assembly refrigerant (gas)
799-703-1120 Vacuum pump (240V) t 1
799-703-1401 Gas leak detector t 1
Lifter
1 793-498-1210 t 2 Removal and Installation of
Operator’s cab glass Y (Suction cup)
operator’s cab glass
2 20Y-54-13180 Adapter t 2
PC400LC-7E0 30-15 C

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
B. Stopper
D1. Push Tool
30-16 C PC400LC-7E0
D7. Push Tool
E2. Push Tool
PC400LC-7E0 30-17 C
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
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.
30-18 C PC400LC-7E0
12
STRIPPING 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 20 AWG 3.96 - 5.53 (.156 - .218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)
0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)
0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)
0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 - .492)
Using wire insulation strippers, 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.
PC400LC-7E0 30-19 C
12
CRIMPING CONTACT TERMINAL (HD30 TYPE)
1. After insulation has been stripped 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.
30-20 C PC400LC-7E0
12
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
1. Grasp contact terminal approximately 25.2 mm (1 in) 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.
PC400LC-7E0 30-21 C
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.
30-22 C PC400LC-7E0
12
CRIMPING 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-7E0 30-23 C
12
INSERTION OF CONTACT TERMINAL (DT TYPE)
1. Grasp the crimped contact terminal approximately 25.2 mm (1 in)
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 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY ENGINE
12
ENGINE
Remark
For 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-7E0 30-25 C
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
RADIATOR ASSEMBLY
REMOVAL
1. Remove covers (1) and (2).
2. Drain coolant.
Coolant: Approximately 36 L (9.51 gal)
3. Disconnect connector (P24), the overflow tube (3), and remove the
sub-tank (4).
4. Remove the mounting bolt and then hoist the engine hood assembly
(5) to remove.
Engine hood: 200 kg (441 lb)
5. Remove the clamp and hoses (6), (7), (8) and (9) between the
radiator and the engine. [*1]
6. Remove radiator front cover (10).
30-26 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
7. Remove undercover.
8. Remove cover (11).
9. Disconnect the lower hose (12).
10. Remove 2 upper mounting bolts (13).
11. Lift and remove radiator assembly (14).
Radiator assembly: 30 kg (66.1 lb)
INSTALLATION
● Carry out installation in the reverse order of removal.
● Fill coolant
Fill coolant from the radiator coolant filler to the specified level. Start the engine and allow the coolant to circulate
through the piping. Check the coolant level again.
[*1]
Radiator-related hose clamps
(8): 3.3 ± 0.49 Nm (2.43 ± 0.361 lbf ft)

(7): 4.4 ± 0.49 Nm (3.25 ± 0.361 lbf ft)
(6): 8.8 ± 0.49 Nm (6.49 ± 0.361 lbf ft)
PC400LC-7E0 30-27 C
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY
12
HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL
WARNING! Ground the work equipment completely.

Stop the engine.
Gradually loosen the hydraulic oil tank cap
to release the internal pressure.
2. Remove the cover under the hydraulic oil tank drain plug. Remove
the hydraulic oil tank drain hose plug to drain hydraulic oil.
Hydraulic oil: Approximately 248 L (65.5 gal)
★ Open the hydraulic oil tank cap before draining to release the
tank inner pressure. Then drain oil from the cooler hose.
3. Disconnect connector (P24) and overflow tube (2). Remove the sub-
tank (3).
4. Remove the mounting bolt and then hoist the engine hood assembly
(4) to remove.
5. Remove covers (5) and (6).
30-28 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY
6. Remove tube (8).
Remove drain plug (7) and then remove fuel tube (8) after draining
oil inside.
7. Remove 3 hydraulic oil cooler left-side mounting bolts (9) and

remove the hydraulic oil cooler front mounting bolt (10).
8. Remove 4 butterfly screws (11) from the screen.
9. Disconnect upper piping (12).
10. Remove net on the hydraulic oil cooler side.
11. Hoist to remove hydraulic oil cooler assembly (13).
Hydraulic oil cooler assembly: 45 kg (99.2 lb)
INSTALLATION
● Fill hydraulic oil tank
Fill the hydraulic oil tank (through the filler port) to the specified level.
Start the engine and allow the oil to circulate through the piping.
Check the oil level again.
PC400LC-7E0 30-29 C
DISASSEMBLY AND ASSEMBLY AFTERCOOLER ASSEMBLY
AFTERCOOLER ASSEMBLY
REMOVAL
1. Open the radiator front cover.
2. Remove undercover (1).
3. Remove cover (2) under the aftercooler.
4. Remove evaporator (3) with the bracket as a unit.
5. Remove plate (4).
6. Remove grease gun holder (5).
7. Loosen hose clamp (6).
8. Remove mounting bolt (7).
30-30 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY AFTERCOOLER ASSEMBLY
9. Extract hoses (9) and (10) from the cooler while pushing down the
aftercooler assembly (8) [*1]
10. Hoist the cooler assembly with nylon slings, etc. before the hose is
completely extracted. Withdraw the hose and pull out the aftercooler
assembly sideways to remove it.
Aftercooler assembly: 25 kg (55.1 lb)
INSTALLATION
[*1]
TIGHTENING TORQUE PROCEDURE
1. Adjust the bridge position so that it will come under the bridge band as shown in the figure below.
2. Tighten till dimension (a) is 8 to 10 mm (0.315 – 0.394 in).
3. Tighten with a torque wrench to 16 – 17 Nm (11.8 – 12.5 lbf ft).
A. Dimension
B. Lapped portion of bridge and band Bridge Punch hole

★ Apply lubricant (Three-Bond band 18B) to the threaded portion
and tighten the bolt.
PC400LC-7E0 30-31 C
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC OIL PUMP ASSEMBLY
12
ENGINE AND HYDRAULIC OIL PUMP ASSEMBLY
REMOVAL
WARNING! Disconnect the negative (–) terminal of the battery.
WARNING! Ground the work equipment completely.

Stop the engine.
Gradually loosen the hydraulic oil tank cap to release the internal pressure.
★ Tag each hose and tube as you disconnect it to prevent a mistake when re-connecting.
1. Drain the coolant.
2. Remove hydraulic oil tank strainer and stop oil using tool C
(oil stopper, adapter).
★ When not using tool C, remove the drain plug and drain the oil
from the hydraulic oil tank and piping.
3. Close the fuel stopper valve on the fuel tank.
4. Disconnect connector (P24) and overflow tube (1) and remove the
sub-tank (2).
30-32 C PC400LC-7E0
5. Remove the mounting bolt. Then hoist the engine hood assembly (3)
to remove it.
6. Remove floor cover (4) on the control valve.

★ Remove cover (4) to remove covers (5) through (8).
7. Remove covers (5), (6), (7) and (8).

★ After removal, place the floor cover in its original position and
temporarily tighten the bolt.
8. Open the cover beside the pump and remove covers (9), (10) and
(11) on the pump side and the floor cover (12) on the pump.
★ Remove in the order of (9) to (12).
PC400LC-7E0 30-33 C
9. Remove undercovers (13) and (14).
10. Disconnect hose (15) under the radiator.
11. Disconnect hoses (16), (17) and (18) on the radiator and overflow
hose (19). [*1]
12. Remove two sound absorbing cover (20), 2 covers (21) and fan
guard (22).
30-34 C PC400LC-7E0
13. Remove the fan (23).
14. Remove air intake tube (24) along with the hose as a unit. [*2]
15. Loosen adjustment nut (25) and locknut (26) and remove V-belt from
the pulley. [*3]
16. Disconnect harness connector (M34), remove the bracket mounting

bolts, remove air conditioner compressor (28) and deposit them on
the floor cover.
17. Remove the terminal of intake air heater harness (29) and clamps
(30).
18. Remove the air intake connector (31).
PC400LC-7E0 30-35 C
19. Remove fuel hose (pump – tank) (32), (33) and fuel supply hose
(tank – block) (34).
20. Remove engine controller cover (35).
21. Disconnect engine controller connectors CE02 (36) and CE03 (37).
[*4]
30-36 C PC400LC-7E0
22. Remove harness clamp (38) at two locations.
23. Remove grounding T11 (39).
24. Disconnect oil level sensor connectors (40) and (P44).
25. Disconnect return hose (41) and the clamp.

★ Attach fuel stopper plug to the hose.
26. Disconnect the turbocharger hose (42).
27. Disconnect the cab heater hose (43).
PC400LC-7E0 30-37 C
28. Disconnect alternator wiring B (44), R (45) and E (46).
29. Disconnect the cab heater hose (47).
30. Remove harness clamps (48) at 3 locations and grounding T12 (49).
31. Disconnect starter terminal B (50) and M7 connector.
32. Remove grounding harness (51) (between engine and frame).
30-38 C PC400LC-7E0
33. Remove hydraulic pump piping.
● (52) EPC source pressure port hose (Collar band: Yellow)
● (53) Rear pressure port hose (Collar band: Yellow)
● (54) Rear pump discharge port hose
● (55) Front pump discharge port hose
● (56) Drain port hose
● (57) Front negative pressure input port hose
● (58) Rear negative pressure input port hose (Collar band: Red)
● (59) Front pressure input port hose
● (60) Pump suction port tube
34. Disconnect pump wiring connector at two locations.

● (61) V22 (PC-EPC solenoid valve) (Collar band: Red)
● (62) V21 (LS-EPC Solenoid valve) (Collar band: White)
35. Using tool B. Remove 4 engine mount bolts (63), front and rear.[*5]
★ Easier to remove if nuts are heated by gas.
PC400LC-7E0 30-39 C
36. Hoist to remove engine assembly (64).
★ Remove after checking that wiring, piping clamps, etc. are
disconnected without omission.
Engine, hydraulic pump assembly: 1700 kg (3750 lb)
INSTALLATION
[*1]
Hose clamp: (18) 3.3 ± 0.49 Nm (2.43 ± 0.361 lbf ft)

(17) 4.4 ± 0.49 Nm (3.25 ± 0.361 lbf ft)
(16) 8.8 ± 0.49 Nm (6.49 ± 0.361 lbf ft)
[*2]
Hose clamp: 9.8 ± 0.5 Nm (7.23 ± 0.369 lbf ft)
[*3]
★ See the paragraph for the “Checking and adjusting air conditioner compressor belt tension” in Testing and adjusting or the
paragraph for the "Removal and installation of engine front seal."
[*4]
Connector screw: 2.82 ± 0.28 Nm (2.08 ± 0.207 lbf ft)
[*5]
Engine mount bolt: 824 – 1030 Nm (608 – 760 lbf ft)
● Fill the coolant

Fill the radiator coolant (through the filler port) to the specified level. Start the engine and allow the coolant to circulate
through piping. Check the coolant level again.
● Fill hydraulic oil tank

Fill the hydraulic oil tank (through the filler port) to the specified level. Start the engine and allow the oil to circulate
through the piping. Check the oil level again.
● Air bleeding
Refer to the paragraph on the "Bleeding air from various parts" in Testing and adjusting.
30-40 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
12
FINAL DRIVE ASSEMBLY
REMOVAL
1. Remove the sprocket. For details, see “Removal and installation of sprocket."
WARNING! Lower the work equipment to the ground. Stop the engine. Then, slowly loosen the
hydraulic oil filler cap to release the internal pressure of the hydraulic tank.
3. Disconnect drain hose (2), travel speed selector hose (3), and motor
hoses (4) and (5).
★ Remove the nipples, too.
4. Remove the 24 mounting bolts and lift off the final drive assembly
(6). [*1]
★ Be extremely careful 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 (1540 lb)
PC400LC-7E0 30-41 C
12
INSTALLATION
[*1]
Mounting bolt: 490 – 608 Nm (361 – 448 lbf ft)
● Refilling hydraulic tank with oil

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the system.
Stop the engine. Then, check the oil level again.
● Bleeding air
See Testing and adjusting, “Bleeding air from various parts."
30-42 C PC400LC-7E0
12
FINAL DRIVE ASSEMBLY
DISASSEMBLY
1. Draining Oil
Remove the drain plug to drain the oil from the final drive assembly.
Final drive case: Approximately 11 L (2.91 gal)
2. Cover
A. Place the final drive on block [1] and remove the mounting
bolts.
B. Using eyebolt [2], remove cover (1).
3. Spacer
Remove spacer (2).
PC400LC-7E0 30-43 C
4. No. 1 Carrier assembly
A. Remove No. 1 carrier assembly (3).
B. Disassemble the No. 1 carrier assembly according to the

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).
5. Sun Gear
Remove spacer (4), No. 1 sun gear (12), and No. 2 sun gear (13).
6. Thrust washer
Remove thrust washer (14).
30-44 C PC400LC-7E0
7. No. 2 carrier assembly
A. Sling No. 2 carrier assembly (15) with wires, etc. and remove it.
B. Disassemble No. 2 carrier assembly using the following

procedure.
i. Push pin (16) to drive out shaft (17) from carrier (18).
ii. Remove thrust washer (19), gear (20), bearing (21), and
thrust washer (22).
8. Nut
A. Remove back plate (23).
B. Using tool E1, remove nut (24).
PC400LC-7E0 30-45 C
9. Hub assembly
A. Using eyebolts [3], remove hub assembly (25) from the travel
motor.
B. Disassemble hub assembly (25) according to the following

procedures.
i. Remove bearing (26) from hub (32).
ii. Remove floating seal (27) from hub (32).
iii. Remove bearings (28) and (29) from hub (32).
30-46 C PC400LC-7E0
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.
ASSEMBLY
★ Clean all the 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, apply a thin coat of engine
oil to the sliding surfaces.
PC400LC-7E0 30-47 C
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, apply a thin film of engine
oil to the sliding surfaces.
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 (6610 – 8610 lbf)
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 (3300 – 4180 lbf)
30-48 C PC400LC-7E0
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
J. Using push-pull gauge [5], measure the tangential force of the

hub in its revolving direction on the motor case.
★ Tangential force: Max. 765 N (162 lbf)
★ The tangential force means the maximum force at the
beginning of rotation.
K. Install lock plate (23), fitting it to the motor spline.
Threads of mounting bolt: Adhesive (LT-2)
Mounting bolt: 66.2 ± 7.4 Nm (48.8 ± 5.46 lbf ft)
PC400LC-7E0 30-49 C
A. Assemble the No. 2 carrier assembly according to the following

procedure.
★ There is a staking 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).
iv. After inserting the pin, stake the pin part of the carrier.
★ After assembling the carrier assembly, check that the
gear (20) turns smoothly.
v. 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).
30-50 C PC400LC-7E0
5. No. 2 sun gear
Install spacer (4) and No. 2 sun gear (13).

procedure.
the end of carrier side hole (h) and the inside wall of the
advance.
i. Install bearing (10) to gear (9) and fit top and bottom thrust
washers (8) and (11). Then set the gear assembly to carrier
(7).
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, stake 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).
PC400LC-7E0 30-51 C
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 mounting bolts.
Cover mounting face: Gasket sealant (LG-6)
Mounting bolt: 98 – 123 Nm (72.3 – 90.7 lbf ft)
● 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.
Final drive case: Approximately 11 L (2.91 gal)
★ After installing the final drive assembly to the chassis, check the oil level again at the specified position.
30-52 C PC400LC-7E0
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 residual
pressure from hydraulic circuit” section in the Testing and Adjusting Chapter of this manual.
WARNING! Lower the work equipment to the ground. Slowly remove the oil filler cap on the fuel tank to
release the residual pressure inside the tank. Then move the work equipment lock lever to
the LOCK position.
1. Disconnect the five swing motor hoses listed below.

● (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. Disconnect the swing motor and swing machinery assembly (6). Use
the forcing screw [1] after removing the mounting bolts. [*1]
3. Slowly, carefully lift and remove the swing motor and swing
machinery assembly (6).
★ Slowly lift the swing motor and swing machinery assembly (for
removal) 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 (1212 lb)
PC400LC-7E0 30-53 C
12
INSTALLATION
● Install in reverse order of removal.
[*1]
Mounting bolt: 824 – 1030 Nm (608 – 760 lb)

Run the engine to circulate the oil through the system.
Stop the engine. Then, check the oil level again.
● Bleeding air
30-54 C PC400LC-7E0
12
SWING MOTOR AND SWING MACHINERY
DISASSEMBLY
1. Draining oil
Loosen the drain plug and drain the oil from the swing machinery case.
Swing machinery case: Approximately 21 L (5.55 gal)
2. Swing motor assembly
A. Set the swing motor and swing machinery assembly on block

[1].
B. Remove 10 mounting 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).
A. Remove No. 1 carrier assembly (3).
PC400LC-7E0 30-55 C
Remove snap ring (4), shaft (5), gear (6), bearing (7), thrust
washer (8), and plate (9).
5. Ring gear
Remove the mounting bolts and ring gear (10).
6. No. 2 sun
Remove No. 2 sun gear (11).
7. Bolt
Remove holder mounting bolt (12).
30-56 C PC400LC-7E0
A. Lift off No. 2 carrier assembly (13).

i. Push in pin (14) and drive out shaft (15) from carrier (16).
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

mounting bolts (23) from cover assembly (22).
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 about 20 tons.
PC400LC-7E0 30-57 C
10. Disassemble the pinion shaft assembly (25) according to the
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 in contact with bearing: D2
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.
30-58 C PC400LC-7E0
2. Cover assembly
A. Using push tool D4, press fit oil seal (28) to cover (29).
Periphery of oil seal: Gasket sealant (LG-6)
★ Make sure that the gasket sealant (LG-6) does not stick to
the oil seal lip and shaft.
B. Install cover assembly (22) to case (31) and tighten mounting

bolts (23).
★ Match the oil path of cover (22) to the drilled hole of case
(31).
Cover fitting face: Gasket sealant (LG-6)
Oil seal lip: Grease (G2-LI)
3. 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.
B. Bearing
Use tool D7, press fit bearing (30).
★ Press both inner race and outer race of the bearing
simultaneously. Do not press only the inner race.
★ After press fitting the bearing, check that the case turns
smoothly.
PC400LC-7E0 30-59 C

procedure.
the end of carrier side hole (a) and the inside wall of the
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). 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).
★ When inserting the pin, do not set the 3 claws (a) on the
periphery to the thin part of the carrier (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, stake the pin part of the carrier.
5. Bolt and O-ring
A. Tighten bolt (12).
B. Fit the o-ring to the case.
30-60 C PC400LC-7E0
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).
★ When installing ring gear (10), set its match mark (d) and the
projection of the case flange (c) as shown in the following
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.
★ Add engine oil (EO30-CD) at this time.
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.
PC400LC-7E0 30-61 C
iii. After installing plate (9), install thrust washer (8), bearing
(7), gear (6), and snap ring (4).
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 (e) down.
30-62 C PC400LC-7E0
10. Swing motor assembly
Install swing motor assembly (1) to ring gear (10).
★ When installing the swing motor assembly, set the relief valve
(f) and the projection of the case (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)
Swing motor assembly: 115 kg (254 lb)

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 (5.55 gal)
PC400LC-7E0 30-63 C
DISASSEMBLY AND ASSEMBLY SWING CIRCLE ASSEMBLY
12
SWING CIRCLE ASSEMBLY
REMOVAL
1. Remove the revolving frame assembly. For details, see "Removal and Installation of Revolving Frame Assembly."
2. Temporarily sling swing circle assembly (1) at 3 points. Remove 40

mounting bolts. Lift off the swing circle assembly. [*1]
Swing circle assembly: 600 kg (1320 lb)
INSTALLATION
● Carry out installation in reverse order of removal.
[*1]
Mating face of swing circle: Gasket sealant (LG-6)
Threads of swing circle mounting bolt: Adhesive (LT-2)
Swing circle mounting bolt: 824 – 1030 Nm (620 – 760 lbf ft)
Target: 927 Nm (684 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 (8.72 gal)
(Use GLT2-L1 for 50°C [122°F] specification)
30-64 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
12
UNDERCARRIAGE AND FRAME
★ Only precautions for assembling the carrier roller assembly are explained below.
Carrier roller assembly: 30 kg (66.1 lb)
ASSEMBLY
★ Press fitting of support (2)
A. Press fitting dimension of shaft: (Shown in the following figure)
B. Using push tool [1], press fit support (2) to shaft (1). Apply
press fitting force of at least 21.6 – 24.5 kN (4860 – 5510 lbf).
● 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 (0.197 – 0.276 in).
PC400LC-7E0 30-65 C
DISASSEMBLY AND ASSEMBLY UNDERCARRIAGE AND FRAME
● 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. Make sure
that the pointer of the gauge does not lower.
Standard pressure: 0.1 MPa (14.5 psi)
★ Using tool F, fill the carrier roller assembly with oil and tighten
the plug.
Carrier roller: 170 – 180 cc (5.75 – 6.09 oz)(EO30-CD)
30-66 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER ASSEMBLY
12
TRACK ROLLER ASSEMBLY
★ Only precautions for the track roller assembly are explained below.
Track roller assembly: 75 kg (165 lb) Single

85 kg (187 lb) Double
ASSEMBLY
● Floating seal
and dry the contact surfaces of the o-ring and floating seal
★ 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 (0.197 – 0.276 in).
● 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 (14.5 psi)
★ Using tool G, fill the track roller assembly with oil and tighten
the plug.
Track roller:
280 – 310 cc (9.47 – 10.50 oz) Single, EO30-CD
280 – 290 cc (9.47 – 9.81 oz) Double, EO30-CD
Plug: 10 – 20 Nm (7.38 – 14.80 lbf ft)
PC400LC-7E0 30-67 C
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
12
IDLER ASSEMBLY
Idler assembly: 230 kg (507 lb)
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 (11.7 ± 0.338 oz). Drain it
or spread cloths to soak it up.
4. Remove floating seal (7) on the opposite side from idler (5) and shaft
and support assembly (6).
30-68 C PC400LC-7E0
5. Remove nut (8), pull out bolt (9), and then remove support (10) from
shaft (11).
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.
PC400LC-7E0 30-69 C
3. Using tool H, install floating seal (7) to idler (5) and shaft and
support assembly (6).

and dry the contact surfaces of the O-ring and floating seal
★ 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 (0.354
– 0.433 in).
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).
★ 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.
30-70 C PC400LC-7E0
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)
(11.7 ± 0.338 oz)
Plug: 130 – 180 Nm (95.9 – 133 lbf ft)
PC400LC-7E0 30-71 C
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
12
RECOIL SPRING ASSEMBLY
Recoil spring (excluding idler): 900 kg (1980 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 (53,700 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 (33.3 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).
30-72 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
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)
PC400LC-7E0 30-73 C
DISASSEMBLY AND ASSEMBLY SPROCKET
C. Apply oil pressure gradually to compress the spring and tighten
nut (4) so the installed length of the spring will be (a), and then
secure it with lock plate (3).
★ Installed length of spring (a): Approximately 690 mm
(27.2 in)
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 (10.8 oz) of grease (G2-LI) to the cylinder, bleed air, and check that the grease flows out of the grease
hole.
SPROCKET
REMOVAL
1. Remove track shoe assembly. For details, see “Removal and installation 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 mounting bolts and lift off sprocket (1). [*1]
Sprocket: 70 kg (154 lb)
INSTALLATION
● [*1]
Thread of sprocket mounting bolt: Gasket sealant (LG-6)
Sprocket mounting bolt: 640 – 785 Nm (472 – 579 lbf ft)
30-74 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY
TRACK SHOE ASSEMBLY
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]
INSTALLATION
● Carry out installation in the reverse order of expansion.
[*1]
Mounting bolt: Anti-seizure compound (MARUZEN

MOLYMAX No. 2 or equivalent)
Mounting bolt: Tighten the 4 bolts first to 392 ± 39 Nm

(289 ± 28.8 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, “Checking and adjusting track shoe
tension.”
Torque for lubricator: 58.8 – 88.3 Nm (43.4 – 65.1 lbf ft)
PC400LC-7E0 30-75 C
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY
[*3]
★ Using the tool, press fit the master pin so that its projection (a) will be as follows.
● Dimension (a): 4.4 ± 2 mm (0.173 ± 0.0787 in)
Supply grease to the space between the bushing and

pin so that filling rate will be 100%.
Grease: NIGTITE 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 O). Do not apply grease to the
parts 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).
30-76 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
12
REVOLVING FRAME ASSEMBLY
REMOVAL
WARNING! Extend the arm and bucket fully, lower the work equipment to the ground, and set the
work equipment lock lever to the LOCK position
1. Remove the work equipment assembly. For details, see “Removal and installation of work equipment assembly.”
2. Remove the counterweight assembly. For details, see “Removal and installation of counterweight assembly.”
3. Disconnect 4 boom cylinder hoses (1).

★ Plug the hoses to stop oil leakage.
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 other side in the same way.
Boom cylinder assembly: 360 kg (794 lb)
PC400LC-7E0 30-77 C
12
6. Disconnect 7 hoses; (5) through (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 mounting 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 (26.2 ft) in total
Rear: 6 m (19.7 ft)
★ If the engine hood interferes with the sling, erect the engine
hood, referring to “Removal and installation of radiator
assembly."
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 (22,000 lb)
30-78 C PC400LC-7E0
12
INSTALLATION
● Carry out installation in reverse order of 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 mounting bolt: Adhesive (LT-2)
Revolving frame mounting bolt
1. Tighten the bolts marked with a star (4 places) according to the following steps.
A. Tighten each bolt to 392 Nm (289 lbf ft) first.
B. Then, tighten the bolt by 90° ± 5°.

● Make a mark on the bolt head with a marker pen (to check the angle).
C. The torque of the bolt tightened in Step B. above must be 1,176 Nm (867 lbf ft) or larger.
2. Tighten each bolt (208-25-71230) which is not marked with a star following above Steps A, B, and C. If the torque
reaches 2,254 Nm (1,660 lbf ft) before completing the above steps and the tightening angle is 35° to 95°, stop tightening.
★ Marks (P) and (S) are the soft zone points.
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 various parts."
PC400LC-7E0 30-79 C
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT ASSEMBLY
COUNTERWEIGHT ASSEMBLY
REMOVAL
1. 1. Open engine inspection cover at the counterweight side.
★ Because the handle of the cover touches the counterweight.
2. Set eyebolt [1] to counterweight assembly (1).
3. Remove 4 mounting bolts (2). [*1]
4. Lift off counterweight assembly (1). [*2]

★ Check where shims have been used.
★ When lifting off the counterweight, take care not to strike it
against the engine, radiator and cooler assembly, etc.
Counterweight assembly: 9,500 kg (20,900 lb)
INSTALLATION
★ If heat insulation cover (3) of the engine compartment is
flattened, replace it.
[*1]
Mounting bolt: 3,430 – 4,212 Nm (2,530 – 3,110 lbf ft)
[*2]
★ Installation and adjustment of counterweight
i. Adjust the level difference from the exterior parts

(horizontal clearance) with shims.
● Shim thickness: 0.5 mm (0.0197 in), 1 mm (0.0394 in)
ii. Insert the shims so the clearance between the door and counterweight and that between the revolving frame and
counterweight will be 10 ± 5 mm (0.394 ± 0.197 in) evenly.
30-80 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
REMOVAL
WARNING! Release the remaining pressure in the hydraulic circuit. For details, see Testing and
adjusting, “Releasing residual pressure from hydraulic circuit.”
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 mounting bolts (17).
PC400LC-7E0 30-81 C
5. Remove center swivel joint assembly (18). [*1]
Center swivel joint assembly: 40 kg (88.2 lb)
INSTALLATION
[*1]
Install the center swivel joint facing in the direction shown in the
diagram. (The diagram shows the machine as seen from above)
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
adjusting, “Bleeding air from various parts.”
DISASSEMBLY
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).
30-82 C PC400LC-7E0
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).
Mounting bolt: 31.4 ± 2.9 Nm (23.2 ± 2.14 lbf ft)
PC400LC-7E0 30-83 C
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
12
HYDRAULIC TANK ASSEMBLY
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. Remove control valve top cover (3).
5. Disconnect drain hoses (5) and (6).
6. Disconnect block (7) together with return hose.
7. Disconnect drain hoses (8), (9), and (10).
8. Disconnect 2 clamps (11).
9. Remove side cover (12).
30-84 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
10. Remove sensor (13).
11. Disconnect suction tube (14).
12. Sling the hydraulic tank assembly temporarily and remove 6

mounting bolts (15). [*1]
13. Lift off hydraulic tank assembly (16).
Hydraulic tank assembly: 200 kg (441 lb)
INSTALLATION
[*1]
Mounting bolt: 254.2 – 308.9 Nm (187 – 228 lbf ft)
● Refilling Hydraulic tank with oil

Capacity of hydraulic tank: Approximately 335 L (88.5 gal)

Quantity of oil in tank at center of oil level gauge: 248 L (65.5 gal)
● Bleeding air
PC400LC-7E0 30-85 C
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY
12
CONTROL VALVE ASSEMBLY
REMOVAL
WARNING! Lower the work equipment to the ground. Stop the engine. Slowly loosen the hydraulic oil
filler cap to release the internal pressure of the hydraulic tank. Set the work equipment
lock lever to the LOCK position.
● Tag each hose and tube as you disconnect it to prevent a mistake when re-connecting.
1. Open engine inspection cover (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)
30-86 C PC400LC-7E0
12
6. Disconnectthe following 4 control valve hoses:
● (16): Port PPS1 hose (Front pump)
● (17): Port PLS2 hose (Hose band: Brown)
● (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 OUT (Hose band: Yellow)
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).
PC400LC-7E0 30-87 C
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)
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

mounting bolts (39).
30-88 C PC400LC-7E0
18. Lift off control valve assembly (40).
Control valve assembly: 250 kg (551 lb)
INSTALLATION
● Refill hydraulic tank with oil
● Bleeding air
DISASSEMBLY
★ Only precautions for assembling the pressure compensation valve assembly and control valve assembly are explained
below.
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL
★ Since there are 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).
PC400LC-7E0 30-89 C
★ There are 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 (5) 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.
6. Install correcting tool L3 to piston (1) for about 1 minute to fit seals
(2) and (5).
★ Check that the seals 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.
Install them again in correcting tool L3 to fit the seals. Then
install them into the piston.
★ After assembling, push the piston with your hand and check that
it is returned by only the spring force.
30-90 C PC400LC-7E0
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.
● 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.
PC400LC-7E0 30-91 C
● Tighten the mounting bolts of the control valve top and bottom
covers in the following order. (A, D, C, and B)
Mounting bolt of control valve top and bottom covers:

156.9 – 176.5 Nm (116 – 130 lbf ft)
30-92 C PC400LC-7E0
● Merge-divider valve
Mating face of merge-divider valve:

SEALEND 242 or equivalent
● Tighten the mounting bolts of the merge-divider valve similarly

to those of the control valve covers.
(1) Mounting bolt of merge-divider valve:

156.9 – 176.5 Nm (116 – 130 lbf ft)
● Tighten the mounting bolts of the boom Hi check valve, quick

return valve, lock valve, and arm plate similarly to those of the
control valve covers.
(2) Mounting bolt of back pressure valve, boom Hi

check valve, quick return valve, lock valve, and arm
plate: 58.8 – 73.6 Nm (43.4 – 54.3 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, “Measuring and adjusting oil pressure in
work equipment, swing, and travel circuits.”
PC400LC-7E0 30-93 C
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
12
HYDRAULIC PUMP ASSEMBLY
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.
1. Remove 2 lower covers (1).
2. Remove the hydraulic tank strainer. Using tool C, to 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 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.
8. Remove stay (5).
30-94 C PC400LC-7E0
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

mounting bolts (17).
12. Lift off hydraulic pump assembly (18). [*1]
Hydraulic pump assembly: 255 kg (562 lb)
PC400LC-7E0 30-95 C
12
INSTALLATION
[*1]
Hydraulic pump involute spline: Anti-friction compound (LM-G)
Mating face of hydraulic pump case: Gasket sealant (LG-6)
Flywheel housing drain plug: 42.1 – 70.6 Nm (31.1 –52.1 lbf ft)
● Refilling the hydraulic tank with oil

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 various parts.”
30-96 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP INPUT SHAFT
12
HYDRAULIC PUMP INPUT SHAFT
REMOVAL
1. Remove the hydraulic pump assembly. Refer to the “Removal of hydraulic pump assembly” 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
[*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 [1].
PC400LC-7E0 30-97 C
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY
12
WORK EQUIPMENT PPC VALVE ASSEMBLY
★ 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 (1.26 in) (Common to all springs)
Installed load:
P1, P2: 35.3 N (7.94 lbf)
P3, P4: 21.6 N (4.86 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.
Mounting bolt of plate (5):

11.8 – 14.7 Nm (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 (28.8 – 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 (50.9 – 64.9 lbf ft)
★ When installing disc (2), adjust the play to 0.5 – 3 mm

(0.0197 – 0.118 in) at 200 mm (7.87 in) from the turning
center of the lever.
30-98 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE ASSEMBLY
12
TRAVEL PPC VALVE ASSEMBLY
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-7E0 30-99 C
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
HYDRAULIC CYLINDER ASSEMBLY
DISASSEMBLY
1. Piston rod assembly
A. Remove the piping from the cylinder assembly.
B. Remove the mounting bolts and disconnect the cylinder head

assembly (1).
C. Pull out piston rod assembly (2).

★ Put a container under the cylinder to receive oil.
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
30-100 C PC400LC-7E0
★ 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 (Ø10: 2 places) (in which the
pins of N2 are inserted in the following figure).
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.
PC400LC-7E0 30-101 C
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).
ASSEMBLY
★ Take care not to damage the packing, 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 – 60°C 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. Install snap ring (21).
30-102 C PC400LC-7E0
2. 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)
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).

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.
PC400LC-7E0 30-103 C
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 Step iv.
● 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.
ii. Using the tool, tighten piston assembly (4) until it reaches
the end of the rod.
Piston assembly: 294 ± 29.4 Nm (217 ± 21.7 lbf ft)
★ After tightening the piston, check that plunger (5) has

some play.
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
30-104 C PC400LC-7E0
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 (43.4 – 54.3 lbf ft)
v. Stake the threaded part [1] in 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 it to the end.
H. Tighten the mounting bolts of cylinder head assembly (7).
Mounting bolt:
Cylinder Name Torque
Bucket 530 ± 78.5 Nm (391 ± 57.9 lbf ft)
Arm 892 ± 137 Nm (658 ± 101 lbf ft)
Boom 530 ± 78.5 Nm (391 ± 57.9 lbf ft)
I. Install the piping.
PC400LC-7E0 30-105 C
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY
12
WORK EQUIPMENT ASSEMBLY
REMOVAL
WARNING! Extend the arm and bucket fully. Lower the work equipment to the ground. Set the work
equipment lock lever to the LOCK position.
WARNING! See Testing and adjusting, “Releasing residual pressure from 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.
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]
30-106 C PC400LC-7E0
● 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 position of the inserted shims.
9. Move the machine in reverse to remove work equipment assembly

(12).
Work equipment assembly:

PC400LC-7E0; 7,400 kg (16,300 lb)
INSTALLATION
[*1]
★ Tighten the locknut so that clearance (a) between the plate and
nut will be 0.5 – 1.5 mm (0.0197 – 0.0591 in).
[*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
PC400LC-7E0 30-107 C
[*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 various parts.”
30-108 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY CAB
12
CAB
REMOVAL
1. Remove rear covers (1), (2), (3), and (4).
2. Remove duct (5), cover (6), and plate (7).
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).
PC400LC-7E0 30-109 C
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.
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 2 in number.
★ Cut the tie-wrap on the monitor wiring harness.
14. Remove cover (29) and monitor assembly (30).
30-110 C PC400LC-7E0
15. Disconnect radio antenna (31).
16. Remove clip (32) and take wiring harness (33) out of grommet (34).
17. Take grommet (35) out of the right front of the cab.
18. Disconnect the windshield washer hose from (36).
19. Remove 4 mounting bolts (37) and 5 mounting bolts (38).

★ Check the types of the bolts.
★ In the initial period, 7 mounting bolts (38) are used.
20. Using lever block [1], lift off cab assembly (39).
Operator's cab assembly: 300 kg (661 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
PC400LC-7E0 30-111 C
22. Bracket (42) for monitor panel assembly (30)
Part No.: 208-53-13910
INSTALLATION
1. Carry out installation in the reverse order of removal.
30-112 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY CAB GLASS (STUCK GLASS)
12
CAB GLASS (STUCK GLASS)
★ The panes of window glass on the 4 sides of the 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 in the cab.
For the procedure for replacing the front window assembly, see “Removal and installation of front window
assembly.”
(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
(16): Center trim seal
PC400LC-7E0 30-113 C
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 pliers [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.
Remark The figure shows the cab from 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
both-sided adhesive tape with knife [4].
2. Remove the window glass.
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 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 not be as
good.
30-114 C PC400LC-7E0
12
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.
3. Apply primer (10).

★ The usable limit of primer (10) is 4 months after the date of
manufacture. Do not use primer (10) after that date.
★ 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
room temperature for at least half a day before stirring it.
If the primer is unpacked just after being taken out of the
refrigerator, water will be condensed. Accordingly, leave the primer at 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 and glass primer.
C. Apply paint primer evenly onto the surfaces to which you will
stick both-sided adhesive tape and to the surfaces outside of this
area (8)(on the cab), which will be coated with adhesive.
Paint primer:
SUNSTAR PAINT PRIMER 580 SUPER or equivalent
★ Do not apply the primer more than 2 times.

If it is applied more than 2 times, its performance will be
degraded.
PC400LC-7E0 30-115 C
★ Parts to be coated with primer: Apply the primer all over

dimension (a).
● Dimension to apply primer (a): 25 mm (0.984 in)
★ 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.
★ Never apply wrong primer. If the glass primer is applied by
mistake, wipe it off with white gasoline.
D. 4) Evenly apply glass primer to the sticking surfaces of window

glass (9).
Glass primer:
SUNSTAR GLASS PRIMER 580 SUPER or equivalent
★ Do not apply the primer more than 2 times.

If it is applied more than 2 times, its performance will be
degraded.
30-116 C PC400LC-7E0
★ 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 border about 5 mm (0.197 in)
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.
★ Never apply wrong primer. If the glass primer is applied by
mistake, wipe it off with white gasoline.
4. Stick both-sided adhesive tape (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 (0.197 in) between them.
A. Stick both-sided adhesive tape (6) for right side window glass
(1) as shown in the figure.
★ 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 (1.97 in)
(g): 90 mm (3.54 in)
(h): 250 mm (9.84 in)
PC400LC-7E0 30-117 C
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 (4.33 in)
(k): 90 mm (3.54 in)
(m): 200 mm (7.87 in)
D. Stick both-sided adhesive tape (6) for front window glass (4) as
shown in the figure.
30-118 C PC400LC-7E0
★ 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 cab (8) with a knife,
and then remove the window glass.
★ Do not remove the tapes left on the window glass and cab
before installing the window 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 (0.118 in).
6. Apply adhesive.
★ Use either of the 2 types of adhesive.
Adhesive (Summer):
SUNSTAR PENGUINE SEAL 580 SUPER "S"
Adhesive (Winter):
SUNSTAR PENGUINE SEAL 580 SUPER "W"
★ The useful limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this date.
★ Keep the adhesive in a dark place where the temperature is below 25°C (77°F).
PC400LC-7E0 30-119 C
★ Never heat the adhesive higher than 30°C (86°F).

★ When reusing the adhesive, remove the all hardened adhesive from the nozzle tip.
A. Break aluminum seal (13) of the outlet of adhesive cartridge

(12) 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 (0.394 in)
● Dimension (r): 15 mm (0.591 in)
C. Set adhesive cartridge (12) to caulking gun [7].

★ An electric caulking gun is more efficient.
D. Remove the release tape from the both-sided adhesive tape on

the glass side.
30-120 C PC400LC-7E0
E. Apply adhesive (15) to the outside of both-sided adhesive tape
(6) of the cab.
★ Apply adhesive (15) to dimensions (s) and (t) of both-sided
adhesive tape (6) of operator's cab (8).
● Dimension (s): 10 mm (0.394 in)
● Dimension (t): 15 mm (0.591 in)
★ 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.
7. Install the window glass.
A. Install window glass (9), matching it to the lines of the

positioning tapes drawn in Step 5.
★ Since the window glass cannot be removed and stuck again,
stick it very carefully.
★ Stick the glass within 5 minutes after applying the adhesive.
B. After sticking window glass (9), press all around it until it is

stuck to the both-sided adhesive tape.
★ Press the corners of the window glass firmly.
PC400LC-7E0 30-121 C
★ 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 (0.0787 in)
● Caulking dimension (u): 5 mm (0.197)
★ 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: SUNSTAR GLASS PRIMER 580 SUPER
Adhesive:
SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
8. Fix the window glass.
A. After installing right window glass (1) on the cab, insert stopper
rubbers Y2 in 2 places (v) at the bottom of the glass to fix the
glass.
30-122 C PC400LC-7E0
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 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 20°C (68°F) 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.
PC400LC-7E0 30-123 C
DISASSEMBLY AND ASSEMBLY WINDOW ASSEMBLY
12
WINDOW ASSEMBLY
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 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) on the 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.
30-124 C PC400LC-7E0
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 (13.2 lbf) is
applied to the rear of the 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.
PC400LC-7E0 30-125 C
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).
30-126 C PC400LC-7E0
12
INSTALLATION
[*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 mounting bolts of roller adjustment brackets (16) and (17)
and adjust the condition of the front window, and then tighten the
mounting bolts again.
Mounting bolt: 9.8 Nm (7.23 lbf ft)
PC400LC-7E0 30-127 C
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 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
(0 – 0.0394 in). 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.
30-128 C PC400LC-7E0
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. Adjust the striker bolts according to the following procedure; Adjust

the "CLOSE" positions of the front window assembly locks.
A. 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).
PC400LC-7E0 30-129 C
B. Open and close the front window assembly and check the
working condition of both locks (20) and (21).
i. If both locks do not work normally, move the striker bolts

toward the rear of the cab and tighten them again.
ii. After moving the striker bolts, check the fitness of the front
window glass and cab-side trim seal which was checked in
Step 6.
iii. Repeat the work in Steps i. and ii. above until the fitness of
the front window and the working condition of both locks
(20) and (21) are acceptable. Then tighten the striker bolts.
7. After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak
into the cab.
8. Adjust the "opening" lock of the front window assembly.
A. After adjusting the "closing" lock of the front window in Step 6,

raise the front window assembly to the ceiling.
B. Set the right and left front window assembly locks at the rear of
the operator's cab to the "OPEN" positions, and then check the
following items.
● Check that right and left locks (20) and (21) are closed
normally.
● Check that right and left locks (20) and (21) are inserted in
parallel in right and left striker plates (22).
● Check that right and left rubber stoppers (24) are in contact
with the front window assembly and their deflection
allowance is 1.5 – 3.0 mm (0.0591 – 0.118 in).
C. After checking the above items, if necessary, adjust them by

moving right and left striker plates (22) at the rear of the cab.
9. Adjust the front window stoppers.
A. After adjusting "closing" lock of the front window assembly in

Step 9, check the contact of both front window stoppers (23).
B. If both stoppers (23) do not contact normally, adjust and fix

them at places where they contact normally.
30-130 C PC400LC-7E0
10. Check the latching effort of the front window assembly.
A. After finishing Steps 6 – 9, 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 cab) and "opening" side (in the rear of the cab).
[*3]
Left lower pin: 27 – 34 Nm (19.9 – 25.1 lbf ft)
Mounting bolt: Adhesive (LT-2)
PC400LC-7E0 30-131 C
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
12
AIR CONDITIONER UNIT ASSEMBLY
REMOVAL
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).
30-132 C PC400LC-7E0
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 mounting bolt (24)and connector (25). [*1]
14. Disconnect heater hoses (22)and (23) and air conditioner tube (26).
[*1]
★ Tag each hose and tube as you disconnect it to prevent a mistake
when re-connecting.
15. Remove the 7 mounting bolts and air conditioner unit assembly (27).
PC400LC-7E0 30-133 C
12
INSTALLATION
★ 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 (5.9 – 8.85 lbf ft)
Hose screw of M16 x 1.5: 12 – 15 Nm (8.85 – 11.1 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 (2.09 ± 0.11 lb)
30-134 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY KOMTRAX TERMINAL ASSEMBLY
12
KOMTRAX TERMINAL ASSEMBLY
REMOVAL
1. Remove covers (1), (2), and (3).
2. Disconnect GPS connector (4) and antenna wire (5).
3. Disconnect connector G01 (6).
4. Remove 4 mounting bolts and remove KOMTRAX terminal

assembly (7).
INSTALLATION
PC400LC-7E0 30-135 C
DISASSEMBLY AND ASSEMBLY MONITOR ASSEMBLY
12
MONITOR ASSEMBLY
REMOVAL
1. Remove cover (1) and disconnect wiring connector P15 of air

conditioner sunlight sensor (2).
★ Raise and remove the cover.
2. Remove the 3 mounting screws and monitor assembly (3).

★ Disconnect monitor panel wiring connectors P01, P02, and P70
before removing the monitor assembly.
INSTALLATION
30-136 C PC400LC-7E0
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
12
PUMP CONTROLLER
REMOVAL
1. Remove covers (1), (2), and (3).
2. Disconnect pump controller wiring connectors C01 (4), C02 (5), and
C03 (6).
3. Remove the 4 mounting bolts and pump controller assembly (7).
INSTALLATION
PC400LC-7E0 30-137 C
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
12
30-138 C PC400LC-7E0
90 OTHERS
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 1 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 5 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 1 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
ELECTRICAL CONNECTORS LEGEND AND LOCATION - SHEET 1 OF 9 . . . . . . . . . . . . . . . . . . . . 90-51
ELECTRICAL CONNECTORS - SHEET 2 OF 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
PC400LC-7E0 90-1 1
OTHERS
12
MEMORANDUM
90-2 PC400LC-7E0
OTHERS HYDRAULIC
12
HYDRAULIC
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 1 OF 5
PC400LC-7E0 90-3
OTHERS HYDRAULIC
12
PC400LC-7E0 90-5
OTHERS HYDRAULIC
12
PC400LC-7E0 90-7
OTHERS HYDRAULIC
12
PC400LC-7E0 90-9
OTHERS HYDRAULIC
12
PC400LC-7E0 90-11
OTHERS HYDRAULIC
12
PC400LC-7E0 90-13
OTHERS HYDRAULIC
12
PC400LC-7E0 90-15
OTHERS HYDRAULIC
12
PC400LC-7E0 90-17
OTHERS HYDRAULIC
12
PC400LC-7E0 90-19
OTHERS HYDRAULIC
12
PC400LC-7E0 90-21
OTHERS HYDRAULIC
12
PC400LC-7E0 90-23
OTHERS ELECTRICAL
12
ELECTRICAL
ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 1 OF 4
PC400LC-7E0 90-25
OTHERS ELECTRICAL
PC400LC-7E0 90-27
OTHERS ELECTRICAL
12
PC400LC-7E0 90-29
OTHERS ELECTRICAL
PC400LC-7E0 90-31
OTHERS ELECTRICAL
12
PC400LC-7E0 90-33
OTHERS ELECTRICAL
12
PC400LC-7E0 90-35
OTHERS ELECTRICAL
12
PC400LC-7E0 90-37
OTHERS ELECTRICAL
12
PC400LC-7E0 90-39
OTHERS ELECTRICAL
12
PC400LC-7E0 90-41
OTHERS ELECTRICAL
12
PC400LC-7E0 90-43
OTHERS ELECTRICAL
12
PC400LC-7E0 90-45
OTHERS ELECTRICAL
12
PC400LC-7E0 90-47
OTHERS ELECTRICAL
12
PC400LC-7E0 90-49
OTHERS ELECTRICAL
12
ELECTRICAL CONNECTORS LEGEND AND LOCATION - SHEET 1 OF 9
PC400LC-7E0 90-51 1
OTHERS ELECTRICAL
12
ELECTRICAL CONNECTORS - SHEET 2 OF 9
PC400LC-7E0 90-53 1
OTHERS ELECTRICAL
12
PC400LC-7E0 90-55 1
OTHERS ELECTRICAL
12
PC400LC-7E0 90-57 1
OTHERS ELECTRICAL
12
PC400LC-7E0 90-59 1
OTHERS ELECTRICAL
12
PC400LC-7E0 90-61 1
OTHERS ELECTRICAL
12
PC400LC-7E0 90-63 1
OTHERS ELECTRICAL
12
PC400LC-7E0 90-65 1
OTHERS ELECTRICAL
12
PC400LC-7E0 90-67 1

Shop Manual: PC400LC

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Shop Manual: PC400LC

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CEBM016902

Copyright 2007 Komatsu

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

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

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

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