SEBM033007

MACHINE MODEL PC400-7 PC400LC-7 PC450-7 PC450LC-7

SERIAL No. 50001 and up 50001 and up 20001 and up 20001 and up

This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. PC400, 400LC, PC450, 450LC-7 mount the SAA6D125E-3 engine. For details of the engine, see the 125-3 Series Engine Shop Manual.

© 2005 All Rights Reserved Printed in Japan 09-05 (01)

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GENERAL

CONTENTS
01 GENERAL ............................................................................................................................ 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................
No. of page 01-1

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20 TESTING AND ADJUSTING ......................................................................... 20-1 30 DISASSEMBLY AND ASSEMBLY
..................................................... 30-1

90 OTHERS ................................................................................................................................

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SAFETY

SAFETY NOTICE

SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is 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 Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • • Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

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SAFETY

SAFETY NOTICE

PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.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. 15.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. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

19.Be sure to assemble all parts again in their original places. Replace any damaged parts 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. 20.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. 21.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. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.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.

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FOREWORD

GENERAL

FOREWORD
GENERAL
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 chapters; these chapters are further divided into the each main group of components.

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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING 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" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

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FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISED EDITION MARK When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item Safety

Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.

k

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

a

Caution

4

Weight

3 2 5 6

Tightening torque

Coat

Oil, water

Drain

00-6

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS
HOISTING k 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 4 • If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

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71%

41%
SAD00479

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter mm 10 11.5 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k 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.
Type 1

k 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. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 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.

Type 3 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 lever (4) to the right (clockwise).
Disassembly

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

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 to connect it.

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 to connect it.

Connection

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS
★ ★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Komatsu code LT-1A Part No. 790-129-9030 Q’ty 150 g Container Tube Main applications, features

Category

LT-1B

790-129-9050

LT-2

09940-00030 790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120 790-129-9140

LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735

Aron-alpha 201 Loctite 648-50 LG-1 LG-5

790-129-9130

79A-129-9110 790-129-9010 790-129-9080

LG-6 Gasket sealant LG-7 Three bond 1211 Three bond 1207B

790-129-9020

790-129-9070

790-129-9090 419-15-18131

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. 20 g Polyethylene Used for plastics (except polyethylene, (2 pcs.) container polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and nonmetal. • Features: Polyethylene Resistance to heat and chemicals 50 g container • Used for anti-loosening and sealant purpose for bolts and plugs. • Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene 2g (max. strength after 30 minutes) container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene 50 cc • Used at joint portions subject to high container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type 1 kg Tube • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case

00-10

FOREWORD

COATING MATERIALS

Category

Komatsu code LM-G

Part No. 09940-00051 09940-00040 SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

Q’ty 60 g 200 g

Container Can Tube

Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type

Molybdenum disulphide lubricant

LM-P

G2-LI

Various

Various • Used for normal temperature, light load bearing at places in contact with water or steam. • Used for heavy load portion

G2-CA Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381

Various

Various

Grease

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can 400 g 16 kg

• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects Bellows type on microorganisms, animals, and plants. Can Glass container Glass container Glass container Can Glass container Ecocart (Special container) Polyethylene container Polyethylene container Polyethylene container Polyethylene container Cartridge Adhesive for cab glass • Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) • Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)

400 g 16 kg

20 ml 417-926-3910 20 ml 22M-54-27230 20 ml

Primer

22M-54-27240

150 ml

22M-54-27250 22M-54-27210

20 ml 320 ml

Adhesive

417-926-3910

320 ml

20Y-54-39850 417-926-3920 20Y-54-55130 22M-54-27220

310 ml 320 ml 333 ml 333 ml

Caulking material

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
Tightening torque Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190 235 – 285 320 – 400 455 – 565 610 – 765 785 – 980 1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630 Tightening torque Thread diameter of bolt mm 6 8 10 12 Width across flats mm 10 13 14 27 Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2 kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2 kgm 1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5 23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100 118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49 Tightening torque

SAD00483

kgm 2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter mm 10 12 16

Width across flat mm 14 17 22 Nm 59 – 74 98 – 123 235 – 285

Tightening torque kgm 6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Norminal No. mm 02 03, 04 05, 06 10, 12 14 14 20 24 33 42

Width across flat mm

Tightening torque (Nm {kgm}) Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010 {3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103} Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

Varies depending on type of connector.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Norminal No. mm 08 10 12 14 16 18 20 24 30 33 36 42 52 08 10 12 14 16 18 20 24 30 33 36 42 52

Width across flat mm 14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm}) Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5 {0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5} Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 10 0 2 24 0 4 43 0 6 77 0 12 Nm Tightening torque 1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22 kgm

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 14 802 10 0 2 12 0 2 24 0 4 36 0 5 Nm Tightening torque 0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51 kgm

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter inch 1 / 16 1/8 1/4 3/8 1/2 3/4 1 301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9 Nm Tightening torque 0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.20 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92 kgm

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ 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.
Tightening torque (Nm {kgm}) Nominal size Width across of hose flats Range 34 – 54 {3.5 – 5.5} 34 – 63 {3.5 – 6.5} 03 22 24 04 05 06 (10) (12) (14) 27 32 36 41 46 55 54 – 93 {5.5 – 9.5} 59 – 98 {6.0 – 10.0} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0} Target 44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} Taper seal type Face seal type

Nominal thread Thread size size - Threads per Root diameter (mm) inch, Thread series (mm) (Reference) – 14 – 18 22 24 30 33 36 42 9 — – 18UN 16 – 11 — – 16UN 16 – 13 — – 16UN 16 1 – 14UNS 3 1 — – 12UN 16 – – – 14.3 – 17.5 – 20.6 25.4 30.2 – – –

02

19

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE
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: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS
Copper wire Norminal number Number of strands 11 26 65 84 85 127 217 Dia. of strands (mm2) 0.32 0.32 0.32 0.45 0.80 0.80 0.80 Cross section (mm2) 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) Current rating (A) Applicable circuit

0.85 2 5 15 40 60 100

2.4 3.1 4.6 7.0 11.4 13.6 17.6

12 20 37 59 135 178 230

Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting

CLASSIFICATION BY COLOR AND CODE
Circuits Priority Classification Primary Code Color Code 2 Color White & Red Code 3 Color White & Black Code 4 Auxiliary WL — — — — — — — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR RY YG Yellow & Green YL GY Green & Yellow GB LY Blue & Yellow LB WB — — White & Black Red & White Rellow & Red Green & White Blue & White BY RB YB GR LR

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

W White WR

B Black —

B Black BW

R Red RW

Y Yellow YR

G Green GW

L Blue LW

1

Color White & Blue Code WG

Black & Red Red & Yellow — — — — RG

5 Color White & Green Code 6 Color — Red & Blue Yellow & White Green & Blue — Red & Green Yellow & Blue Green & Black Blue & Black RL YW GL n n

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE 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. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches
1 mm = 0.03937 in

0 0 10 20 30 40 (A) 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583

2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622

3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661

4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780

7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858

9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898

00-16

FOREWORD

CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583

2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622

3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661

4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780

7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858

9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898

Kilogram to Pound
1 kg = 2.2046 lb

0 0 10 20 30 40 50 60 70 80 90 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42

1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62

2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83

3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03

4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24

5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44

6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64

7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85

8 17.64 39.68 61.73 83.78 105.82 127.87 149.91 171.96 194.01 216.05

9 19.84 41.89 63.93 85.98 108.03 130.07 152.12 174.17 196.21 218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon
1l = 0.2642 U.S. Gal

0 0 10 20 30 40 50 60 70 80 90 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775

1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040

2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304

3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568

4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832

5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096

6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361

7 1.849 4.491 7.133 9.774 12.416 15.058 17.700 20.341 22.983 25.625

8 2.113 4.755 7.397 10.039 12.680 15.322 17.964 20.605 23.247 25.889

9 2.378 5.019 7.661 10.303 12.944 15.586 18.228 20.870 23.511 26.153

Liter to U.K. Gallon
1l = 0.21997 U.K. Gal

0 0 10 20 30 40 50 60 70 80 90 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797

1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017

2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237

3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457

4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677

5 1.100 3.300 5.499 7.969 9.899 12.098 14.298 16.498 18.697 20.897

6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117

7 1.540 3.740 5.939 8.139 10.339 12.528 14.738 16.938 19.137 21.337

8 1.760 3.950 6.159 8.359 10.559 12.758 14.958 17.158 19.357 21.557

9 1.980 4.179 6.379 8.579 10.778 12.978 15.178 17.378 19.577 21.777

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3

1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5

2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7

3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0

4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2

5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4

6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7

7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9

8 57.9 130.2 202.5 274.9 347.2 419.5 491.8 564.2 636.5 708.8 781.2 853.5 925.8 998.2 1070.5 1142.8 1215.1 1287.5 1359.8 1432.1

9 65.1 137.4 209.8 282.1 354.4 426.8 499.1 571.4 643.7 716.1 788.4 860.7 933.1 1005.4 1077.7 1150.0 1222.4 1294.7 1367.0 1439.4

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2

0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1138 1280 1422 1565 1707 1849 1991 2134 2276 2418 2560 2702 2845 2987 3129 3271 3414

1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1010 1152 1294 1437 1579 1721 1863 2005 2148 2290 2432 2574 2717 2859 3001 3143 3286 3428

2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1024 1166 1309 1451 1593 1735 1877 2020 2162 2304 2446 2589 2731 2873 3015 3158 3300 3442

3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1038 1181 1323 1465 1607 1749 1892 2034 2176 2318 2460 2603 2745 2887 3030 3172 3314 3456

4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470

5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1067 1209 1351 1493 1636 1778 1920 2062 2205 2347 2489 2631 2773 2916 3058 3200 3343 3485

6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1081 1223 1365 1508 1650 1792 1934 2077 2219 2361 2503 2646 2788 2930 3072 3214 3357 3499

7 99.6 241.8 384.0 526.3 668.5 810.7 953.0 1095 1237 1380 1522 1664 1806 1949 2091 2233 2375 2518 2660 2802 2944 3086 3229 3371 3513

8 113.8 256.0 398.3 540.5 682.7 825.0 967.2 1109 1252 1394 1536 1678 1821 1963 2105 2247 2389 2532 2674 2816 2958 3101 3243 3385 3527

9 128.0 270.2 412.5 554.7 696.9 839.2 981.4 1124 1266 1408 1550 1693 1835 1977 2119 2262 2404 2546 2688 2830 2973 3115 3257 3399 3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice 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.
1°C = 33.8°F

°C –40.4 –37.2 –34.4 –31.7 –28.9 –28.3 –27.8 –27.2 –26.7 –26.1 –25.6 –25.0 –24.4 –23.9 –23.3 –22.8 –22.2 –21.7 –21.1 –20.6 –20.0 –19.4 –18.9 –18.3 –17.8 –17.2 –16.7 –16.1 –15.6 –15.0 –14.4 –13.9 –13.3 –12.8 –12.2 –40 –35 –30 –25 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10

°F –40.0 –31.0 –22.0 –13.0 –4.0 –2.2 –0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0

°C –11.7 –11.1 –10.6 –10.0 –9.4 –8.9 –8.3 –7.8 –7.2 –6.7 –6.1 –5.6 –5.0 –4.4 –3.9 –3.3 –2.8 –2.2 –1.7 –1.1 –0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

°F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

°C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 0 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

°F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0

°C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175

°F 117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0

00-21

FOREWORD

UNITS

UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

}.

00-22

04-05

01 GENERAL
SPECIFICATION DRAWINGS ......................................................................................................................01- 2 SPECIFICATIONS ........................................................................................................................................01- 4 WEIGHT TABLE............................................................................................................................................01- 8 FUEL, COOLANT AND LUBRICANTS .........................................................................................................01- 12

PC400/450(LC)-7

01-1

GENERAL

SPECIFICATION DRAWINGS

SPECIFICATION DRAWINGS
DIMENSIONS

WORKING RANGES

01-2

PC400/450(LC)-7

GENERAL

SPECIFICATION DRAWINGS

DIMENSIONS Fixed gauge specification
Item A B C D E F G H Overall length Overall height Overall width Track shoe width Height of machine cab Tail swing radius Track overall length Length of track on ground Min. ground clearance Unit mm mm mm mm mm mm mm mm mm PC400-7 11,940 3,635 3,340 600 3,265 3,645 5,055 4,020 555 PC400LC-7 11,940 3,635 3,440 700 3,265 3,645 5,355 4,350 550 PC450-7 12,040 3,660 3,340 600 3,265 3,645 5,055 4,020 555 PC450LC-7 12,040 3,660 3,340 600 3,265 3,645 5,355 4,350 550

Variable gauge specification
Item A B C D E F G H Overall length Overall height Overall width Track shoe width Height of machine cab Tail swing radius Track overall length Length of track on ground Min. ground clearance Unit mm mm mm mm mm mm mm mm mm PC400-7 11,940 3,635 3,490 600 3,265 3,645 5,055 4,020 685 PC400LC-7 11,940 3,635 3,490 600 3,265 3,645 5,355 4,350 685 PC450-7 12,040 3,660 3,490 600 3,265 3,645 5,055 4,020 685 PC450LC-7 12,040 3,660 3,490 600 3,265 3,645 5,355 4,350 685

WORKING RANGES
Working range A B C D E F G Max. digging reach Max. digging depth Max. digging height Max. vertical wall depth Max. dumping height Min. dumping height Max. reach at ground level Unit mm mm mm mm mm mm mm PC400-7 12,025 7,820 10,915 6,870 7,565 — 11,820 PC400LC-7 12,025 7,820 10,915 6,870 7,565 — 11,820 PC450-7 12,005 7,790 10,925 6,600 7,625 — 11,800 PC450LC-7 12,005 7,790 10,925 6,600 7,625 — 11,800

PC400/450(LC)-7

01-3

GENERAL

SPECIFICATIONS

SPECIFICATIONS
PC400-7, PC400LC-7
PC400-7 Machine model Fixed gauge spec. PC400LC-7 Fixed gauge spec.

Variable gauge spec.

Variable gauge spec.

Serial Number Bucket capacity Weight of machine Max. digging depth Working ranges Max. vertical wall depth Max. digging reach Max. reach at ground level Max. digging height Max. dumping height Max. digging force (using power max. function) Swing speed Swing max. slope angle Travel speed Gradeability Ground pressure [standard shoe width] Overall length (for transport) Overall width Overall width of track
Overall width of track when extended

50001 and up m3 kg mm mm mm mm mm mm kN {kg} kN {kg} rpm deg. km/h deg. kPa {kg/cm }
2

1.4 41,200 7,820 6,870 12,025 11,820 10,915 7,565 256.0 {26,100} (274.6 {28,000}) 9.1 20 Lo: 3.0, Mi: 4.4, Hi: 5.5 35 77.7{0.79} [600] 11,940 3,340 3,340 — 3,635 3,265 1,320 555 3,645 4,735 9,210 4,020 2,740 3,265 79.9 {0.82} [600] 11,940 3,490 2,990 3,490 3,635 3,265 1,320 685 3,645 4,735 9,210 4,020 2,890 3,265 73.9 {0.75} [700] 11,940 3,440 3,440 — 3,635 3,265 1,320 555 3,645 4,735 9,210 4,020 2,740 3,265 42,400 42,200

1.4 43,500 7,820 6,870 12,025 11,820 10,915 7,565 256.0 {26,100} (274.6 {28,000}) 9.1 20 Lo: 3.0, Mi: 4.4, Hi: 5.5 35 65.3 {0.67} [700] 11,940 3,490 2,990 3,490 3,635 3,265 1,320 685 3,645 4,735 9,210 4,020 2,890 3,265

Performance

[mm] mm mm mm mm mm mm mm mm mm mm mm mm mm mm

Overall height (for transport) Overall height to top of machine Dimensions Ground clearance of upper structure Min. ground clearance Tail swing radius Min. swing radius of work equipment Height of work equipment at min. swing radius Length of track on ground Track gauge Height of machine cab

: The “Mi” mode is on the multi-monitor specification machine only

01-4

PC400/450(LC)-7

GENERAL

SPECIFICATIONS

Machine model Serial Number Model Type No. of cylinders – bore × stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption Performance Engine mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}

PC400-7 50001 and up

PC400LC-7

SAA6D125E-3 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler 6 – 125 × 150 11.045 {11,045} 246.4/1,850 {330/1,850} 1,334/1,400 {136/1,400} 1,930 1,000 203 {151} 24V, 7.5 kW 24V, 35A 12V, 110 Ah × 2 ALW-4 2 on each side 7 on each side Assembly-type triple grouser, 45 on each side 8 on each side Assembly-type triple grouser, 48 on each side

Starting motor Alternator Battery Radiator core type Undercarriage Carrier roller Track roller Track shoe Hydraulic motor Control valve Hydraulic pump Type × No. Delivery Set pressure Type × No. Control method Travel motor l /min MPa {kg/cm2}

HPV190+190, variable displacement, piston type x2 345 × 2 37.8 {380} 6-spool type + 1-spool type × 1 Hydraulic KMV200ADT-2, Variable displacement, piston type (with brake valve, parking brake): × 2 KMF230ABE-5, Fixed displacement piston type
(with safety valve, holding brake, reverse rotation preventive valve): × 1

Hydraulic system

Swing motor

Boom Hydraulic cylinder Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins Hydraulic tank Hydraulic filter Hydraulic cooler mm mm mm mm mm Double-acting piston 160 110 1,570 3,830 2,260

Arm Double-acting piston 185 120 1,820 4,325 2,505 Closed box type Tank return side CF40-1 (Air cooled)

Bucket Double-acting piston 160 110 1,270 3,140 1,870

PC400/450(LC)-7

01-5

GENERAL

SPECIFICATIONS

PC450-7, PC450LC-7
PC450LC-7 Machine model Fixed gauge spec. PC450LC-7 Fixed gauge spec.

Variable gauge spec.

Variable gauge spec.

Serial Number Bucket capacity Operating weight Max. digging depth Working ranges Max. vertical wall depth Max. digging reach Max. reach at ground level Max. digging height Max. dumping height Max. digging force (using power max. function) Swing speed Swing max. slope angle Travel speed Gradeability Ground pressure [standard shoe width] Overall length (for transport) Overall width
Overall width of track Overall width of track when extended

20001 and up m3 kg mm mm mm mm mm mm kN {kg} 42,700 7,790 6,600 12,005 11,800 10,925 7,625 258.9 {26,400} (275.5 {28,300}) rpm deg. km/h deg. kPa {kg/cm2} [mm] mm mm mm 80.5 {0.82} [600] 12,040 3,340 3,340 — mm mm mm mm mm mm mm 3,660 3,265 1,320 555 3,645 4,805 9,230 9.1 17 Lo: 3.0, Mi: 4.4, Hi: 5.5 35 82.9 {0.85} [600] 12,040 3,490 2,990 3,490 3,660 3,265 1,320 685 3,645 4,805 9,230 76.5 {0.78} [600] 12,040 3,340 3,340 — 3,660 3,265 1,320 555 3,645 4,805 9,230 1.4 44,000 43,700 7,790 6,600 12,005 11,800 10,925 7,625 258.9 {26,400} (275.5 {28,300}) 9.1 17 Lo: 3.0, Mi: 4.4, Hi: 5.5 35 78.1 {0.80} [600] 12,040 3,490 2,990 3,490 3,660 3,265 1,320 685 3,645 4,805 9,230 1.4 44,600

Performance Dimensions

Overall height (for transport) Overall height to top of machine Ground clearance of upper structure Min. ground clearance Tail swing radius
Min. swing radius of work equipment

Height of work equipment at min. swing radius Length of track on ground Track gauge Height of machine cab

mm mm mm

4,020 2,740 3,265

4,020 2,890 3,265

4,350 2,740 3,265

4,350 2,890 3,265

: The “Mi” mode is on the multi-monitor specification machine only

01-6

PC400/450(LC)-7

GENERAL

SPECIFICATIONS

Machine model Serial Number Model Type No. of cylinders – bore × stroke Piston displacement Performance Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption Engine mm l {cc} kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}

PC450-7 20001 and up SAA6D125E-3

PC450LC-7

4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler 6 – 125 × 150 11.045 {11,045} 246.4/1,850 {330/1,850} 1,334/1,400 {136/1,400} 1,930 4,000 203 {151} 24V, 7.5 kW 24 V, 35 A 12V, 110 Ah × 2 ALW-4 2 on each side 7 on each side Assembly-type triple grouser, 45 on each side 8 on each side Assembly-type triple grouser, 48 on each side

Starting motor Alternator Battery Radiator core type Undercarriage Carrier roller Track roller Track shoe Hydraulic pump Type × No. Delivery Set pressure Type × No. Control method l /min MPa {kg/cm2}

HPV190+190, ariable displacement, piston type × 2 345 × 2 37.8 {380} 6-spool type + 1-spool type × 1 Hydraulic

Control valve Hydraulic motor

Travel motor

Hydraulic system

KMV200ADT-2, Variable displacement, piston type (with brake valve, parking brake): × 2 KMF230ABE-5, Fixed displacement piston type × 2
(with safety valve, holding brake, reverse rotation preventive valve): × 1

Swing motor

Boom Hydraulic cylinder Cylinder type Inside diameter of cylinder Outside diameter of piston rod Stroke Max. distance between pins Min. distance between pins Hydraulic tank Hydraulic filter Hydraulic cooler mm mm mm mm mm
Double-acting piston

Arm
Double-acting piston

Bucket
Double-acting piston

160 110 1,570 3,830 2,260

185 130 1,985 4,740 2,755 Closed box type Tank return side CF40-1 (Air cooled)

160 110 1,270 3,140 1,870

PC400/450(LC)-7

01-7
(3)

GENERAL

WEIGHT TABLE

WEIGHT TABLE
PC400-7, PC400LC-7 k This weight table is for use when handling components or when transporting the machine. Unit: kg
Machine model Serial Number Engine assembly • Engine • Damper • Hydraulic pump Radiator, oil cooler assembly Hydraulic tank, filter assembly (excluding hydraulic oil) Fuel tank (excluding fuel) Revolving frame Operator's cab Operator's seat Counterweight Swing machinery (including swing motor) Control valve (with service valve) Swing motor Travel motor Center swivel joint Fixed gauge specification • Track frame assembly • Track frame • • Center frame • • Crawler frame • Swing circle • Idler • Idler cushion • Carrier roller • Track roller • Final drive (including travel motor) 10,173 5,506 — — 1,500 1,150 14.7 210 195 198 251 3,297 279 35 9,220 526 257 105 208 × 2 40
Variable gauge specification

PC400-7 50001 and up

PC400LC-7

1,500 1,150 14.7 210 195 198 251 3,297 279 35 9,500 526 257 105 208 × 2 40 Fixed gauge specification 10,965 6,077 — — 605 × 2 230 × 2 338 × 2 32 × 4 72 × 16 722 × 2
Variable gauge specification

11,367 6,766 3,229 1,754 × 2 605 × 2 230 × 2 338 × 2 32 × 4 72 × 14 722 × 2

11,934 7,096 3,229 1,921 × 2

01-8
(4)

PC400/450(LC)-7

GENERAL

WEIGHT TABLE

Unit: kg Machine model Serial Number Track shoe assembly • Standard triple grouser shoe (600 mm) • Standard triple grouser shoe (700 mm) • Wide triple grouser shoe (800 mm) • Wide triple grouser shoe (900 mm) Boom assembly Arm assembly Bucket assembly Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Link assembly Boom pin Arm pin Bucket pin Link pin 4,470 4,890 5,320 — 3,290 1,374 1,366 355 × 2 510 280 258 92 + 20 × 2 + 73 + 27 + 54 17 + 23 38 × 2 34 × 2 4,760 5,210 5,670 6,130 3,290 1,374 1,366 355 × 2 510 280 258 92 + 20 × 2 + 73 + 27 + 54 17 + 23 38 × 2 34 × 2 PC400-7 50001 and up PC400LC-7

PC400/450(LC)-7

01-9

GENERAL

WEIGHT TABLE

PC450-7, PC450LC-7 Unit: kg
Machine model Serial Number Engine assembly • Engine • Damper • Hydraulic pump Radiator oil cooler assembly Hydraulic tank, filter assembly (excluding hydraulic oil) Fuel tank (excluding fuel) Revolving frame Operator’s cab Operator’s seat Counterweight Swing machinery Control valve Swing motor Travel motor Center swivel joint Fixed gauge specification • Track frame assembly • Track frame • • Center frame • • Crawler frame • Swing circle • Idler • Idler cushion • Carrier roller • Track roller • Final drive (including travel motor) 10,462 5,506 — — 605 230 × 2 338 × 2 32 × 4 81 × 6, 72 × 8 722 × 2 1,500 1,150 14.7 210 195 198 251 3,402 279 35 9,220 526 257 105 208 × 2 40
Variable gauge specification

PC450-7 20001 and up

PC450LC-7

1,500 1,150 14.7 210 195 198 251 3,402 279 35 9,220 526 257 105 208 × 2 40 Fixed gauge specification 11,269 6,077 — — 605 230 × 2 338 × 2 32 × 4 81 × 8, 72 × 8 722 × 2
Variable gauge specification

11,697 6,766 3,229 1,754 × 2

12,244 7,096 3,229 1,921 × 2

01-10

PC400/450(LC)-7

GENERAL

WEIGHT TABLE

Unit: kg Machine model Serial Number Track shoe assembly • Standard triple grouser shoe (600 mm) • Standard triple grouser shoe (700 mm) • Wide triple grouser shoe (800 mm) Boom assembly Arm assembly Bucket assembly Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Link assembly Boom pin Arm pin Bucket pin Link pin 4,470 4,890 — 3,380 1,622 1,941 355 × 2 580 280 258 92 + 20 × 2 + 73 + 27 + 54 17 + 23 38 × 2 34 × 2 4,760 5,210 — 3,380 1,622 1,941 355 × 2 580 280 258 92 + 20 × 2 + 73 + 27 + 54 17 + 23 38 × 2 34 × 2 PC450-7 20001 and up PC450LC-7

PC400/450(LC)-7

01-11

GENERAL

FUEL, COOLANT AND LUBRICANTS

FUEL, COOLANT AND LUBRICANTS

01-12

PC400/450(LC)-7

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE RELATED PARTS ..................... 10- 2 RADIATOR • OIL COOLER • AFTERCOOLER ................................ 10- 3 POWER TRAIN ....................................... 10- 4 FINAL DRIVE .......................................... 10- 6 SPROCKET ............................................. 10- 7-1 SWING MACHINERY .............................. 10- 8 SWING CIRCLE ...................................... 10- 10 TRACK FRAME AND RECOIL SPRING . 10- 12 IDLER ...................................................... 10- 14 CARRIER ROLLER ................................. 10- 16 TRACK ROLLER ..................................... 10- 17 TRACK SHOE ......................................... 10- 18 HYDRAULIC PIPING DRAWING ............ 10- 22 HYDRAULIC TANK.................................. 10- 24 HYDRAULIC PUMP ................................ 10- 26 LS(PC)-EPC VALVE ................................ 10- 44 VARIABLE VOLUME VALVE .................. 10- 47 CONTROL VALVE ................................... 10- 50 MAIN RELIEF VALVE .............................. 10- 64 CLSS ....................................................... 10- 66 SELF PRESSURE REDUCING VALVE... 10- 69 SWING MOTOR ...................................... 10- 72 CENTER SWIVEL JOINT ........................ 10- 80 TRAVEL MOTOR..................................... 10- 82 TRAVEL JUNCTION VALVE.................... 10- 93 VALVE CONTROL ................................... 10- 95 TRAVEL PPC SHUTTLE VALVE ............. 10- 96 WORK EQUIPMENT • SWING PPC VALVE ................................................ 10-100 TRAVEL PPC VALVE .............................. 10-104 SERVICE PPC VALVE ............................ 10- 111 SOLENOID VALVE .................................. 10- 112 PPC ACCUMULATOR............................. 10- 114 RETURN OIL FILTER ............................. 10- 115 BOOM HYDRAULIC DRIFT PREVENTION VALVE........................ 10- 116 ARM HYDRAULIC DRIFT PREVENTION VALVE ................................................ 10-121 QUICK RETURN VALVE......................... 10-125 LIFT CHECK VALVE................................ 10-127 ATTACHMENT CIRCUIT SELECTOR VALVE................................................ 10-128 HOLDING VALVE .................................... 10-130 HYDRAULIC CYLINDER......................... 10-136 WORK EQUIPMENT ............................... 10-138 PC400/450(LC)-7 AIR CONDITIONER .................................10-144 ENGINE CONTROL .................................10-145 ELECTRONIC CONTROL SYSTEM........10-151 MONITOR SYSTEM.................................10-178 7-SEGMENT MONITOR SYSTEM........ 10-197-1 SENSOR ..................................................10-198

10-1
(4)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE RELATED PARTS

ENGINE RELATED PARTS

1. 2. 3. 4.

Drive plate Torsion spring Stopper pin Friction plate

5. 6. 7. 8.

Damper assembly Muffler Rear engine mount Front engine mount

Outline
• The damper assembly is a wet type. Oil capacity: 1.3 l

10-2

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RADIATOR • OIL COOLER • AFTERCOOLER

RADIATOR • OIL COOLER • AFTERCOOLER

1. 2. 3. 4. 5. 6. 7. 8. 9.

Oil cooler Radiator Radiator cap Reservoir tank Net Shroud Radiator inlet hose Radiator outlet hose Aftercooler

10. Condenser 11. Fuel cooler

Specifications Radiator : ALW-4 Oil cooler : CF40-1

PC400/450(LC)-7

10-3

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

POWER TRAIN

POWER TRAIN

1. 2. 3. 4. 5. 6.

Idler Center swivel joint Control valve Final drive Travel motor (KMV 200ADT-2) Engine (SAA6D125-3E)

7. 8. 9. 10. 11. 12.

Hydraulic pump (HPV190+190) Travel speed solenoid valve Swing brake solenoid valve Swing machinery Swing motor (KMF230ABE-5) Swing circle

10-4

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

FINAL DRIVE

FINAL DRIVE

10-6

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

FINAL DRIVE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Level plug Drain plug No. 1 planetary gear (No. of teeth: 43) No. 1 sun gear (No. of teeth: 10) No. 2 sun gear (No. of teeth: 18) No. 1 planetary carrier No. 2 planetary carrier Cover Ring gear (No. of teeth: 98) Sprocket Floating seal Travel motor No. 2 planetary gear (No. of teeth: 38)

Specification Reduction ratio: – 10 + 98 × 18 + 98 = –68.600 10 18

Unit: mm
No. 14 15 16 Check item Backlash between No. 1 sun gear and No. 1 planetary gear Backlash between No. 1 planetary gear and ring gear Backlash between No. 2 planetary carrier and motor Backlash between No. 2 sun gear and No. 2 planetary gear Backlash between No. 2 planetary gear and ring gear Backlash between No. 2 planetary carrier and No. 2 sun gear Amount of wear on sprocket tooth Width of sprocket tooth Standard size 90 Standard clearance 0.15 – 0.54 0.18 – 0.66 0.06 – 0.24 Criteria Clearance limit 1.10 1.30 — Replace 0.15 – 0.51 1.00 Remedy

17

18

0.17 – 0.60

1.20

19

0.15 – 0.54

20 21

Repair limit: 6 Repair limit 87 Rebuild or replace

PC400/450(LC)-7

10-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SPROCKET

SPROCKET

Unit: mm
No. 1 2 3 4 Check item Wear of tooth tip Thickness of tooth root Width of tooth Wear of tooth shape Standard size 355 20.8 90 Criteria Repair limit 343 14.8 87 Build-up welding or replace Remedy

Repair limit: 6 (measure with sprocket tooth shape)

10-7-1
(6)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SPROCKET

SPROCKET TOOTH SHAPE OF REAL DIMENSION

a 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.

PC400/450(LC)-7

10-7-2
(6)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MACHINERY

SWING MACHINERY

10-8

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MACHINERY

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Swing pinion (No. of teeth: 13) Cover Case No. 2 planetary gear No. 2 sun gear Ring gear No. 1 sun gear Swing motor Oil level gauge No. 1 planetary gear No. 1 planetary carrier No. 2 planetary carrier Drain plug

Specification Reduction ratio: 19 + 68 × 16 + 68 = 24.039 19 16

Unit: mm
No. 14 Check item Backlash between swing motor shaft and No. 1 sun gear Backlash between No. 1 sun gear and No. 1 planetary gear Backlash between No. 1 planetary gear and ring gear Backlash between No. 1 planetary carrier and No. 2 sun gear Backlash between No. 2 sun gear and No. 2 planetary gear Backlash between No. 2 planetary gear and ring gear Backlash between coupling and swing pinion Backlash between swing pinion and swing circle Clearance between plate and coupling Standard clearance 0.18 – 0.28 0.15 – 0.51 Criteria Clearance limit — 1.00 Remedy

15

16

0.17 – 0.60

1.10

17

0.40 – 0.75

1.20 Replace

18 19 20 21 22

0.16 – 0.55 0.17 – 0.60 0.08 – 0.25 0.00 – 1.21 0.57 – 1.09 Standard size

1.00 1.10 — 2.00 — Repair limit — Apply hard chrome plating, recondition, or replace

23

Wear of swing pinion surface contacting with oil seal

150 –0.100

0

PC400/450(LC)-7

10-9

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING CIRCLE

SWING CIRCLE

1. Swing circle inner race (No. of teeth: 84) 2. Ball 3. Swing circle outer race a. Inner race soft zone “S” position b. Outer race soft zone “S” position

Specifications 84 = –6.462 13 Amount of grease: 33 l (G2-LI) Reduction ratio: –

Unit: mm
No. Check item Axial clearance of bearing (when mounted on chassis) Standard clearance 0.5 – 1.6 Criteria Repair limit 3.2 Remedy

4

Replace

10-10

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK FRAME AND RECOIL SPRING

TRACK FRAME AND RECOIL SPRING

1. 2. 3. 4. 5. 6. 7. 8. 9.

Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard

The dimensions and the number of track rollers depend on the model, but the basic structure is not different. Number of track rollers
Model PC400-7, 450-7 PC400LC-7, 450LC-7 Q’ty 7 8

10-12

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK FRAME AND RECOIL SPRING

Standard shoe
Model Item Shoe width Link pitch No. on track (one side) PC400-7 600 mm 228 mm 46 (Pieces) PC400LC-7 700 mm 228 mm 46 (Pieces) PC450-7 600 mm 228 mm 49 (Pieces) PC450LC-7 600 mm 228 mm 49 (Pieces)

Unit: mm
No. Check item Criteria Standard size 10 Vertical width of idler guide Track frame Idler support Track frame 11 Horizontal width of idler guide Idler support Standard size 12 Recoil spring Free length × OD 795 × 241 Installation length 648 Installation load 173.3 kN {17,680 kg} 261 — 259 Repair limit Free length — Installation load 138.56 kN {14,140 kg} Replace 123 120 266 Tolerance
+2 –1

Remedy Repair limit 127 118 271 Rebuild or replace

±0.5
+3 –1

PC400/450(LC)-7

10-13

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

IDLER

IDLER

10-14

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm
No. Check item Outside diameter of protruding Outside diameter of tread Depth of tread Total width Width of tread Standard size 704 660 22 202 48.5 Standard size 95 Standard size 102.6 Tolerance Shaft –0.120 –0.207 Hole +0.360 +0.220 Criteria Repair limit — 648 28 — — Standard clearance 0.340 –0.507 Replace bushing Standard interference 0.064 –0.149 Rebuild or replace Remedy

1 2 3 4 5

6

Clearance between shaft and bushing

Tolerance Shaft +0.087 +0.037 Hole –0.027 –0.079

7

Interference between idler and bushing

PC400/450(LC)-7

10-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CARRIER ROLLER

CARRIER ROLLER

Unit: mm
No. 1 2 3 4 5 Check item Outside diameter of flange Outside diameter of tread Width of tread Thickness of tread Width of flange Standard size 50 7 8 Interference between roller and bushing Axial clearance of roller 57 Standard size 175 148 50.3 32 19 Tolerance Shaft –0.250 –0.270 +0.117 +0.087 Hole +0.099 –0.032 +0.040 0 Criteria Repair limit — 134 — 25 — Standard Interference Replace interference limit 0.218 – 0.369 0.047 – 0.177 Clearance limit — — — Remedy

6

Interference between shaft and bushing

Standard clearance 0.5 – 0.7

10-16

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK ROLLER

TRACK ROLLER

Unit: mm
No. 1 2 3 4 5 6 Check item Outside diameter of outer flange Outside diameter of inner flange (double flange) Outside diameter of tread Thickness of tread Overall width Width of tread Width of outer flange Singe flange
Double flange

Criteria Standard size 240 237 200 56.2 278 54.6 51.6 32.6 32.6 23.0 0.4 – 1.0 Standard size 80 Standard size 87.6 Tolerance Shaft –0.250 –0.350 Hole +0.174 +0.029 Repair limit — — 188 50.2 — — — — — — — Standard clearance 0.279 – 0.524 Clearance limit 1.5

Remedy

Rebuild or replace

7 8 9

Singe flange
Double flange

Width of inner flange (Double flange) Axial play

10

Clearance between shaft and bushing

Tolerance Shaft +0.108 +0.008 Hole –0.006 –0.036

11

Interference between roller and bushing

Standard Interference interference limit 0.014 – 0.144 —

Replace bushing

PC400/450(LC)-7

10-17

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK SHOE

TRACK SHOE
TRACK SHOE

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

10-18

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK SHOE

Unit: mm
No. 1 Check item Link pitch Standard size 228.9 Standard size 71.5 12 Standard size 129 34.5 184 Shoe bolt pitch 144 76.2 Inside width Link Overall width Tread width Protrusion of pin Protrusion of regular bushing Overall length of pin Overall length of bushing Thickness of spacer Bushing Press-fitting force Regular pin Master pin 106 51.6 44.8 4.4 5.25 252 164.5 — 118 – 304 kN {12 – 31 ton} 176 – 451 kN {18 – 46 ton} 137 – 284 kN {14 – 29 ton} — Adjust or replace Repair or replace Replace Criteria Repair limit 231.9 When turned 66.5 7 Repair limit 119 24.5 Repair or replace Adjust or replace Reverse or replace Remedy

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Bushing outside diameter Thickness of bushing metal Link height Thickness of link metal (bushing press-fitting portion)

: Dry type track link PC400/450(LC)-7

10-19

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK SHOE

Unit: mm
No. Check item a. Regular link Shoe bolt 20 b. Master link No. of shoes (each side) Standard size 71 22 Interference between regular pin and link 47 Standard size 47 Standard size 47 Standard size 47 Tightening torque (Nm {kgm}) Triple shoe 393±39 {40±4} Additinal tightening angle (deg.) — PC400-7, PC450-7: 46 PC400LC-7, PC450LC-7: 49 Tolerance Shaft +0.494 +0.454 +0.235 +0.085 Tolerance Shaft +0.235 +0.085 Tolerance Shaft +0.03 0 Tolerance Shaft –0.2 –0.4 Hole +0.915 +0.415 Hole –0.218 –0.280 Hole +0.915 +0.415 Hole +0.074 0 –0.218 –0.280 Standard interference 0.380 – 0.494 0.303 – 0.515 Standard clearance 0.180 – 0.830 Standard interference 0.218 – 0.310 Standard clearance 0.615 – 1.315 Adjust or replace Criteria Additinal tightening angle (deg.) 120±10 Lower limit torque (Nm {kgm}) — — Retighten Remedy

Tightening torque (Nm {kgm}) —

21

Interference between bushing and link

23

Clearance between regular pin and bushing

24

Interference between master pin and bushing

25

Clearance between master pin and bushing

10-20

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK SHOE

TRIPLE GROUSER SHOE

Unit: mm
No. 1 2 3 4 5 6 7 Length at tip Height Thickness Length at of base Check item Standard size 37 13 33 27 25.5 17.5 23.5 Rebuild or replace Criteria Repair limit 22 Remedy

PC400/450(LC)-7

10-21

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PIPING DRAWING

HYDRAULIC PIPING DRAWING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Bucket cylinder Arm cylinder Boom cylinder Swing motor Control valve Oil cooler Hydraulic filter Hydraulic pump L.H. travel motor Hydraulic tank Multi-pattern selector valve L.H. PPC valve Safety lever (electric type) Center swivel joint R.H. PPC valve Travel PPC valve Attachment circuit selector valve Holding valve Accumulator 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

10-22

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PIPING DRAWING

PC400/450(LC)-7

10-23

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC TANK

HYDRAULIC TANK

1. 2. 3. 4. 5. 6. 7. 8.

Oil filler cap Breather Hydraulic tank Sight gauge Strainer Filter element Strainer Bypass valve

Specifications Tank capacity: 335 l Amount of oil inside tank: 248 l Pressure valve • Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} • Suction cracking pressure: 0 – 0.49 kPa {0 – 0.005 kg/cm2} • Bypass valve set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm2} Breather • Intake valve set pressure: 2.0 ± 0.3 kPa {0.02 ± 0.003 kg/cm2} • Exhaust valve set pressure: 98 ± 14.7 kPa {1.0 ± 0.15 kg/cm2}

10-24

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

HYDRAULIC PUMP
HPV190+190

1. 2. 3. 4. 5. 6. 7.

Front main pump Rear main pump LS valve PC valve LS-EPC valve PC-EPC valve Variable volume valve

IM ISIG PAF PFC PAR PRC PBF PD1F PENF PBR PD2F PD2R

: : : :

PC mode selector current LS set selector current Front pump delivery Front pump delivery pressure detection : Rear pump delivery : Rear pump delivery pressure detection : Front pump pressure input : Case drain port : Front pump control pressure detection : Rear pump pressure input : Drain plug : Drain plug

PENR : Rear pump control pressure detection port PLSF : Front load pressure input PLSFC: Front load pressure detection port PLSR : Rear load pressure input PLSRC: Rear load pressure detection port PS : Pump suction PLSCR: LS set selector pressure detection port PM : PC set selector pressure detection port PEPC : EPC basic pressure input PDIR : Air bleeder PEPB : EPC basic pressure detection port

Outline • This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.

10-26
(4)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

1. 2. 3. 4. 5. 6.

Shaft (Front) Cradle Case (Front) Rocker cam Shoe Piston

7. 8. 9. 10. 11. 12.

Cylinder block Valve plate End cap Shaft (Rear) Case (Rear) Servo piston

PC400/450(LC)-7

10-27

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

Function • The rotation and torque transmitted to the pump shaft are converted into hydraulic energy, and pressurized oil is discharged according to the load. It is possible to change the discharge amount by changing the swash plate angle.

Structure • • • Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).

• •

10-28

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

Operation 1) Operation of pump i Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle is called the swash plate angle.) ii Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F – E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in. iii If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)

PC400/450(LC)-7

10-29
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

2) Control of discharge amount • If the swash plate angle becomes larger, the difference between volumes E and F becomes larger and discharge amount Q increases. • Swash plate angle is changed by servo piston (12). • Servo piston (12) moves in a reciprocal movement ( ) according to the signal pressure from the PC and LS valves. This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides in a rotating movement in direction of arrow. • With servo piston (12), the area receiving the pressure is different on the left and the right, so main pump discharge pressure (self pressure) PP is always brought to the chamber receiving the pressure at the small diameter piston end. • Output pressure Pen of the LS valve is brought to the chamber receiving the pressure at the large diameter end. The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).

10-30

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

LS VALVE

1. 2. 3. 4. 5. 6. 7. 8.

Plug Locknut Sleeve Spring Seat Spool Piston Sleeve

PA PP PDP PLP PLS PPL PSIG

: : : : : : :

Pump port Pump port Drain port LS control pressure output port LS pressure input port PC control pressure input port LS mode selection pilot port

PC VALVE

1. 2. 3. 4. 5. 6. 7. 8.

Servo piston assembly Plug Pin Spool Retainer Seat Cover Wiring

PA PA2 PDP PM PPL

: : : : :

Pump port Pump pressure pilot port Drain port PC mode selector pressure pilot port PC control pressure output port

PC400/450(LC)-7

10-31

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

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 1.2 2.6 MPa {12 27 kg/cm2}. (2) PC valve When the pump discharge pressure PP1 (selfpressure) and PP2 (other pump pressure) are high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. In other words, If the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount Q is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The controller senses the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set value, the command current to the PCEPC valve solenoid from the controller increases according to the drop in the engine speed to reduce the pump swash plate angle.

10-32
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

OPERATION

(1) LS valve 1) 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 MPa {0 kg/cm2}. (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 PC400/450(LC)-7

of the piston, so the swash plate is moved to the minimum angle by the difference in the area of the piston (12).

10-33

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

2) 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.

10-34

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

3) 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.

PC400/450(LC)-7

10-35

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

4) 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 = 2.6 MPa {27 kg/cm2 }. However, if PSIG (the output pressure of 0 2.9 MPa {0 30 kg/cm2} 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 = 2.6 1.2 MPa {27 12 kg/cm2}.

10-36
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

(2) PC Valve 1) When pump controller is normal a. When the load on the actuator is small and pump pressures PP1 and PP2 are low i) 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. a Other pump pressure This is the pressure of the pump at the opposite end. For the F pump, it is the R pump pressure For the R pump, it is the F pump pressure

PC400/450(LC)-7

10-37

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

ii) 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.

10-38

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

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.

PC400/450(LC)-7

10-39

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

b. 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.

10-40

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

The relation of average pump pressure (PP1 + PP2)/2 and the position of servo piston (9) forms a bent line because of the doublespring 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 PCEPC 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.

PC400/450(LC)-7

10-41

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

2) When pump controller is abnormal and emergency pump drive switch is ON a. 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.

10-42

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

b. 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 in item 2)-b, 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 PC400/450(LC)-7

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 , which is to the left of curve for when the pump controller is normal.

10-43

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

LS(PC)-EPC VALVE

LS(PC)-EPC VALVE

1. 2. 3. 4.

Body Spool Spring Rod

5. Coil 6. Plunger 7. Connector

PSIG : To LS(PC) valve PT : To tank PEPC: From self-reducing pressure valve

10-44

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

LS(PC)-EPC VALVE

Function • • The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. When it receives signal current i from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS valve.

Operation 1. When signal current is 0 (coil de-energized) • When there is no signal current flowing from the controller to coil (5), coil (5) is de-energized. • For this reason, spool (2) is pushed to the left in the direction of the arrow by spring (3). • As a result, port PEPC closes and the pressurized oil from the main pump does not flow to the LS valve. At the same time, the pressurized oil from the LS valve passes from port PSIG(PM) through port PT and is drained to the tank.

PC400/450(LC)-7

10-45

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

LS(PC)-EPC VALVE

2. When signal current is very small (coil energized) • When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated which pushes plunger (6) to the left. • Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port PEPC to port PSIG(PM). • When the pressure at port PSIG(PM) rises and the load of spring (3) + the force acting on surface a of spool (2) becomes greater than the propulsion force of plunger (6), spool (2) is pushed to the right. The circuit between port PEPC and port PSIG(PM) is shut off, and at the same time, port PSIG(PM) and port PT are connected. • As a result, spool (2) is moved up or down until the propulsion force of plunger (6) is balanced with the load of spring (3) + pressure of port PSIG(PM). • Therefore, the circuit pressure between the EPC valve and the LS valve is controlled in proportion to the size of the signal current.

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

10-46
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

VARIABLE VOLUME VALVE

VARIABLE VOLUME VALVE

1. 2. 3. 4.

Block Plug Spring Piston

PM : To PC valve PT : To tank PEPC: From self-reducing pressure valve

PC400/450(LC)-7

10-47

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

VARIABLE VOLUME VALVE

Function • This stabilizes the EPC output pressure.

Operation • The output pressure from EPC flows to port PM, and when the propulsion force of piston (4) becomes larger than the load of spring (3), piston (4) is pushed to the left and the volume at port PM increases. When the propulsion force of piston (4) becomes less than the load on spring (3), piston (4) is pushed to the right and the volume at port PM goes down.

10-48

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

CONTROL VALVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 6-spool valve Cover 1 Cover 2 Pump merge-divider valve Back pressure valve Boom lock valve Boom, arm Hi valve Quick return valve Boom Hi check valve

Outline • This control valve consists of a 7-spool valve (6 spool valve + boom • arm Hi valve). A merge-divider valve, back-pressure valve, boom hydraulic drift prevention valve, quick return valve, and Hi valve check valve are installed to it. • Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the assembly, the assembly is small in size and easy to maintain. • Since one spool of this control valve is used for one work equipment unit, its structure is simple.

A1 A2 A3 A4 A5 A6 A-1 A-2 B1 B3 B4 B5 B6 B-1 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10

: : : : : : : : : : : : : : : : : : : : : : : :

To bucket cylinder bottom o left travel motor To boom cylinder bottom To swing motor To right travel motor To arm cylinder head To boom cylinder bottom To attachment To bucket cylinder head To bottom cylinder head To swing motor To right travel motor To arm cylinder bottom To arm cylinder bottom From bucket PPC valve From bucket PPC valve From left travel PPC valve From left travel PPC valve From boom PPC valve From boom PPC valve From swing PPC valve From swing PPC valve From right travel PPC valve From right travel PPC valve

P11 P12 BP1 PB5 PLS1 PLS2 PP1 PP2 PPS1 PPS2 PR PS PST PX1 PX2 SA SB T T1 TS TSW

: From arm PPC valve : From arm PPC valve : Boom RAISE PPC output pressure : From 2-stage safety valve solenoid valve : To rear pump control : To front pump control : To rear pump control : To front pump control : From rear main pump : From front main pump : To solenoid valve, PPC valve, EPC valve : From pump merge-divider solenoid valve : From travel junction valve : From 2-stage solenoid valve : From 2-stage solenoid valve : Pressure sensor fitting port : Pressure sensor fitting port : To tank : To tank : To tank : To swing motor

10-50

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

7-spool valve (1/9)

PC400/450(LC)-7

10-51

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(2/9)

10-52

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(3/9)

1. Unload valve 2. Pressure compensation valve (Arm OUT) 3. Pressure compensation valve (Right travel reverse) 4. Pressure compensation valve (Left swing) 5. Pressure compensation valve (Boom RAISE) 6. Pressure compensation valve (Left travel reverse) 7. Pressure compensation valve (Bucket CURL) 8. Pressure compensation valve (Boom RAISE)

Pressure compensation valve (Arm IN) Pressure compensation valve (Bucket DUMP) Pressure compensation valve (Left travel forward) Pressure compensation valve (Boom LOWER) Pressure compensation valve (Right swing) Pressure compensation valve (Right travel forward) 15. Pressure compensation valve (Arm IN) 16. Main relief valve

9. 10. 11. 12. 13. 14.

PC400/450(LC)-7

10-53

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(4/9)

1. 2. 3. 4. 5.

Spool (Arm) Spool (Right travel) Spool (Swing) Spool (Boom) Spool (Left travel)

6. 7. 8. 9. 10.

Spool (Bucket) Spool (Boom Hi) Spool (Arm Hi) Unload valve Main relief valve Unit: mm

No.

Check item Standard size

Criteria Repair limit Installed load 416.5 N {42.5 kg} 429.9 N {42.9 kg} 393 N {40.1 kg} 251 N {25.1 kg} 416 N {42.5 kg} Free length — — — — — Installed load 333.2 N {34 kg} 336.1 N {34.3 kg} 314.6 N {32.1 kg} 201.0 N {20.5 kg} 333.2 N {34.0 kg}

Remedy

11

Spool return spring

Free length × OD

Installed length 51.2 51.2 51.2 51.2 51

54.2 × 34.8 12 13 14 15 Spool return spring Spool return spring Spool return spring Spool return spring 54.6 × 34.8 54.5 × 34.8 54.9 × 24.2 57.2 × 32.8

If damaged or deformed, replace spring

10-54

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(5/9)

1. 2. 3. 4. 5. 6. 7. 8.

Safety-suction valve (Arm OUT) Suction valve (Right travel reverse) Suction valve (Boom RAISE) Suction valve (Left travel reverse) Safety-suction valve (Boom Hi) Safety-suction valve (Arm IN) Safety-suction valve (Bucket DUMP) Suction valve (Left travel forward)

9. 10. 11. 12. 13. 14. 15. 16.

Safety-suction valve (2-stage) (Boom LOWER) Suction valve (Right travel forward) Safety-suction valve (Arm IN) LS shuttle valve (Arm, right travel) LS select valve LS shuttle valve (Boom, left travel, bucket) LS check valve Pressure relief plug Unit: mm

No.

Check item Standard size

Criteria Repair limit Installed load 1.5 N {0.15 kg} Free length — Installed load 1.2 N {0.12 kg}

Remedy

17

Check valve spring

Free length × OD

Installed length 8.5

If damaged or deformed, replace spring

11.5 × 4.6

PC400/450(LC)-7

10-55

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(6/9)

ARM CONTROL VALVE 1. 2. 3. 4. Unload valve Main relief valve Safety valve (Boom RAISE) Lift check valve 5. Safety-suction valve 6. Spool 7. Pressure compensation valve (OUT) 8. LS shuttle valve 9. Pressure compensation valve (IN) 10. Safety-suction valve 11. Check valve for regeneration circuit

R. H. TRAVEL CONTROL VALVE 12. Suction valve 13. Spool 14. Pressure compensation valve (Reverse) 15. LS shuttle valve 16. Pressure compensation valve (Forward) 17. Suction valve

10-56

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No. Check item Standard size 18 Regeneration valve spring
Free length × OD

Criteria Repair limit Installed load 6.2 N {0.6 kg} 29.4 N {3 kg} 29.4 N {3 kg} Free length — — — Installed load 4.9 N {0.5 kg} 23.5 N {2.4 kg} 23.5 N {2.4 kg}

Remedy

Installed length 19.5 28 28

31.5 × 10.3 19 20 Piston return spring Piston return spring 36.9 × 11.1 36.9 × 11.1

If damaged or deformed, replace spring

PC400/450(LC)-7

10-57

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(7/9)

SWING CONTROL VALVE 1. Spool 2. Pressure compensation valve (Left) 3. LS select valve 4. Pressure compensation valve (Right)

ARM CONTROL VALVE 5. Suction valve 6. Spool 7. Pressure compensation valve (RAISE) 8. Hydraulic drift prevention valve 9. LS shuttle valve 10. Pressure compensation valve (Lower) 11. Safety-suction valve 12. Check valve for regeneration circuit

L. H. TRAVEL CONTROL VALVE 13. Pump merge-divider valve (Travel junction valve) 14. Return spring 15. Suction valve 16. Spool 17. Pressure compensation valve (Reverse) 18. LS shuttle valve 19. Pressure compensation valve (Forward) 20. Suction valve

10-58

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No. Check item Standard size 21 Regeneration valve spring
Free length × OD

Criteria Repair limit Installed load 6.2 N {0.6 kg} 17.5 N {1.8 kg} 29.4 N {3 kg} 50.0 N {5.1 kg} Free length — — — — Installed load 4.9 N {0.5 kg} 14.0 N {1.4 kg} 23.5 N {2.4 kg} 40.0 N {4.1 kg}

Remedy

Installed length 19.5 28 28 23

31.5 × 10.3 22 23 24 Piston return spring Piston return spring Spool return spring 48.1 × 10.8 36.9 × 11.1 30.7 × 20.5

If damaged or deformed, replace spring

PC400/450(LC)-7

10-59

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(8/9)

BUCKET CONTROL VALVE 1. 2. 3. 4. 5. 6. Safety-suction valve Spool Pressure compensation valve (CURL) LS shuttle valve Pressure compensation valve (DUMP) Safety-suction valve

BOOM, ARM HI VALVE 7. 8. 9. 10. 11. 12. 13. Boom Hi spool Pressure compensation valve (Boom RAISE) Boom Hi check valve Quick-return valve Pressure compensation valve (Arm IN) Arm Hi spool Safety-suction valve Unit: mm

No.

Check item Standard size

Criteria Repair limit Installed load 17.5 N {1.8 kg} 29.4 N {3 kg} Free length — — Installed load 14.0 N {1.4 kg} 23.5 N {2.4 kg}

Remedy

14

Piston return spring

Free length × OD

Installed length 28 28

48.1 × 10.8 15 Piston return spring 36.9 × 11.1

If damaged or deformed, replace spring

10-60

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(9/9)

1. 2. 3. 4. 5. 6. 7. 8.

Unload valve Main relief valve Pump merge-divider valve (Main) Return spring Pump merge-divider valve (For LS) Return spring Valve (Sequence valve) Spring (Sequence valve)

9. 10. 11. 12. 13. 14. 15. 16.

LS bypass plug Screw Poppet Spring (Pressure reducing valve pilot) Spring (Pressure reducing valve main) Valve (Pressure reducing valve) Spring (Safety valve) Ball

10-62

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No. Check item Standard size 17 Check valve spring
Free length × OD

Criteria Repair limit Installed load 1.5 N {0.15 kg} 156.8 N {16.0 kg} 177.5 N {18.1 kg} 199.8 N {20.4 kg} Free length — — — — Installed load 1.2 N {0.12 kg} 125.5 N {12.8 kg} 142.0 N {14.5 kg} 160.0 N {16.3 kg}

Remedy

Installed length 8.5 3.3 63 59

11.5 × 4.6 18 19 20 Spool return spring Spool return spring Sequence valve spring 46.6 × 21.8 64.5 × 32.3 70.9 × 18.0

If damaged or deformed, replace spring

PC400/450(LC)-7

10-63

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MAIN RELIEF VALVE

MAIN RELIEF VALVE

1. Spring 2. Poppet

Function • The relief valve set pressure is set to 2 stages. When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.

Operation • • The relief valve set pressure is determined by the installed load of spring (1). (First stage) It is unnecessary to set the first and second stage individually. The second stage is set when the first stage is set.

1. When pilot pressure P is OFF: Low-pressure setting The set pressure is determined by the installed load of spring (1). 2. When pilot pressure P is ON: High-pressure setting In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter (d1) so the set pressure becomes higher.

10-64
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

CLSS
OUTLINE OF CLSS

Features • CLSS stands for Closed Center Load Sensing System, and has the following features.

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.

1) Fine control not influenced by load 2) Control enabling digging even with fine control 3) Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations 4) Energy saving using variable pump control

10-66
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

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.

PC400/450(LC)-7

10-67

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

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

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SELF PRESSURE REDUCING VALVE

SELF PRESSURE REDUCING VALVE
Function • This value reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves, PPC valves, etc.

Operation 1. When engine is stopped • Poppet (11) is pressed by spring (12) against the seat and port PR is not connected to TS. • Valve (14) is pressed by spring (13) against the left side and port P2 is connected to PR. • Valve (7) is pressed by spring (8) against the left side and port P2 is not connected to A2.

PC400/450(LC)-7

10-69

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SELF PRESSURE REDUCING VALVE

2. When in neutral or load pressure P2 is low (When the boom is lowered and arm is at the IN position and they are moving down under their own weight) Note: When load pressure A2 is lower than selfpressure reducing valve output pressure PR. • Valve (7) receives the force of spring (8) and PR pressure (which is 0 MPa {0 kg/cm2} when the engine is stopped) in the direction to close the circuit between ports P2 and A2. If the hydraulic oil flows in port P2, the fdx P2 pressure becomes equal to the total force of spring (8) and the value of area of ød × PR pressure, then the area of the pass between ports P2 and A2 is adjusted so the P2 pressure will be kept constant above the PR pressure. If the PR pressure rises above the set level, puppet (11) opens and the hydraulic oil flows from the PR port through orifice “a” in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice “a” in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.

3. When load pressure P2 is high • If load pressure A2 rises and the pump discharge increases because of operation of the work equipment, the fdx P2 pressure rises higher than the total of the force of spring (8) and the value of ød × PR pressure, and then valve (7) moves to the right stroke end. • As a result, the area of the pass between ports P2 and A2 increases and the pass resistance lowers and the loss of the engine power is reduced. • If the PR pressure rises above the set pressure, poppet (11) opens and the hydraulic oil flows from the PR port through orifice “a” in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice “a” in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.

10-70
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SELF PRESSURE REDUCING VALVE

4. When abnormal high pressure is generated • If the PR pressure on the self-pressure reducing valve rises abnormally high, ball (16) separates from the seat against the force of spring (15) and the hydraulic oil flows from output port PR to TS. Accordingly, the PR pressure lowers. By this operation, the hydraulic devices (PPC valves, solenoid valves, etc.) are protected from abnormal pressure.

PC400/450(LC)-7

10-71
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

SWING MOTOR
KMF230ABE-5

Specifications B S T MA MB : From swing lock solenoid valve : From control valve : To tank : From control valve : From control valve
Model Theoretical displacement Safety valve set pressure Rated revolving speed Brake release pressure KMF230ABE-5 229.4 cm³/rev 27.9 +0.5 MPa +0 {285 +0.5 kg/cm2} +0 1,413 rpm 1.9 ± 0.4 MPa {19 ± 4 kg/cm2}

10-72

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

1. 2. 3. 4. 5. 6. 7.

Brake spring Drive shaft Spacer Case Disc Plate Brake piston

8. 9. 10. 11. 12. 13. 14.

Housing Piston Cylinder block Valve plate Reverse prevention valve Center shaft Center spring

15. Safety valve 16. Check valve 17. Shuttle valve

10-74

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

Unit: mm
No. Check item Standard size 18 Check valve spring Free length × OD 66.5 × 25.6 19 Shuttle valve spring 24.5 × 11.6 Installed length 45 14.5 Installed load 6.96 N {0.71 kg} 7.45 N {0.76 kg} Criteria Repair limit Free length — — Installed load 5.59 N {0.57 kg} 5.98 N {0.61 kg} If damaged or deformed, replace spring Remedy

PC400/450(LC)-7

10-75

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

RELIEF VALVE
1. Outline The relief portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). 2. Function When the swing is stopped, the outlet port circuit of the motor from the control valve is closed, but the motor continues to rotate under inertia, so the pressure at the output side of the motor becomes abnormally high, and this may damage the motor. To prevent this, the abnormal high pressure oil is relieved to port S from the outlet port of the motor (high-pressure side) to prevent any damage. 3. Operation 1) When starting swing • When the swing control lever is operated to swing right, the pressure oil from the pump passes through the control valve and is supplied to port MA. As a result, the pressure at port MA rises, the starting torque is generated in the motor, and the motor starts to rotate. The oil from the outlet port of the motor passes from port MA through the control valve and returns to the tank. (Fig. 1) 2) When stopping swing • When the swing control lever is returned to neutral, the supply of pressure oil from the pump to port MA is stopped. With the oil from the outlet port of the motor, the return circuit to the tank is closed by the control valve, so the pressure at port MB rises. As a result, rotation resistance is generated in the motor, so the braking effect starts. • If the pressure at port MB becomes higher than the pressure at port MA, it pushes shuttle valve A (4) and chamber C becomes the same pressure as port MB. The oil pressure rises further until it reaches the set pressure of relief valve (1). As a result, a high braking torque acts on the motor and stops the motor. (Fig.2) • When relief valve (1) is being actuated, the relief oil and oil from port S passes through check valve B (3) and is supplied to port MA. This prevents cavitation at port MA.

10-76
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

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

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

PC400/450(LC)-7

10-77
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

REVERSAL PREVENTION VALVE
Outline diagram

1. 2. 3. 4. 5. 6. 7.

Valve body Spool (MA side) Spring (MA side) Plug Spool (MB side) Spring (MB side) Plug

Explanation of effect

10-78

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

Outline This valve reduces the swing back generated in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. This is effective in preventing spillage of the load and reducing the cycle time when stopping the swing (the positioning ability is good and it is possible to move swiftly to the next job.

Operation 1. When brake pressure is being generated at port MB • Pressure MB passes through the notch and goes to chamber d, spool (5) pushes spring (6) according to the difference in area D1 > D2, moves to the left, and MB is connected to e. When this happens, pressure MA is below the set pressure of spring (3), so spool (2) does not move. For this reason, the pressure oil is closed by spool (2), and the braking force is ensured.

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

PC400/450(LC)-7

10-79
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

1. 2. 3. 4. 5.

Cover Body Slipper seal O-ring Shaft

A1 A2 C1 B2 D1 E

: To L.H. travel motor port PB : From control valve port A2 : To R.H. travel motor port PA : From control valve port B2 : To R.H. travel motor port PB : To L.H. and R.H. travel motors port P

T2 T1 D2 B1 C2

: To tank : From L.H. and R.H. travel motors port T : From control valve port B5 : To L.H. travel motor port PA : From control valve port A5

Unit: mm
No. Check item Clearance between rotor and shaft Standard Size 80 Criteria Standard clearance — Repair limit — Remedy If damaged or deformed, replace spring

6

10-80

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

TRAVEL MOTOR
KMV280ADT

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

Specifications Model: Theoretical delivery KMV200ADT Min 130 cm3/rpm Max 200 cm3/rpm Brake releasing pressure: 1.0 ± 0.4 MPa {10 ± 4 kg/cm2} Travel speed switching pressure: 0.8 +0.4 MPa {8 +4 kg/cm2} –0.1 –1 (Differentical pressure)

10-82

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

1. 2. 3. 4. 5. 6. 7.

Output shaft Motor case Piston Cylinder Valve plate End cover Slow return valve

8. 9. 10. 11. 12. 13. 14.

Regulator piston Plate Disc Check valve spring Check valve Counterbalance valve Spool return spring

15. 16. 17. 18. 19. 20.

Safety valve Rgegulator valve Spring Brake spring Brake piston Check valve

PC400/450(LC)-7

10-83

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

Unit: mm
No. Check item Standard size 21 Spool return spring Free length × OD 62.52 × 32.0 22 23 Check valve spring Regulator piston spring 62.5 × 20.0 55.0× 9.0 Installed length 42.0 39.0 50.0 Installed load 426.6N {43.5 kg} 3.04 N {0.31 kg} 98.1 N {10 kg} Criteria Repair limit Free length — — — Installed load 341.3 N {32.2 kg} 2.45 N {0.25 kg} 78.5 N {8 kg} Replace spring if damaged or deformed Remedy

10-84

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

Operation of moter 1) At low speed (motor swash plate angle at maximumu)

• •

The solenoid valve is de-energized, so the pilot pressure oil from the main pump does not flow to port P For this reason, regulator valve (16) is pushed down by spring (17). The main pressure oil from the control valve pushes check valve (20), goes to end cover (6), in regulator valve (16) and acts also on chamber b. When this happens, the propulsion force of regulator piston (8) acts in a downward direction.

As a result, valve plate (5) and cylinder block (4) move in the maximum swash plate angle direction, the motor capacity becomes maximum, and the system is set to low speed.

PC400/450(LC)-7

10-85

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

2) At high speed (motor swash plate angle at minimum)

• • • •

When the solenoid valve is energized, the pilot pressure oil from the main pump flows to port P, and pushes regulator valve (16) up. As a result, the oil in chamber b is drained inside the case, and acts on chamber a via regulator valve (16). Because of this, the propulsion force of the pressure oil at chamber a of regulator piston (8) acts in a upward direction. As a result, valve plate (5) and cylinder block (4) move in the minimum swash plate angle direction, the motor capacity becomes minimum, and the system is set to hign travel speed.

10-86

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

PARKING BRAKE
1. When starting to travel

Operation • When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (13), opens the circuit to the parking brake, and flows into chamber e of brake piston (19). It overcomes the force of spring (18), and pushes piston (19) to the right. When this happens, the force pushing plate (9) and disc (10) together is lost, so plate (9) and disc (10) separate and the brake is released.

PC400/450(LC)-7

10-87

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

2. When stopping travel

Operation • When the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber e of brake piston (19) passes through the throttle of slow return valve (7) until spool (13) of the counterbalance valve returns to neutral. When spool (13) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from the throttle f of brake piston (19) and brake piston (19) is pushed fully to the left by spring (18). As a result, plate (9) and disc (10) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (7) when the brake piston returns, and this ensures that the brake is applied after the machine stops.

• •

10-88

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

Operation of brake valve • The brake valve consists of a check valve (1), counterbalance valve (2), and safety valve (3) in a circuit as shown in the diagram on the right. • The function and operation of each component is as given below. 1) Counterbalance valve, check valve Function • When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount).

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

PC400/450(LC)-7

10-89

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

The pressurized oil at the supply side flows from orifice E1 in spool (13) and orifice E2 in the piston to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure, spool (13) is pushed to the right. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate.

Operation of brake when traveling downhill • If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber S1 through orifices E1 and E2 will also drop. When the pressure in chamber S1 drops below the spool switching pressure, spool (13) is returned to the left by spring (14), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. 2) Safety valve (2-direction operation, 2-stage set safety valve) Function • When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve. However, the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment.

10-90
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) • When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. • If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [x/4 (D12 – D2) × pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the opposite side.

2) When stopping travel (low-pressure setting) • When the travel lever is placed at neutral, the pressure in chamber PA drops and counterbalance valve spool (13) returns to the neutral position. While the counterbalance valve spool (13) is returning to the neutral position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left, and the set load becomes smaller. Because of this, the set pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing speed. [Set pressure of safty valve]
When starting or traveling: When stopping: High-pressure setting Low-pressure setting 40.2 MPa {410 kg/cm2} 27.5 MPa {27.5 kg/cm2}

PC400/450(LC)-7

10-91

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

3) When pressure in chamber MA has become high (when rotating counterclockwise) • When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia.

If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [x/4 (D3 2 – D1 2) × pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the opposite side.

Operation of mechanism for varying set pressure 1) When starting travel (high-pressure setting) • When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (19), and opens the pilot circuit to the safety valve. The oil passes from chamber G to passage H and flows into chamber J, pushes the piston to the right, and compresses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a large drawbar pull is made available.

10-92

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL JUNCTION VALVE

TRAVEL JUNCTION VALVE
Function • This valve connects both travel circuits to each other so that the hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. • When the machine is steered, outside pilot pressure PST closes the travel junction valve to secure high steering performance. Operation When pilot pressure is turned ON • If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (14), travel junction spool (13) moves to the left stroke end and the junction circuit between port PTL (Left travel circuit) and PTR (Right travel circuit) is closed.

PC400/450(LC)-7

10-93

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL JUNCTION VALVE

When pilot pressure is turned OFF • If pilot pressure PST from the solenoid valve is 0, travel junction spool (13) is pressed by the force of spring (14) against the right side and the pass between ports PTL and PTR is open.

If the oil flow rates in both travel motors become different from each other, the oil flows through the route between port PTL, travel junction spool (13), and port PTR so that the oil flow rates will be equalized again.

10-94

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

VALVE CONTROL

VALVE CONTROL

Lever positions 1. 2. 3. 4. 5. 6. 7. Travel PPC valve Service PPC valve Service pedal L.H. travel lever R.H. travel lever R.H. PPC valve R.H. work equipment control lever 8. 9. 10. 11. 12. 13. Solenoid valve Accumulator Control valve Hydraulic pump Junction box L.H. work equipment control lever 14. L.H. PPC valve (1) Hold (2) Boom “RAISE” (3) Boom “LOWER” (4) Bucket “DUMP” (5) Bucket “CURL” (6) Hold (7) Arm “IN” (8) Arm “OUT” (9) Swing “RIGHT” (10) Swing “LEFT” (11) Neutral (12) Travel “REVERSE” (13) Travel “FORWARD”

PC400/450(LC)-7

10-95

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC SHUTTLE VALVE

TRAVEL PPC SHUTTLE VALVE
Function • If boom RAISE or arm IN are operated when the machine is traveling, the stroke of the spools for the boom and arm is controlled by the travel PPC pressure and this limits the flow of oil to the boom and arm cylinders. When the boom and arm stroke is controlled, the travel PPC pressure passes through the circuit inside the control valve to actuate the system.

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

10-96

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC SHUTTLE VALVE

PC400/450(LC)-7

10-97

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC SHUTTLE VALVE

2. When travel is operated • When the travel lever is operated to right REVERSE (or FORWARD), the right (REVESE (or FORWARD) PPC pressure pushes spool (7) to the left (or right). • Spool (7) pushes piston (3), orifice (5) closes, and stroke limit signal chamber a is shut off from the drain circuit of the travel PPC valve. • At the same time, the right REVERSE (or FORWARD) PPC pressure passes through orifice (6) in piston (4), acts on the right end face of piston (8), and pushes piston (8) to the left. • If arm IN is operated, spool (1) moves to the right, but the maximum stroke of the spool is limited by the amount of movement st2 of piston (8) and becomes st1. • If boom RAISE is operated, spool (9) tries to move to the left, but the travel PPC pressure enters stroke control signal chamber b, so the spool does not move.

10-98

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC SHUTTLE VALVE

PC400/450(LC)-7

10-99

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

WORK EQUIPMENT • SWING PPC VALVE

P T

: From self pressure reducing valve : To tank

P1 P2 P3 P4

: Left PPC: Arm OUT / Right PPC: Boom LOWER : Left PPC: Arm IN / Right PPC: Boom RAISE : Left PPC: Swing LEFT / Right PPC: Bucket CURL : Left PPC: Swing RIGHT / Right PPC: Boom LOWER

10-100

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

1. 2. 3. 4. 5. 6.

Spool Metering spring Centering spring Piston Disc Nut (For connection of lever)

7. 8. 9. 10. 11.

Joint Plate Retainer Body Filter

Unit: mm
No. Check item Standard size 12 Centering spring (For P3 and P4) Free length × OD 42.4 × 15.5 13 14 Centering spring (For P1 and P2) Metering spring 44.4 × 15.5 26.5 × 8.2 Installed length 34 34 24.9 Installed load 17.1 N {1.8 kg} 29.4 N {3.0 kg} 16.7 N {1.7 kg} Criteria Repair limit Free length — — — Installed load 13.7 N {1.4 kg} 23.5 N {2.4 kg} 13.7 N {1.4 kg} If damaged or deformed, replace spring Remedy

PC400/450(LC)-7

10-101

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

Operation 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1)

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

10-102

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

3) During fine control (when control lever is returned) • When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil.

4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D.

PC400/450(LC)-7

10-103

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

TRAVEL PPC VALVE

P T P1 P2

: From self pressure reducing valve : To tank : Left reverse : Left forward

P3 P4 P5 P6

: Right reverse : Right forward : Travel signal : Steering signal

10-104

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

1. 2. 3. 4. 5.

Plate Body Piston Collar Metering spring

6. 7. 8. 9. 10.

Centering spring Valve Damper Steering signal Steering signal valve spring

PC400/450(LC)-7

10-105

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

Unit: mm
No. Check item Standard size 1 Metering spring Free length × OD 26.5 × 8.15 2 3 Centering spring Steering signal spring 48.1 × 15.5 12.8 × 7.3 Installed length 24.7 32.5 8.5 Installed load 16.7 N {1.7 kg} 108 N {11 kg} 8.8 N {0.9 kg} Criteria Repair limit Free length — — — Installed load 13.7 N {1.4 kg} 86.3 N {8.8 kg} 7.1 N {0.72 kg} If damaged or deformed, replace spring Remedy

10-106

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

Travel signal/Steering function • • Travel signal If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5. Steering signal If the operation quantities of both levers are different from each other as in the steering operation, the higher one of the PPC output pressures on both sides is output as the steering signal. Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neutral. Accordingly, if the machine is being steered is judged by the signal of port P6.

Operation 1. While in NEUTRAL The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not output.

PC400/450(LC)-7

10-107

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

2. While travelling straight (The following drawing shows the circuit for traveling straight forward.) While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal valve is kept in neutral and the steering signal (Port P6) is not output.

10-108

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

3. When steered or pivot-turned (The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.) If the operation quantities of both levers are different from each other as in the steering operation (If the difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal. In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2. The pressure in right spring chamber (l) is P4. If (P4 – P2) × (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.

PC400/450(LC)-7

10-109

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

4. When pivot-turned (The following drawing shows the circuit for left reverse and right forward operation.) While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and outputs the steering signal (port P6).

10-110

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SERVICE PPC VALVE

SERVICE PPC VALVE
a Refer to the section WORK EQUIPMENT • SWING PPC VALVE for function of this valve. 1. 2. 3. 4. 5. 6. 7. 8. T P P1 P2 Spool Metering spring Centering spring Piston Lever Plate Retainer Body : : : : To tank From main pump Port Port

Unit: mm
No. Check item Standard size 9 Centering spring Free length × OD 33.9 × 15.3 10 Metering spring 22.7 × 8.1 Installed length 28.4 22 Installed load 124.5 N {12.7 kg} 16.7 N {1.7 kg} Criteria Repair limit Free length — — Installed load 100 N {10.2 kg} 13.7 N {1.4 kg} If damaged or deformed, replace spring Remedy

PC400/450(LC)-7

10-111

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SOLENOID VALVE

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

1. 2. 3. 4. 5. 6. 8.

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

T A1 A2 A3 A4 A5 A6

: To tank A8 : To main valve (2-stage relief : To No. 1 pump (CO valve) valve) : To main valve (Travel junc- P1 : From main pump tion valve) ACC : To accumulator : To main valve (Merge-divider valve) : To both travel motors : To swing motor : To 2-stage safety valve at boom cylinder head

10-112

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SOLENOID VALVE

1. 2. 3. 4. 5. 6.

Connector Moving core Coil Spool Block Spring

Operation WHEN SOLENOID IS TURNED OFF • Since the signal current does not flow from the controller, solenoid (3) is turned off. Accordingly, spool (4) is pressed by spring (6) against the left side. By this operation, the pass from P to A is closed and the hydraulic oil from the main pump does not flow into the actuator. At this time, the oil from the actuator is drained through ports A and T into the tank.

WHEN SOLENOID IS TURNED ON • The signal current flows from the controller to solenoid (3), and the latter is turned on. Accordingly, spool (4) is pressed against to the right side. By this operation, the hydraulic oil from the main pump flows through port P and spool (4) to port A, then flows into the actuator. At this time, port T is closed and the oil does not flow into the tank.

PC400/450(LC)-7

10-113

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PPC ACCUMULATOR

PPC ACCUMULATOR
1

2

1. 2. 3. 4. 5. 6.

Gas plug Shell Poppet Holder Bladder Oil port

3

Specifications Gas capacity: 300 cc (for PPC)
4

5

6

SBP00290

10-114

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

RETURN OIL FILTER

RETURN OIL FILTER
FOR BREAKER

1. 2. 3. 4. 5.

Drain plug Element Case Head cover Relief valve

Specifications Rated pressure : 6.9 MPa {70 kg/cm2} Flow : 200 l/min. Relief valve cracking pressure: 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2} Filter mesh size : 6 µm Filtering area : 4,570 cm2

PC400/450(LC)-7

10-115

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

BOOM HYDRAULIC DRIFT PREVENTION

BOOM HYDRAULIC DRIFT PREVENTION VALVE
Function • When the boom lever is not being operated, these valves act to prevent the oil at the boom bottom from leaking from spool (1) and prevent the boom from moving down.

Operation 1. Boom RAISE When the boom RAISE is operated, the main pressure oil acts in the left direction on ringshaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When it overcomes the force of spring (4), poppet (5) moves to the left. In addition, the main pressure oil acts in the right direction on seat diameter d3 of valve (6). When it overcomes the force of spring (4), valve (6) moves to the right. As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.

10-116

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

BOOM HYDRAULIC DRIFT PREVENTION

PC400/450(LC)-7

10-117

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

BOOM HYDRAULIC DRIFT PREVENTION

2. Boom at HOLD • When the boom is raised and the control lever is returned to the HOLD position, the oil that has flowed into the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of valve (6). • Valve (6) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. As a result, the boom is held in position.

10-118

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

BOOM HYDRAULIC DRIFT PREVENTION

PC400/450(LC)-7

10-119

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

BOOM HYDRAULIC DRIFT PREVENTION

3. Boom LOWER • When boom LOWER is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the boom flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B goes to port A and flows to the control valve.

10-120

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ARM HYDRAULIC DRIFT PREVENTION

ARM HYDRAULIC DRIFT PREVENTION VALVE
(If equipped)
Function • When the arm lever is not being operated, these valves act to prevent the oil at the arm head from leaking from spool (1) and prevent the arm from moving down.

Operation 1. Arm DUMP When the arm DUMP is operated, the main pressure oil acts in the left direction on ringshaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When it overcomes the force of spring (4), poppet (5) moves to the left. As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.

PC400/450(LC)-7

10-121

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ARM HYDRAULIC DRIFT PREVENTION

2. Arm at HOLD • When the arm DUMP is operated and the control lever is returned to the HOLD position, the oil that has flowed into the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at the head of the arm cylinder are shut off. • At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the head of the arm cylinder are shut off. • In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of valve (6). As a result, the arm is held in position.

10-122

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ARM HYDRAULIC DRIFT PREVENTION

3. Arm IN • When arm IN is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber b inside the poppet is drained through orifice c. The oil at the head end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B goes to port A and flows to the control valve.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ARM HYDRAULIC DRIFT PREVENTION

4. When abnormally high pressure is generated • If abnormally high pressure is generated in the boom cylinder bottom circuit, the hydraulic oil in port B pushes check valve (6) open, then safety valve (3) operates.

If the hydraulic drift prevention valve for the arm cylinder head circuit is installed (optional), the hydraulic oil in the boom cylinder bottom circuit or that in the arm cylinder head circuit, having higher pressure, pushes check valve (6) open, then safety valve (3) operates.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

QUICK RETURN VALVE

QUICK RETURN VALVE
Function When arm OUT is operated, this valve reduces the pressure loss of the large amount of oil returning from the cylinder bottom. Operation 1. Arm at OUT When arm OUT is operated, the pilot pressure from the PPC valve pushes pilot spool (1), and the pressure oil from chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port A, the pressure at port A and acts on ring -shaped area C (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) moves to the left and the pressure oil from port A goes to port B. From port B, the oil is drained directly to the tank.

PC400/450(LC)-7

10-125

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

QUICK RETURN VALVE

2. Arm at HOLD The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at the bottom end of the arm acts in the right direction on ring-shaped area C (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) is closed by the total of this force and the force of spring (3), so port A and port B are shut off.

10-126

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

LIFT CHECK VALVE

LIFT CHECK VALVE
Function This valve applies back pressure to the drain circuit to prevent generation of negative pressure on the hydraulic devices for the work equipment (motors, cylinders, etc.) Operation 1. While engine is stopped Any oil is not supplied from the pump to the selfpressure reducing valve and valve (1) is pressed by only the force of spring (2) toward the right and drain circuit “a” of the control valve is connected through orifice “b” of valve (1) to port T.

2. While engine is running • Output pressure PR of the self-pressure reducing valve is applied through the control valve to spring chamber “c” of the back pressure valve. • Output pressure PR applied to spring chamber “c” is applied to the left end of valve (1) (area of 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) is balanced so that the back pressure PA will be as follows. PA = {(Area of ød) × PR + Force of spring (2)} / (Area of ød1)

PC400/450(LC)-7

10-127

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE

ATTACHMENT CIRCUIT SELECTOR VALVE

1. Spool 2. Spring

: To control valve V : To hydraulic tank T ATT : To attachment ACC: To accumulator P1 : From attachment circuit selector solenoid valve TS : To hydraulic tank Unit: mm

No.

Check item Standard size

Criteria Repair limit Installed load 833 N {85.0 kg} Free length — Installed load 666 N {68.0 kg}

Remedy Replace spring if any damages or deformations are found

3

Spool return spring

Free length × OD 132.0 × 29

Installed length 114.5

10-128

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE

Function When a breaker is installed, the return oil from the breaker does not pass through the main valve, but returns directly to the hydraulic tank. When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected. Operation 1. When attachment other than breaker is installed Spool (1) is pushed fully to the left by the force of spring (2), ATT port and port V are interconnected, and ATT port and port T are shut off, so the attachment and main valve are interconnected.

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

PC400/450(LC)-7

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HOLDING VALVE

HOLDING VALVE
Downward movement prevention valve (For boom and arm)

: From control valve V : To hydraulic tank T CY : To hydraulic cylinder PI : From PPC valve PCY : Fror pressure pickup and equalizer circuits

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HOLDING VALVE

1. 2. 3. 4. 5. 6.

Pilot spool Spring (1st stage of spool) Spring (2nd stage of spool) Safety valve Check valve Spring

Unit: mm
No. Check item Standard size 7 Check valve spring Free length × OD 20.8 × 12.2 8 9 10 Spool return spring Spool return spring Spool return spring 41.1 × 9.6 41.9 × 25.8 43.2 × 25.4 Installed length 13.5 35 41 41 Installed load 12.7 N {1.3 kg} 58.8 N {6.0 kg} 78.4 N {8.0 kg} 125.4 N {12.8 kg} Criteria Repair limit Free length — — — — Installed load 9.8 N {1.0 kg} 47.0 N {4.8 kg} 62.7 N {6.4 kg} 100.4 N {10.2 kg} If damaged of deformed, replace spring Remedy

PC400/450(LC)-7

10-131

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HOLDING VALVE

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

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HOLDING VALVE

2. When oil is sent from main valve to cylinder [When piping is normal] • If pressure Pa of the oil sent from the main valve to chamber “a” is higher than the total of pressure Pb in chamber “b” connected to the work equipment cylinder and the force of spring (6), check valve (5) opens and chambers and the oil flows from the main valve to the work equipment cylinder. [When piping bursts] • If piping A between the main valve and the work equipment cylinder bursts, the oil in chamber “a” flows out through the burst part and pressure Pa in chamber “a” lowers. • If Pa lowers below the total of pressure Pb in chamber “b” and the force of spring (6), check valve (5) closes and chambers “a” and “b” are shut off from each other. Accordingly, pressure Pb in the cylinder is held and the work equipment does not fall suddenly.

PC400/450(LC)-7

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HOLDING VALVE

3. When oil is returned from work equipment cylinder to main valve [When piping is normal] • The work equipment cylinder holding pressure is applied to chamber “b” and check valve (5) closes. • The pilot pressure from the PPC valve is applied to port Pi. If it is higher than the force of spring (2) (area of ød), spool (1) moves to the right standby position (1st-stage stroke). • At this time, chambers “a” and “b” are not connected to each other. • If the pilot pressure rises higher than the force of spring (3) (area of ød), spool (1) moves further to the right and chambers “a” and “b” connected to each other (2nd-stage stroke). • Accordingly, the oil is returned from the work equipment cylinder to the main valve.

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

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-136

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC CYLINDER

Unit: mm
No. Check item Cylinder Clearance between piston rod and bushing Boom Arm Bucket Boom Arm Bucket Boom Arm Bucket Standard size 110 120 100 110 110 100 100 110 100 Criteria Tolerance Shaft –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 Hole +0.261 +0.047 +0.263 +0.048 +0.257 +0.047 +0.169 +0.100 +0.169 +0.100 +0.187 +0.097 +0.190 +0.070 +0.195 +0.099 +0.187 +0.097 Standard clearance 0.083 – 0.351 0.084 – 0.353 0.083 – 0.347 0.136 – 0.259 0.136 – 0.259 0.133 – 0.277 0.106 – 0.280 0.135 – 0.285 0.133 – 0.277 Clearance limit 0.412 0.412 0.447 — — — — — — Replace bushing Remedy

1

2

Clearance between piston rod support pin and bushing

3

Clearance between cylinder bottom support pin and bushing

Replace pin or bushing

PC400/450(LC)-7

10-137

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

WORK EQUIPMENT

10-138

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm
No. Check item Standard size 120 Criteria Tolerance Shaft –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 –0.036 –0.090 Hole +0.173 +0.101 +0.180 +0.112 +0.172 +0.081 +0.138 +0.077 +0.172 +0.081 +0.190 +0.097 0.5 – 1.0 2.0 Standard clearance 0.137 – 0.263 0.148 – 0.270 0.117 – 0.262 0.113 – 0.228 0.117 – 0.262 0.133 – 0.280 Clearance limit 1.0 Remedy

1

Clearance between connecting pin and bushing of revolving frame and boom Clearance between connecting pin and bushing of boom and arm Clearance between connecting pin and bushing of arm and link Clearance between connecting pin and bushing of arm and bucket Clearance between connecting pin and bushing of link and bucket Clearance between connecting pin and bushing of link and link Bucket clearance (a) Bucket clearance (b)

2

120

1.0

3

100

1.0

Replace

4

100

1.0

5

100

1.0

6 7 8

100

1.0

Adjust shims

PC400/450(LC)-7

10-139

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

1. Dimension of arm

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm
Model PC400-7 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Arm as individual part When pressfitting bushing Min. 19 Max. 3,140 3,140 PC450-7

ø110 +0.1 / +0

–0.036 –0.090

ø110 +0.1 / +0

–0.036 –0.090

ø129.3 +1.5 / 126 ± 1.2 +0 ø355 +0.5 / 351 –0.3 +0 –0.8 ø120 +0.1 / +0
–0.036 –0.090

ø129.3 +1.5 / 126 ± 1.2 +0 ø355 +0.5 / 351 –0.3 +0 –0.8 ø120 +0.1 / +0
–0.036 –0.090

514.8 195 1,038 3,375 2,977.5 502 720 719 537.1 1,850

570.6 208.2 1,132.2 3,375 2,975.1 506.8 720 719 537.1 1,817

ø100 +0.1 / +0

–0.036 –0.090

ø100 +0.1 / +0

–0.036 –0.090

ø371 +1 / 370 ± 0.5 +0 ø100 +0.1 / +0
–0 –0.036 –0.090

ø371 +1 / 370 ± 0.5 +0 ø100 +0.1 / +0
–0 –0.036 –0.090

355 –0.5 370 1,870

355 –0.5 370 1,870

18

PC400/450(LC)-7

10-141

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

2. Dimension of bucket

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm
Model PC400-7 No. 1 2 3 4 5 6 7 8 A 9 B C 10 11 12 13 14 15 16 17 18 19 20 21 22 A B A B 534.1 ± 0.5 56.3 ± 0.5 96° 1’ 537.1 1,839 190 — 62° 1’ 534.1 ± 0.5 56.3 ± 0.5 94° 14’ 537.1 1,806 198 — 46° 1’ PC450-7

ø140.1 +0.1 +0 ø130 +0.063 –0 ø100 +0.1 +0
371 +1 +0 57 72 144 562.5 +0.5 –2.5

ø140.1 +0.1 +0 ø130 +0.063 –0 ø100 +0.1 +0
371 +1 +0 58 72 144 562.5 +0.5 –2.5

ø26 ø165

ø26 ø165

ø230
146.1 137.6 R115 R85 410 ± 1 64

ø230
135.5 142.0 R115 R85 410 ± 1 64

PC400/450(LC)-7

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AIR CONDITIONER

AIR CONDITIONER
AIR CONDITIONER PIPING

1. 2. 3. 4. 5. 6. 7. 8.

Hot water pick-up piping Receiver tank Hot water return piping Condenser Air conditioner compressor Refrigerant piping Air conditioner unit Duct

A. Fresh air B. Recirculated air C. Hot air/cold air

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

ENGINE CONTROL
1. Operation of system Starting engine • When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.

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

Stopping engine • When the engine controller detects that the starting switch is at the OFF position, it cuts the signal to the supply pump drive solenoid to stop the engine.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

2. Components of system Fuel control dial 1. 2. 3. 4. 5. 6. Knob Dial Spring Ball Potentiometer Connector

Function • The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine controller. The hatched area in the graph on the right is the abnormality detection area and the engine speed is set at low idling.

10-146

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

3. Engine controller

Input and output signals

PC400/450(LC)-7

10-147

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

CN1 [CN-E11] Pin No. Signal name Input/ Output

CN2 [CN-E12] Pin No. CN2-1 GND Input Input Output CN2-2 NC CN2-3 NC CN2-4 RS232C_1RX CN2-5 NC CN2-6 NC CN2-7 NC CN2-8 NC CN2-9 Sensor 5V power supply 2 CN2-10 Fuel control dial CN2-11 S_NET_SHIELD GND CN2-12 CAN_SHIELD CN2-13 NC CN2-14 RS232C_1TX CN2-15 G_SHIELD (GND) CN2-16 Ne_SHIELD (GND) CN2-17 Fuel temperature sensor CN2-18 NC CN2-19 Sensor 5V power supply 1 CN2-20 Boost pressure sensor CN2-21 S_NET (+) CN2-22 CAN0_L CN2-23 NC CN2-24 FWE_switch CN2-25 G pulse (–) CN2-26 Ne pulse (–) CN2-27 Coolant temperature sensor (High) CN2-28 NC CN2-29 Analog GND CN2-30 NC CN2-31 S_NET (+) CN2-32 CAN0_H CN2-33 NC CN2-34 GND (232C_GND) CN2-35 G pulse (+) CN2-36 Ne pulse (+) CN2-37 Coolant temperature sensor (Low) CN2-38 NC CN2-39 Analog GND CN2-40 Common rail pressure sensor Input Input Input Input Input Input Input Input Input Input Input Input/ Output Input/ Output Input Input Signal name Input/ Output

CN1-1 POWER (+24V constant) CN1-2 POWER (+24V constant) CN1-3 Model selection 1 CN1-4 GND CN1-5 NC CN1-6 NC CN1-7 GND CN1-8 GND CN1-9 NC CN1-10 GND CN1-11 NC CN1-12 NC CN1-13 Key switch (ACC) CN1-14 NC CN1-15 Engine oil pressure switch (For high pressure)

Input Input Output Input

Input Input Output Input Input Input Input Input Output Input Input Input Input Input Output

Output Output

CN1-16 Memory clear CN1-17 Model selection 3 CN1-18 NC CN1-19 Key switch (ACC) CN1-20 Starting switch (C) Engine oil pressure switch (For low CN1-21 pressure) CN1-22 Auto deceleration signal CN1-23 Model selection 2 CN1-24 NC

Input Input Output Input Input/ Output Input/ Output

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

CN3 [CN-E13] Pin No. Signal name Input/ Output

CN3-1 Power supply for power CN3-2 Power supply for power CN3-3 NC CN3-4 NC CN3-5 Injector #3 (+) CN3-6 Injector #2 (+) CN3-7 NC CN3-8 Output mode selection 1 (Test mode) CN3-9 Lever neutral flag (Test mode) CN3-10 Engine rotation pulse output CN3-11 Power GND CN3-12 Supply pump 1 (+) CN3-13 Supply pump 2 (+) CN3-14 Injector #1 (+) CN3-15 Injector #3 (–) CN3-16 Injector #2 (–) CN3-17 NC CN3-18 Output mode selection 2 (Test mode) CN3-19 NC CN3-20 Q command output CN3-21 Power supply for power CN3-22 Supply pump 1 (–) CN3-23 Supply pump 2 (–) CN3-24 Injector #1 (–) CN3-25 Injector #6 (+) CN3-26 Injector #4 (+) CN3-27 NC CN3-28 Auto deceleration flag (Test mode) CN3-29 NC CN3-30 GND CN3-31 Power GND CN3-32 Power GND CN3-33 Injector #5 (–) CN3-34 Injector #5 (+) CN3-35 Injector #6 (–) CN3-36 Injector #4 (–) CN3-37 NC CN3-38 Auto deceleration control (Test mode) CN3-39 NC CN3-40 GND Output Output Output Output Output Input Input Output Output Input Input Input Output Input Output Output Output Output Output Input Input Input Output Output Output Output Output Output Output Input Input

PC400/450(LC)-7

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

ELECTRONIC CONTROL SYSTEM
CONTROL FUNCTIONS

a For the self-diagnosis function, see “TROUBLE SHOOTING”

PC400/450(LC)-7

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

TOTAL SYSTEM DIAGRAM

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(1)

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

PC400/450(LC)-7

10-153

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1. Engine and Pump control function

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

Function • The operator can set the work mode switch on the monitor panel to mode A, E, or B (or L) and select proper engine torque and pump absorption torque according to the type of work. • The engine throttle and pump controller detects the speed of the engine governor set with the fuel control dial and the actual engine speed and controls them so that the pump will absorb all the torque at each output point of the engine, according to the pump absorption torque set in each mode. : The L mode is on the multi-monitor specification machine only.

PC400/450(LC)-7

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1) Control method in each mode Mode A, Mode E • Matching point in mode A: Rated speed
Mode A Mode E 246.3 kW/1,850 rpm {331 HP/1,850 rpm} 213.3. kW/1,720 rpm {286 HP/1,720 rpm}

If the pump load increases and the pressure rises, the engine speed lowers. At this time, the controller lowers the pump discharge so that the engine speed will be near the full output point. If the pressure lowers, the controller increases the pump discharge so that the engine speed will be near the full output point. By repeating these operations, the controller constantly uses the engine near the full output point.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

Mode B / (Mode
Mode Partial output point

L)
Mode B 82% Mode 61% L

Mode B Mode L

194.9 kW/1,730 rpm {261 HP / 1,730 rpm} 150.8 kW/1,250 rpm {202 HP / 1,250 rpm}

At this time, the controller keeps the pump absorption torque along the constant horsepower curve and lower the engine horsepower by the composite control of the engine and pump. By this method, the engine is used in the low fuel consumption area. : The L mode is on the multi-monitor specification machine only.

PC400/450(LC)-7

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ELECTRONIC CONTROL SYSTEM

2) Function to control pump during travel • When the travel is operated in A operation, or E or B working mode, the working mode stays as it is, and the pump absorption torque and engine speed rise to A travel mode.

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

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

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

2. Pump/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.

PC400/450(LC)-7

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1) LS control function • The change point (LS set differential pressure) of the pump discharge in the LS valve is changed by changing the output pressure from the LSEPC valve to the LS valve according to the operating condition of the actuator. • By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved. 2) Cut-off function • When the cut-off function is turned on, the PCEPC current is increased to near the maximum value. • By this operation, the flow rate in the relief state is lowered to reduce fuel consumption. • Operating condition for turning on cut-off function
Condition • The average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm2} and the one-touch power maximizing function is not turned on

The cut-off function does not work, however, while the machine is travelling in mode A or the arm crane operation width swing lock switch is turned on. 1) 2-stage relief function • The relief pressure in the normal work is 34.8 MPa {355 kg/cm2}. If the 2-stage relief function is turned on, however, the relief pressure rises to about 37.2 MPa {380 kg/cm2}. By this operation, the hydraulic force is increased further. • Operating condition for turning on 2-stage relief function
Relief pressure 34.8 MPa {355 kg/cm2} 37.2 MPa {380 kg/cm2}

Condition • • • • • • Condition During travel When swing lock switch is turned on When boom is lowered When one-touch power maximizing function is turned on When L mode is operated

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

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ELECTRONIC CONTROL SYSTEM

3. One-touch power maximizing/machine push-up function

Function • • Power can be increased for a certain time by operating the left knob switch. When the machine push-up switch is operated, the boom pushing force is increased.

PC400/450(LC)-7

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ELECTRONIC CONTROL SYSTEM

1) One-touch power maximizing function • When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 7% to increase the digging force. • If the left knob switch is turned on in working mode “A” or “E”, each function is set automatically as shown below.

Working mode A, E

Engine/Pump control Matching at rated output point

2-stage relief function 34.8 MPa {355 kg/cm2} 37.2 MPa {380 kg/cm2}

Operation time Automatically reset at 8.5 sec

Software cut-off function Cancel

2) Machine push-up function • Operate switch (1) to increase the boom pushing force when digging ditches or holes on hard ground.
2-stage safety valve function Setting of safety valve at boom cylinder 14.7 MPa {150 kg/cm2} Setting of safety valve at boom cylinder 28.4 MPa {290 kg/cm2}

Switch

OFF

ON

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ELECTRONIC CONTROL SYSTEM

4. Auto-deceleration function

Function • If all the control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is automatically lowered to the medium level to reduce fuel consumption and noise. If any lever is operated, the engine speed rises instantly to the set level.

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ELECTRONIC CONTROL SYSTEM

Operation WHEN CONTROL LEVERS ARE SET IN NEUTRAL • If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,300 rpm) for 4 seconds, the engine speed lowers to the second deceleration level (about 1,300 rpm) and keeps at that level until any lever is operated again.

WHEN ANY CONTROL LEVER IS OPERATED • If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly to the level set with the fuel control dial.

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5. Auto-warm-up/Overheat prevention function

Function • After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the engine. If the coolant temperature rises too high during work, the pump load is reduced to prevent overheating.

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1) Auto-warm-up function • After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the engine.
Operating condition (All) Coolant temperature: Below 30°C. Engine speed: Max. 1,200 rpm Operated Engine speed: Max. 1,200 rpm

Resetting condition (Any one) Auto Manual Coolant temperature: Above 30°C Auto-warm-up operation time: Min. 10 minutes Fuel control dial: Kept at 70% of full level for 3 sec. or longer

Reset

Engine speed: Any level

2) Overheat prevention function • If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to prevent overheating.

This function is turned on when the coolant temperature rises above 95°C.

Operating condition

Operation/Remedy Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds

Resetting condition Coolant temperature: Below 105°C Fuel control dial: Return to low idle position once. • Under above condition, controller is set to condition before operation of function. (Manual reset) Resetting condition Coolant temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition Coolant temperature: Below 100°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition Coolant temperature: Below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)

Coolant temperature: Above 105°C

Operating condition Coolant temperature: Above 102°C

Operation/Remedy Work mode: Mode A, E, OR B Engine speed: Keep as is. Monitor alarm lamp: Lights up. Lower pump discharge. Operation/Remedy Work mode: Mode A Engine speed: Keep as is. Lower pump discharge.

Operating condition Coolant temperature: Above 100°C

Operating condition Coolant temperature: Above 95°C

Operation/Remedy Work mode: Travel Engine speed: Keep as is. Lower travel speed.

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6. Swing control function

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

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1) Swing lock and swing holding brake functions • The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake function (automatic) is used to prevent hydraulic drift after the machine stops swinging. • Swing lock switch and swing lock/holding brake
Lock switch Lock lamp

2) Quick hydraulic oil warm-up function when swing lock switch is turned on • If swing lock switch (4) is turned on, the pump-cut function is cancelled and the relief pressure rises from 34.8 MPa {355 kg/cm2} to 37.2 MPa {380 kg/cm2}. If the work equipment is relieved under this condition, the hydraulic oil temperature rises quickly and the warm-up time can be shortened.

Function

Operation If swing lever is set in neutral, swing brake operates in about 7 sec. If swing lever is operated, brake is released and machine can swing freely. Swing lock operates and machine is locked from swinging. Even if swing lever is operated, swing lock is not reset and machine does not swing.

OFF

OFF

Swing holding brake

ON

ON

Swing lock

: Operation of swing holding brake release switch

If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing, the swing lock can be reset with the swing holding brake release switch.
Swing holding brake release switch Swing lock switch Swing brake ON (When control has trouble) ON OFF OFF (When controller is normal) ON OFF Swing holding brake is turned on

Swing Swing Swing lock is lock is lock is turned on canceled turned on

a 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. a If the swing lock is reset, swinging is stopped by only the hydraulic brake of the safety valve. Accordingly, if swinging is stopped on a slope, the upper structure may drift hydraulically.

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7. Travel control function

Function • The pumps are controlled and the travel speed is changed manually or automatically, to secure proper travel performance matched to the type of work and jobsite during travel.

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1) Pump control function during travel • If the machine travels in a work mode other than mode A, the work mode and the engine speed are kept as they are and the pump absorption torque is increased. a For details, see ENGINE/PUMP COMPOSITE CONTROL FUNCTION. 1. Travel speed change function i) Manual change with travel speed switch If the travel speed switch is changed between Lo, ( Mi), and Hi, the governor/ pump controller controls the pump capacity and motor capacity at each gear speed as shown at right to change the travel speed.
Travel speed switch Pump capacity (%) Motor capacity Travel speed (km/h) Lo (Low speed) 90 Max. 3.2 ( Mi) (Middle Speed) 82 Max. 4.5 Hi (High speed) 100 Min. 5.5

ii)

Automatic change according to engine speed If the fuel control dial is used to set the engine speed to less than 1,200 rpm: • When traveling in Lo, it will not switch even when set to Hi or Mi. • When traveling in Hi or Mi, it will switch automatically to Lo. iii) Automatic changes according to pump discharge pressure When traveling with the travel speed switch set to Hi or Mi, it the load increases, such as when traveling uphill, and the travel pressure goes above 3.23 MPa {330 kg/cm2} for more than 0.5 sec, the travel motor capacity will automatically change to low speed (equivalent to Lo). (The travel speed switch will stay at Hi or Mi.) After continuing to travel in Lo, if the load increases, such as when traveling on level ground or traveling downhill, and the travel pressure goes below 18.6 MPa {190 kg/cm2} for more than 0.5 sec, the travel motor capacity will automatically change and will return to Hi or Mi. : The “Mi” mode is on the multi-monitor specification machine only.

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8. ATT flow control, circuit selector function (if equipment)

Function This function is available only with the ATT specification. The function acts as follows according to the flow command and working mode from the monitor. 1) It throttles the ATT PPC pressure and controls the flow when the pedal is fully depressed. 2) In mode B and the other modes, it switches to ATT single acting (B) or double acting (other modes). : The ATT flow control adjustment function is on the multi-monitor specification machine only.

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9. System component parts
1) Engine revolution sensor

1. 2. 3. 4.

Sensor Locknut Wiring harness Connector

Function • The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine throttle and pump controller. A magnet is used to sense the gear teeth. Each time a gear tooth passes in front of the magnet, a current is generated.

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2) PPC oil pressure switch

1. Plug 2. Switch 3. Connector Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) Pressure: 0.3 ± 0.5 MPa {3.0 ± 0.5 kg/cm2} Function • The junction block has 7 pressure switches, which check the operating condition of each actuator by the PPC pressure and transmit it to the engine throttle and pump controller.

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3) Pump pressure sensor

1. Sensor 2. Connector Function • The pump pressure sensor is installed to the inlet circuit of the control valve. It converts the pump discharge pressure into a voltage and transmits it to the engine throttle and pump controller.

Operation • • The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance, then converts the change of the resistance into a voltage and transmits it to the amplifier (voltage amplifier). The amplifier, amplifies the received voltage and transmits it to the engine throttle and pump controller. Relationship between pressure P (MPa {kg/cm2}) and output voltage (V) is as follows. V = 0.08 [0.008] × P + 0.5

• •

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Pump controller

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Input and output signals
CN-1 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 NC R pump pressure sensor NC NC NC NC NC F boom pressure sensor NC Signal GND Knob SW NC Buchet CURL PPC pressure sensor NC NC NC Starting switch (Terminal C) NC Arm IN PPC pressure sensor NC NC POT_PWR Starting switch (terminal ACC) NC Output Input Input Input Input Signal name Input/ Output CN-2 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 NC Swing emergency switch NC 232C_RxD NC NC Model selection 4 Attachment circuit selector signal NC NC NC CAN shield Model selection 5 232C_TxD NC Travel steering signal pressure SW Model selection 3 NC Auto deceleration signal NC S_NET CAN0_L NC FWE_SW NC NC Model selection 2 NC GND (pulse GND) NC GND (S_NET GND) CAN0_H NC GND (232C GND) Service valve pressure switch NC Model selection switch 1 Swing lock switch GND (pulse GND) Engine speed sensor Input Input Input Input Input/ output Input Input/ output Input/ output Input Output Input Input Output Input Input Input Signal name Input/ Output

Input Output

Input Input Input Input Input

Input

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CN-3 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name VB (controller power) VIS (solenoid power) SOL_COM (solenoid common gnd) Battery relay drive NC LS-EPC Travel junction SOL NC NC Boom RAISE pressure SW VB (controller power) VIS (solenoid power) SOL_COM (solenoid common gnd) KEY_SIG NC PC-EPC Pump merge/divider solenoid Heater relay drive Bucket DUMP pressure switch Boom LOWER pressure switch GND (controller GND) NC SOL_COM (solenoid common gnd) KEY_SIG NC Service flow adjustment EPC (1) Travel Hi/Lo selector solenoid 2-stage relief solenoid Swing pressure switch Arm IN pressure switch NC GND (controller GND) GND (controller GND) NC NC NC Swing parking brake solenoid NC Travel pressure switch Arm OUT pressure switch Input/ Output Input Input Output Output Output Input Input Input Input Input Input Output Output Output Input Input Input Input Input Output Output Output Input Input Input Input

Output Input Input

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MONITOR SYSTEM

MONITOR SYSTEM

The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)

The monitor panel also has various mode selector switches and functions to operate the machine control system.

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1. Monitor panel

Outline • The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.

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Input and output signals
CN-1 Pin Signal name No. 1 Key ON 2 Key ON 3 Washer motor output 4 Starting signal 5 Limit switch (W) 6 GND 7 GND 8 VB + 9 Wiper motor (+) 10 Wiper motor (-) 11 Buzzer ON signal 12 Limit switch (P) Input/ output Input Input Output Input Input CN3 Pin No. 1 2 3 4 5 6 7 8 Signal name NC NC NC NC NC NC RS230C CTS RS230C RXD Input/ output Input Input Input Input Input Input Input Input Input/ Output Input/ Output Input Input Input Input Input

Input Output Output Input Input

9 RS230C RXD 10 RS230C RXD 11 BOOTSW 12 NC 13 GND

CN-2 Pin Signal name No. 1 Engine coolant temperature 2 Fuel level 3 Radiator coolant level 4 (Hydraulic oil level) 5 Air cleaner clogging 6 NC 7 Engine oil pressure 8 Engine oil level 9 N/W signal 10 N/W signal 11 12 13 14 15 16 17 18 19 20 Battery charge Hydraulic oil temperature (analog) GND (for analog signal) Buzzer drive Limit SW (window) Buzzer cancel Swing lock Preheat Light switch N/W GND

Input/ output Input Input Input Input Input Input Input Input Input/ Output Input/ Output Input Input Input Input Input Input Input Input

14 CAN (SHIELD) 15 CAN (+) 16 CAN (-)

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MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Wiper motor Preheating monitor Swing lock monitor Engine coolant temperature monitor Hydraulic oil temperature gauge Engine coolant temperature gauge Working mode monitor Service monitor Travel speed monitor Fuel gauge

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Fuel level monitor Hydraulic oil temperature monitor Power max. monitor Auto-deceleration monitor Radiator coolant level caution Battery charge caution Engine oil pressure caution Engine oil level caution Air cleaner clogging Maintenance time warning caution

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MONITOR SYSTEM

MONITOR ITEMS AND DISPLAY
Symbol Display item Display method

Swing lock switch OFF Swing lock ON OFF ON

Swing holding brake release switch OFF OFF ON ON

Swing lock monitor OFF ON Flashes ON

Continuous set time Preheating Up to 30 sec. From 30 sec. to 40 sec. More than 40 sec.

Preheating monitor status ON Flashes OFF

Power Max. switch status Power Max Being pressed Not being pressed

Power Max. monitor status Lights up but goes out after approx. 9 sec when kept pressed Flashes

Engine coolant temperature Hydraulic oil temperature Fuel level See gauge display on the next page

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Gauge

Range A1 A2

Temperature, volume 105 102 100 80 60 30 105 102 100 80 40 20 467 381 295 147.5 114 80.5

Indicator Red Red Green Green Green White Red Red Green Green Green White Green Green Green Green Green Red

Buzzer sound

Engine coolant temperature (°C)

A3 A4 A5 A6 B1 B2

Hydraulic oil temperature (°C)

B3 B4 B5 B6 C1 C2

Fuel level (l)

C3 C4 C5 C6

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MONITOR SYSTEM

Checks before starting (caution lamps all light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed.
Check before starting item When engine is stopped When engine is running When abnormal, lights up and buzzer sounds

Symbol

Display item

Engine oil pressure

q

Battery charge

q

Lights up when abnormal

Radiator coolant level

q

Lights up when abnormal

When abnormal, lights up and buzzer sounds

Engine oil level

q

Lights up when abnormal

Air cleaner clogging

q

Lights up when abnormal

Maintenance

Lights up when there is a warning. Lights up for only 30 sec. after key is turned ON, then goes out.

The problems that have occurred are displayed in order from the left. When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed.
Condition of hydraulic oil Low temperature (below B6 or equivalent) Normal (B6 – B2) High temperature (below B2) Color of symbol Black on white background No display White on red background

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Display category

Symbol

Display item

Display range

Display method

Wiper

ON

INT

OFF

Displays set condition

Working mode

Displays set mode

Monitor

Travel speed

Displays set speed

Auto-deceleration

ON

OFF

Displays actuation status

Service meter

Service meter indicator

When service meter is working

Lights up when service meter is working

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MONITOR SYSTEM

SWITCHES

1. 2. 3. 4. 5. 6. 7. 8. 9.

Selector switch Selector switch Display brightness, contrast adjustment switch Control switch Window washer switch Wiper switch Maintenance switch Travel speed selector switch Auto-deceleration switch

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Working mode selector switch The condition of the machine changes according to the switch that is pressed (A, E, L, B). It is possible to check the condition on the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right. Selector switch This is used when making detailed settings in each working mode. (For details, see ATTACHMENT FLOW CONTROL FUNCTION for modes A and E.) Maintenance switch Check the condition of the maintenance items. (For details, see MAINTENANCE FUNCTION.) Auto-deceleration switch Each time the auto-deceleration switch is pressed, the auto-deceleration function is switched ON/OFF. Use the auto-deceleration monitor display to check the present condition. When the working mode switch is operated to switch the working mode, it is automatically set to ON. Travel speed selector switch Each time the travel speed selector switch is pressed, the travel speed changes. Lo o Hi o Lo …… Use the travel speed monitor display to check the present condition. The relationship between the set speed and the monitor display in the table on the right. Wiper switch Each time the wiper switch is pressed, the wiper setting changes OFF o INT o ON o OFF o …… Use the wiper monitor display to check the present condition. The relationship between the wiper setting and the monitor display is as shown in the table on the right.

Switch that is pressed [A] [E] [L] [B]

Display A E L B

Working mode status after setting A mode (default) E mode Heavy-lift mode Swing priority mode

Display Crawler symbol + Lo Crawler symbol + Mi Crawler symbol + Hi

Setting Low speed (default) Medium speed High speed

Display None Wiper symbol + INT Wiper symbol + ON

Setting OFF INT ON

Wiper actuation status Stowing stopped or now stowing Intermittent actuation Continuous actuation

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Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts. Control switch This is used for control when using the maintenance function or select function. (For details, see each function.) Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For details, see each function.)

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SELECT MODE FUNCTION • This is used when setting the flow in each working mode. It is possible to make the setting when genuine attachment piping is installed and the initial value setting function on the service menu has been used to set to ATTACHMENT INSTALLED. It is possible to check on the working mode monitor if this function can be set.
Working mode A mode E mode B mode Monitor display [A] + crusher symbol [E] + crusher symbol [B] + flow symbol

MEHOD OF USE a Carry out the setting on the normal screen 1. A mode, E mode 1) Press select switch (1) on the monitor to move to the adjustment screen. 2) Press control switch (2) to select the flow level.
Control switch Actuation Flow level bar graph extends to the right

Flow level bar graph retracts to the left

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

Flow level 8 7 6 5 4 3 2 1

Flow (L/min.) 530 430 370 300 230 165 100 30

Remarks Default

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2. B mode 1) Press select switch (1) on the monitor to move to the screen for selecting the 3-stage flow level. 2) Press control switch (2), or input [01] – [03] with the numeral 10-key pad to choose one on the three flow levels.

No. 01

10-key pad operation

02

03

3) After completing the level selection, press input confirmation switch (3). The selected flow level is selected. a Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the operator screen. This function can be used to return to the previously set flow. 4) After the flow level is confirmed, the screen changes to the screen shown in the diagram on the right. With this screen, it is possible to make fine adjustment to the flow. 5) Press control switch (2) and select the flow level.
Control switch Actuation Flow level bar graph extends to the right

No. 01 02 03

Flow level (L/min.) 230 190 150

Remarks Default

Flow level bar graph retracts to the left

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MONITOR SYSTEM

6) After completing the level selection, press input confirmation switch (3). The selected flow level is confirmed and the screen moves to the operator screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. a Before the input confirmation switch is pressed, the flow level is not confirmed, se press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right. 7) Check the set value with the working mode monitor. The relationship between the display level and the set value is as shown in the table on the right, and it is possible to check the level of the flow that can be set.

Flow level 7 6 5 4 3 2 1

When flow is 140 l/ min. 200 180 160 140 120 100 80

When flow is 220 l/ min. 280 260 240 220 200 180 160

When flow is 300 l/ min. 360 340 320 300 280 260 240

Remarks

Default

Display level 8 7 6 5 4 3 2 1

Set value (l/min.) 220 or 360 200 or 340 180 or 320 160 or 300 140 or 280 120 or 260 100 or 240 80

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MAINTENANCE FUNCTION
When the maintenance time for replacement, inspection, or filling has approached for the 10 maintenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the starting switch is turned ON to remind the operator to perform lubrication maintenance. a Maintenance items
No. 01 02 03 04 05 06 07 08 09 10 Item Engine oil Engine oil filter Fuel filter Hydraulic filter Hydraulic tank breather Corrosion resistor Damper case oil Final case oil Machinery case oil Hydraulic oil Replacement interval (hours) 500 500 500 1000 500 1000 1000 2000 1000 5000

a The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the ramaining time. The relationship is as shown in the table below.
Display None Condition Remaining time for maintenance for all items is more than 30 hours There is one or more items with less than 30 hours remaining time for maintenance There is one or more items with less than 0 hours remaining time for maintenance

Notice display (black symbol displayed on yellow background) Warning display (wiper symbol displayed on red background)

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METHOD OF CHECKING STATUS MAINTENANCE ITEMS
a Operate as follows when on the operator screen. 1. Press maintenance switch (1) and switch to the maintenance list display screen. a The maintenance items are displayed as symbols on the screen. 2. Press control switch (2), or use the 10-key pad to input the number (01 – 10) of the maintenance item to select the item. a The cursor moves and the item is highlighted. a The display method is the same as described on the previous page (relationship between remaining time and caution display). If the remaining time is less than 30 hours, the item is displayed in yellow, and if it is less than 0 hours, it is displayed in red.

MAINTENANCE OPERATION
1. After completing the selection, press input confirmation switch (3). The screen will change to the maintenance reset screen. 2. Use the maintenance reset screen to check the content, and if there is any problem, press input confirmation switch (3) to move to the check screen. If the wrong item is selected, press return switch (4) to return to the maintenance list screen. 3. Check the content on the check screen, and if there is no problem, press input confirmation switch (3) to reset the maintenance time. After the reset is completed, the screen returns to the maintenance list display screen. To check the remaining time, or if the wrong item is selected, press return switch (4) to return to the maintenance list screen. a The check screen shows the symbol for the maintenance item and the set time in large letters. a The background color of the symbol for the item where the maintenance item was reset is the same as the background of the screen, so it is possible to check that it has been reset.

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BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION
This function is used to adjust the brightness and contrast of the display.

ADJUSTMENT METHOD
a Operate as follows when on the operator screen. 1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen. a Relationship between menu symbol and content.
No. 01 02 Symbol Return mark Content Return Contrast

03

Brightness

2. Press control switch (2), or use the 10-key pad to input the number (00 – 02) to select either contrast or brightness. After completing the selection, press input confirmation switch (3) and return to the adjustment screen. Then press return switch (4) or use the 10-key pas to set to [00] and press input confirmation switch (3) to return to the normal screen. 3. Press control switch (2) and adjust the brightness and contrast as desired.
Control switch Actuation Flow level bar graph extends to the right

Flow level bar graph retracts to the left

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SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF position, keep return switch (1) and control switch (2) of the monitor pressed at the same time, and the service meter is shown on the display. This display is shown only while the two switches are being pressed. When the switches are released, the display goes out. Note that it takes 3 – 5 seconds after the switches are pressed for the service meter display to appear.

DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the normal screen, if monitor return switch (1) and working mode (A) switch are kept pressed at the same time, all the LCD display will light up and the whole screen will become white, so the display can be checked. If any part of the display is black, the LCD is broken.

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MONITOR SYSTEM

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 display appears on the operator screen. On the operator screen, the user code is displayed on the portion for the hydraulic oil temperature gauge.

If more than one user code is generated at the same time, the user codes are displayed in turn for 2 seconds each to display all the user codes.

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MONITOR SYSTEM

While the user code is being displayed, if the input confirmation switch is pressed, the service code and failure code can be displayed.

If there is more than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed. Even i f service codes/f ailure codes have occurred, if they did not cause the user code to be displayed, this function does not display them.

If the telephone number has been set using the telephone number input on the service menu, it is possible to switch on the service code/failure code and display the telephone symbol and telephone number. For details of inputting and setting the telephone number, see SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING AND ADJUSTING section.

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7-SEGMENT MONITOR SYSTEM

7-SEGMENT MONITOR SYSTEM

SJP08775 OR 08931

The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)

The monitor panel also has various mode selector switches and functions to operate the machine control system.

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PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

1. Monitor panel

OUTLINE • The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode). The switches are flat sheet switches.

INPUT AND OUTPUT SIGNALS CN-P01
Pin No. 1 2 3 4 5 6 7 8 9 Signal name Key switch (Battery) Key switch (Battery) Washer motor output Key switch (Terminal C) Wiper contact W GND GND VB + (24 V) Wiper motor (+)

CN-P02
Pin No. 1 2 3 4 5 6 7 8 9 Fuel Radiator water level NC Air cleaner clogging sensor NC Engine oil pressure sensor Engine oil level sensor Network signal Signal name Engine water temperature

10 Wiper motor (–) 11 (Buzzer ON signal input) 12 Wiper contact P

10 Network signal 11 Charge level 12 NC 13 GND (For analog signal) 14 NC 15 Wind limit switch 16 Buzzer cancel 17 Swing lock 18 Preheating 19 Limit switch 20 Network (GND)

PC400/450(LC)-7

10-197-2
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Display section of monitor

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Service meter display Coolant temperature gauge Coolant temperature caution Digital meter display (Service code and user code are displayed when trouble occurs Fuel level caution Fuel level gauge Engine oil level caution lamp Preheating pilot lamp Swing holding brake pilot lamp Oil maintenance pilot lamp Battery charge caution lamp Air cleaner clogging caution lamp Engine oil pressure caution lamp

10-197-3
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PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Monitored items and display Symbol Displayed item Display range
Max. 1,500 rpm Max. 0.05 MPa {0.5 kg/cm²} Min. 1,500 rpm Max. 0.15 MPa {1.5 kg/cm²}

When engine is stopped

While engine is running

Engine oil pressure

Lights when normal. (Goes off when engine is started.)

Flashes and buzzer sounds when abnormal.

Air cleaner clogging

When clogged

Goes off.

Flashes when abnormal.

Charge level

When charge is abnormal

Lights when normal. (Goes off when engine is started.) Flashes when abnormal.

Flashes when abnormal.

Engine oil level

Below low level

Goes off.

Packing (Swing lock)

When swing is locked

Lights up when swing is locked. Flashes when swing holding brake release switch is turned on.

Oil maintenance

See "OIL MAINTENANCE FUNCTION" on next page.

Preheating

When preheated

Lights up for 30 sec. when starting switch is set to HEAT. Then, flashes for 10 sec. to indicated completion of preheating.

Coolant temperature

Flashes at 102°C or higher. Flashes and buzzer sounds at 105°C or higher.

Fuel level

Flashes when below low level.

PC400/450(LC)-7

10-197-4
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Oil maintenance function
1. Function and operation At a set time after the engine oil is replaced, the oil maintenance function is turned on to notify the operator by the LED lamp on the monitor panel that it is time to replace the oil. The function to indicate the phone number of the place to make contact for service on the LCD unit is installed, too. 1) Check of elapsed time Nothing is displayed normally until point B shown in the figure at right after this function is reset. If the key is turned on with the buzzer cancel switch processed (for 2.5 seconds), however, the elapsed time is displayed on the service meter section. 2) Display of replacement of oil If time passes point B after this function is reset, the elapsed time is displayed on the service meter section and the LED flashes when the key is turned on. 2. Setting of time interval 1) The time interval is set in the interval setting mode. It can be set to "125h", "250h", "500h", "Not set", or "Demo-mode". The default is "Not set". 2) To enter the interval setting mode, press and hold the clock switch for 2.5 seconds. 3) If the buzzer cancel switch is pressed in the interval setting mode, the clock display section changes to "—" o "125" o "250" o "500" o "d" in order. ("—" corresponds to "Not set" and "d" corresponds to "Demomode".) 4) To save the time interval, set a desired time (mode) on the monitor panel and press and hold the clock switch for 2.5 seconds.

10-197-5
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PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

3. Timing and contents of display 1) When replacement of oil is displayed 2) The elapsed time is displayed for 10 seconds after all segments are turned on. Phone number is displayed for the next 10 seconds. If the phone number has not been input, however, the elapsed time is displayed for 20 seconds after all segments are turned on. 3) When elapsed time is checked The elapsed time is displayed for 10 seconds after all segments are turned on. 4. Resetting elapsed time 1) When the replacement of oil and elapsed time are displayed, press the buzzer cancel switch 10 seconds after all segments are turned on (while the elapsed time is disp l aye d) and h ol d f or 3 se con ds. Th e elapsed time is reset. After this operation, "0h" is displayed for 1 second. 2) When the set time is changed, the elapsed time is reset to "0h". 5. Demo-mode 1) In the demo-mode, the time is set to 250h, the elapsed time is set to 240h, and replacement of oil is displayed when the key is turned on. The elapsed time does not increase, however. The time can be reset in this mode. Turn on the key 3 times in this mode, and the time interval is automatically set to "Not set" at the 4th time and after. The elapsed time is set to "0h" and counting of elapsed time is started.

PC400/450(LC)-7

10-197-6
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Mode selector switches
1. 2. 3. 4. Travel speed switch Auto-deceleration switch Wiper switch Work mode selector switch (Including setting switch)

There are 4 sets of the mode selector switches on the switch section. Each time one switch is pressed, the machine condition changes. The current condition is indicated by the lighting of the LED above the switch.

Operations table of switch section a The bold letters are the positions of the switches reset when the starting switch is turned on.
Item Work mode Operation A↔E↔B ON ↔ OFF OFF ↔ Intermittent ↔ ON Hi ↔ Lo

The initial setting of only the work mode after the starting switch is turned on can be changed. a For how to change the setting, see "Work mode default setting mode" in TROUBLESHOOTINGDisplay and special functions of monitor panel.

Auto-deceleration Wiper Travel speed

10-197-7
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PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SENSOR

SENSOR
• The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the chassis ground.
Name of sensor Engine oil level Engine oil pressure Hydraulic oil temperature Coolant temperature Fuel level Air cleaner clogging Type of sensor Contact Contact Resistance Resistance Resistance Contact type When normal ON (closed) OFF (open) — — — OFF (open) When abnormal OFF (open) ON (closed) — — — ON (closed)

10-198

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SENSOR

Engine oil level sensor 1. 2. 3. 4. Connector Bracket Float Switch

Engine oil pressure sensor (For low pressure) 1. 2. 3. 4. 5. 6. Plug Contact ring Contact Diaphragm Spring Terminal

Coolant temperature sensor Hydraulic oil temperature sensor

1. Thermistor 2. Body 3. Tube

4. Tube 5. Wire 6. Connector

PC400/450(LC)-7

10-199

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SENSOR

Fuel level sensor 1. 2. 3. 4. Float Connector Cover Variable resistor

Air cleaner clogging sensor

10-200

PC400/450(LC)-7

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2 STANDARD VALUE TABLE FOR CHASSIS .................................................................................................. 20-3 TESTING AND ADJUSTING ...................................................................................................................... 20-101 TROUBLESHOOTING ................................................................................................................................ 20-201

a 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. k 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. k When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. k 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. k Be careful not to get caught in the fan, fan belt or other rotating parts. PC400/450(LC)-7

20-1
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE
Machine model Engine Item Measurement condition High idling Engine speed Low idling Rated speed Intake air pressure Exhaust gas pressure Exhaust gas color At high idling Valve clearance (normal temperature) Compression pressure Blow-by pressure Intake valve mm Exhaust valve Oil temperature: 40 – 60°C (Engine speed) (Coolant temperature: within operating range) At rated output (Coolant temperature: within operating range) At high idling Oil pressure At high idling At low idling At low idling Oil temperature Fan, alternator belt tension Air conditioner compressor belt tension (SAE30) (SAE10W) (SAE30) (SAE10W) °C mm MPa {kg/cm2} 0.39 – 0.69 {4.0 – 7.0} 0.34 – 0.64 {3.5 – 6.5} Min. 0.15 {Min. 1.5} Min. 0.1 {Min. 1.0} 90 – 120 Approx. 13 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7} 120 Approx. 13
MPa {kg/cm2}

PC400, 400LC-7 PC450, 450LC-7 SAA6D125E-3 Unit Standard value 1,930 ± 50 rpm 1,000 ± 25 1,850 kPa {mmHg} °C Bosch index Min 107 {Min. 800} Max. 700 Max. 4.0 Max. 1.0 0.33 0.71 (rpm) kPa {mmH2O} Min. 2.9 {Min. 30} (150 – 200) Max. 1.18 {Max. 120} Permissible value 1,930 ± 50 1,000 ± 25 1,850 87 {650} Max. 700 6.0 2.0 — — 2.0 {20} (150 – 200) 1.96 {200}

At rated output All speed range (intake air temp: 20°C) At sudden acceleration

All speed range (inside oil pan) Deflection when pressed with finger force of approx. 58.8 N {6 kg} Deflection when pressed with finger force of approx. 58.8 N {6 kg}

mm

14 – 16

14 – 16

20-2
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS
Applicable model Category Item Measurement conditions • Engine water temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idling • Arm in relief condition • Engine water temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idling • Arm relief + One-touch power max. switch in ON condition • Engine at high idling • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition Unit PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

2 pumps at relief

1,930 ± 100

1,930 ± 100

Engine speed

At 2-pump relief + one touch power up

rpm

1,830 ± 100

1,830 ± 100

Speed when autodeceleration is operated Boom control valve Spool stroke Arm control valve Bucket control valve Swing control valve Travel control valve Travel of control levers Boom control lever Arm control lever Bucket control lever Swing control lever Travel control lever Play of control levers Boom control lever Operating effort of control levers Arm control lever Bucket control lever Swing control lever Lever Pedal

1,300 ± 100

1,300 ± 100

mm

9.5 ± 0.5

9.5 ± 0.5

85 ± 10 • Engine stopped • At center of control lever grip • Max. reading up to stroke end (excepting lever play in NEUTRAL position) 85 ± 10 mm 85 ± 10 85 ± 10 115 ± 12 Max. 10 15.7 ± 4.9 {1.6 ± 0.4} • Hydraulic oil temperature: Within operation range • Engine at high idling • Hydraulic oil temperature: Within operating range • At center of control lever grip • Max. reading up to stroke end 15.7 ± 4.9 {1.6 ± 0.4} 12.7 ± 2.9 {1.3 ± 0.3} 12.7 ± 2.9 {1.3 ± 0.3} 24.5 ± 5.9 {2.5 ± 0.6} 74.5 ± 18.6 {7.6 ± 1.9}

85 ± 10 85 ± 10 85 ± 10 85 ± 10 115 ± 12 Max. 15 Max. 24.5 {Max. 2.5} Max. 24.5 {Max. 2.5} Max. 21.6 {Max. 2.2} Max. 21.6 {Max. 2.2} Max. 39.2 {Max. 4.0} Max. 107.6 {Max. 11}

N {kg}

Travel control

PC400/450(LC)-7

20-3
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement conditions • Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Hydraulic pump output pressure with all control levers in NEUTRAL position RAISE At lowpressure setting At highpressure setting Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

Unload pressure

4.2 ± 1.0 {42 ± 10}

4.2 ± 1.0 {42 ± 10}

34.81 +1.47 –0.98 (37.27 +1.47 ) –0.98 {355 +15 (380 +15 )} –10 –10 Boom • Hydraulic oil temperature: Within operation range • Engine at high idling 18.14 ± 0.98 {185 ± 10} 31.38 ± 1.47 {320 ± 15} 34.81 +1.47 –0.98 (37.27 +1.47 ) –0.98 {355 +15 (380 +15 )} –10 –10 +1.47 34.81 –0.98 (37.27 +1.47 ) –0.98 {355 +15 (380 +15 )} –10 –10 30.89 +1.47 –2.45 {315 +15 } –25 37.27 +2.94 –0.98 {380 +30 } –10

33.34 – 36.77 (35.79 – 39.23)
{340 – 375 (365 – 400)}

16.67 – 19.61 {170 – 200} 29.2 – 33.34 {300 – 340} 33.34 – 36.77 (35.79 – 39.23)
{340 – 375 (365 – 400)}

Arm Hydraulic pressure

Bucket

• Working mode: A mode • Hydraulic pump output pressure with all measurement circuits relieved • Values inside parenthesis: Hydraulic oil pressure with onetouch power max. switch in ON mode (reference only)

LOWER

33.34 – 36.77 (35.79 – 39.23)
{340 – 375 (365 – 400)}

MPa {kg/cm2}

Swing Travel • Hydraulic oil temperature: Within operation range • Engine at high idling • Self-reducing pressure valve output pressure with all control levers in NEUTRAL position When all control levers in NEUTRAL position When traveling at half stroke (without load)

27.95 – 32.85 {285 – 335} 35.79 – 40.70 {365 – 415}

Control circuit source pressure

3.24 ± 0.2 {33 ± 2}

2.84 – 3.43 {29 – 35}

• Hydraulic oil temperature: Within operation range • Engine at high idling LS differential pressure • Working mode: A mode • Traveling speed: Hi • Hydraulic oil pump pressure – LS pressure

4.2 ± 1.0 {42 ± 10}

4.2 ± 1.0 {42 ± 10}

2.65 ± 0.1 {27 ± 1}

2.65 ± 0.1 {27 ± 1}

20-4
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement conditions Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

Swing brake angle

• Hydraulic oil temperature: Within operating range • Bucket: Empty • Engine at high idling • Working mode: A mode • Swing circle misalignment amount when stopping after one turn

deg. (mm)

PC400: Max. 120 PC450: Max. 130

PC400: Max. 150 PC450: Max. 160

90° Time taken to start swing • Hydraulic oil temperature: Within operation range • Bucket: Empty • Engine at high idling • Working mode: A mode • Time required for passing points 90 and 180 degrees from starting point

3.7 ± 0.4

Max. 4.6

sec.

180°

5.4 ± 0.5

Max. 6.4

Swing

Time taken to swing

• Hydraulic oil temperature: Within operating range • Bucket: Empty • Engine at high idling • Working mode: A mode • Time required for 5 more turns after making initial one turn

sec.

33.0 ± 3.3

Max. 38

Hydraulic drift of swing

• Hydraulic oil temperature: Within operation range • Engine stopped • Keeping upper structure transverse on slope of 15 degrees • Notching a mating mark on inner and outer races of swing circle • Mating mark misalignment amount during 5 minutes

mm

0

0

PC400/450(LC)-7

20-5
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement conditions • Hydraulic oil temperature: Within operation range • Engine at high idling • Swing lock switch: ON • Leakage amount for one minute during swing relief Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

Swing

Leakage from swing motor

l/min

Max. 5.5

Max. 11

Lo

STD: 63.2 ± 12.6 LC: 67.3 ± 13.5

STD: 42.0 – 80.0 LC: 45.0 – 84.5

Travel speed (Idle travel)

• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required for track shoes to make 5 turns after making one initial idle turn

Mi

sec.

STD: 45.1 ± 6.8 LC: 48.1 ± 7.2

STD: 31.5 – 55.0 LC: 34.0 – 58.0

Hi

STD: 34.5 ± 35 LC: 36.7 ± 3.6

STD: 28.0 – 41.5 LC: 32.0 – 44.0

Lo

24.0 ± 4.8

18.9 – 31.0

Travel speed (Actual travel)

• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Flat ground • Time required for traveling 20 m after 10 m trial run

Mi

sec.

17.1 ± 2.6

14.4 – 21.0

Travel

Hi

13.1 – 1.3

11.7 – 15.1

Travel deviation

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

mm

Max. 200

Max. 300

20-6
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement conditions Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

Hydraulic drift of travel

• Hydraulic oil temperature: Within operating range • Engine stopped • Parking machine on slope 12 degrees with sprocket facing upslope • Sliding distance for 5 minutes • Hydraulic oil temperature: Within operating range • Engine at high idling • Travel: Lock sprocket. • Oil leakage amount for one minute with traveling in relief condition

mm

0

0

Travel Leakage of travel motor

l/min

Max. 20

Max. 40

Whole work equipment (tooth tip fall amount) Hydraulic drift of work equipment Boom cylinder (cylinder retraction amount) Arm cylinder (cylinder extension amount)

PC400: Max. 600 PC450: Max. 700

PC400: Max. 900 PC450: Max. 1,050

Bucket cylinder (cylinder retraction amount)

• Hydraulic oil temperature: Within operation range • Flat and level ground • Work equipment in measurement posture as illustrated above • Bucket load: 3,060 kg • Engine stopped • Work equipment control lever in NEUTRAL position • Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting

Work equipment

PC400: Max. 25 PC450: Max. 29 mm

PC400: Max. 38 PC450: Max. 44

PC400: Max. 85 PC450: Max. 100

PC400: Max. 128 PC450: Max. 150

PC400: Max. 30 PC450: Max. 35

PC400: Max. 45 PC450: Max. 53

PC400/450(LC)-7

20-7
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement conditions Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value for new machine Service limit value

RAISE

PC400: 4.0 ± 0.4 PC450: 4.2 ± 0.4

PC400: Max. 4.8 PC450: Max. 5.0

Boom

• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required from raise stroke end till bucket touches ground

LOWER

PC400: 2.9 ± 0.3 PC450: 2.8 ± 0.3

PC400: Max. 3.4 PC450: Max. 3.3

CURL

Work equipment speed

Work equipment

PC400: 4.3 ± 0.4 PC450: 4.7 ± 0.5

PC400: Max. 5.0 PC450: Max. 5.4

Arm

• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required from dumping stroke end to digging stroke end

sec.

DUMP

3.6 ± 0.4

Max. 4.3

CURL

3.6 ± 0.4

Max. 4.3

Bucket

• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required from dumping stroke end to digging stroke end

DUMP

2.9 ± 0.3

Max. 3.5

20-8
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement Condition Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

Boom

• Hydraulic oil temperature: Within operation range • Engine at low idling • Working mode: A mode • Time required from raise stroke end till bucket touches ground and pushes up machine front

sec.

Max. 3.0

Max. 3.6

Arm

• Hydraulic oil temperature: Within operation range • Engine at low idling • Working mode: A mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again

Work equipment

Time lag

PC400: Max. 3.0 PC450: Max. 4.0

PC400: Max. 3.6 PC450: Max. 4.6

sec.

Bucket

• Hydraulic oil temperature: Within operation range • Engine at low idling • Working mode: A mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again • Hydraulic oil temperature: Within operation range • Engine at high idling • Leakage amount for one minute with cylinder or travel to be measured in relief condition

Max. 3.0

Max. 5.0

Internal leackage

Cylinders

4.5 cc/min 10

20

Center swivel joint

50

PC400/450(LC)-7

20-9
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement Condition • Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Traveling speed: Lo • Flat and level ground • Swerving amount (X) when traveling 20 m after initial trial run of 10 m Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

Performance in compound operation

Swerving amount in simultaneous operation of work equipment and travel

mm

Max. 400

Max. 440

Performance of hydraulic pump

Hydraulic pump delivery

See next page

l/min

See next page

20-10
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category Item Measurement Condition Unit

PC400, 400LC-7 PC450, 450LC-7 Standard value Permissible value

Discharge amount of hydraulic pump (A mode)

Performance of hydraulic pump • Pump speed: At 1,950 rpm, PC current 280 mA Test pump discharge pressure (MPa {kg/cm2}) P1 Discharge pressure of other pump (MPa {kg/cm2}) P2 Average pressure (MPa {kg/cm2}) P1+P2 2 Standard value for discharge amount Q (l/min) See graph Judgement standard lower limit Q (l/min) See graph

Check point

As desired a a

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.

PC400/450(LC)-7

20-11
(1)

TESTING AND ADJUSTING
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE ...................................................... 20-102 MEASURING ENGINE SPEED .................................................................................................................. 20-104 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................ 20-105 MEASURING EXHAUST TEMPERATURE ................................................................................................ 20-106 MEASURING EXHAUST GAS COLOR ...................................................................................................... 20-107 ADJUSTING VALVE CLEARANCE ............................................................................................................ 20-108 MEASURING COMPRESSION PRESSURE.............................................................................................. 20- 110 MEASURING BLOW-BY PRESSURE ........................................................................................................ 20- 112 MEASURING ENGINE OIL PRESSURE .................................................................................................... 20- 113 HANDLING OF FUEL SYSTEM DEVICES................................................................................................. 20- 114 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM .................................................................. 20- 114 MEASURING FUEL PRESSURE ............................................................................................................... 20- 115 BLEEDING AIR FROM FUEL CIRCUIT ..................................................................................................... 20- 116 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE .................................................................................... 20- 118 ADJUSTING ENGINE SPEED SENSOR ................................................................................................... 20- 119 TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION ........................................ 20-120 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................ 20-121 MEASURING CLEARANCE OF SWING CIRCLE BEARING..................................................................... 20-122 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................. 20-123 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....................................................................................................... 20-124 MEASURING BASIC PRESSURE IN CONTROL CIRCUIT ....................................................................... 20-128 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ................................... 20-129 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.................................... 20-132 MEASURING SOLENOID VALVE OUTPUT PRESSURE.......................................................................... 20-137 MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................... 20-140 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES................................................ 20-142 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT ................................... 20-143 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT.............................................................. 20-145 MEASURING OIL LEAKAGE...................................................................................................................... 20-146 BLEEDING AIR FROM EACH PART.......................................................................................................... 20-149 TESTING PROCEDURE OF DIODE .......................................................................................................... 20-152 SPECIAL FUNCTIONS OF MONITOR PANEL .......................................................................................... 20-153 SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL ............................................................... 20-179-2 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER ................................................. 20-180 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM .......... 20-181 PM-CLINIC SERVICE ................................................................................................................................. 20-183

PC400/450(LC)-7

20-101
(7)

TESTING AND ADJUSTING

TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE

TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
symbol Testing/Adjusting item Measuring intake air pressure (boost pressure) Measuring exhaust temperature Part No. Part name Q’ty Remarks –101 – 200 kPa {–760 – 1,500 mmHg} –99.9 – 1,299°C

A B

799-201-2202 Boost gauge kit 799-101-1502 Digital thermometer

1 1

1 799-201-1502 Handy smoke meter Measuring exhaust gas color C 2 Commercially available Commercially available Smoke meter

1

1

Pollution level: 0 – 70 % (With standard color) (Pollution level × 1/10 Bosch index)

Adjusting valve clearance

D

Feeler gauge

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 1 4 4

Air intake side: 0.35 mm, Exhaust side: 0.57 mm 0 – 6.9 MPa {0 – 70 kg/cm2} For 125E-3 engine

1 795-502-1590 Compression gauge Measuring compression pressure E 2 3 Measuring blow-by pressure F 795-471-1410 Adapter 6217-71-6112 795-799-1170 Gasket Puller

799-201-1504 Blow-by checker 799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester 2 799-401-2320 Hydraulic tester 1 799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester

Measuring engine oil pressure

G

1

(Pressure gauge): 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} (Pressure gauge): 58.8 MPa {600 kg/cm2} (Pressure gauge): 0.98MPa {10 kg/cm2}

Measuring fuel pressure

H

Same as G

2 799-401-2320 Hydraulic tester Measuring clearance of swing circle bearing Measuring and adjusting oil pressures in work equipment, swing, and travel circuits J 1 k 2 Commercially available Dial gauge

with magnet Same as G

799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring

(Size): 10 × 1.25 mm

1 Measuring basic pressure in control circuit L 2

799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring

Same as G1

Same as K2

Testing and adjusting oil pressure in pump PC control circuit

1 M 2

799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring

Same as G

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TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE

symbol

Testing/Adjusting item

Part No.

Part name

Q’ty

Remarks

1 Testing and adjusting pressure in pump LS control circuit N 2

799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester 799-101-5220 Nipple 07002-11023 O-ring Differential pressure gauge

1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Same as G1

Same as M2

3 799-401-2701 1 Measuring solenoid valve output pressure P 2

799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester 799-401-3100 Adapter 799-401-3200 Adapter 799-101-5002 Hydraulic tester 790-261-1203 Digital hydraulic tester

Same as G1 (Size): 02 (Size): 03 Same as G1 (Size): PF1/4 + PT1/4

Measuring PPC valve output pressure

Q

1

2 970-301-1740 Joint Measuring oil leakage Testing wear of sprocket Measuring coolant and oil temperatures Measuring operating effort and pressing force Measuring stroke and hydraulic drift Measuring work equipment speed Measuring voltage and resistance R — — — — — — Commercially available Measuring cylinder

799-627-1120 Wear gauge 799-101-1502 Digital thermometer 79A-264-0021 Push-pull scale 79A-264-0091 Push-pull scale Commercially available Commercially available Commercially available Scale Stopwatch Tester

Same as B 0 – 294 N {0 – 30 kg} 0 – 490 N {0 – 50 kg}

a 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.

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TESTING AND ADJUSTING

MEASURING ENGINE SPEED

MEASURING ENGINE SPEED
1. Turn the starting switch ON and set the monitor panel to “Monitoring”. a For the operating method, see “Special functions of monitor panel”. • Monitoring code: 01002 Engine Speed 01006 Engine Speed a 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. a The engine speed is displayed in rpm. 4) Measuring 2-pump relief + one-touch power maximizing speed (near rated speed): i) Start the engine and set the fuel control dial in the high idling position (MAX). ii) Set the working mode switch in the Amode position. iii) While relieving the arm circuit by moving the arm in, keep pressing the one-touch power maximizing switch. a 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. 5) Measuring auto-deceleration speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Turn the auto-deceleration switch ON. 3) Set the work equipment control and swing control levers in neutral. a The engine speed lowers to a certain level about 5 seconds after all the levers are set in neutral. This level is the autodeceleration speed.

2. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 3. Measure the engine speed under each measurement condition. 1) 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. 2) 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 Amode position. iii) Turn the auto-decelerator switch OFF. iv) Set the work equipment control, swing control, and travel levers in neutral. 3) Measuring 2-pump relief speed: i) Start the engine and set the fuel control dial in the high idling position (MAX). ii) Set the working mode switch in the Amode position. iii) Relieve the arm circuit by moving the arm in.

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TESTING AND ADJUSTING

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
a Measuring instruments for intake air pressure (boost pressure)
Symbol A Part No. 799-201-2202 Part Name Boost gauge kit

4. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 5. Set the working mode switch in the A-mode position. 6. While running the engine at high idling, relieve the boom circuit by raising the boom and measure the intake air pressure (boost pressure).

a When installing and removing the measuring instruments, take care not to touch a hot part of the engine. 1. Open the engine hood and remove intake air pressure pick-up plug (1).

7. After finishing measurement, remove the measuring instruments and return the removed parts. 2. Install nipple [1] of boost gauge kit A and connect gauge [2].

3. Run the engine at a medium or higher speed and drain the oil from the hose. a Insert the connecting parts of the gauge and hose about a half and open the self-seal on the hose side repeatedly, and the oil will be drained. a If Pm kit A is available, you may drain the oil by using the air bleeding coupling (790-2611130) in the kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil.

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TESTING AND ADJUSTING

MEASURING EXHAUST TEMPERATURE

MEASURING EXHAUST TEMPERATURE
a Measuring instrument of exhaust gas temperature
Symbol B Part No. 799-101-1502 Part Name Digital thermometer

k Install and remove the measuring instrument after the exhaust manifold is cooled. 1. Open the engine hood and remove exhaust temperature pick-up plug (1).

5. Procedure for measuring exhaust temperature periodically for preventive maintenance (Pm Clinic), etc. 1) Set the working mode switch in the A-mode position. 2) Run the engine at high idling, relieve the arm circuit by moving the arm in, and measure the exhaust temperature. a Measure the exhaust temperature after it is stabilized.

6. After finishing measurement, remove the measuring instruments and return the removed parts. 2. Install sensor [1] of digital thermometer B and connect them to meter [2]. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part.

3. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 4. Procedure for measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. a Set the digital thermometer in the PEAK mode.

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PC400/450(LC)-7

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

MEASURING EXHAUST GAS COLOR
a Measuring instrument of exhaust gas color
Symbol 1 C 2 Part No. 799-101-9000 Commercially available Part Name Handy smoke checker Smoke meter

k When installing and removing the measuring instruments, take care not to touch a hot part. a If an air source and an electric power source are not available in the field, use handy smoke checker C1. When recording official data, use smoke meter C2. 1. Measuring with handy smoke checker C1 1) Stick a sheet of filter paper to C1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Run the engine and raise engine coolant temperature to operating range. 4) Accelerate the engine suddenly or run it at high idling and operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.

2) Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter C2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. 3) Connect the power cable to a receptacle of AC 100 V. a Before connecting the cable, check that the power switch of the smoke meter is turned off. 4) Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. 5) Turn on the power switch of smoke meter C2.

5) Remove the filter paper and compare it with the attached scale. 6) After finishing measurement, remove the m ea su ri ng i ns tr um ent an d re tur n the removed parts. 2. Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of exhaust pipe (1) and fix it to the exhaust pipe with a clip.

6) Run the engine and raise engine coolant temperature to operating range. 7) Accelerate the engine suddenly or run it at high idling and press the accelerator pedal of smoke meter C2 and collect the exhaust gas into the filter paper. 8) Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. 9) After finishing measurement, remove the me as ur in g in str u men t a nd r etu r n t he removed parts.

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TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE
a Adjusting instrument for valve clearance
Symbol D Part No. Commercially available Part Name Feeler gauge

the compression top dead center. In this case, rotate the crankshaft one more turn.

1. Open the engine hood and remove all cylinder head covers (1). a Remove all the intermediate clamps of the fuel high-pressure tube and disconnect the sleeve nuts on the common rail side and injector side, and you can remove the cylinder head covers. a Use ring wrenches (on the market) for highpressure pipes to disconnect and connect the fuel high-pressure tubes. a Remove the air intake connector, too, from the top of the No. 1 cylinder head cover. a After removing the head covers, tighten the sleeve nuts temporarily so that the fuel highpressure tubes will not interfere with the rocker arms.

5. Insert feeler gauge D in clearance “b” between rocker arm (3) and crosshead (4) and adjust the valve clearance with adjustment screw (5). a With the feeler gauge inserted, turn the adjustment screw to a degree that you can move the filler gauge lightly. 6. Fix adjustment screw (5) and tighten locknut (6). 3 Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.

2. Remove the belt protection covers (2 pieces) and loosen the fan belt and alternator belt. 3. Remove the radiator undercover. 4. Rotate the crankshaft forward to bring the stamped “1.6TOP” line “a” of the damper to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Crank the crankshaft with the crank pulley mounting bolt (width across flats: 24 mm) only in the forward direction so that the bolt will not be loosened. a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at 7. Turn the crankshaft forward by 120° each time and repeat steps 2 – 5 for each cylinder according to the firing order. • Firing order: 1 – 5 – 3 – 6 – 2 – 4

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PC400/450(LC)-7

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

8. After finishing adjustment, return the removed parts.

3 Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} a After tightening the sleeve nuts permanently, tighten the clamp bolts of the fuel high-pressure tubes permanently. 3 Fuel high-pressure tube sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm} 3 Fuel high-pressure tube clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3 Air intake connector clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm} a Adjust the belt tension. For details, see TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION.

PC400/450(LC)-7

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TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE
a Measuring instruments for compression pressure
Symbol 1 E 2 3 Part No. 795-502-1590 795-471-1410 6217-71-6112 795-799-1170 Part Name Compression gauge Adapter Gasket Puller

k When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. 1. Run the engine and warm up the engine oil temperature to 40 – 60°C. 2. Open the engine hood and remove cover (1) of the cylinder head to be measured. a Remove all the intermediate clamps of the fuel high-pressure tube and disconnect the sleeve nuts on the common rail side and injector side, and you can remove the cylinder head cover. a Use ring wrenches (on the market) for highpressure pipes to disconnect and connect the fuel high-pressure tubes. a Remove the air intake connector, too, from the top of the No. 1 cylinder head cover.

4. Install adapter E2 and connect it to compression gauge E1. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}

5. Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. 6. Remove the engine undercover and disconnect engine intermediate connectors ER02 and ER03.

3. Using puller E3, remove injector (2). a Loosen the nuts of the wiring harness alternately. a After removing the injector, tighten the sleeve nut temporarily so that the fuel highpressure tube will not interfere with the rocker arm.

k If the connectors are not disconnected, the engine starts during measurement, and that is dangerous. Accordingly, be sure to disconnect the connectors. k Cover the connectors on the controller side (chassis side) with a vinyl sheet, etc. to prevent electric leakage and grounding fault.

7. Turn the starting switch ON and prepare the monitor panel for measuring engine speed. a See MEASURING ENGINE SPEED.

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PC400/450(LC)-7

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

8. Crank the engine with the starting motor and measure the compression pressure. a Measure the pressure when the pointer of the gauge is stabilized. a While measuring the compression pressure, measure the engine speed, too, and check that it is in the measurement condition range. 9. After finishing measurement, remove the measuring instruments and return the removed parts. 3 Injector holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 3 Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} a After tightening the sleeve nuts permanently, tighten the clamp bolts of the fuel high-pressure tubes permanently. 3 Fuel high-pressure tube sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm} 3 Fuel high-pressure tube clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3 Air intake connector clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm}

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TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE
a Measuring instrument for blow-by pressure
Symbol F Part No. 799-201-1504 Part Name Blow-by checker

1. Remove the engine undercover. 2. Install nozzle [1] of blow-by checker F to blow-by hose (1) and connect it to gauge [2] by the hose.

3. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 4. Run the engine at high idling and measure the blow-by pressure under the following condition. • Work equipment mode: A • Swing lock switch: ON (High pressure relief) • Work equipment, swing, and travel circuits: Relieve by moving arm in. a Read the blow-by checker when its pointer is stabilized.

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

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PC400/450(LC)-7

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE
a Measuring instruments for engine oil pressure
Symbol 1 2 Part No. 799-101-5002 790-261-1203 799-401-2320 Part Name Hydraulic tester Digital hydraulic tester Hydraulic tester

G

1. Open the engine hood and remove oil pressure pick-up plug (1) from the engine cylinder block.

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

2. Install nipple [1] of hydraulic tester G1 and connect it to hydraulic tester G2.

3. Run the engine and raise engine coolant temperature to operating range. 4. Measure the engine oil pressure at low idling and high idling.

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TESTING AND ADJUSTING

HANDLING OF FUEL SYSTEM DEVICES RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM

HANDLING OF FUEL SYSTEM DEVICES
a Precautions for testing and adjusting fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and adjusting the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. a Precautions for replacing fuel filter cartridge Always use a Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than a Komatsu genuine filter is used, the fuel system may have trouble. So never use any thing but a Komatsu genuine filter.

RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
a Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Fuel supply pump High-pressure circuit: Fuel supply pump – Common rail – Fuel injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following.

k Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

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PC400/450(LC)-7

TESTING AND ADJUSTING

MEASURING FUEL PRESSURE

MEASURING FUEL PRESSURE
a Measuring instruments for fuel pressure
Symbol 1 2 Part No. 799-101-5002 790-261-1203 799-401-2320 Part Name Hydraulic tester Digital hydraulic tester Hydraulic tester

3. Run the engine at high idling and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal. 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}

H

a Measure only the fuel pressure in the low-pressure circuit from the feed pump to the fuel filter and fuel supply pump.

k Since the pressure in the high-pressure circuit from the fuel supply pump to the common rail and fuel injector is very high, it cannot be measured. 1. Open the engine hood and remove fuel pressure pick-up plug (1).

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

2. Install nipple [1] of hydraulic tester H1 and connect them to hydraulic tester H2.

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TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL CIRCUIT

a If fuel is used up or if a fuel circuit device is removed and installed, bleed air from the fuel circuit according to the following procedure. a Open the engine hood. 1. Remove fuel filter (1) and fill it with fuel and install it again. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Add fuel through inlet ports (1a) (8 places) of the filter. Since hole (1b) is the outlet port (clean side), do not add fuel through it. a If clean fuel is not available, do not remove the filter but fill it with the fuel from the fuel tank by operating the priming pump.

2. Remove plug (2a) of the fuel filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the plug hole and install the plug. 3 Plug: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}

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PC400/450(LC)-7

TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL CIRCUIT

3. Remove air bleed plug (2b) of the fuel filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the plug hole and install the plug. 3 Air bleed plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} 4. Loosen air bleeder (4) of the fuel supply pump and operate priming pump (3) 90 – 100 times. a Operate the priming pump until fuel flows from air bleeder (2b) and tighten the air bleeder. Then operate the priming pump several more times, until it becomes heavy. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm} 5. Start the engine with the starting motor. a Air in the high-pressure circuit is automatically bled when the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 2.

PC400/450(LC)-7

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TESTING AND ADJUSTING

INSPECTION OF FUEL CIRCUIT FOR LEAKAGE

INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
k Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, inspect it for fuel leakage according to the following procedure. a Clean and degrease the engine and the parts around it in advance so that you can inspect it easily for fuel leakage. 1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. 2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. 3. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 4. Run the engine at low idling. 5. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 6. Run the engine at high idling. 7. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 8. Run the engine at high idling and load it. a Relieve the oil by moving the arm in. 9. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. a If any fuel leakage is not detected, inspection is completed.

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PC400/450(LC)-7

TESTING AND ADJUSTING

ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEED SENSOR
a Adjust the engine speed sensor for the pump controller according to the following procedure. a The engine G speed sensor and engine Ne speed sensor for the engine controller cannot be adjusted. a Open the engine hood and remove engine speed sensor (1) before adjusting it and check that its tip is free from steel chips and flaws, and then install it again.

1. Screw in sensor (1) until its tip touches the tooth tip of flywheel ring gear (2). 2 Threads: Hydraulic sealant 2. Return sensor (1) by 1/2 – 2/3 turns. a Adjust clearance “a” between the sensor tip and gear tooth tip to 0.75 – 1.00 mm. 3. Secure sensor (1) with nut (3). 3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}

4. After finishing adjustment, check that the monitor panel displays the engine speed normally in the monitoring mode. a For the operating method, see “Special functions of monitor panel”. a Monitoring code: 01006 (Engine speed)

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TESTING AND ADJUSTING

TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION

TESTING AND ADJUSTING 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. a Deflection “a” when pressing force is approximately 58.8 N {approximately 6 kg}: 13 mm Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen bolts and nuts (1), (2), and (3). 2. Turn nut (4) to move alternator (5) and adjust the belt tension. a If nut (4) is • Tightened clockwise, the belt tension is decreased. • Loosened counterclockwise, the belt tension is increased. a Check breakage of the pulleys, wear of the V-grooves and V-belts, and contact of the belts and V-grooves. a If a belt is lengthened to the adjustment limit, cut, or cracked, replace it with a new belt. 3. Tighten nuts and bolts (3), (2), and (1). a If a V-belt is replaced, readjust its tension after 1 operating hour.

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TESTING AND ADJUSTING

TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION

TESTING AND ADJUSTING 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. a Deflection “a” when pressing force is approximately 58.8 N {approximately 6 kg}: 14 mm – 16 mm Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen bolts (1) and (2). 2. Move compressor (3) to adjust the belt tension. a Check breakage of the pulleys, wear of the V-grooves and V-belts, and contact of the belts and V-grooves. a If a belt is lengthened to the adjustment limit, cut, or cracked, replace it with a new belt. 3. Tighten bolts (2) and (1). a If a V-belt is replaced, readjust its tension after 1 operating hour.

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TESTING AND ADJUSTING

MEASURING CLEARANCE OF SWING CIRCLE BEARING

MEASURING CLEARANCE OF SWING CIRCLE BEARING
a Measuring instrument for clearance of swing circle bearing
Symbol J Part No. Commercially available Part Name Dial gauge

4. Set the arm at almost right angle to the ground and lower the boom until the track shoe at the front end of the machine rises. a At this time, the front end of the upper structure rises and the rear end lowers. 5. Under this condition, read dial gauge J. a Dial gauge J indicates the clearance of the bearing.

a When measuring the clearance of the swing circle bearing on the actual machine, observe the following procedure. k While measuring, do not put your hands or foot under the undercarriage.

1. Fix dial gauge J to outer race (1) or inner race (2) of the swing circle and apply the probe to the end face of inner race (2) or outer race (1) on the opposite side. a Set dial gauge J on the front or at rear side of the machine.

6. Return the machine to the position of step 2 and check that dial gauge J indicates 0 again. a If dial gauge J does not indicate 0, repeat steps 3 – 5.

2. Set the work equipment in the maximum reach position and set the bucket tip at the height of the revolving frame bottom. a At this time, the front end of the upper structure lowers and the rear end rises. 3. Set the dial gauge to 0 point.

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TESTING AND ADJUSTING

TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING AND ADJUSTING 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). a As the square bar [1], use angle iron which has less deflection. 3. Measure maximum distance “a” between square bar [1] and track shoe. • Standard maximum distance “a” : 10 – 30 mm Adjusting a 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.

k 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). a If the track shoe is not tensed well, drive the machine forward and in reverse slowly.

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TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
a Testing and adjusting instruments for oil pressure in work equipment, swing, and travel circuits
Symbol 1 K 2 Part No. 799-101-5002 790-261-1203 799-101-5220 07002-11023 Part Name Hydraulic tester Digital hydraulic tester Nipple (10 × 1.25 mm) O-ring

a 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 MPa {1 kg/cm2, 1 PSI).

2) Install nipple K2 and connect it to oil pressure gauge [1] of hydraulic tester K1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.

3) Run the engine and raise the hydraulic oil temperature to the operating range. Measuring 1. Preparation work

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1) 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

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TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

2. Combination of pump, actuator, and valve a 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. a 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. a 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

a 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. a If the swing lock switch is turned ON, the 2stage 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 1) Start the engine and turn the swing lock switch ON. 2) Run the engine at high idling and relieve the swing circuit and measure the oil pressure. a The pressure measured when the swing motor safety valve is relieved is indicated. a The swing motor relief pressure is lower than the main relief valve. 6. Measuring travel circuit relief pressure 1) Start the engine and lock the travel mechanism.

(F unload valve) (F main relief valve) Service Boom Hi Arm Hi Front Bucket Left travel Boom Safety valve for service F main relief valve F main relief valve F main relief valve RAISE: F main relief valve LOWER: Safety-suction valve

k Set pin [2] between the sprocket and track frame to lock the travel mechanism securely.

(Pump merge-divider valve) (Travel junction valve) (Self-pressure reducing valve) Swing Rear Right travel Arm Lo Swing motor safety valve R main relief valve R main relief valve

(R unload valve) (R main relief valve) (Centralized safety valve) (Back pressure valve)

3. Measuring unload pressure 1) Start the engine. 2) Run the engine at high idling and set all the control levers in neutral and measure the oil pressure. a The pressure measured when the unload valve is unloaded is indicated. 4. Measuring work equipment circuit relief pressure 1) Start the engine and move the cylinder to be measured to the stroke end. 2) Run the engine at high idling and relieve the cylinder and measure the oil pressure. a The pressure measured when the main relief valve is relieved is indicated.

2) Run the engine at high idling and relieve the travel circuit and measure the oil pressure. a The pressure measured when the main relief valve is relieved is indicated. The travel circuit is always relieved at high pressure.

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Adjusting a The unload valve cannot be adjusted. 1. Adjusting main relief pressure a 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 a When adjusting the main relief valve on the front pump side, remove the control valve top cover. a When adjusting the main relief valve on the rear pump side, remove the control valve undercover (if the covers are installed). a 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.) a 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.

5) Connect pilot hose (5). 6) 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) a If the high relief pressure of the boom LOWER circuit is abnormal, adjust the high pressure setting side of boom LOWER safetysuction valve (8) according to the following procedure. a 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.

1) Disconnect pilot hose (5). 2) Fixing holder (6), loosen locknut (7). 3) Turn holder (6) to adjust the pressure. a If the holder is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} 4) Fixing holder (6), tighten locknut (7). 3 Locknut: 49.0 – 58.8 Nm {5 – 6 kgm}

1) Disconnect pilot hose (9). 2) Fixing holder (10), loosen locknut (11). 3) Turn holder (10) to adjust the pressure. a If the holder is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of holder: Approx. 25.3 MPa {Approx. 258 kg/cm2} 4) Fixing holder (10), tighten locknut (11). 3 Locknut: 93 – 123 Nm {9.5 – 12.5 kgm}

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4. Adjusting swing relief pressure a If the relief pressure of the swing circuit is abnormal, adjust swing motor safety valve (14) according to the following procedure.

5) Connect pilot hose (9). 6) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above. a 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) a 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. a 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. 1) Disconnect pilot hose (9). 2) Fixing holder (12), loosen locknut (13). 3) Turn holder (12) to adjust the pressure. a If the holder is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of holder: Approx. 25.3 MPa {Approx. 258 kg/cm2} 4) Fixing holder (12), tighten locknut (13). 3 Locknut: 78 – 93 Nm {8.0 – 9.5 kgm} 5) Connect pilot hose (9). 6) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.

1) Fixing adjustment screw (15), loosen locknut (16). 2) Turn adjustment screw (15) to adjust the pressure. a If the adjustment screw is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of adjustment screw: 4.70 MPa {47.9 kg/cm2} 3) Fixing adjustment screw (15), tighten locknut (16). 3 Locknut: 147 – 196 Nm {15 – 20 kgm}

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

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MEASURING BASIC PRESSURE IN CONTROL CIRCUIT

MEASURING BASIC PRESSURE IN CONTROL CIRCUIT
a Measuring instruments for basic pressure in control circuit
Symbol 1 L 2 Part No. 799-101-1502 790-261-1203 799-101-5220 07002-11023 Part Name Hydraulic tester Digital hydraulic tester Nipple (10 × 1.25 mm) O-ring

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.

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1. Remove the control valve top cover and remove control circuit basic pressure pick-up plug (1). a The figure shows the control valve seen from inside of the pump room.

5. After finishing measurement, remove the measuring instruments and return the removed parts. a The relief valve for the control circuit basic pressure is not adjustable.

2. Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.

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TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
a Testing and adjusting instruments for oil pressure in pump PC control circuit
Symbol 1 M 2 Part No. 799-101-1502 790-261-1203 799-101-5220 07002-11023 Part Name Hydraulic tester Digital hydraulic tester Nipple (10 × 1.25 mm) O-ring

2) Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}. • The figure shows the pump discharge pressure side.

Measuring a 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. k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. • The figure shows the PC valve output pressure side.

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

3) Run the engine and raise the hydraulic oil temperature to the operating range.

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4) Run the engine at high idling and measure the pump discharge pressure and PC valve output pressure (servo piston inlet pressure) at the same time under the following condition. • Working mode: A • Swing lock switch: ON (2-stage relief solenoid valve is turned ON and oil is relieved at high pressure) • Work equipment, swing, and travel circuits: Relieve by moving arm IN. a Judging method: If the pump discharge pressure and PC valve output pressure (servo piston output pressure) are as follows, they are normal.
Measured pressure Pump discharge pressure PC valve output pressure Pressure ratio 1 Approx. 0.6 (Approx. 3/5)

2. Measuring PC-EPC valve output pressure 1) Open the pump room cover and remove PC-EPC valve output pressure pick-up plug (5).

2) Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.

a 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”. 5) After finishing measurement, remove the measuring instruments and return the removed parts.

3) Run the engine and raise the hydraulic oil temperature to the operating range.

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4) Set all the control levers in neutral and measure the oil pressure while running the engine at low idling and high idling. a If the PC-EPC valve output pressure changes as shown below, it is normal.
Engine Low idling Neutral High idling Control lever Oil pressure 2.94 MPa {30 kg/cm2} 0 MPa {0 kg/cm2}

5) After finishing measurement, remove the measuring instruments and return the removed parts. Adjusting a 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 is drastically reduced. • The engine speed is normal but the work equipment speed is low. • (6): Front pump PC valve • (7): Rear pump PC valve a The width across flats of the PC valve locknut is 13 mm, and the adjustment screw (inside width) is 4 mm. Do not turn any other locknuts or adjustment screws since they effect the hydraulic pumps.

2. Turn adjustment screw (9) to the right or left to adjust. a 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). a The adjustable range of the adjustment screw is as follows. • Counterclockwise: Max. 1 turn • Clockwise: Max. 1 turn 3. Tighten locknut (8). 3 Locknut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}

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.

1. Loosen locknut (8). a 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).

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TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
a Testing and adjusting instruments for oil pressure in pump LS control circuit
Symbol 1 N Part No. 799-101-5002 790-261-1203 799-101-5220 07002-11023 799-401-2701 Part Name Hydraulic tester Digital hydraulic tester Nipple (10 × 1.25 mm) O-ring
Differential pressure gauge

2) Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}. • The figure shows the pump discharge pressure side.

2 3

Measuring a 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.

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1. Measuring LS valve output pressure (servo piston inlet pressure) a Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and compare them. 1) Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (3), and (4). • (1): Front pump discharge pressure pickup plug • (2): Rear pump discharge pressure pickup plug • (3): Front LS valve output pressure pickup plug • (4): Rear LS valve output pressure pickup plug

The figure shows the LS valve output pressure side.

3) Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. • When measuring front circuit: Left track shoe • When measuring rear circuit: Right track shoe

k Since the track shoe pushed up will be driven idle for measurement, secure sufficient work area.

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TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

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

4) Run the engine at high idling and measure the pump discharge pressure and LS valve output pressure (servo piston inlet pressure) at the same time under the following condition. • Working mode: A • Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only the travel lever operated halfway (with the track shoe on one side driven idle). a Check the safety around the machine, drive the track shoe pushed up idle. a Judging method: If the pump discharge pressure and LS valve output pressure (servo piston output pressure) are as follows, they are normal.
Measured pressure Pump discharge pressure LS valve output pressure Pressure ratio Travel lever All levers operated in neutral halfway Almost same 1 Approx. 0.6 (Approx. 3/5)

• •

(5): Front LS valve output pressure pickup plug (6): Rear LS valve output pressure pickup plug

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

2) Install nipple N2 and connect it to differential pressure gauge N3 or the oil pressure gauge of hydraulic tester N1. a 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.

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TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

a When using oil pressure gauge: Use the oil pressure gauge of 58.8 MPa {600 kg/cm2}. Since the differential pressure is about 2.9 MPa {30 kg/cm2} at maximum, measure it by installing the same gauge to the pick-up plugs alternately. • The figure shows the pump discharge pressure side.

The figure shows the LS valve output pressure side.

4) Run the engine at high idling and measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time under the following condition. • Working mode: A • Travel speed: Hi • Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only the travel lever operated halfway (with the track shoe on one side driven idle). a Check the safety around the machine, drive the track shoe pushed up idle. a Calculation of LS differential pressure (When oil pressure gauge is used): LS differential pressure = Pump discharge pressure – LS pressure a If the LS differential pressure is as follows, it is normal.
LS differential pressure Unload pressure Set all levers in (See standard values neutral table) Specified LS differenOperate travel lever tial pressure halfway (See standard values (Run track shoe idle) table) Operation of lever

3) Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. • When measuring front circuit: Left track shoe • When measuring rear circuit: Right track shoe k Since the track shoe pushed up will be driven idle for measurement, secure sufficient work area.

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

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TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

3. Measuring LS-EPC valve output pressure 1) Open the pump room cover and remove LSEPC valve output pressure pick-up plug (7).

4) Operate the travel speed switch and travel lever and measure the oil pressure while running the engine at high idling. a If the LS-EPC valve output pressure changes as shown below, it is normal.
Travel speed Lo Hi Travel lever Netral Fine operation (Note) Oil pressure 2.94 MPa {30 kg/cm2} 0 MPa {0 kg/cm2}

Note: Operate the travel lever to a degree that the PPC oil pressure switch is turned ON (Stop before the machine starts traveling). 2) Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}. 5) After finishing measurement, remove the measuring instruments and return the removed parts. Adjusting a 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

3) Run the engine and raise the hydraulic oil temperature to the operating range.

1. Fixing adjustment screw (10), loosen locknut (11). 2. Turn adjustment screw (10) to adjust the differential pressure. a If the adjustment screw is • Turned to the right, differential pressure rises. • Turned to the left, differential pressure lowers. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. 1.3 MPa {Approx. 13.3 kg/cm2}

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TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

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

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TESTING AND ADJUSTING

MEASURING SOLENOID VALVE OUTPUT PRESSURE

MEASURING SOLENOID VALVE OUTPUT PRESSURE
a Measuring instruments for solenoid valve output pressure
Symbol 1 P 2 Part No. 799-101-5002 790-261-1203 799-401-3100 799-401-3200 Part Name Hydraulic tester Digital hydraulic tester Adapter (Size 02) Adapter (Size 03)

2. Install adapter P2 and reconnect the hose. 3. Install nipple [1] of hydraulic tester P1 and connect it to hydraulic gauge [2]. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}. a The figure shows the measuring instruments connected to the outlet hose of the 2-stage relief solenoid valve.

a Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal. k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure.

1. Remove the control valve top cover and disconnect outlet hoses (1) – (7) of the solenoid valve to be removed. a 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.

4. Run the engine and raise the engine oil temperature to the operating range.

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

1 2 3 4 5 6 7

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. a For the conditions for turning the solenoid valve ON and OFF, see the operations table of each solenoid valve. a The operating condition of the solenoid valve can be checked with the monitoring function of the monitor panel (For the operating method, see “Special functions of machine monitor”).

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MEASURING SOLENOID VALVE OUTPUT PRESSURE

a If the output pressure is as follows, the solenoid valve is normal.
Solenoid valve OFF (Deenergized) Output pressure 0 MPa {0 kg/cm2} Almost same as control basic pressure (See standard values table)

ON (Energized)

6. After finishing measurement, remove the measuring instruments and return the removed parts. Operation table of 2nd-stage relief solenoid valve
Operating condition When overheating No. 1 setting is turned ON When all of work equipment, swing, and travel signals are turned OFF When swing lock switch is turned ON When travel signal is turned ON When in L-mode When boom LOWER signal is turned ON When signal other than swing sinWhen left knob switch gle operation signal is turned ON is turned ON When swing single operation signal is turned ON ON Operation OFF

When in A/E-mode

OFF

When not under above condition

Operation table of machine push-up solenoid valve
Operating condition OFF Machine push-up switch ON Operation ON OFF

Operation table of swing holding brake solenoid valve
Operating condition Work equipment, swing, travel signal When one of them is turned ON When all are turned OFF Operation OFF ON

Operation table of travel speed shifting solenoid valve
Operating condition 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 When travel signal is turned OFF When F or R pump pressure is 2 When travel signal is above 32.3 MPa {330 kg/cm } turned ON When F or R pump pressure is below 18.6 MPa {190 kg/cm2} Operation

OFF

When travel speed switch is set to Mi or Hi

ON

When not under above condition

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MEASURING SOLENOID VALVE OUTPUT PRESSURE

Operation table of merge-divider solenoid valve
When in B-mode Operating condition When service signal is turned ON When travel operation is performed singly When not in L-mode When travel signal is When work equipment, turned ON switch, and service signals are turned ON When F or R pump pressure is above 19.6 MPa {200 kg/cm2} When F or R pump pressure is below 14.7 MPa {150 kg/cm2} Operation ON

OFF ON OFF ON OFF

When travel signal is When swing signal is turned OFF turned OFF When not under above condition

When F or R pump pressure is above 16.7 MPa {170 kg/cm2} When in L-mode When F or R pump pressure is below 11.8 MPa {120 kg/cm2} When F or R pump pressure is When arm IN and above 24.5 MPa {250 kg/cm2} bucket CURL PPC pressures are above When F or R pump pressure is 1.9 MPa {19.5 kg/cm2} below 19.6 MPa {200 kg/cm2}

Operation table of travel junction solenoid valve
Operating condition When travel steering signal is turned ON When travel steering signal is turned OFF When travel system is When F or R pump pressure is operated singly above 34.3 MPa {350 kg/cm2} When not under above condition ON OFF Operation

Operation table of PPC lock solenoid valve
Operating condition Lock Safety lock lever Free OFF ON

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TESTING AND ADJUSTING

MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE OUTPUT PRESSURE
a Measuring instruments for PPC valve output pressure
Symbol 1 2 Part No. 799-101-5002 790-261-1203 790-301-1740 Part Name Hydraulic tester Digital hydraulic tester Joint (PF 1/4 + PT 1/8)

Q

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1. Remove the control valve top cover and operator’s cab undercover. 2. Disconnect PPC oil pressure switch or PPC pressure sensors (1) – (10) of the solenoid valve to be removed. a 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, reconnect it to the connector and clamp it to the nearest bracket.
No.

3. Install joint Q2 and nipple [1] of hydraulic tester Q1 and connect them to oil pressure gauge [2]. a Use joint Q2 only when measuring the pressure at the pressure sensor mounting part. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}. a The figure shows the measuring instruments installed to the mounting part of the arm IN PPC pressure sensor.

Circuit to be measured
Boom RAISE (S06) Boom LOWER (S02) Arm IN (S04) Arm OUT (S08) Bucket CURL (S01) Bucket DUMP (S05)

No.

Circuit to be measured Swing LEFT (S07) Swing RIGHT (S03) Travel (S30)

1 2 3 4 5 6

7 8 9

10 Steering (S31)

4. Run the engine and raise the engine oil temperature to the operating range.

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MEASURING PPC VALVE OUTPUT PRESSURE

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. a If the PPC valve output pressure is as follows, the solenoid valve is normal.
Operation of lever In neutral Operated to stroke end Output pressure 0 MPa {0 kg/cm2} Almost same as control basic pressure (See standard values table)

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

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TESTING AND ADJUSTING

ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES

ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
a If the work equipment and swing levers have excessive play, adjust them according to the following procedure. 1. Remove the work equipment and swing PPC valve assembly. 2. Remove bellows (1). 3. Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4). a Do not move the piston at this time. 4. Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 98 – 127 Nm {10 – 13 kgm} 5. Install bellows (1). 6. Install the work equipment and swing PPC valve assembly.

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TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
a 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 1) Set the machine in the position of measuring hydraulic drift and stop the engine. a Fill the bucket with a rated load or with dirt and sand. 2. Testing arm cylinder 1) Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine.

2) 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. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator.

2) 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. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. [Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) 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. 2) 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. 3) 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.

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TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT

3. Testing PPC valve While the pressure in the accumulator is high, set the safety lock lever in the LOCK/FREE position and measure the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. a 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).

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TESTING AND ADJUSTING

RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT

RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
1. Releasing residual pressure in hydraulic tank k Since the hydraulic tank is enclosed and pressurized, release the residual pressure in it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable position and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank. 3. Releasing residual pressure in swing motor circuit a 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 control lever in the swing direction only.) 4. Releasing residual pressure in travel motor circuit a 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.

2. Releasing residual pressure in hydraulic cylinder circuit

k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the residual pressure in the piping according to the following procedure. 1) Release the residual pressure in the hydraulic tank. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK. a Keep the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch ON and set the safety lock lever in the FREE position, then operate the work equipment control levers on both sides forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. However, the accumulator pressure is released after the control valve is operated 2 – 3 times. 3) Run the engine at low idling for 5 seconds to heighten the pressure in the accumulator. a When starting engine, set the safety lock lever in the LOCK position. 4) Repeat steps 2) and 3) above 2 – 3 times, and the residual pressure in the piping is released.

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MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE
a Measuring device for oil leakage
Symbol R Part No. Commercially available Part Name Measuring cylinder

2. Measuring oil leakage from arm cylinder 1) Run the engine and raise the engine oil temperature to the operating range. 2) Move the arm cylinder to the IN stroke end and stop the engine.

1. Measuring oil leakage from boom cylinder 1) Run the engine and raise the engine oil temperature to the operating range. 2) Move the boom cylinder to the RAISE stroke end and stop the engine.

k Release the residual pressure in the piping on the boom cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT. (Operate the control lever in the boom RAISE direction only.) 3) Disconnect hose (1) on the cylinder head side and block the hose side with a plate. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-01044 (Flange #10)

k Release the residual pressure in the piping on the arm cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT. (Operate the control lever in the arm IN direction only.) 3) Disconnect hose (2) on the cylinder head side and block the hose side with a plate. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-01044 (Flange #10)

k Take care not to “move the arm OUT”. 5) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 4) Run the engine at high idling and relieve the boom circuit by raising the boom.

4) Run the engine at high idling and relieve the arm circuit by moving the arm IN.

k Take care not to “lower the boom”. 5) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 6) After finishing measurement, return the removed parts.

6) After finishing measurement, return the removed parts.

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MEASURING OIL LEAKAGE

3. Measuring oil leakage from bucket cylinder 1) Run the engine and raise the engine oil temperature to the operating range. 2) Move the bucket cylinder to the CURL stroke end and stop the engine.

k Release the residual pressure in the piping on the bucket cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT. (Operate the control lever in the arm CURL direction only.) 3) Disconnect hose (3) on the cylinder head side and block the hose side with a plate. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-01044 (Flange #10)

4. Measuring oil leakage from swing motor 1) Run the engine and raise the engine oil temperature to the operating range. 2) Disconnect drain hose (4) and block the hose side with a plug. a Use the following part to block the hose side. 07376-70522 (Plug #05)

3) Turn the swing lock switch ON. 4) Run the engine at high idling and relieve the swing circuit by swinging. a Measure the oil leakage for 1 minute after 30 seconds since relieving is started. a After measuring 1 time, swing 180°, and then measure again. 5) After finishing measurement, return the removed parts. 4) Run the engine at high idling and relieve the bucket circuit by curling the bucket.

k Take care not to “dump the bucket”. 5) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 6) After finishing measurement, return the removed parts.

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MEASURING OIL LEAKAGE

5. Measuring oil leakage from travel motor 1) Remove the travel motor cover. 2) Run the engine and raise the engine oil temperature to the operating range, and then lock the travel system and stop the engine.

k Put pin [1] between the sprocket and track frame to lock the travel system securely.

3) Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Use the following part to block the hose side. 07376-70522 (Plug #05)

k Wrong operation of the lever can cause an accident. Accordingly, make signs and checks securely. a Measure the oil leakage for 1 minute after 30 seconds since relieving is started. a 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. 5) After finishing measurement, return the removed parts.

4) Run the engine at high idling and relieve the travel circuit.

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BLEEDING AIR FROM EACH PART

BLEEDING AIR FROM EACH PART
1 Bleeding air from hydraulic pump q 2 Starting engine q q q q q Air bleeding procedure 3 4 5 Bleeding Bleeding Bleeding air from air from air from swing travel cylinder motor motor q q q (See note) (See note) 6 Check oil level and starting work q q q

Air bleeding item Work • • • • • • • • • • • • • • • Replacing hydraulic oil Cleaning strainer 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

q q q

q q q

q q q

q

q

q

q

q

Note:

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 1) Loosen bleeder (1) and check that oil flows out. 2) If the oil does not flow out, disconnect drain hose (2) and fill the pump case with oil through the drain port. a Fix the drain hose adapter to a place higher than the oil level in the hydraulic tank. a Fill the pump case with oil until oil containing no bubbles flows out of the bleeder. 3) After oil containing no bubbles flows out of bleeder (1), tighten air bleeder (1). 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} a If the drain hose has been disconnected, connect it after tightening the air bleeder.

2. Starting engine When running the engine after performing step 1, keep its speed at low idling for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation has started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial. (Set the starting switch to the ON position and hold the fuel control dial in the MAX position for 3 seconds, the automatic warm-up operation is reset.)

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BLEEDING AIR FROM EACH PART

3. Bleeding air from cylinder a 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. 1) Run the engine at low idling for about 5 minutes. 2) Running the engine at low idling, raise and lower the boom 4 – 5 times. a Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil. 3) Running the engine at high idling, perform step 2). 4) Running the engine at low idling, move the piston rod to the stroke end and relieve the oil. 5) Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4). 4. Bleeding air from swing motor 1) Run the engine at low idling. 2) Loosen hose (3) of port S slowly and check that oil flows out.

5. Bleeding air from travel motor 1) Remove the travel motor cover. 2) Run the engine at low idling. 3) Loosen bleeder (4) and check that oil flows out. 4) After oil containing no bubbles flows out, tighten bleeder (4). 3 Bleeder: 9.8 – 12.74 Nm {1.0 – 1.3 kgm}

k At this time, do not perform the swinging operation. 3) If the oil does not flow out, stop the engine and disconnect the hose of port S and fill the pump case with oil. a After filling the pump case with oil, connect the hose of port S, and then repeat steps 1) and 2). 4) After oil containing no bubbles flows out, tighten the hose of port S. 5) Slowly swing 2 turns or more in each direction.

5) Using the work equipment, raise the track shoe on either side. 6) Drive the raised track shoe idle slowly for about 2 minutes. a Drive the track shoe on the opposite side idle similarly.

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BLEEDING AIR FROM EACH PART

6. Check oil level and starting work 1) 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.

2) Check the oil level by sight gauge (5) of the hydraulic tank. a If the oil level is between lines H and L, it is normal. a If the oil level is below line L, add new oil.

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TESTING PROCEDURE OF DIODE

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

1. When using a digital tester 1) Set the tester in the diode range and check the indicated value. a If an ordinary tester is used, the voltage of the battery in itself is indicated. 2) 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. 3) Judge the condition of the diode from the indicated value. • The indicated value does not change: There is no continuity (Defective). • The indicated value changes: There is continuity (Normal) (Note). Note: In the case of a silicon diode, the tester indicates a value of 460 – 600.

2. When using an analog tester 1) Set the tester in the resistance range. 2) Apply the test pins as shown 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. 3) Judge the condition of the diode from movement of the pointer. • The pointer does not move in step i) above but moves in step ii): Normal (Moving angle (resistance) depends on the type and measurement range of the tester) • The pointer moves in both step i) and step ii): Defective (Internal short circuit) • The pointer does not move in either step i) or step ii): Defective (Internal disconnection)

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SPECIAL FUNCTIONS OF MONITOR PANEL

SPECIAL FUNCTIONS OF MONITOR PANEL

[1] Numeral input switch 1 [2] Numeral input switch 2 [3] Numeral input switch 3 [4] Numeral input switch 4 [5] Numeral input switch 5

[6] Numeral input switch 6 [7] Numeral input switch 7 [8] Numeral input switch 8 [9] Numeral input switch 9 [0] Numeral input switch 0

[ [ [ [

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

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SPECIAL FUNCTIONS OF MONITOR PANEL

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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Function of inputting and setting password Screen to display KOMATSU logo Function of check before starting Function of displaying maintenance items Function of displaying caution items Function of checking working mode and travel speed Function of displaying ordinary screen Function of adjusting brightness and contrast of display Function of adjusting flow rate for breaker and attachments Function of checking maintenance information Function of displaying service meter Function of checking display LCD Function of displaying cautions Function of displaying user code Function of displaying error code and failure code 22 Function of adjustment [07] 21 Function of initial setting and default [06] 17 18 19 20 16 Function of abnormality record [02] Service Menu Function of monitoring [01] Electrical system Mechanical system

Function of maintenance record [03] Function of maintenance mode change [04] Function of phone No. entry [05] Mode in which key is ON Language Unit With/Without service circuit Pump absorption torque Adjustment of flow for attachment during compound operation

23

Function of cylinder cut out mode operation [09]

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SPECIAL FUNCTIONS OF MONITOR PANEL

Operation and display of Operator ’s Menu (Outline)
a Only outline of the operating method is described in this section. For details of contents and operation of each menu, see OPERATION MANUAL or the volume of STRUCTURE AND FUNCTION. 1. Function of inputting and setting password When the starting switch is turned ON, the screen to input a password is displayed. a This screen is displayed only when the password function is set. 2. Screen to display KOMATSU logo When a password is input (if it is set) or when the starting switch is turned ON, the KOMATSU logo is displayed for 2 seconds.

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

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

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5. Function of displaying caution items After the screen for check before starting is displayed, if any check item is abnormal, the corresponding symbol mark is displayed.

6. Function of checking working mode and travel speed After the screen for check before starting is displayed, the symbol marks of the working mode and travel speed are displayed in large size for 2 seconds to urge the operator to check the setting.

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

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

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SPECIAL FUNCTIONS OF MONITOR PANEL

9. Function of adjusting flow rate for breaker and attachments (for machine with breaker or attachment) The operator can adjust the pump flow rate for the breaker or an attachment with the selector switch. a The symbol marks and description of the breaker and attachment shown on the screen are partly different.

10. Function of checking maintenance information The operator can check the detailed information about the maintenance items (set time and elapsed time) and reset them after checking with the maintenance switches. a The maintenance function is set and reset and the maintenance time is set with the service menu.

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

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

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SPECIAL FUNCTIONS OF MONITOR PANEL

13. Function of displaying cautions If there is any abnormal item in the calculation items, the corresponding symbol mark is displayed in large size for 2 seconds, then it is displayed in small size until the abnormal item is repaired.

14. Function of displaying user code If the machine has any failure, the corresponding user code is displayed to urge the operator to take a proper remedy, depending on the degree of the failure. a If any switch is operated while the user code is displayed, the service code and failure code screen appears (See 15).

a User codes and instructions given to operator
User code E02 Failure mode Instructions given to operator If the emergency pump drive switch is set in the upper (emergency) position, the machine can operate normally. Have the machine inspected immediately, however. Set the swing holding brake release switch in the upper (release) position to release the brake. Apply the swing brake manually with the swing lock switch, if necessary. The brake may not be released, depending on the cause of the failure. In any case, have the machine inspected immediately.

Error in pump control system

E03

Error in swing brake system

E10

Error in engine controller power supply or abnormality in engine controller drive system circuit (Engine stops)

Have the machine inspected immediately.

E11 E14

Error in engine controller system Set the machine in a safe position and have the machine inspected immedi(Engine protection output is down) ately. Error in throttle system Error in engine sensor (coolant temperature, fuel temperature, or oil pressure) Error in network Set the machine in a safe position and have the machine inspected immediately. Although the machine can operate normally, have the machine inspected immediately. Set the machine in a safe position and have the machine inspected immediately.

E15

E0E

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15. Function of displaying error code and failure code While a user code is displayed, if the following switches are operated, the phone mark (if registered), phone No. (if registered), error code, and failure code are displayed in order. • Operation of switch: [ ] a The following are displayed in order repeatedly as the switch is operated. (1) Phone mark (2) Phone No. (3) Error code and failure code a The phone mark and phone No. are displayed only when the phone No. is registered in the monitor panel. The phone No. is registered, changed, or deleted with the service menu. a For details of the displayed error code and failure code, see the error codes and failure codes table.

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Table for Error and Failure Code Nos.
History division Electrical system User code Error code Code Contents Code Failure code Component Trouble Short Circuit Short Circuit Short Circuit Disconnection Malfunction Defective communication (Abnormality in related component) Defective communication (Abnormality in related component)

— — — — — —

E112 Wiper Drive (For) S/C E113 Wiper Drive (Rev) S/C E114 Washer Drive S/C E115 Wiper Working Abnormality E116 Wiper Parking Abnormality E117 Eng. Controller S-NET Comm Err.

DY2DKB Wiper motor (Forward) DYDEKB Wiper Motor (Reverse) Windshield Washer DY2CKB Motor DY20KA Wiper Motor DY20MA Wiper Motor DAC0KR Engine Controller

E118 Pump Controller S-NET Comm Err.

DAB0KR Pump Controller DAFRMC DW91KB DW45KB DWJ0KB DWK0KB DW43KB DW91KA DW45KA DWJ0KA DWK0KA DW43KA

E0E E128 Monitor Comm. Abnormality — E201 Travel Junction Sol. S/C

Monitor CAN CommuniDefective Operation cation Travel Neutral Solenoid Valve Swing Holding Brake Solenoid Valve Pump Merge-divider Solenoid Valve 2-stage Relief Solenoid Valve Short Circuit Short Circuit Short Circuit Short Circuit

E03 E203 Swing Brake Sol. S/C — — — — E204 Merge-divider Sol. S/C E205 2-stage Relief Sol. S/C E206 Travel Speed Sol. S/C E211 Travel Junction Sol. Disc.

Travel Speed Hi/Lo Short Circuit Selector Solenoid Valve Travel Neutral Solenoid Valve Swing Holding Brake Solenoid Valve Pump Merge-divider Solenoid Valve 2-stage Relief Solenoid Valve Disconnection Disconnection Disconnection Disconnection

E03 E213 Swing Brake Sol. Disc. — — — — E214 Merge-divider Sol. Disc. E215 2-stage Relief Sol. Disc. E216 Travel Speed Sol. Disc. E217 Model Selection Abnormality

Travel Speed Hi/Lo Disconnection Selector Solenoid Valve Disagreement of Model Selection Signals Disconnection Short Circuit Disconnection Malfunction Malfunction Lowering of Output Voltage Malfunction Short Circuit Short Circuit

Pump Controller Model DA2SKQ Selection Wiring Harness DA2SKA Pump Controller S-NET Communication

E0E E218 S-Net Comm. Disc. — — — — — — — E222 LS-EPC Sol. S/C E223 LS-EPC Sol. Disc. E224 F Pump P. Sensor Abnormality E225 R Pump P. Sensor Abnormality E226 Press. Sensor Power Abnormality E227 Engine Speed Sensor Abnormality E228 Service Return Relay S/C

DXE0KB LS-EPC Solenoid Valve DXE0KA LS-EPC Solenoid Valve F Pump Pressure SenDHPAMA sor DHPBMA DA25KP R Pump Pressure Sensor Pump Controller Power Supply Output ATT Selector Relay

DLE2MA Engine Speed Sensor D196KB DXA0KB TVC Solenoid Valve

E02 E232 PC-EPC Sol. S/C

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Code

Contents

Code D196KA DXE4KB DXE4KA DHS3MA DHS4MA DHX1MA

Component ATT Selector Relay ATT Flow Throttle EPC Valve ATT Flow Throttle EPC Valve Arm IN PPC Pressure Sensor Bucket CURL PPC Pressure Sensor

Trouble Disconnection Disconnection Short Circuit Disconnection Malfunction Malfunction Malfunction Defective Operation Short Circuit Disagreement of Speed Signal Disagreement of Speed Signal

E02 E233 PC-EPC Sol. Disc. — — — — — — E238 Service Return Relay Disc. E245 Service Current EPC S/C E246 Service Current EPC Disc. E247 Arm Curl PPC Sen. Abnormality E248 Bucket Curl PPC Sen. Abnormality E251 Overload Sensor Abnormality

DXA0KA TVC Solenoid Valve

E0E E257 Pump Comm. Abnormality — E315 Battery Relay Drive S/C

Pump Controller CAN DA2RMC Communication D110KB DLE3LC Battery Relay NE Speed Sensor

E11 E91B Engine Ne Sensor Problem E11 E91C Engine G Sensor Problem E11 E920 Engine Type Selection Error E11 E921 Engine Type Mismatch E14 E931 Fuel Dial sys. error E15 E934 Engine Coolant Sensor Hi Error E15 E936 Engine Oil Press. Sw. Error E11 E93C Engine Boost Sensor Error E15 E93D Engine Fuel Temp. Sensor Error E0E E953 Engine Comm. Abnormality — E954 Short Engine Starter SW.

DLH1LC G Speed Sensor

Engine Controller Model Disagreement of Model DB29KQ Selection Wiring HarSelection Signals ness DB20KQ Engine Controller DK10KX Throttle Angle Sensor Disagreement of Model Selection Signals Out of input signal range Electrical system

Engine Coolant TemperDGE2KX Out of input signal range ature Sensor DDE2L6 Engine Oil Pressure Switch Disagreement of signal with operation of engine Out of input signal range Out of input signal range Defective Operation Short Circuit Defective Operation Lowering of source voltage (Input) Short Circuit

DH30KX Boost Pressure Sensor Fuel Temperature SenDGE4KX sor DB2RMC Engine Controller CAN Communication

DD11KB Starter SW Engine Controller SDB2SMC NET Communication DB22KK D1D0KB DB2AMA DGE3L6 AD11KB AD51KB AD11KA AD51KA DH40KX Engine Controller Load Power Supply Line Engine Controller Load Power Supply Relay

E0E E955 Engine S-NET error E10 E956 Engine Power Failure (1) E15 E957 Engine Power Failure (2) — E95A Engine Q-adj. Sw. Signal Error

Rotary Switch in Engine Malfunction Controller Engine Coolant Temper- Disagreement of signal ature Sensor with operation of engine Supply Pump (1) Solenoid Valve Supply Pump (2) Solenoid Valve Supply Pump (1) Solenoid Valve Supply Pump (2) Solenoid Valve Common Rail Pressure Sensor Short Circuit Short Circuit Disconnection Disconnection Out of input signal range

E15 E96A Engine Coolant Sensor Lo Error E11 E970 PCV1 Over Current E11 E971 PCV2 Over Current E11 E974 PCV1 Line Cut E11 E975 PCV2 Line Cut E11 E977 Rail Press. Sensor Error

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History division

User code

Error code

Failure code

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Code

Contents

Code AD00L2

Component Common Rail

Trouble Abnormally High Fuel Pressure Malfunction Out of control Lowering of Function Malfunction Abnormality in Controller

E11 E979 Rail Press. High 1 E11 E97A Rail Press. High 2 E15 E97B Rail press. low E11 E97C Rail press. too low E11 E97D Rail Press. Out of Control E11 E980 Eng. Controller Abnormality E11 E981 Fuel Injector 1 Disc. E11 E982 Fuel Injector 2 Disc. E11 E983 Fuel Injector 3 Disc. E11 E984 Fuel Injector 4 Disc. E11 E985 Fuel Injector 5 Disc. E11 E986 Fuel Injector 6 Disc. E11 E98A Fuel Injector 1 – 3 S/C E11 E98B Fuel Injector 4 – 6 S/C E22 E922 Eng. Hi Out of Std — — — — — — — — Eng. Lo Out of Std Aircleaner Clogging Charge Voltage Low Eng. Oil Press. Low Eng. Oil LvI. Low Eng. Coolant Overheat Eng. Coolant Lvl Low Hydr. Oil Overheat

AD00MA Common Rail AD10L3 Supply Pump AD10MB Supply Pump AD10MA Supply Pump DB20KT Engine Controller

ADA1KA Injector 1 Solenoid Valve Disconnection ADB1KA Injector 2 Solenoid Valve Disconnection ADC1KA Injector 3 Solenoid Valve Disconnection ADD1KA Injector 4 Solenoid Valve Disconnection ADE1KA Injector 5 Solenoid Valve Disconnection ADF1KA Injector 6 Solenoid Valve Disconnection ADAZKB ADDZKB A000N1 A000N2 Injector 1, 2, 3 Solenoid Valve Injector 4, 5, 6 Solenoid Valve Engine Engine Short Circuit Short Circuit Overrun Clogging Defective Charge Lowering of Oil Pressure Lowering of level Overheating Lowering of level Overheating

AA10NX Air Cleaner Element AB00KE Alternator B@BAZG Engine Oil B@BAZK Engine Oil B@BCNS Coolant B@BCZK Coolant B@HANS Hydraulic Oil

a The items in this table are arranged in the order of the error codes. a The error codes having no numbers in the user code column and the failure codes having no numbers in the user code column and error code column are not displayed on the normal screen, even if abnormality related to them occurs. They are simply recorded in the failure history of the service menu (Electrical equipment system or mechanical equipment system). a The history division column shows in which division each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the failure history. a Letter “E” at the head of each error code indicates the following condition. • With E: The failure has not been repaired yet. • Without E: The failure has been repaired.

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Mechanical system

Out of input signal range

Electrical system

History division

User code

Error code

Failure code

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Operation and display of Service Menu
How to select service menu a When using the service menu, perform the following special operation to change the screen. 1) Checking display Check that the ordinary screen is displayed. a The service menu can be selected only while the ordinary screen is displayed.

2) Operating switches Operate the following switches. • Operation of switches: [ ] o [1] o [2] o [3] (While pressing [ ], press the numeral keys) 3) Displaying menu screen The initial screen of the service menu is displayed. Select a menu which you will use.
No. 00 01 02 03 04 05 06 07 09 Service menu Return (Finish service menu) Monitoring Abnormality record Maintenance record Maintenance mode change Phone number entry Initial setting/Default Adjust Cylinder cut out mode operation

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

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16. Function of monitoring [01] The monitor panel monitors the signals from various switches, sensors, and actuators installed to various parts of the machine. The operator can display and check the monitoring information in real time by the following operation. 1) Selecting menu On the initial screen of the service menu, select “01 Monitoring” and press the [ ] switch.

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

3) Operating for monitoring After the monitoring infomation screen appears, operate the machine to check the monitoring information.

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4) Function of holding monitoring information If the [ ] switch is pressed during the monitoring operation, all the monitoring information is held. If the [ ] switch is pressed while the monitoring information is held, the monitoring information is released.

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

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Monitoring items list
Code No. 00000 Return 99999 To Display Screen 00200 Controller Model Select 00201 Controller Model Select 01002 Engine Speed 01601 2nd Eng. Speed Command 01100 F Pump Pressure 01101 R Pump Pressure 07200 Arm Curl PPC Pressure 07300 Bucket Curl PPC Pressure 04102 Engine Coolant Temp. Hi 14200 Fuel Temperature 04401 Hydr. Oil Temperature 01300 PC-EPC Sol. Curr. 01500 LS-EPC Sol. Curr. 01700 Service Sol. Curr. 03200 Battery Voltage 03500 Battery Relay O/P Vol. 04300 Battery Charge Vol. 01006 Engine Speed 04107 Engine Coolant Temp. Low 36400 Rail Pressure 36500 Boost Pressure 36700 Torque Ratio 03000 Fuel Dial Vol. 04200 Fuel Level Sensor Vol. 04106 Engine Coolant Temp. Vol. Hi 04105 Engine Coolant Temp. Vol. Lo 14201 Fuel Temp. Sensor Vol. 36501 Boost Press. Sensor Vol. 36401 Rail Press. Sensor Vol. 17200 PCV Close Angle 17300 Eng. Control Mode 31701 Throttle Level 36100 Fuel Delivery Command 36200 Rail Pressure Command 36300 Injection Timing Angle % mm3/st MPa CA r/min r/min MPa MPa MPa MPa °C °C °C mA mA mA V V V r/min °C MPa kPa % V V V V V V V CA Monitoring item Unit (Default: ISO) SI meter (Not displayed) (Not displayed) Numerals Numerals rpm rpm kg/cm2 kg/cm
2 2

inch

Remarks Finish Menu Display and Execution Menu

rpm rpm psi psi psi psi °F °F °F mA mA mA V V V rpm °F psi psi % V V V V V V V CA

kg/cm

kg/cm2 °C °C °C mA mA mA V V V rpm °C kg/cm2 kg/cm2 % V V V V V V V CA Numeral % mm3/st kg/cm2 CA

% mm3/st psi CA

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SPECIAL FUNCTIONS OF MONITOR PANEL

Code No.

Monitoring item Swing Travel

Unit (Default: ISO) SI meter ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF inch

Remarks

01900 Pressure Switch 1

Boom Lower Boom Raise Arm Curl Arm Dump Bucket Curl

01901 Pressure Switch 2

Bucket Dump Service Travel Steering Travel Junction Swing Brake

02300 Solenoid 1

Merge-divider 2-stage Relief Travel Speed

02301 Solenoid 2

Service Return Lever Sw.

02200 Switch Input 1

Swing Release Sw. Swing Brake Sw. Model Select 1 Model Select 2

02201 Switch Input 2

Model Select 3 Model Select 4 Model Select 5

02202 Switch Input 3

Key Switch (ACC)

03700 Controller Output 1 Batt. Relay Dr. Key Switch Start 04500 Monitor Input 1 Preheat Light Rad. Level Aircleaner 04501 Monitor Input 2 Eng. Oil Level Battery Charge Swing Brake Sw. Bzzr Cancel Sw. 04502 Monitor Input 3 Window Limit Sw. W Limit Sw. P Limit Sw.

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Code No.

Monitoring item Key SW (C) Eng. Oil Press. Lo

Unit (Default: ISO) SI meter ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF Alphanumerals Alphanumerals ON/OFF ON/OFF Numerals Numerals Numerals inch

Remarks

17400

Eng. Controller Input

Eng. Oil Press. Hi Machine Sel. 1 Machine Sel. 2 Machine Sel. 3

36800 Q Adjust Switch R (ROT-SW1) 36801 Q Adjust Switch L (ROT-SW2) 05100 S-NET Connection Pump Controller Eng. Controller

20200 Monitor Prog. Version 20212 Pump Con. Prog. Version 20209 Eng. Con. Prog. Version

a As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be selected. The unit of display can be changed with “Selecting unit” in the “Setting initial values” function of the service menu. a “CA” of the unit of display denotes the crankshaft angle.

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SPECIAL FUNCTIONS OF MONITOR PANEL

17. Function of abnormality record [02] The monitor panel classifies and records the past failures into the electrical system group and mechanical system group. The operator can display and check those failures by the following operation. 1) Selecting menu On the initial screen of the service menu, select “02 Abnormality Record” and press the [ ] switch.

2) Selecting sub-menu On the abnormality record menu screen, select a sub-menu and press the [ } switch.
No. 00 01 02 Sub-menu of abnormality record Return (Finish sub-menu) Electrical systems Mechanical systems

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

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

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5) Resetting electrical system abnormality record a Only the abnormality record of the electrical system can be reset (deleted). The abnormality record of the mechanical system cannot be reset. a If necessary, reset each item or all items of the abnormality record of the electrical system according to the following procedure. i) While the electrical system abnormality record screen is displayed, operate the following switches to display the reset screen. • Operation of switches: [ ] + [1] [2] [3] a This operation is the same as that for selecting the service menu. ii) Operate the switches according to the direction shown on the reset screen. a When resetting only 1 item, be sure display it with the [ ] switch or [ ] switch, and then perform the reset procedure. a When resetting all the items, you can perform the reset procedure, regardless of the item displayed on the screen.

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SPECIAL FUNCTIONS OF MONITOR PANEL

18. Function of maintenance record [03] The monitor panel records the maintenance information about the filters and oils. The operator can display and check that information by the following operation. 1) Selecting menu On the initial screen of the service menu, select “03 Maintenance Record” and press the [ ] switch.

2) Displayed information (1) Names of oils and filters (2) Number of replacement times up to now (3) Service meter reading at previous replacement

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SPECIAL FUNCTIONS OF MONITOR PANEL

19. Function of maintenance mode change [04] The condition for setting the operation of the maintenance display function can be changed according to the following procedure. • Set the function effective or ineffective. • Change the set replacement interval. 1) Selecting menu On the initial screen of the service menu, select “04 Maintenance Mode Change” and press the [ ] switch.

2) Selecting item to be changed On the screen of maintenance mode changing menu, select an item to be changed.
No. 00 01 02 03 04 05 06 07 08 09 10 11 12 Item of maintenance mode change Return Use/Disuse maintenance mode Replacement interval of engine oil Replacement interval of engine oil filter Replacement interval of fuel filter Replacement interval of hydraulic oil filter Replacement interval of hydraulic tank breather Replacement interval of corrosion resistor (if equipped) Check and refill interval of damper case oil Replacement interval of final drive case oil Replacement interval of machinery case oil Replacement interval of hydraulic oil Return all items to initial values

a Menus “01” and “12” are used to set the whole maintenance mode and menus “02” – “11” are used to set the items one by one. 3) Contents of setting of “maintenance mode On/Off” • On: The function of displaying all the oil and filter items becomes effective (This setting is applied, even if On/Off is set for each item). • Off: The function of displaying all the oil and filter items becomes ineffective (This setting is applied, even if On/Off is set for each item).

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4) Contents of setting of each item (1) Default: Maintenance time set in monitor. (Value recommended by manufacturer. Constant value.) (2) Set value: Maintenance time which operation can set freely. Monitor panel operates according to this value in maintenance mode. (This value can be changed by 50 hours with [ ] and [ ] switches.) (3) Off: Function of displaying this maintenance item becomes ineffective. (4) On: Function of displaying this maintenance item becomes effective. a The lower limit of the set time is 50 h. 5) Contents of setting “Return all items to initial values” If this menu is selected and the [ ] switch is pressed, all the information items are changed to the initial values.

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SPECIAL FUNCTIONS OF MONITOR PANEL

20. Function of phone number entry [05] The operator can input a phone No. and change it according to the following procedure. Once the phone No. is input, it and service code are displayed alternately when the user code is displayed. a If a phone No. is not input, the phone No. screen is not displayed. 1) Selecting menu On the initial screen of the service menu, select “05 Phone Number Entry” and press the [ ] switch. 2) Selecting input screen Select “Entry” to display the phone No. input screen. a Even if a phone No. has been registered, if the phone No. input screen is displayed, the registered phone No. is cleared.

3) Inputting and setting phone No. On the phone No. input screen, input a phone No. according to the following procedure (The phone No. is input from the cursor at the left end automatically). i) Input a No. with the numeral keys from the cursor at the left end. ii) After finishing inputting the No., press the [ ] switch. a Up to 12 digits can be input. You do not need to input a digit to an unnecessary place, however. a If you input a wrong No., press the [B] switch, and the cursor returns 1 place by 1. a If the phone No. is input, the “Entry” screen above is displayed again. If the phone No. is displayed on this screen, it is input normally.

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SPECIAL FUNCTIONS OF MONITOR PANEL

21. Function of initial setting and default [06] The operator can change the following items related to the monitor panel and machine, if necessary. • Working mode when starting switch is turned ON • Language displayed on service menu • Unit displayed in monitoring function mode • With/Without attachment 1) Selecting menu On the initial screen of the service menu, select “06 Function of initial setting and default” and press the [ ] switch. 2) Selecting sub-menu Select a sub-menu to change its setting and press the [ ] switch.
No. 00 01 02 03 04 Sub-menu of initial value/default Return (Finish initial value/default) Key-on mode Language Unit With/Without service circuit

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

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4) Function of setting language The operator can select Japanese or English as the language displayed on the service menu. a The default language of the monitor panel is English. a When using a spare monitor panel in the Japanese language area, select Japanese with this function.

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

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

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TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

22. Function of adjustment [07] The operator can adjust various items of the machine on the monitor panel. 1) Selecting menu On the initial screen of the service menu, select “07 Adjustment” and press the [ ] switch. 2) Selecting sub-menu Select a sub-menu to change its setting and press the [ ] switch.
No. 00 01 02 Sub-menu of adjustment Return (Finish adjustment) Pump absorption torque Adjustment of oil flow for attachment in compound operation

3) Function of pump absorption torque The operator can adjust the pump absorption torque within the ranges shown in the following table.
Adjustment Adjustment Adjustment Adjustment value torque value torque 220 221 222 223 224 +8.0 kgm +6.0 kgm +4.0 kgm +2.0 kgm 0.0 kgm 225 226 227 228 –2.0 kgm –4.0 kgm –6.0 kgm –8.0 kgm

4) Function of adjustment of oil flow for attachment in compound operation The operator can adjust the oil flow for the attachment in compound operation within the ranges shown in the following table.
Adjustment value 370 371 372 373 Oil flow for attachment 0.5 times 0.7 times 1.0 times 0.4 times

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23. Function of cylinder cut out mode operation [09] The operator can operate the machine in the cylinder cut out mode with the monitor panel. Cylinder cut out mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). 1) Selecting menu On the initial screen of the service menu, select “09 Cylinder cut out mode operation” and press the [ ] switch. 2) Setting cylinders to be disabled Press switches [1] – [6] on the monitor panel corresponding to the cylinder Nos. to be disabled. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed white in a white frame, the cylinder is disabled (If setting is wrong, press the same switch again). a Only one or more cylinders can be disabled for the reduced cylinder mode operation. 3) Cancellation of disabled cylinders Press switches [1] – [6] on the monitor panel corresponding to the disabled cylinder Nos. to cancel disabling of those cylinders. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed black in a black frame, disabling of the cylinder is cancelled.

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4) Function of holding engine speed If the [ ] switch is pressed while the reduced cylinder mode operation screen is used, the engine speed is held and displayed on the lower line. If the [ ] switch is pressed while the engine speed is held, holding of the engine speed is cancelled and the engine speed displayed on the lower line goes off. a If the holding function is used, the held engine speed is displayed in ( ) on the lower line and the current engine speed is displayed on the upper line. a The holding function can be used both in and out of the cylinder cut out mode.

[Reference]: How to use holding function effectively The engine speed displayed by the holding function is held on the screen until the holding function is cancelled, regardless of setting and cancellation of the cylinder cut out mode. Accordingly, a defective cylinder can be found out effectively according to the following procedure. (1) Run the engine normally (without disabling any cylinder) and hold the engine speed. (2) Disable a cylinder to be checked. (3) Run the engine under the same condition as the normal operation in step (1) and compare the engine speed at this time with the held engine speed. (4) Cancel the cylinder cut out mode, regardless of the change of the engine speed. (5) Repeat steps (2) – (4) to check the other cylinders. a If the engine speed does not lower at all or lowers less when a cylinder is selected for the cylinder cut out mode operation, combustion in that cylinder must be abnormal.

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SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Section to display special functions 1. Display section 2. Service meter section

Section to operate special function 1 (Basic operation) 3. Caution buzzer stop switch 4. Auto-decelerator switch 5. Setting switch (Black switch) 6. Travel speed shifting switch

Section to operate special function 2 (Selecting operation and special operation) 7. Working mode selector (UP) switch 8. Working mode selector (DOWN) switch

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SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

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 display section (1) and service meter section (2). 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 or displayed automatically when a trouble occurs. 2. Special functions: Service menu The items in this menu are not displayed normally. Each serviceman can display them by operating special switches. These functions are used for special setting, testing, adjusting, or troubleshooting. Flow of each function Ordinary functions (Operator menu) 1 Function of displaying service meter O <Automatic> 2 Function of displaying user code <Operation of switch> O Special functions (Service menu) 3 Function of displaying service code [01] 4 Monitoring function [02] 5 Function of selecting maintenance period [04] 6 Function of selecting default working mode [05] 7 Function of setting installation of attachment [16] 8 Special function of monitoring replacement of engine oil

a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.

Display of operator menu
a Only outline of the operator menu is described in this section. For details of each menu, see OPERATION MANUAL or the volume of STRUCTURE AND FUNCTION. 1. Function of displaying service meter While the machine is used normally, the monitor panel displays the following information. • Display section (1): Nothing is displayed • Service meter section (2): Service meter

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2. Function of displaying user code If the machine has any trouble, the corresponding user code is displayed automatically in display section (1) and the caution buzzer is turned ON to urge the operator to take a proper remedy, depending on the degree of the trouble. a Service meter section (2) continues displaying the service meter. a For displayed user codes and the remedies shown to the operator, see "User codes and remedies shown to operator". a Each user code simply shows occurrence of a trouble to the operator. To find out the cause of the trouble, a serviceman must check the service code with the "Function of displaying service code [01]" in the service menu. <Reference> A user code is displayed only when a serious trouble occurs. Even if a user code is not displayed, a trouble may have occurred. If you feel any abnormality, be sure to check for a service code with the "Function of displaying service code [01]" in the service menu. a User codes and remedies shown to operator User code E02 Error mode Error in pump control system Remedy (shown to operator) If the emergency pump drive switch is set in the upper position, the machine can operate normally. Have the machine inspected immediately, however. Set the swing holding brake release switch in the upper position to release the brake. When applying the swing brake, operate the swing lock switch manually. The brake may not be released, depending on the cause of the failure. In this case, have the machine inspected immediately. Caution buzzer q

E03

Error in swing brake system

q

Error in engine controller power supply E10 Abnormality in engine con- Have the machine inspected immediately. troller drive system circuit (Engine is stopped) E11 Error in engine controller system (Engine output is reduced for protection) Move the machine to safe place and have it inspected immediately. Move the machine to safe place and have it inspected immediately. Have the machine inspected, although it can be operated normally. Move the machine to safe place and have it inspected immediately.

q

q

E14 Error in throttle system Error in engine sensor E15 (coolant temperature, fuel temperature, oil pressure) E0E Error in network

q q q

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SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Operation and display of service menu
How to select service menu a When using the general functions in the service menu, perform the following switch operation to change the screen of the monitor panel. 3. Function of displaying service code [01] 4. Monitoring function [02] 5. Function of selecting maintenance period [04] 6. Function of selecting default working mode [05] 7. Function of setting installation of attachment [16] 1) Operating switches While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds. 2) Displaying display section and service meter section If the switches are operated as shown above, the first menu No. [01] (Monitoring function) is displayed in service meter section (2). a Nothing is displayed in display section (1). 3) Selecting menu While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a menu you will use. • UP switch (7): Increase Menu No. • DOWN switch (8): Decrease Menu No. Menu No. 01 02 04 05 16 Service menu (Excluding special functions) Function of displaying error code Monitoring function Function of selecting maintenance period Function of selecting default working mode Function of setting installation of attachment

4) Executing menu Select a menu you will use and press set switch (5), and the menu is executed. 5) Finishing service menu While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds (similarly to the selecting operation). a The service menu is finished and the ordinary screen appears. a The service menu can be also finished by turning the starting switch OFF while the service menu is selected. (In this case, the ordinary screen appears when the starting switch is turned ON again.)

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a To use the following special function, you must operate the switches differently from the above. See details of this function "8. Special function of monitoring replacement of engine oil". 3. Function of displaying service code [01] With this function, you can check the service code of a trouble which is occurring at present or has occurred in the past. 1) Selecting and executing function i) Select menu No. [01] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Information displayed in display section and service meter section 1 (When service code is recorded) If a service code is recorded, the following information is displayed in display section (1) and service meter section (2). (a): Service code (b): Service meter reading increased after trouble occurred (c): Mark [E] to indicate that trouble is occurring at present a Mark [E] to indicate that a trouble is occurring at present indicates that the service code is being detected now. It is not displayed if the trouble has been repaired or the service code is not detected. a For the service codes which the monitor panel and engine throttle and pump controller can detect, see the "Service codes table". 3) Information displayed in display section and service meter section 2 (When service code is not recorded) If a service code is not recorded, display section (1) and service meter section (2) display as shown in the figure. 4) Number of recorded service codes and display order of them This function can record up to 20 service codes, which are displayed in order from the latest one. a If a new trouble occurs while 20 service codes are recorded, the oldest service code is deleted and the service code of the new trouble is recorded.

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5) Change of displayed service codes While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to change the displayed service codes. • UP switch (7): Next service code appears. • DOWN switch (8): Previous service code appears. 6) How to delete service code i) While holding caution buzzer stop switch (3), turn the starting switch OFF and keep holding caution buzzer stop switch (3). ii) Under the above condition, turn the starting switch ON again and hold caution buzzer stop switch (3) for 5 seconds. a A service code having the mark [E] is not deleted.

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Service codes table User code — — — — — — — E0E — E03 — — — — E03 — — — — — — — — — — — — E02 E02 — — — — — — E0E — E11 E11 E11 E11 E14 E15 E15 Service code E112 E113 E114 E115 E116 E117 E118 E128 E201 E203 E204 E205 E206 E211 E213 E214 E215 E216 E217 E218 E222 E223 E224 E225 E226 E227 E228 E232 E233 E238 E245 E246 E247 E248 E251 E257 E315 E91B E91C E920 E921 E931 E934 E936 Trouble Short circuit in wiper motor drive forward system Short circuit in wiper motor drive reverse system Short circuit in windshield washer drive system Trouble in operation of windshield wiper Trouble in storage of windshield wiper Abnormality in engine controller S-NET Abnormality in pump controller S-NET Abnormality in communication (monitor) Short circuit in travel junction solenoid Short circuit in swing holding brake solenoid Short circuit in merge-divider solenoid Short circuit in 2-stage relief solenoid Short circuit in travel speed shifting solenoid Disconnection in travel junction solenoid Disconnection in swing holding brake solenoid Disconnection in merge-divider solenoid Disconnection in 2-stage relief solenoid Disconnection in travel speed shifting solenoid Abnormality in input model code Disconnection in S-NET signal line Short circuit in LS-EPC solenoid Disconnection in LS-EPC solenoid Abnormality in F pump pressure sensor Abnormality in R pump pressure sensor Abnormality in pressure sensor power supply Abnormality in engine speed sensor Short circuit in ATT return selector relay Short circuit in PC-EPC solenoid Disconnection in PC-EPC solenoid Disconnection in ATT return selector relay Short circuit in ATT flow adjustment EPC Disconnection in ATT flow adjustment EPC Abnormality in arm IN PPC pressure sensor Abnormality in bucket CURL PPC pressure sensor Abnormality in overload sensor Abnormality in communication (pump) Short circuit in battery relay output line Abnormality in engine Ne speed sensor system Abnormality in engine G speed sensor system Abnormality in model selection system Abnormality in model checking Abnormality in fuel control dial system Abnormality in coolant high temperature sensor Abnormality in engine oil pressure switch system

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User code E11 E15 E0E — E0E E10 E15 — E15 E11 E11 E11 E11 E11 E11 E11 E15 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E22

Service code E93C E93D E953 E954 E955 E956 E957 E95A E96A E970 E971 E974 E975 E977 E979 E97A E97B E97C E97D E980 E981 E982 E983 E984 E985 E986 E98A E98B E922

Trouble Abnormality in boost pressure sensor system Abnormality in fuel temperature sensor system Abnormality in communication (engine) Short circuit in starting switch C terminal system Abnormality in network system Abnormality in power supply system 1 Abnormality in power supply system 2 Abnormality in Q-adjustment switch signal Abnormality in coolant low temperature sensor system Overcurrent in fuel supply pump PCV1 system Overcurrent in fuel supply pump PCV2 system Disconnection in fuel supply pump PCV1 system Disconnection in fuel supply pump PCV2 system Abnormality in common rail fuel pressure sensor system Abnormality in common rail fuel high pressure 1 Abnormality in common rail fuel high pressure 2 No-pressure feed by supply pump 1 No-pressure feed by supply pump 2 Abnormality in common rail fuel pressure Abnormality in controller Disconnection in fuel injector 1 system Disconnection in fuel injector 2 system Disconnection in fuel injector 3 system Disconnection in fuel injector 4 system Disconnection in fuel injector 5 system Disconnection in fuel injector 6 system Short circuit in fuel injector 1 – 3 systems Short circuit in fuel injector 4 – 6 systems Out of engine high idle standard

a "E" at the head of each service code indicates the following condition. • With E: The trouble has not been repaired. • Without E: The trouble has been repaired.

20-179-9
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

4. Monitoring function [02] With this function, you can monitor the revolution speed, oil pressure, current, voltage, input condition, output condition, etc. in real time by the signals from the sensors, switches, and solenoids installed to various parts of the machine. 1) Selecting and executing function i) Select menu No. [02] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Selecting and executing monitoring code While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a monitoring code displayed in service meter section (1). • UP switch (7): Increase code No. • DOWN switch (8): Decrease code No. a This function displays monitoring code [00200] and its information first. a For the items and code Nos. which you can monitor, see the "Monitoring codes table".

3) Information displayed in display section and service meter section 1 (When numeral code is displayed) If a numeral monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (Value is displayed)

4) Information displayed in display section and service meter section 2 (When 6-bit code is displayed) If a 6-bit monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (6 pieces of information are displayed in bits) a In the 6-bit display mode, only the top and bottom of the 7-segments mark are used to display. "Solid black" indicates the ON state, and "white on black background" indicates the OFF state. a For the No. of each bit, see the "Monitoring codes table" and the drawing attached to it. PC400/450(LC)-7

20-179-10
(7)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Monitoring codes table Code 00200 00201 01002 01601 01100 01101 07200 07300 04102 14200 04401 01300 01500 01700 03200 03500 04300 01006 04107 36400 36500 36700 03000 04200 04106 04105 14201 36501 36401 17200 17300 31701 36100 36200 36300 Controller model code Controller model code Engine speed 2nd throttle command F pump pressure R pump pressure Arm IN PPC pressure Bucket curl PPC pressure Engine coolant temperature (high) Fuel temperature Hydraulic oil temperature PC-EPC solenoid current LS-EPC solenoid current Service solenoid current Power supply voltage Battery relay output voltage Charge voltage Engine speed Engine coolant temperature (low) Common rail fuel pressure Boost pressure Converted torque Fuel control dial voltage Fuel sensor voltage Engine coolant temperature sensor voltage high Engine coolant temperature sensor voltage low Fuel temperature sensor voltage Boost pressure sensor voltage Common rail pressure sensor voltage PCV valve closing timing Engine control mode Throttle angle Fuel injection rate command Common rail pressure command Fuel injection timing command Monitoring item Unit Numeral Numeral rpm rpm kg/cm2 kg/cm2 kg/cm2 kg/cm2 °C °C °C mA mA mA V V V rpm °C kg/cm2 kg/cm2 % V V V V V V V CA Numeral % mm3/st kg/cm2 CA Remarks

20-179-11
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Code

Monitoring item a b c d e f a b c d a b Swing Travel Boom LOWER Boom RAISE Arm IN Arm OUT Bucket CURL Bucket DUMP Service Travel differential pressure Travel junction Swing holding brake Pump merge-divider 2-stage relief Travel speed shifting ATT return selection a Knob switch Swing brake release switch Swing holding brake switch Model selection 1 Model selection 2 Model selection 3 Model selection 4 Model selection 5 Key switch (ACC) Battery relay drive a b Key switch Start Preheating Light Radiator coolant level Air cleaner Engine oil level Charge voltage b c a b

Unit (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit)

Remarks

01900

Pressure switch 1

01901

Pressure switch 2

02300

Solenoid 1

c d e

02301 02200

Solenoid 2 Switch input 1

02201

Switch input 2

c d e

02202 03700

Switch input 3 Controller output 1

04500

Monitor input 1

c d e a

04501

Monitor input 2

b c

PC400/450(LC)-7

20-179-12
(7)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Code

Monitoring item a b Swing holding brake switch Buzzer cancel switch Window limit switch W limit switch P limit switch Key switch (C) Engine oil pressure low Engine oil pressure high Model selection 1 Model selection 2 Model selection 3

Unit (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) (6 bit) Numeral and alphabet Numeral and alphabet (6 bit) (6 bit) Numeral Numeral Numeral

Remarks

04502

Monitor input 3

c d e a b c d e f

17400

Engine controller input state

36800 36801 05100 20200 20212 20209

Right Q-adjustment switch (ROT-SW1) Left Q-adjustment switch (ROT-SW2) S-NET connection state Program version (monitor) Program version (pump controller) Program version (engine controller) a b Pump controller Engine controller

a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or (d) and (e) light up. Display of numeral code Display of 6-bit code

20-179-13
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

5. Function of selecting maintenance period [04] With this function, you can adjust the maintenance period of the engine oil for the function of the engine oil replacement monitor. 1) Selecting and executing function i) Select menu No. [04] in the menu selection mode. ii) Press set switch (5) to execute this function.

2) Selecting maintenance period The current display mode or maintenance period is displayed in service meter section (2). Press set switch (5) to select a maintenance period. a Nothing is displayed in display section (1). a Each time the set switch is pressed, the display mode or maintenance period changes in the following order. Display 0 125 250 500 d Display mode/ Maintenance period Maintenance function is reset. 125-hour interval 250-hour interval 500-hour interval Demonstration mode

3) Settling maintenance period The display or maintenance period becomes effective when it is selected. Accordingly, perform the ordinary finishing operation. <Special functions of engine oil replacement monitor> a For the method of displaying the engine oil replacement monitor, method of checking the elapsed time after replacement of engine oil, method of clearing the elapsed time, and method of displaying demonstration mode, see "8. Special functions of engine oil replacement monitor".

PC400/450(LC)-7

20-179-14
(7)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

6. Function of selecting default working mode [05] With this function, you can freely select the working mode which is set automatically when the starting switch is turned ON (When the machine is delivered, mode A is set). 1) Selecting and executing function i) Select menu No. [05] in the menu selection mode. ii) Press set switch (5) to execute this function.

2) Selecting default working mode The currently set working mode is displayed in service meter section (2). Press working mode selector switches (7) and (8) to select a working mode. • UP switch (7): Next mode is displayed. • DOWN switch (8): Previous mode is displayed. a Nothing is displayed in display section (1). a The working mode changes in the following order: A o E o B 3) Settling default working mode Press set switch (5) to settle the selected working mode.

20-179-15
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

7. Function of setting installation of attachment [16] With this function, you can set installation of attachment. a When an attachment is installed, if INSTALLED is not set with this function, the Bmode function (automatic single/double operation selecting function) cannot be used. 1) Selecting and executing function i) Select menu No. [16] in the menu selection mode. ii) Press set switch (5) to execute this function. a While this function is executed, [16SET] is displayed in the service meter section (2) and [0] or [1] is displayed in display section (1). 2) Selecting installation of attachment i) The current setting is displayed in service meter section (1). Check the actual installation of attachment and setting. • [0]: Attachment is not installed. • [1]: Attachment is installed. ii) While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select [0] or [1]. • UP switch (7): [1] is selected. • DOWN switch (8): [0] is selected. 3) Settling installation of attachment Press set switch (5) to settle the selected setting of installation of attachment.

PC400/450(LC)-7

20-179-16
(7)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

8. Special functions of engine oil replacement monitor 1) Ordinary display of engine oil replacement monitor If the rest of time before the set engine oil replacement time is 10 hours or shorter, engine oil replacement monitor (10) lights up and display the elapsed time in service meter section (2) for 20 seconds each time the starting switch is turned ON. 2) Checking elapsed time To check the elapsed time while engine oil replacement monitor (10) is OFF, turn the starting switch OFF and press set switch (5) and then turn the starting switch ON and keep holding set switch (5). 3) Clearing elapsed time To clear the elapsed time after replacing the engine oil, hold set switch (5) for 3 seconds while the elapsed time is displayed in service meter section (2). a If the above operation is performed, the elapsed time in the monitor panel is set to 0 hours. 4) Function of demonstration mode If the demonstration mode is selected, you can perform demonstration of the oil maintenance function when teaching the operation to a customer. The functions and display of the demonstration mode are as follows. i) The internally set interval is recognized as 250 hours and the elapsed time is recognized as 240 hours. ii) When the starting switch is turned ON after the demonstration mode is set, the ordinary display is repeated up to 3 times (number of the times of turning the starting switch ON). iii) After the demonstration is finished, resetting of maintenance setting [0] is recognized. a When the demonstration is repeated 3 times, resetting of maintenance setting is recognized. If setting is necessary at this time, see "Function of selecting maintenance period".

20-179-17
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER

HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER

k The engine controller has a high-voltage circuit (110 – 130 V) to drive the fuel injector. This circuit is connected to the wiring harness and connectors between the engine controller and fuel injector. a Normally, the engine controller outputs the high voltage to the fuel injector only while the engine is running and stops outputting if the engine stops.

k If you touch the high-voltage circuit directly, you may get an electric shock. To avoid this, observe the following precautions. 1. The following connectors are used in the highvoltage circuit. • Engine controller connector: CB3 • Junction connector: ER03 • Injector connectors: CN1, CN2, CN3, CN4, CN5, CN6 • Injector head terminal (in head cover) 2. When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF. 3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position, but must not turn it to the START position.

20-180
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM

PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM
a When carrying out troubleshooting for an electric circuit related to the monitor panel, engine controller, or pump controller, expose the related connectors according to the following procedure. 1. Monitor panel 1) Remove cover (1). a The cover is fixed with the upper and lower 2 clips. You can remove the cover by pulling it up. a If the sunlight sensor for the air conditioner is installed, disconnect connector P15 on the back side of the cover. 2. Engine controller 1) Open the right side cover and remove radiator sub tank (3) and bracket together.

2) Remove the 3 mounting screws and disconnect monitor panel (2) from the mount. a Take care not to drop the mounting screws in the console. 3) Insert or connect T-adapters in or to connectors P01, P02, P70 of the monitor panel.

2) Remove the 4 mounting bolts and pull out engine controller (4). 3) Insert or connect T-adapters in or to connectors CB1, CB2, and CB3 of the engine controller. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}

PC400/450(LC)-7

20-181
(1)

TESTING AND ADJUSTING

PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM

3. Pump controller a The pump controller is installed inside the cover at the rear of the operator’s seat. 1) Remove the 3 mounting bolts and cover (5).

2) Insert or connect T-adapters in or to connectors C01, C02, and C03 of the pump controller. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}

20-182
(1)

PC400/450(LC)-7

PM-CLINIC SERVICE

PC400/450(LC)-7

20-183
(1)

MEASURING PROCEDURES

Positions to install measuring devices (Related to engine)

20-184
(1)

PC400/450(LC)-7

MEASURING PROCEDURES

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

PC400/450(LC)-7

20-185
(1)

20-186
(1)

PC400/450(LC)-7

PC400/450(LC)-7

20-187
(1)

Pm-CLINIC SERVICE PC400 (LC), 450 (LC)-7
Visual check of welded structures
a If any crack is found, draw its shape below.

Arm 1. Arm cylinder bracket T Left T Right 2. Arm foot T Left T Right T End plate 3. Arm top boss T Left T Right

Boom 4. Boom top bracket T Left T Right 5. Boom cylinder bracket T Left T Right 6. Arm cylinder bracket T Left T Right 7. Boom lower plate T Left T Right 8. Boom foot T Left T Right

Revolving frame 9. Boom bracket T Left T Right Track frame 10. Circle bracket T Front T Rear T Left T Right

20-188
(1)

PC400/450(LC)-7

UNDERCARRIAGE INSPECTION
Y

(Program form No.: SELA195001)

Komatsu Undercarriage Inspection

Customer name: Address:

T20606

Model Location Soil condition Working condition

PC400/450-7

Serial# SMR Dealer nspector

Equip#

Work Order No Wet,AR,HD or Dry Shoe width (mm) Shoe type
(yyyy/m/d)

DRY

TRIPLE

LH R RH LH M RH LH RH

Insp.Date(yyyy/mm/dd) New 100% Measured Wear mm 915.6 927.6 915.6 927.6

Wear %

New

SMR Hours on Rebuilt Parts:

NORMAL Wear type Comments/Observation

228.90 231.90 228.90 231.90 129.0 129.0 119.0 119.0 New Turned Turned

LH RH LH RH LH Front RH LH Rear RH LH Front RH LH Rear RH 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 LH LH LH LH LH LH LH LH LH LH RH RH RH RH RH RH RH RH RH RH LH RH

71.5 71.5 37.0 37.0 148.0 148.0 148.0 148.0 22.0 22.0 22.0 22.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 200.0 0.0 0.0

66.5 New 66.5 22.0 22.0 134.0 134.0 134.0 134.0 28.0 28.0 28.0 28.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 188.0 6.0 6.0

1.3

10

Remarks:

PC400/450(LC)-7

20-189
(1)

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204 CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM.................................................................................................................................... 20-217 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-234 T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-256 TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED .................................................. 20-301 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................................................................. 20-501 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) ................................. 20-601 TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................... 20-701

PC400/450(LC)-7

20-201
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

allow any unauthorized person to come near.

the engine to cool down before starting troubleshooting.

k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.

k 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 manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. 4) Check the stroke of the control valve spool. 5) 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. a 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 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) 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.

20-202
(1)

PC400/450(LC)-7

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC400/450(LC)-7

20-203
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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). 1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, 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) Defective contact of connectors (defective contact between male and female) Problems with defective 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 oxidization of the contact surfaces.

2) Defective 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.

20-204
(1)

PC400/450(LC)-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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 defective 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. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a 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.

PC400/450(LC)-7

20-205
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) 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. a 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. a 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. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-206
(1)

PC400/450(LC)-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Connecting connectors 1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. a 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. a 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. a 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.

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. 1. Male connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c

PC400/450(LC)-7

20-207
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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 the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air 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. a 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. a After completely drying the connector, blow it with contact restorer and reassemble.

20-208
(1)

PC400/450(LC)-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) 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.

2. 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. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a 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. a If there is any change, there is probably defective contact in that circuit.

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POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. 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. 1) 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. 2) 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 main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) 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.

4) 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.

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POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) 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. (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. 6) 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.

7) Cleaning operations After repairing the hydraulic equipment (pump, c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he 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 ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

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CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING
Item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Check fuel level, type of fuel Check for impurities in fuel Check hydraulic oil level Check hydraulic oil strainer Check swing machinery oil level Check engine oil level (oil pan oil level) Check coolant level Check dust indicator for clogging Check hydraulic filter Check final drive oil level Judgement value — — — — — — — — — — — — — — — — 20 – 30V — — — — Action Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Replace Add oil Tighten or replace Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace

Hydraulic, Electrical mechanical equipment equipment

Lubricating oil, coolant Electrics, electrical equipment

1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring 1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding 1. 2. 3. 4. 5. Check battery voltage (engine stopped) Check battery electrolyte level Check for discolored, burnt, exposed wiring Check for missing wiring clamps, hanging wiring Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) 6. Check for blown, corroded fuses 7. Check alternator voltage (engine running at 1/2 throttle or above)

8. Check operating sound of battery relay (when switch is turned ON/OFF)

— After running for several minutes : 27.5 – 29.5V — Replace

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CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Classification of troubleshooting
Mode Code display E mode H mode S mode Content Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are displayed. Troubleshooting of electrical system Troubleshooting of hydraulic and mechanical systems Troubleshooting of engine

Steps for troubleshooting
If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. 1. Troubleshooting steps when calling User Code display in the monitor panel In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error Code for the electrical system, carry out the troubleshooting along the corresponding code display. 2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is recorded in the failure history: If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system Failure Code, using the failure history function of the monitor panel. a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to check if the same abnormality still persists. a Failure Code in the mechanical system cannot be deleted. 3. Troubleshooting steps without User Code display and no failure history is available If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from among “Failure like Phenomena and Troubleshooting No.” and carry out E mode or H mode troubleshooting related to the phenomenon in question.

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CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Phenomena considered to be failures and troubleshooting Nos.
Troubleshooting No. Phenomena considered to be failures Display of code E-mode H-mode S-mode

Possible faults related to user code, error code, or failure code 1 2 3 User code is displayed on monitor panel When failure history is checked, error code is displayed in electrical system When failure history is checked, error code is displayed in mechanical system According to displayed code

Possible faults related to engine 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Engine does not start Engine does not start easily (It always takes time to start) Engine does not crank Engine cranks but exhaust smoke does not come out Exhaust smoke comes out but engine does not start Engine speed does not rise sharply (Follow-up performance is low) Engine stops during operation Engine rotation is abnormal (Engine hunts) Output is insufficient (Power is low) Exhaust gas color is bad (Incomplete combustion) Oil is consumed much or exhaust gas color is bad Oil becomes dirty quickly Fuel is consumed much Coolant contains oil (or it blows back or reduces) Engine oil pressure caution lamp lights up (Oil pressure lowers) Oil level rises (Water or fuel is mixed in oil) Water temperature rises too high (Overheating) Abnormal sound comes out Vibration is excessive Engine is not preheated normally Automatic warm-up function does not work Automatic decelerator does not work E-2 E-3 E-4 H-5 E-1 S-1 S-2 a) S-2 b) S-2 c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16

Possible faults related to work equipment, swing, and travel 25 26 27 28 29 Speed or power of whole work equipment, travel, and swing is low Engine speed lowers extremely or engine stalls Work equipment, travel, and swing systems do not work Abnormal sound comes out from around hydraulic pump Fine control performance or response is low E-5 H-1 H-2 H-3 H-4 H-6 S-6 S-4

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CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Troubleshooting No. Phenomena considered to be failures Display of code E-mode H-mode S-mode

Possible faults related to work equipment 30 31 32 33 34 35 36 37 38 39 40 Speed or power of boom is low Speed or power of arm is low Speed or power of bucket is low Work equipment does not move singly Hydraulic drift of work equipment is large Time lag of work equipment is large When a work equipment device is relieved singly, other work equipment device moves One-touch power maximizing function does not work Machine push-up function does not work normally Attachment circuit is not selected (when attachment is installed) Oil flow in attachment circuit cannot be adjusted (when attachment is installed) Possible faults related to compound operation 41 42 43 In compound operation of work equipment, speed of part loaded more is low When machine swings and raises boom simultaneously, boom rising speed is low When machine swings and travels simultaneously, travel speed lowers largely Possible faults related to travel 44 45 46 47 48 49 Machine deviates during travel Travel speed is low Machine is not steered well or steering power is low Travel speed does not change or it is lower or higher than set speed Travel motor does not work (only 1 side) Travel alarm does not sound or does not stop sounding Possible faults related to swing 47 48 50 51 52 53 Machine does not swing Swing acceleration or swing speed is low Upper structure overruns remarkably when it stops swinging Large shock is made when upper structure stops swinging Large sound is made when upper structure stops swinging Hydraulic drift of swing is large Possible faults related to monitor panel (Operator menu: Ordinary screen) 54 55 56 57 No items are displayed on monitor panel Some items are not displayed on monitor panel Items displayed on monitor panel are not matched to machine model Fuel level monitor lights red while engine is running E-9 E-10 E-11 E-12 H-24 H-25 H-26 H-27 H-28 H-29 E-31 H-19 H-20 H-21 H-22 H-23 H-16 H-17 H-18 E-6 E-7 E-8 H-7 H-8 H-9 H-10 H-11 H-12 H-13 H-14 H-15 H-30 H-31

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CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Troubleshooting No. 58 59 60 61 62 63 64 Phenomena considered to be failures Engine coolant temperature gauge does not indicate normally Hydraulic oil temperature gauge does not indicate normally Fuel level gauge does not indicate normally Swing lock monitor does not indicate normally When monitor switches are operated, no items are displayed Windshield wiper or windshield washer does not operate Alarm buzzer cannot be cancelled Display of code E-mode E-13 E-14 E-15 E-16 E-17 E-18 E-19 H-mode S-mode

Possible faults related to monitor panel (Service menu: Special function screen) 65 66 67 68 69 70 71 72 73 74 Monitoring function does not indicate “Boom RAISE” normally. Monitoring function does not indicate “Boom LOWER” normally. Monitoring function does not indicate “Arm IN” normally. Monitoring function does not indicate “Arm OUT” normally. Monitoring function does not indicate “Bucket CURL” normally. Monitoring function does not indicate “Bucket DUMP” normally. Monitoring function does not indicate “Swing” normally. Monitoring function does not indicate “Travel” normally. Monitoring function does not indicate “Travel differential pressure” normally. Monitoring function does not indicate “Service” normally. Other failure 75 Air conditioner does not operate (Troubleshooting for air conditioner system) E-31 E-20 E-21 E-22 E-23 E-24 E-25 E-26 E-27 E-28 E-29

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
Connectors list
a The address of each connector roughly shows the place of the connector in the connectors stereogram and the circuit diagram of each system.
Connector No. A01 A02 A03 A04 A05 A06 A07 A09 A10 A11 A12 A13 A14 A15 A16 A20 A21 A22 A23 A31 A33 A34 A35 A40 A41 A42 A43 A44 A50 A51 A52 A60 A61 A70 A73 A80 AL/B AL/E AL/R C01 C02 C03 C09 CB1 Type X X DT SWP SWP SWP SWP SWP Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal D X L M Terminal Terminal M D M KES0 D D X D D D DT Terminal Terminal Terminal DRC DRC DRC S DRC No. of pins 4 4 12 6 14 14 16 8 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 2 1 2 3 3 1 2 3 2 8 1 1 1 24 40 40 8 24 Name of device Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Battery relay (Terminal E) Battery relay (Terminal BR) Battery relay (Terminal N) Battery relay (Terminal B) Air cleaner clogging sensor Radiator water level sensor Fusible link (65 A) Fusible link (30 A) Horn (Low tone) Horn (High tone) Intermediate connector Travel alarm Right headlamp Windshield washer motor (Tank) F pump oil pressure sensor R pump oil pressure sensor Fuel level sensor Hydraulic oil temperature sensor Boom cylinder bottom pressure sensor for overload alarm Fuel priming pump Intermediate connector Alternator B terminal Alternator E terminal Alternator R terminal Pump controller Pump controller Pump controller Model selection connector (Pump controller) Pump controller Stereogram T-1 T-1 N-2 O-1 T-1 O-1 S-1 N-2 H-2 I-2 I-2 I-2 F-1 J-3 J-3 D-1 D-2 F-2 F-2 H-9 H-9 D-2 G-9 G-9 G-9 H-9 J-3 D-5 L-5 L-8 L-7 G-9 L-5 H-1 G-9 S-1 AE-6 AE-6 AE-6 U-9 U-9 W-9 W-9 I-9 H-3 D-6 Address M E circuit circuit H-6 D-7 H-6 H-6 D-7 H-5 H-5 A-4 I-1 I-1 I-1 I-1 I-1 I-1 L-5 J-6 J-5 J-6 K-4 K-5 K-6 K-6 P circuit G-7 G-7 G-7 G-6 G-6 G-5 G-5 G-5 J-8

D-7 F-1 F-1

D-8

J-8 J-8 J-8 K-8 K-9 K-9 K-9 K-9

D-9

K-9 K-9

J-7 K-5 K-7 K-5 L-5 L-5 K-4 K-5 K-3 G-4

A-3 A-3 A-2 K-1

A-8 A-8

A-6

A-8 A-7 A-6 B-1 L-8

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Connector No. CB2 CB3 CB5 CN1 CN2 CN3 CN4 CN5 CN6 D01 D02 E06 ENE ER02 ER03 F02 FB1 G GND GND2 GND3 H08 H09 H10 H11 H12 H15 HT/B HT/S J01 J02 J03 J04 J05 J06 J07 J08 K19 K30 K31 M07 M09 M13 M19 M21 M22 M23 M26 M27 M29 M30

Type DRC DRC DT DT DT DT DT DT DT SWP SWP M DT HD30 HD30 M — YAZAKI DT Terminal Terminal M S S S S S090 Terminal Terminal J J J J J J J J M DT DT M M M YAZAKI PA Y090 Y090 S YAZAKI 040 040

No. of pins 40 40 8 2 2 2 2 2 2 8 8 3 2 31 31 2 — 2 2 1 1 8 8 16 16 12 20 1 1 20 20 20 20 20 20 20 20 2 3 3 3 1 2 2 9 2 2 12 18 20 16

Name of device Pump controller Pump controller Model selection connector (Engine controller) No. 1 fuel injector No. 2 fuel injector No. 3 fuel injector No. 4 fuel injector No. 5 fuel injector No. 6 fuel injector Concentrated diode Concentrated diode Fuel control dial Engine speed sensor Intermediate connector Intermediate connector Rotary lamp Fuse box Engine G sensor Joint connector (with diode) Engine grounding Engine grounding Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Heater relay B terminal Heater relay S terminal Junction connector (Black) Junction connector (Black) Junction connector (Green) Junction connector (Green) Junction connector (Pink) Junction connector (Orange) Junction connector (Orange) Junction connector (Pink) Pump resistor (For driving pump in emergency) CAN terminal resistance CAN terminal resistance Light switch Working lamp (Right front) Speaker (Right) Cigarette lighter Radio Horn switch One-touch power maximizing switch Intermediate connector Air conditioner unit Air conditioner control panel Air conditioner control panel

Stereogram I-9 J-9 J-9 AI-2 AI-3 AJ-3 AJ-5 AJ-6 AJ-6 W-7 W-5 P-7 AJ-5 AF-8 AF-8 AA-9 V-2 AH-2 AJ-6 AJ-5 AE-7 W-6 W-6 T-9 S-9 S-9 O-7 AH-9 AJ-7 T-9 T-9 U-9 V-3 V-3 W-3 W-5 W-5 W-5 K-9 N-4 P-8 E-9 AC-9 N-3 U-2 O-7 T-1 W-4 W-4 U-2 U-2

Address M E circuit circuit K-1 A-5 A-3 A-7 K-3 K-2 K-2 K-2 K-3 K-2 A-9 A-8 K-7 J-3 I-5 I-3 E-7 K-3

P circuit L-8

A-4 A-4

K-6

I-9

G-8

J-8 J-8 D-6 D-6 D-5 C-2

I-7 I-6 I-7

E-2 E-2 E-2 A-2

C-9 D-9 D-9 E-9 E-9 F-9 F-9

H-9 H-9 H-9 I-9 I-9 I-9 A-9 K-6

A-2 A-4 C-1 K-7

B-9 C-1 C-9 C-9 D-9 D-9 D-9 E-9 B-1 A-9 E-1

F-9

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Connector No. M31 M32 M33 M33 M34 M37 M38 M38 M40 M41 M42 M43 M45 M46 M71 M72 M73 M79 NE OL P01 P02 P03 P05 P15 P70 PCV1 PCV2 PSH PSL PFUEL PIM R10 R11 R13 R20 R22 R30 R31 S01 S02 S03 S04 S05 S06 S07 S08 S09 S10 S11 S14

Type M M M
SUMITOMO

No. of pins 2 2 2 4 1 1 1 2 2 2 1 1 12 4 2 4 2 2 2 2 12 20 2 2 2 16 2 2 1 1 3 3 5 5 5 5 5 5 5 4 2 2 3 2 2 2 2 2 2 2 3

X Terminal Terminal M M M M M D X M M M M YAZAKI DT 070 040 M M Y050 040
SUMITOMO SUMITOMO

Terminal Terminal AMP
SUMITOMO

R R R R R R R D X X D X X X X X X X M

Address StereoM E gram circuit circuit Optional power supply (2) W-7 Optional power supply (1) W-6 Optional power supply (3) V-9 Air conditioner unit W-4 Air conditioner compressor electromagnetic clutch I-9 Horn switch (High tone) H-1 Horn switch (Low tone) G-1 Machine push-up switch Q-8 Working lamp Z-8 K-8 Working lamp (Additional) Y-7 K-8 J-7, K-7 Intermediate connector H-9 Working lamp (Rear) J-9 K-7 Intermediate connector W-7 RS232C junction connector V-9 Room lamp AA-8 DC/DC converter U-2 Speaker (Left) AD-8 12-V accessory outlet V-9 Engine Ne sensor AJ-5 K-4 Engine oil level sensor AJ-3 K-2 Monitor panel N-6 A-7 K-7 Monitor panel N-5 A-6 K-6 Buzzer cancel switch Q-8 D-1 Rotary lamp switch U-2 Air conditioner daylight sensor N-5 Monitor panel N-5 A-5 K-6 Fuel supply pump PCV1 AH-2 K-1 Fuel supply pump PCV2 AI-2 K-1 Engine oil pressure switch (High pressure) AH-2 L-5 Engine oil pressure switch (Low pressure) AG-1 L-5 Common rail pressure sensor AJ-4 K-5 Boost pressure sensor AJ-8 K-5 Light relay P-7 E-1 Starting motor cutout relay (PPC lock) P-8 E-1 Starting motor cutout relay (Personal code) Q-8 F-1 ATT circuit selector relay W-7 Power supply relay for engine controller W-6 G-9 Air conditioner blower relay W-4 Air conditioner compressor relay W-3 Bucket CURL pressure sensor K-3 Boom LOWER oil pressure switch L-2 Swing RIGHT oil pressure switch L-2 Arm IN pressure switch K-3 Bucket DUMP oil pressure switch L-2 Boom RAISE oil pressure switch L-2 Swing LEFT oil pressure switch L-2 Arm DUMP oil pressure switch L-1 Service oil pressure switch (Intermediate connector) L-1 Service front oil pressure switch K-1 Service rear oil pressure switch L-1 Safety lock lever switch S-1 K-9 Name of device

P circuit

A-1

A-4

E-1 E-1

E-1

E-9

K-3 K-2 K-2 K-3 K-2 K-2 K-2 K-2 K-1 K-1 K-1 E-9

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Connector No. S21 S22 S25 S30 S31 ST ST/B T05 T06 T06A T11 THL TWH TWL V01 V02 V03 V04 V05 V06 V08 V12 V21 V22 V30 W03 W04 X05

Type Terminal Terminal S090 X X DT Terminal Terminal Terminal M Terminal DT DT DT DT DT D D D D D D D D X M M M

No. of pins 6 6 16 2 2 2 1 1 1 1 1 3 2 3 2 2 2 2 2 2 2 2 2 2 2 2 6 4

Name of device Emergency pump drive switch Swing holding brake release switch Intermediate connector Travel oil pressure switch Travel steering oil pressure switch Starting motor Starting motor B terminal Floor frame grounding Radio body grounding Intermediate connector Cab grounding Spill fuel temperature sensor Engine water temperature sensor (High temperature) Engine water temperature sensor (Low temperature) PPC oil pressure lock solenoid valve Travel junction solenoid valve Merge-divider solenoid valve Travel speed solenoid valve Swing holding brake solenoid valve Machine push-up solenoid valve 2nd-stage relief solenoid valve ATT return selector solenoid valve PC-EPC solenoid valve LS-EPC solenoid valve ATT flow adjustment EPC solenoid valve Rear limit switch (Window) Wiper motor Swing lock switch

Stereogram R-9 R-8 R-9 P-1 P-1 AF-7 AF-7 V-3 S-9 T-2 AJ-4 AE-7 AG-8 J-3 J-2 J-2 J-2 J-2 J-2 J-1 J-1 L-6 L-6 P-1 AB-9 Y-5 Q-8

Address M E circuit circuit

K-3 J-8

P circuit C-1 D-1 C-2 A-9 A-9 K-6

K-8 K-3 K-5 K-5 K-5 K-5 K-4 K-4 K-4 K-4 K-4 K-4 L-7 L-7 F-1 K-8 B-9 D-2

A-1

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Connector type D or DT L J M R S X PA SWP DRC 040 070 Y050 S090 Y090 YAZAKI SUMITOMO KES0 Terminal Terminal

Detailed information Japanese and German makes DT type connector (08192-XXXXX) Product of Yazaki Corporation L type connector (08056-2XXXX) Product of Sumitomo Wiring Systems 090 type splice Product of Yazaki M type connector (08056-0XXXX) Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector Product of Yazaki S type connector (08056-1XXXX) Product of Yazaki X type connector (08055-0XXXX) Product of Yazaki PA type connector Product of Yazaki SWP type connector (08055-1XXXX) Japanese and German makes DRC type connector Product of Japan AMP 040 type connector Product of Japan AMP 070 type connector Product of Yazaki 050 type connector Product of Sumitomo 090 type connector Product of Yazaki 090 type connector Yazaki-made connector Product of Sumitomo Wiring Systems 6098 type connector KESO type connector (08027-0XXXX) Round pin type single terminal connector Round terminal

PC400/450(LC)-7

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Connector Location Stereogram

20-222
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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

PC400/450(LC)-7

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

PC400/450(LC)-7

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Monitor Panel System Circuit Diagram (M Circuit)

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging system, light system, and communication network system from the general electric circuit diagram.

PC400/450(LC)-7

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Engine Control System Circuit Diagram (E Ciruit)

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by extracting the engine controller system from the general electric circuit diagram.

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

Pump Controller System Circuit Diagram (P Circuit)

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CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram.

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CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
a The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.

No.of pins 1

X type connector Male (female housing) Part No.: 08055-00181 Female (male housing) Part No.: 08055-00191 T-adapter Part No. 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 — Terminal part No.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20 Terminal part No.: 79A-222-3380 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20

Part No.: 08055-00491 Terminal part No.: 79A-222-3390 • Electric wire size: 0.85 • Grommet: Black • Q’ty : 20 Terminal part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20 —

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CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

SWP type connector Male (female housing) Female (male housing) T-adapter 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

PC400/450(LC)-7

20-235
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No. of pins

SWP type connector Male (female housing) Female (male housing) T-adapter Part No.

16

799-601-7320

Part No.: 08055-11681 — Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20 Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20

Part No.: 08055-11691 Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20 Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20 —

20-236
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins 1

M type connector Male (female housing) Part No.: 08056-00171 Female (male housing) Part No.: 08056-00181 T-adapter Part No. 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

PC400/450(LC)-7

20-237
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

S type connector Male (female housing) Female (male housing) T-adapter Part No.

8

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10 (White)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12 (White)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16 (White)

799-601-7330

Part No.: 08056-11671

Part No.: 08056-11681

20-238
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

S type connector Male (female housing) Female (male housing) T-adapter Part No.

10 (Blue)

12 (Blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16 (Blue)

799-601-7170

Part No.: 08056-11672

Part No.: 08056-11682

PC400/450(LC)-7

20-239
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins 7 11

MIC type connector Male (female housing) Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2680 (Q’ty: 5) Female (male housing) Body part No.: 79A-222-2630 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) T-adapter Part No. — —

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

Body part No.: 79A-222-2660 (Q’ty: 5)

Body part No.: 79A-222-2650 (Q’ty: 5)

13

799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2)

Body part No.: 79A-222-2690 (Q’ty: 2)

20-240
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

MIC type connector Male (female housing) Female (male housing) T-adapter Part No.

17

799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2)

Body part No.: 79A-222-2720 (Q’ty: 2)

21

799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2) Terminal part No.: 79A-222-2770 (Q’ty: 50)

Body part No.: 79A-222-2740 (Q’ty: 2) Terminal part No.: 79A-222-2760 (Q’ty: 50) —

PC400/450(LC)-7

20-241
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

AMP040 type connector Male (female housing) Female (male housing) T-adapter Part No.

8

799-601-7180

Housing part No.: 79A-222-3430 (Q’ty: 5)

12

799-601-7190

Housing part No.: 79A-222-3440 (Q’ty: 5)

16

799-601-7210

Housing part No.: 79A-222-3450 (Q’ty: 5)

20

799-601-7220

Housing part No.: 79A-222-3460 (Q’ty: 5)

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

20-242
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

AMP070 type connector Male (female housing) Female (male housing) T-adapter Part No.

10

799-601-7510

Part No.: 08195-10210

12

799-601-7520

Part No.: 08195-12210

14

799-601-7530

Part No.: 08195-14210

18

799-601-7540

Part No.: 08195-18210

20

799-601-7550

Part No.: 08195-20210

PC400/450(LC)-7

20-243
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

L type connector Male (female housing) Female (male housing) T-adapter Part No.

2

No.of pins

Connector for PA Male (female housing) Female (male housing) T-adapter Part No.

9

No.of pins

Bendix MS connector Male (female housing) Female (male housing) T-adapter Part No.

10

799-601-3460

20-244
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

KES 1 (Automobile) connector Male (female housing) Female (male housing) T-adapter Part No.

2

Part No.: 08027-10210 (Natural color) 08027-10220 (Black)

Part No.: 08027-10260 (Natural color) 08027-10270 (Black)

3

Part No.:08027-10310

Part No.:08027-10360

4

Part No.: 08027-10410 (Natural color) 08027-10420 (Black)

Part No.: 08027-10460 (Natural color) 08027-10470 (Black)

6

Part No.: 08027-10610 (Natural color) 08027-10620 (Black)

Part No.: 08027-10660 (Natural color) 08027-10670 (Black)

PC400/450(LC)-7

20-245
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

KES 1 (Automobile) connector Male (female housing) Female (male housing) T-adapter Part No.

8

Part No.: 08027-10810 (Natural color) 08027-10820 (Black)

Part No.: 08027-10860 (Natural color) 08027-10870 (Black)

No.of pins

Connector for relay (Socket type) Male (female housing) Female (male housing) T-adapter Part No.

5

799-601-7360

6

799-601-7370

20-246
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

No.of pins

F type connector Male (female housing) Female (male housing) T-adapter Part No.

4

PC400/450(LC)-7

20-247
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 Series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female termial) T-adapter Part No.

799-601-9210

18-8 (1)

Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)

Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)

Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female termial)

799-601-9220

Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206 18-14 (2) Pin (female terminal)

Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106 Pin (male termial)

799-601-9220

Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206

Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106

20-248
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 Series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female termial) T-adapter Part No.

799-601-9230

18-20 (3)

Part No.:08191-31201, 08191-31202 Pin (female terminal)

Part No.:08191-34101, 08191-34102 Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202 Pin (male terminal)

Part No.:08191-33101, 08191-33102 Pin (female termial)

799-601-9240

18-21 (4)

Part No.:08191-41201, 08191-42202 Pin (female terminal)

Part No.:08191-44101, 08191-44102 Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202

Part No.:08191-43101, 08191-43102

PC400/450(LC)-7

20-249
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 Series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female termial) T-adapter Part No.

799-601-9250

24-9 (5)

Part No.:08191-51201, 08191-51202 Pin (female terminal)

Part No.:08191-54101, 08191-54102 Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202 Pin (male terminal)

Part No.:08191-53101, 08191-53102 Pin (female termial)

799-601-9260

Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206 24-16 (6) Pin (female terminal)

Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106 Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206

Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106

20-250
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 Series connector Body (plug) Pin (male terminal) Body (receptacle) Pin (female termial) T-adapter Part No.

799-601-9270

24-21 (7)

Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206 Pin (female terminal)

Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)

Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 24-22 (8) Pin (female terminal)

Part No.: 08191-84101, 08191-84103, 08191-84105,

08191-84102 08191-84104 08191-84106

Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82203, 08191-82205,

08191-82202 08191-82204 08191-82206

Part No.: 08191-83101, 08191-83103, 08191-83105,

08191-83102 08191-83104 08191-83106

PC400/450(LC)-7

20-251
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code) HD30 Series connector Body (plug) Pin (male termial) Body (receptacle) Pin (female terminal) T-adapter Part No.

799-601-9290

24-31 (9)

Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206 Pin (female terminal)

Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206

Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106

20-252
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins DT Series connector Body (plug) Body (receptacle) T-adapter Part No.

2

799-601-9020

Part No.: 08192-12200 (normal type) 08192-22200 (fine wire type)

Part No.: 08192-12100 (normal type) 08192-22100 (fine wire type)

3

799-601-9030

Part No.: 08192-13200 (normal type) 08192-23200 (fine wire type)

Part No.: 08192-13100 (normal type) 08192-23100 (fine wire type)

4

799-601-9040

Part No.: 08192-14200 (normal type) 08192-24200 (fine wire type)

Part No.: 08192-14100 (normal type) 08192-24100 (fine wire type)

6

799-601-9050

Part No.: 08192-16200 (normal type) 08192-26200 (fine wire type)

Part No.: 08192-16100 (normal type) 08192-26100 (fine wire type)

PC400/450(LC)-7

20-253
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins DT Series connector Body (plug) Body (receptacle) T-adapter Part No.

8

8GR: 8B: 8G: 8BR:

799-601-9060 799-601-9070 799-601-9080 799-601-9090

Part No.: 08192-1820 08192-2820

(normal type) Part No.: 08192-1810 (fine wire type) 08192-2810

(normal type) (fine wire type)

12

12GR: 12B: 12G: 12BR:

799-601-9110 799-601-9120 799-601-9130 799-601-9140

Part No.: 08192-1920 08192-2920

(normal type) Part No.: 08192-1910 (fine wire type) 08192-2910

(normal type) (fine wire type)

20-254
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins DTM Series connector Body (plug) Body (receptacle) T-adapter Part No.

2

799-601-9010

Part No.: 08192-02200

Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins DTHD Series connector 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)

PC400/450(LC)-7

20-255
(1)

TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH TABLE

T-BRANCH BOX AND T-BRANCH TABLE
a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker Ass'y. 799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300

799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340

Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP SWP SWP SWP M M M M M M

Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P 1P 2P 3P 4P 6P 8P 12P 14P 16P 1P 2P 3P 4P 6P 8P

20-256
(1)

PC400/450(LC)-7

Part No.

Connector type or No. of pins part name

TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH TABLE

799-601-2500

799-601-2700

799-601-2800

799-601-2900

799-601-3000

799-601-5500

799-601-6000

799-601-6500

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

S S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 HD30 HD30 HD24 HD30 HD30 HD30 HD30 Plate Measurement box Case Case DEUTSCH DEUTSCH For NE, G sensor For fuel, boost 799-601-9420 press. 799-601-9430 PVC socket

799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410

8P 10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2 10P 12P 14P 18P 20P 5P 6P 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Brown 12P-Gray 12P-Black 12P-Green 12P-Brown 18-8 18-14 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD 40P 24P 2P 3P 2P

PC400/450(LC)-7

20-257
(1)

Part No.

Connector type or No. of pins part name

799-601-9300

TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH TABLE

Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if the power is supplied normally.
Type of power supply Fuse No. Fuse capacity Destination of powerDestination of power Pump controller (Controller power supply) Swing holding brake solenoid (When emergency brake is released) PC-EPC solenoid (When emergency pump is driven) Pump controller (Solenoid power supply) Machine push-up solenoid ATT return selector relay & solenoid Starting motor cutout relay (For PPC lock) PPC lock solenoid Cigarette lighter Windshield washer motor Horn (Spare) Rotary lamp Right front working lamp & boom working lamp One-touch power maximizing switch (Input to pump controller input) Radio (Spare) Air conditioner unit Monitor panel Starting motor cutout relay (For personal code) Light relay (For right front working lamp & boom working lamp) Headlamp & additional headlamp Service power supply 1 (M32 connector) Travel alarm Service power supply 2 (DC/DC converter) Radio (For backing up) Monitor panel (For backing up) Starting switch Room lamp (Spare)

1

10 A

Switch power supply (Fusible link: A34)

2 3 4 5 6 7 8 9 10 11 12

20 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A 20 A 20 A 20 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A

Switch power supply (Fusible link: A34)

Switch power supply (Fusible link: A34)

13 14 15 16 17 18 19 20

Constant power supply (Fusible link: A35)

20-258
(1)

PC400/450(LC)-7

TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304 Error Code in Electrical System [E112] (Short-circuiting in normal rotation system of windshield wiper motor drive)........................................ 20-306 Error Code in Electrical System [E113] (Short-circuiting in reverse rotation system of windshield wiper motor drive)....................................... 20-308 Error Code in Electrical System [E114] (Short-circuiting in window washer drive system) ......................... 20-310 Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion) ........................................... 20-312 Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper) ................................. 20-314 Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)............................................. 20-316 Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)........................................... 20-318 Error Code in Electrical System [E128] (Monitor Comm. Abnormality)....................................................... 20-320 Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid) ............................ 20-322 Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid) ........................ 20-324 Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid).................................... 20-326 Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid) ................................... 20-327 Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid) ........................ 20-328 Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid).............................. 20-329 Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid).......................... 20-330 Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)..................................... 20-332 Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)..................................... 20-333 Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid).......................... 20-334 Error Code in Electrical System [E217] (Abnormal input model code)........................................................ 20-336 Error Code in Electrical System [E218] (S-Net Comm. Disc.)..................................................................... 20-338 Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid) ........................................... 20-340 Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system) ................................ 20-341 Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality) .................................................. 20-342 Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality) .................................................. 20-344 Error Code in Electrical System [E226] (Press. Sensor Power Abnormality).............................................. 20-346 Error Code in Electrical System [E227] (Abnormality in engine rotation sensor) ........................................ 20-348 Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay).................. 20-349 Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid) .......................................... 20-350 Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)................................ 20-352 Error Code in Electrical System [E238] (Disconnection in attachment return switching relay) ................... 20-354 Error Code in Electrical System [E245] (Short-circuiting in attachment oil flow rate adjusting EPC).......... 20-356 Error Code in Electrical System [E246] (Disconnection in attachment oil flow rate adjusting EPC) ........... 20-357 Error Code in Electrical System [E247] (Arm IN PPC pressure sensor abnormality) ................................. 20-358 Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)....................... 20-360 Error Code in Electrical System [E257] (Pump Abnormality) ...................................................................... 20-362 Error Code in Electrical System [E315] (Battery Relay Drive S/C) ............................................................. 20-364 Error Code in Electrical System [E91B] (Engine Ne sensor problem) ........................................................ 20-366 Error Code in Electrical System [E91C] (Engine G sensor problem) .......................................................... 20-367 Error Code in Electrical System [E920] (Engine type selection error)......................................................... 20-368 Error Code in Electrical System [E921] (Engine type mismatch) ................................................................ 20-370 Error Code in Electrical System [E931] (Fuel dial sys. error)...................................................................... 20-372 Error Code in Electrical System [E934] (Engine coolant sensor Hi error)................................................... 20-374

PC400/450(LC)-7

20-301
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TROUBLESHOOTING

Error Code in Electrical System [E936] (Engine oil press. sw. error) .......................................................... 20-376 Error Code in Electrical System [E93C] (Engine boost sensor error) ......................................................... 20-378 Error Code in Electrical System [E93D] (Engine fuel temp. sensor error) .................................................. 20-380 Error Code in Electrical System [E953] (Engine Comm. Abnormality)........................................................ 20-382 Error Code in Electrical System [E954] (Short engine starter sw.).............................................................. 20-384 Error Code in Electrical System [E955] (Engine S-NET error) .................................................................... 20-386 Error Code in Electrical System [E956] (Engine power failure (1)) ............................................................. 20-388 Error Code in Electrical System [E957] (Engine power failure (2)) ............................................................. 20-390 Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error).................................................... 20-392 Error Code in Electrical System [E96A] (Engine coolant sensor Lo error) .................................................. 20-394 Error Code in Electrical System [E970] (PCV1 over current) ...................................................................... 20-396 Error Code in Electrical System [E971] (PCV2 over current) ...................................................................... 20-397 Error Code in Electrical System [E974] (PCV1 line cut).............................................................................. 20-398 Error Code in Electrical System [E975] (PCV2 line cut).............................................................................. 20-399 Error Code in Electrical System [E977] (Rail press. sensor error) .............................................................. 20-400 Error Code in Electrical System [E979] (Rail press. high)........................................................................... 20-402 Error Code in Electrical System [E97A] (Rail press. abnormal) .................................................................. 20-402 Error Code in Electrical System [E97B] (Rail press. low)............................................................................ 20-403 Error Code in Electrical System [E97C] (Rail press. too low) ..................................................................... 20-405 Error Code in Electrical System [E97D] (Rail press. out of control) ............................................................ 20-405 Error Code in Electrical System [E980] (Eng. Controller Abnormality) ....................................................... 20-406 Error Code in Electrical System [E981] (Fuel Injector 1 Disc.).................................................................... 20-408 Error Code in Electrical System [E982] (Fuel Injector 2 Disc.).................................................................... 20-409 Error Code in Electrical System [E983] (Fuel Injector 3 Disc.).................................................................... 20-410 Error Code in Electrical System [E984] (Fuel Injector 4 Disc.).................................................................... 20- 411 Error Code in Electrical System [E985] (Fuel Injector 5 Disc.).................................................................... 20-412 Error Code in Electrical System [E986] (Fuel Injector 6 Disc.).................................................................... 20-413 Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C) ............................................................... 20-414 Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C) ............................................................... 20-416 Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)........................... 20-418 Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard) ............................ 20-418 Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging) ........................................................ 20-420 Failure Code in Mechanical System [AB00KE] (Charge Voltage Low) ....................................................... 20-420 Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)...................................................... 20-424 Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)........................................................ 20-426 Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat).................................................... 20-427 Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)....................................................... 20-428 Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)........................................................ 20-429

20-302
(1)

PC400/450(LC)-7

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work.
User Code Display in monitor panel Failure content Response from monitor panel or controller Phenomenon occurring on machine Relative information Error Code Display in monitor panel Failure Code Display in monitor panel Failure phenomenon

Title of failure phenomenon shown in failure history

Failure status as detected by monitor panel or controller Action taken by the monitor panel or controller to protect an affected system or equipment, when they detect some failure. Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or controller Information on the failure occurred as well as the troubleshooting Cause Standard value in normalcy and references for troubleshooting <Content Included> • Standard value in normalcy by which to pass “Good” or “No Good” judgement over the presumed cause • Reference for passing the above “Good” or “No Good” judgement <Phenomenon of Wiring Harness Failure> • Disconnection There is a faulty contact at the connector or disconnection of wiring harness occurred. • Defective grounding A wiring harness that is not connected with a grounding circuit has a contact with the grounding circuit. • Short-circuiting A wiring harness that is not connected with a 24 V electric circuit has a contact with the electric circuit. <Precaution for Troubleshooting> 1) Connector No. display method and handling of T-adapter Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed. • If there is no indication of “male” or “female” in a specific connector No., disconnect the connector and insert the T-adapter into both male and female sides. • If there is an indication of “male” or “female” in a specific connector No., disconnect the connector and connect the T-adepter with only one side of either “male” or “female”. 2) Entry sequence of pin No. and handling of circuit tester lead Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the following manner unless otherwise instructed. • Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness. • Connect the negative (–) lead with the pin No. indicated at the front or the wiring harness.

1

2 Presumed cause and standard value in normalcy

Cause that presumably triggered failure in 3 question (The assigned No. is for filing purpose only. It does not stand for any priority) 4

5

20-304
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PC400/450(LC)-7

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.

PC400/450(LC)-7

20-305
(1)

TROUBLESHOOTING

E112

Error Code in Electrical System [E112] (Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code — Failure content Response from Monitor Panel Phenomenon occurring on machine Relative information Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between (3) and (1) Between (3) and grounding Continuity and resistance value Continued Above 1 Mz Error Code E112 Failure Code DY2DKB Failure phenomenon Short-circuiting in normal rotation system of windshield wiper motor drive (in monitor panel system)

• Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided. • Power supply to the windshield wiper motor normal rotation circuit is turned OFF.

• The windshield wiper stops moving.

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) (9) and W04 (male) (3) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective P01 Between (9) and grounding Windshield wiper switch OFF ON Voltage Below 3 V Below 3 V 20 – 30 V (at constant cycle)

20-306
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E112

Electric Circuit Diagram for Windshield Wiper Motor

PC400/450(LC)-7

20-307
(1)

TROUBLESHOOTING

E113

Error Code in Electrical System [E113] (Short-circuiting in reverse rotation system of windshield wiper motor drive)
User Code — Failure content Error Code E113 Failure Code DY2EKB Failure phenomenon Short-circuiting in reverse rotation system of windshield wiper motor drive (in Monitor Panel system)

• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the windshield wiper was set in motion.

Response from • Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF. Monitor Panel Phenomenon occurring on machine Relative information Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between (1) and (3) Between (1) and grounding Continuity and resistance value Continued Above 1 Mz • The windshield wiper stopped moving.

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) (10) and W04 (male) (1) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective P01 Between (10) and grounding Windshield wiper switch OFF ON Voltage Below 3 V Below 3 V 20 – 30 V (at constant cycle)

20-308
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E113

Electric Circuit Diagram for Windshield Wiper Motor

PC400/450(LC)-7

20-309
(1)

TROUBLESHOOTING

E114

Error Code in Electrical System [E114] (Short-circuiting in window washer drive system)
User Code — Failure content Error Code E114 Failure Code DY2CKB Failure phenomenon Short-circuiting in window washer drive system (in Monitor Panel system)

• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was switched ON.

Response from • Power supply to the grounding in the window washer motor circuit was switched OFF. Monitor Panel Phenomenon occurring on machine Relative information Cause Window washer drive 1 motor defective (Internal short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. A50 (male) Between (1) and (2) Resistance value 5 – 20 z • The window washer stopped moving.

Presumed cause and standard value in normalcy

Short-circuiting of wiring harness 2 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. Between wiring harness from P01 (female) (3) to J04 to A50 (female) (2) and grounding, or between wiring harness between P01 (female) (3) and D02 (female) (8) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective P01 Between (3) and grounding Window washer switch OFF ON Voltage 20 – 30 V Below 1 V

20-310
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E114

Electrical Circuit Diagram for Window Washer Motor

PC400/450(LC)-7

20-311
(1)

TROUBLESHOOTING

E115

Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion)
User Code — Failure content Error Code E115 Failure Code DY20KA Failure phenomenon Abnormal operation of windshield wiper (in Monitor Panel system)

• A W signal is not inputted at both ends of movement, when it is in motion.

Response from • Power to the windshield wiper motor is turned OFF. Monitor Panel Phenomenon occurring on machine Relative information • The windshield wiper motor does not work. • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Windshield wiper motor 1 defective (Internal disconnection) Presumed cause and standard value in normalcy W04 (female) Windshield wiper blade At upper end of operation range Outside upper end of operation range Resistance value Below 1 z Above 1 Mz

Between (6) and (5)

Disconnection of wiring harness 2 (Disconnection or faulty contact with connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Wiring harness between P01 (female) (5) and W04 (male) (6) Wiring harness between W04 (male) (5) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. P01 3 Monitor panel defective Between (5) and grounding Windshield wiper blade At upper end of operation range Outside upper end of operation range Voltage Below 1 V 20 – 30 V

20-312
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E115

Windshield Wiper Motor Electrical Circuit Diagram

PC400/450(LC)-7

20-313
(1)

TROUBLESHOOTING

E116

Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper)
User Code — Failure content Error Code E116 Failure Code DY20MA Failure phenomenon Abnormal in retracting windshield wiper (in Monitor Panel system)

• P signal in the retraction range is not inputted, when the wiper is retracted.

Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is Monitor Panel retracted. Phenomenon occurring on machine Relative information • The windshield wiper cannot be retracted completely. • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No.: 04502 Monitor Input 3) Cause Windshield wiper motor 1 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between (4) and (5) Windshield wiper blade Retraction range Operation range Resistance value Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (12) and W04 (male) (4) Between wiring harness W04 (male) (5) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective P01 Between (12) and grounding Windshield wiper blade Retraction range Operation range Voltage Below 1V 20 – 30 V

20-314
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E116

Windshield Wiper Motor Electrical Circuit Diagram

PC400/450(LC)-7

20-315
(1)

TROUBLESHOOTING

E117

Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)
User Code — Failure content Error Code E117 Failure Code DAC0KR Failure phenomenon Eng. Controller S-NET Comm. Err. (Monitor panel system)

• The monitor panel detected communication failure in the S-NET communication circuit to the engine controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall. • Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) Resistance value Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding Resistance value Above 1 Mz

Presumed cause and standard value in normalcy

Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Below 1 V

4

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CB2 Between (21), (31) and (11) Voltage 6–9V

5 Monitor panel defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02 Between (9), (10) and (20) Voltage 6–9V

20-316
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E117

Electrical circuit diagram related to S-NET communication

PC400/450(LC)-7

20-317
(1)

TROUBLESHOOTING

E118

Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)
User Code — Failure content Error Code E118 Failure Code DAB0KR Failure phenomenon Pump Controller S-NET Comm. Err. (Monitor panel system)

• The monitor panel detected communication failure in the S-NET communication circuit to the pump controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall. • Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) Resistance value Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding Resistance value Above 1 Mz

Presumed cause and standard value in normalcy

Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Below 1 V

4

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02 Between (21) and (31) Voltage 6–9V

5 Monitor panel defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02 Between (9), (10) and (20) Voltage 6–9V

20-318
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E118

Electrical circuit diagram related to S-NET communication

PC400/450(LC)-7

20-319
(1)

TROUBLESHOOTING

E128

Error Code in Electrical System [E128] (Monitor Comm. Abnormality)
User Code E0E Failure content Error Code E128 Failure Code DAF0MC Failure phenomenon Monitor Comm. Abnormality (Monitor panel system)

• The monitor panel detected communication failure in the CAN communication circuit to the engine controller or pump controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) Wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) Resistance value Resistance value Below 1 z • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.

Disconnection of wiring harness 1 (Disconnection or defective contact with connector)

Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit) Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding Resistance value Above 1 Mz

Presumed cause and standard value in normalcy

Resistance value

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit) Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding Voltage Below 1 V

Voltage

Below 1 V

4

CAN terminal resistor defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male) Between (1) and (2) Voltage 40 – 80 z

Monitor panel, engine 5 controller, or pump controller defective

If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)

20-320
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E128

Electrical circuit diagram related to CAN communication

PC400/450(LC)-7

20-321
(1)

TROUBLESHOOTING

E201

Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid)
User Code — Failure content Error Code E201 Failure Code DW91KB Failure phenomenon Short-circuiting in travel interlocking solenoid (Pump controller system)

• Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.

• Power supply to the travel interlocking circuit is switched OFF. Response from • Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the controller engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits connot be disconnected) • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) Cause Travel interlocking solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male) Between (1) and (2) Between (2) and grounding Resistance value 20 – 60 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (7) to V02 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3 Pump controller defective C03 Between (7) and grounding R.H. & L.H. travel control lever Neutral Steering Voltage Below 1 V 20 – 30 V

Electrical Circuit for Travel Interlocking Solenoid

20-322
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E203

Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid)
User Code E03 Failure content Error Code E203 Failure Code DW45KB Failure phenomenon Short-circuiting in swing holding brake solenoid (Pump controller system)

• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the circuit.

• Power supply to the swing holding brake solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the swing and steering brake does not return to controller normalcy, unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • The upper structure cannot swing. (The swing holding brake cannot be released.) • Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing holding brake releasing switch to the RELEASE position. (In this case, however, the holding brake does not work, when stopping the machine) Cause Swing holding brake solenoid defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male) Between (1) and (2) Between (2) and grounding Grounding fault of wiring harness 2 (Contact with grounding circuit) Resistance value 20 – 60 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (37) to D01 to J02 to X05 to V05 (female) (2), or C03 (female) (37) and S25 (female) (8) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3 Pump controller defective C03 Between (37) and grounding L.H. work equipment control lever NEUTRAL Swing operated Voltage Below 1 V 20 – 30 V

20-324
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E203

Electrical Circuit Diagram for Swing Holding Brake Solenoid

PC400/450(LC)-7

20-325
(1)

TROUBLESHOOTING

E204

Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid)
User Code — Failure content Error Code E204 Failure Code DWJ0KB Failure phenomenon Short-circuiting in merge/divide solenoid (Pump controller system)

• Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.

• Power supply to the merge/divide solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation. (F•R pumps cannot be disconnected.) • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) Cause Merge/divide solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male) Between (1) and (2) Between (2) and grounding Resistance value 20 – 60 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3 Pump controller defective C03 Between (17) and grounding L.H. and R.H. travel control levers NEUTRAL When operating one side only Voltage Below 1 V 20 – 30 V

Electrical Circuit Diagram for Merge/Divide Solenoid

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TROUBLESHOOTING

E205

Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid)
User Code — Failure content Error Code E205 Failure Code DWK0KB Failure phenomenon Short-circuiting in 2-stage relief solenoid (Pump controller system)

• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.

• Power supply to the 2-stage relief solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.) • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) Cause 2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male) Between (1) and (2) Between (2) and grounding Resistance value 20 – 60 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to V08 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Pump controller defective C03 Between (28) and grounding Working mode Other than L mode L mode Voltage Below 1 V 20 – 30 V

Electric Circuit Diagram for 2-stage Relief Solenoid

PC400/450(LC)-7

20-327
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TROUBLESHOOTING

E206

Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid)
User Code — Failure content Error Code E206 Failure Code DW43KB Failure phenomenon Short-circuiting in travel speed shifting solenoid (Pump controller system)

• Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.

• Power supply to the travel speed shifting solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • The travel speed does not turn to Hi. (The travel motor swash plate angle does not turn to minimum.) • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) Cause Travel speed shifting solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male) Between (1) and (2) Between (2) and grounding Resistance value 20 – 60 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3 Pump controller defective C03 Between (27) and grounding Travel speed + travel lever Lo + Neutral Hi + Travel operation Voltage Below 1 V 20 – 30 V

Electrical Circuit Diagram for Travel Speed Shifting Solenoid

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E211

Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid)
User Code — Failure content Error Code E211 Failure Code DW91KA Failure phenomenon Disconnection in travel interlocking solenoid (Pump controller system)

• No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • It is difficult to steer the machine while traveling. (L.H. and R.H. travel circuits cannot be disconnected.) • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E201].) Cause Travel interlocking 1 solenoid defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male) Between (1) and (2) Resistance value 20 – 60 z

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit) Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (7) to V02 (female) (2) Wiring harness between C03 (female) (3), (13), (23) and V02 (female) (1) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (7) to V02 (female) (2) and grounding Voltage Below 1 V

4

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (7) and (3), (13), (23) Resistance value 20 – 60 z

Electrical Circuit Diagram for Travel Interlocking Solenoid

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E213

Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid)
User Code E03 Failure content Error Code E213 Failure Code DW45KA Failure phenomenon Disconnection in swing holding brake solenoid (Pump controller system)

• No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine • The machine's upper structure does not swing. (The swing holding brake cannot be released.) • Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing by moving the swing holding brake release switch to the RELEASE position. (In this case, however, the holding brake does not work, when stopping the machine) • While in troubleshooting, hold both the swing lock switch and the swing holding brake release switch in the OFF position. • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E203].) Cause Swing holding brake 1 solenoid defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male) Between (1) and (2) Resistance value 20 – 60 z

Relative information

Swing lock switch 2 defective (Internal disconnection)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (3) and (4) Swing lock switch OFF ON Resistance value Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

Assembled-type diode 3 D01 defective (Internal disconnection)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male) Between (7) and (3) Digital type circuit tester Diode mode Continuity Continued

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector) Wiring harness between C03 (female) (37) and D01 (female) (7) Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Wiring harness from X05 (male) (4) to V05 (female) (2) Wiring harness between C03 (female) (3), (13), (23) and V05 (female) (1) Resistance value Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of position during the troubleshooting. 5 Wiring harness (Contact with 24V circuit) Between wiring harness between C03 (female) (37) and Voltage Below 1 V D01 (female) (7) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (37) and (3), (13), (23) Disconnect D01 and connect pins (3) and (7) of the female side. Resistance value 20 – 60 z

6

Pump controller defective

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E213

Electrical Circuit Diagram for Swing Holding Brake Solenoid

PC400/450(LC)-7

20-331
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TROUBLESHOOTING

E214

Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)
User Code — Failure content Error Code E214 Failure Code DWJ0KA Failure phenomenon Disconnection in merge/divide solenoid (Pump controller system)

• No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • In L mode, speeds of the work equipment and swing in its single operation are too fast. (F•R pumps cannot be disconnected.) • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E204].) Cause Merge/divide solenoid 1 defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male) Between (1) and (2) Resistance value 20 – 60 z

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit) Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2) Wiring harness between C03 (female) (3), (13), (23) and V03 (female) (1) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2) and grounding Voltage Below 1 V

4

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (17) and (3), (13), (23) Resistance value 20 – 60 z

Electrical Circuit Diagram for Merge/Divide Solenoid

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E215

Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)
User Code — Failure content Error Code E215 Failure Code DWK0KA Failure phenomenon Disconnection in 2-stage relief solenoid (Pump controller system)

• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.) • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E205].) Cause 2-stage relief solenoid 1 defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male) Between (1) and (2) Resistance value 20 – 60 z

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit) Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to V08 (female) (2) Wiring harness between C03 (female) (3), (13), (23) and V08 (female) (1) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (28) to V08 (female) (1) and grounding Voltage Below 1 V

4

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (28) and (3), (13), (23) Resistance value 20 – 60 z

Electrical Circuit Diagram for 2-stage Relief Solenoid

PC400/450(LC)-7

20-333
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TROUBLESHOOTING

E216

Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid)
User Code — Failure content Error Code E216 Failure Code DW43KA Failure phenomenon Disconnection in travel speed shifting solenoid (Pump controller system)

• No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The travel speed does not shift to Hi. (The travel motor swash plate angle does not turn to minimum.) • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E206].) Cause Travel speed shifting 1 solenoid defective (Internal disconnection) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male) Between (1) and (2) Resistance value 20 – 60 z

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit) Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2) Wiring harness between C03 (female) (3), (13), (23) and V04 (female) (1) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2) and grounding Voltage Below 1 V

4

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (27) and grounding (3), (13), (23) Resistance value 20 – 60 z

Electrical Circuit Diagram for Travel Speed Shifting Solenoid

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E217

Error Code in Electrical System [E217] (Abnormal input model code)
User Code — Failure content Error Code E217 Failure Code DA2SKQ Failure phenomenon Abnormality in inputting model code (Pump controller system)

• A model code signal for a model which is not registered in the controller is inputted.

• The controller controls the machine as a default model (PC750). Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • Since the controller controls the machine as PC750/800, the working speed changes and operation becomes difficult. • The model name (number) recognized by the controller can be checked in the monitoring function. (Code No. 00200: Controller model code) • Input of the model selection signal (ON or OFF) can be checked in the monitoring function. (Code No. 02201: Switch input 2) Cause Model selection connector defective 1 (Internal disconnection or short-circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C09 (female) Between (4), (5), (6) and (8) Between (1), (2), (3), (7) and (8) Resistance value Min. 1 Mz Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Presumed cause and standard value in normalcy Wiring harness between C02 (female) (37) and C09 (male) (1) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Wiring harness between C02 (female) (27) and C09 (male) (2) Wiring harness between C02 (female) (17) and C09 (male) (3) Wiring harness between C02 (female) (13) and C09 (male) (7) Wiring harness between C09 (male) (8), J05, and grounding Grounding fault of wiring harness 3 (Contact with grounding circuit) Resistance value Resistance value Resistance value Resistance value Resistance value Max, 1 z Max, 1 z Max, 1 z Max, 1 z Max, 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (7) and C09 (male) (4) and grounding Resistance value Min. 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Pump controller defective C02 Between (7) and grounding Between (37), (27), (17), (13) and grounding Voltage 5 – 30 V Max. 1 V

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TROUBLESHOOTING

E217

Electrical circuit diagram related to model selection connector (for pump controller)

PC400/450(LC)-7

20-337
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TROUBLESHOOTING

E218

Error Code in Electrical System [E218] (S-Net Comm. Disc.)
User Code E0E Failure content Error Code E218 Failure Code DA2SKA Failure phenomenon S-Net Comm. Disc. (Pump controller system)

• The pump controller detected communication failure in the S-NET communication circuit to the monitor panel or engine controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall. • Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector) Grounding fault of wiring harness 2 (Contact with grounding circuit) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) Resistance value Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding Resistance value Min. 1 Mz

Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Max. 1 V

4 Monitor panel defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02 Between (9), (10) and (20) Voltage 6–9V

5

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CB2 Between (21), (31) and (11) Voltage 6–9V

6 Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02 Between (21) and (31) Voltage 6–9V

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E218

Electrical Circuit Diagram for S-NET Communication

PC400/450(LC)-7

20-339
(1)

TROUBLESHOOTING

E222

Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid)
User Code — Failure content Error Code E222 Failure Code DXE0KB Failure phenomenon Disconnection in LS-EPC solenoid (Pump controller system)

• Abnormal current flew to the LS-EPC solenoid circuit.

• The controller reduces the output to the LS-EPC solenoid circuit to 0. Response from • Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting controller switch is once turned OFF. Phenomenon occurring on machine Relative information • The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too fast. (The LS valve set pressure cannot be controlled.) • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01500 LS-EPC solenoid current) Cause LS-EPC solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V22 (male) Between (1) and (2) Between (1) and grounding Resistance value 7 – 14 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (6) and V22 (female) (1) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3 Pump controller defective C03 (female) Between (6) and (3) (13) (23) Between (6) and grounding Resistance value 7 – 14 z Above 1 Mz

Electrical Circuit Diagram for LS-EPC Solenoid

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E223

Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system)
User Code — Failure content Error Code E223 Failure Code DXE0KA Failure phenomenon Disconnection in LS-EPC solenoid (Pump controller system)

• No current flows to the LS-EPC solenoid circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too fast. (The LS valve set pressure cannot be controlled.) • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01500 LS-EPC solenoid current) Cause LS-EPC solenoid 1 defective (Internal short-circuiting) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V22 (male) Between (1) and (2) Resistance value 7 – 14 z

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (6) and V22 (female) (1) and grounding Wiring harness between C03 (female) (3) (13) (23) and V22 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (6) and V22 (female) (1) and grounding Voltage Below 1 V

4 Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (6) and (3) (13) (23) Resistance value 7 – 14 z

Electrical Circuit Diagram for LS-EPC Solenoid

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E224

Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality)
User Code — Failure content Error Code E224 Failure Code DHPAMA Failure phenomenon F Pump P. Sensor Abnormality (Pump controller system)

• Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.

Response from • The controller sets the F pump pressure to 0 MP {0 kg/cm2} for control. • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine Relative information • The travel speed does not shift automatically (The travel load pressure cannot be detected). a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the front pump pressure sensor (pressure) can be checked in the monitoring function. (Code No. 01100: Front pump pressure) Cause 1 Sensor power supply system defective Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Front pump pressure 2 sensor defective (Internal defect) A51 Between (B) and (A) Between (C) and (A) Power supply Signal Voltage 4.5 – 5.5 V 0.5 – 4.5 V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Presumed cause and standard value in normalcy Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between C01 (female) (22) and A51 (female) (B) Wiring harness between C01 (female) (10) and A51 (female) (A) Wiring harness between C01 (female) (8) and P30 (female) (C) Grounding fault of wiring harness 4 (Contact with grounding circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (8) and A51 (female) (C) and grounding Resistance value Min. 1 Mz

Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness A51 (female) (B) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (8) and A51 (female) (C) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Max. 1 V Max. 1 V

a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective C01 Between (22) and (10) Between (8) and (10) Voltage 4.5 – 5.5 V 0.5 – 4.5 V

20-342
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E224

Electrical circuit diagram related to front pump pressure sensor

PC400/450(LC)-7

20-343
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TROUBLESHOOTING

E225

Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality)
User Code — Failure content Error Code E225 Failure Code DHPBMA Failure phenomenon R Pump P. Sensor Abnormality (Pump controller system)

• Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.

Response from • The controller sets the R pump pressure to 0 MP {0 kg/cm2} for control. • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine Relative information • The travel speed does not shift automatically (The travel load pressure cannot be detected). a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function. (Code No. 01101: Rear pump pressure) Cause 1 Sensor power supply system defective Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Rear pump pressure 2 sensor defective (Internal defect) A52 Between (B) and (A) Between (C) and (A) Power supply Signal Voltage 4.5 – 5.5 V 0.5 – 4.5 V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Presumed cause and standard value in normalcy Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between C01 (female) (22) and A52 (female) (B) Wiring harness between C01 (female) (10) and A52 (female) (A) Wiring harness between C01 (female) (2) and A52 (female) (C) Grounding fault of wiring harness 4 (Contact with grounding circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding Resistance value Min. 1 Mz

Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness A52 (female) (B) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Max. 1 V Max. 1 V

a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective C01 Between (22) and (10) Between (2) and (10) Voltage 4.5 – 5.5 V 0.5 – 4.5 V

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E225

Electrical circuit diagram related to rear pump pressure sensor

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E226

Error Code in Electrical System [E226] (Press. Sensor Power Abnormality)
User Code — Failure content Error Code E226 Failure Code DA25KP Failure phenomenon Press. Sensor Power Abnormality (Pump controller system)

• Abnormal current flowed in the pressure sensor power supply (5 V) circuit.

• Power to the power supply (5 V) circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Standard value in normalcy and references for troubleshooting a Disconnect the connector when the engine starting switch is in OFF, and hold it in the ON position during the troubleshooting. Disconnect the parts shown at right in order. If the error code goes off when one of those parts is disconnected, that part is defective. Front pump pressure sensor Rear pump pressure sensor Arm IN PPC pressure sensor Bucket CURL PPC pressure sensor Connector A51 Connector A52 Connector S04 Connector S01 • The pressure sensor signal is not input normally. • The error code of abnormality in the pressure sensor is displayed, too.

Pressure sensor 1 defective (Internal short-circuiting)

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (22), A51 (female) (B) and grounding [Front pump pressure sensor system] Grounding fault of wiring harness 2 (Contact with grounding circuit) Between wiring harness between C01 (female) (22), A51 (female) (B) and grounding [Rear pump pressure sensor system] Between wiring harness between C01 (female) (22), S04 (female) (A) and grounding [Arm IN PPC pressure sensor system] Between wiring harness between C01 (female) (22), S01 (female) (A) and grounding [Bucket CURL PPC pressure sensor system] Resistance value Resistance value Resistance value Resistance value Min. 1 Mz

Min. 1 Mz

Min. 1 Mz

Min. 1 Mz

3 Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C01 Between (22) and (10) Voltage 4.5 – 5.5 V

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E226

Electrical circuit diagram related to pressure sensor power supply

PC400/450(LC)-7

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TROUBLESHOOTING

E227

Error Code in Electrical System [E227] (Abnormality in engine rotation sensor)
User Code — Failure content Error Code E227 Failure Code DLE2MA Failure phenomenon Abnormality in engine rotation sensor (Pump controller system)

• A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.

Response from • The controller exercises a control equivalent to E mode. controller • If the failure cause disappears of itself, the signal input returns to normalcy. Phenomenon occurring on machine Relative information • The machine lacks power a bit. (The engine rotation sensing does not work.) • The engine speed (in the pump controller system) is not monitored on the monitor panel. • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No.: 01006 Engine RPM) Cause Engine rotation sensor fault 1 (Internal short-circuiting or disconnection) 2 Engine rotation sensor adjustment improper Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. ENE (male) Between (1) and (2) Between (1) and grounding Presumed cause and standard value in normalcy Resistance value 500 – 1,000 z Above 1 Mz

For the inspection and adjustment, refer to the section of “Adjusting Engine Rotation Sensor” in this manual. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (40) and ENE (female) (1) Wiring harness between C02 (female) (29) (39) and ENE (female) (2) Resistance value Resistance value Below 1 z Below 1 z

Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (40) and ENE (female) (1) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Pump controller defective C02 (female) Between (40) and (29) (39) Between (40) and grounding Resistance value 500 – 1,000 z Above 1 Mz

Electrical Circuit Diagram for Engine Rotation Sensor

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E228

Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay)
User Code — Failure content Error Code E228 Failure Code D196KB Failure phenomenon Short-circuiting in attachment return switching relay (Pump controller system)

• Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).

Response from • The controller turned OFF power to the attachment return switching relay circuit. controller • Even when the failure cause disappears of itself, the current does not return to normalcy. Phenomenon occurring on machine Relative information • The hydraulic circuit for attachments is not switched to the single operation circuit. (The switching valve is not switched to the tank circuit.) • It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No.: 02301 Solenoid 2) • This error code detects abnormality on the primary side (coil side) of the attachment return selector relay and cannot detect abnormality on the secondary side (contact side). Cause Attachment return 1 switching relay defective (Internal short-circuiting) Short-circuiting of wiring harness 2 (Contact with 24 V circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male) Between (1) and (2) Resistance value 100 – 500 z

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (8) and R20 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Pump controller defective C02 Between (8) and grounding Working mode Other than B mode B mode Voltage 20 – 30 V Below 1 V

Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid

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E232

Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid)
User Code E02 Failure content Error Code E232 Failure Code DXA0KB Failure phenomenon Disconnection in PC-EPC solenoid (Pump controller system)

• Abnormal current flew to the PC-EPC solenoid circuit.

• The controller reduces the output to the PC-EPC solenoid circuit to OFF. Response from • Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting controller switch is once turned OFF. Phenomenon occurring on machine • As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled.) • Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01300 PC-EPC solenoid current) • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated in a working mode equivalent to E mode by turning the emergency pump drive switch to the emergency position. (At that time the monitor panel continues to display Error Code No. [E233], but this is not abnormal) • Turn the emergency driving switch normal position during the troubleshooting. Cause PC-EPC solenoid defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male) Between (1) and (2) Between (1) and grounding Resistance value 7 – 14 z Above 1 Mz

Relative information

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Presumed cause and standard value in normalcy Emergency pump driving switch defective 2 (Internal short-circuiting or grounding fault) S25 (male) Between (3) and (4) Between (3) and grounding Grounding fault of wiring harness 3 (Contact with grounding circuit) Normal Emergency pump drive switch Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (16) to S25 (female) (3) and grounding Between wiring harness from S25 (female) (2) to V21 (female) (1) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Pump controller defective C03 (female) Between (16) and (3) (13) (23) Between (16) and grounding Resistance value 7 – 14 z Above 1 Mz

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E232

Electrical Circuit Diagram for PC-EPC Solenoid

PC400/450(LC)-7

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E233

Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)
User Code E02 Failure content Error Code E233 Failure Code DXA0KA Failure phenomenon Disconnection in PC-EPC solenoid (Pump controller system)

• No current flows to the PC-EPC solenoid circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the current returns to normalcy. Phenomenon occurring on machine Relative information • As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled.) • Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01300 PC-EPC solenoid current) • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated in a working mode equivalent to E mode by turning the emergency pump driving switch to the emergency position. Cause PC-EPC solenoid 1 defective (Internal short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male) Between (1) and (2) Resistance value 7 – 14 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Emergency pump driving 2 switch defective (Internal disconnection) S25 (male) Between (2) and (3) Between (5) and (6) Emergency pump driving switch Normal Emergency Normal Emergency Resistance value Below 1 z Above 1 Mz Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between C03 (female) (16) and S25 (female) (3) Wiring harness between S25 (female) (2) and V21 (female) (1) Wiring harness between C03 (female) (3) (13) (23) and S25 (female) (6) Wiring harness between S25 (female) (5) and V21 (female) (2) Short-circuiting of wiring harness 4 (Contact with 24 V circuit) Resistance value Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (16) and S25 (female) (3) and grounding Between wiring harness between S25 (female) (2) and V21 (female) (1) and grounding Voltage Voltage Below 1 V Below 1 V

5

Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (16) and (3) (13) (23) Resistance value 7 – 14 z

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E233

Electrical Circuit Diagram for PC-EPC Solenoid

PC400/450(LC)-7

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E238

Error Code in Electrical System [E238] (Disconnection in attachment return switching relay)
User Code — Failure content Error Code E238 Failure Code D196KA Failure phenomenon Disconnection in attachment return switching relay (Pump controller system)

• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V voltage is not generated.

Response from • None in particular controller • If the failure cause disappears, the governor returns to normalcy. Phenomenon occurring on machine Relative information • The hydraulic circuit for attachments cannot be switched to the single operation. (The switching valve cannot be switched to the tank circuit.) • It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No.: 02301 Solenoid 2) • This error code detects abnormality on the primary side (coil side) of the attachment return selector relay and cannot detect abnormality on the secondary side (contact side). Cause 1 Fuse No. 2 fault Attachment return 2 switching relay defective (Internal disconnection) Standard value in normalcy and references for troubleshooting If fuse No.2 has been blown, there is a big possibility that grounding fault occurred in the relay circuit. (See Cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male) Between (1) and (2) Resistance value 100 – 500 z

Presumed cause and standard value in normalcy

Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (8) and R20 (female) (2) Wiring harness from R20 (female) (1) to J03 to FB1-2 outlet Resistance value Resistance value Below 1 z Below 1 z

Grounding fault of wiring harness 4 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (8) and R20 (female) (2) and grounding Between wiring harness from R20 (female) (1) to J03 to FB1-2 outlet and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Pump controller defective C02 Between (8) and grounding Working mode Other than B mode B mode Voltage 20 – 30 V Below 1 V

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E238

Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid

PC400/450(LC)-7

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TROUBLESHOOTING

E245

Error Code in Electrical System [E245] (Short-circuiting in attachment oil flow rate adjusting EPC)
User Code — Failure content Error Code E245 Failure Code DXE4KB Failure phenomenon Short-circuiting in attachment oil flow rate adjusting EPC (Pump controller system)

• Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.

• The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF. Response from • Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless controller the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.) • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current) Cause Attachment oil flow rate adjusting EPC defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V30 (male) Between (1) and (2) Between (1) and grounding Resistance value 7 – 14 z Above 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (female) (1) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3 Pump controller defective C03 (female) Between (26) and (3) (13) (23) Between (26) and grounding Resistance value 7 – 14 z Above 1 Mz

Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid

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E246

Error Code in Electrical System [E246] (Disconnection in attachment oil flow rate adjusting EPC)
User Code — Failure content Error Code E246 Failure Code DXE4KA Failure phenomenon Disconnection in attachment oil flow rate adjusting EPC (Pump controller system)

• No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.

Response from • None in particular (The solenoid does not work, as there is no current flowing to it) controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself. Phenomenon occurring on machine Relative information • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.) • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current) Cause Attachment oil flow rate adjusting EPC defective 1 (Internal short-circuiting or grounding fault) Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit) Pump controller defective Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V30 (male) Between (1) and (2) Resistance value 7 – 14 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (male) (1) and grounding Between wiring harness between C03 (female) (3) (13) (23) and V30 (male) (2) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (female) (1) and grounding Voltage Below 1 V

4

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (26) and (3) (13) (23) Resistance value 7 – 14 z

Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid

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E247

Error Code in Electrical System [E247] (Arm IN PPC pressure sensor abnormality)
User Code — Failure content Error Code E247 Failure Code DHS3MA Failure phenomenon Arm IN PPC pressure sensor abnormality (Pump controller system)

• Signal voltage from the arm IN PPC pressure sensor is below 0.3 V or above 4.42 V.

Response from • The controller sets the arm IN PPC pressure to 0 MP {0 kg/cm2} for control. • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine Relative information • If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The arm IN PPC circuit pressure cannot be detected). a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function. (Code No. 07200: Arm IN PPC pressure) Cause Sensor power supply 1 system defective Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Arm IN PPC pressure 2 sensor defective (Internal defect) S04 Between (A) and (C) Between (B) and (C) Power supply Signal Voltage 4.5 – 5.5 V 0.5 – 4.5 V

The pressure voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Presumed cause and standard value in normalcy Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between C01 (female) (22) and S04 (female) (A) Wiring harness between C01 (female) (10) and S04 (female) (C) Wiring harness between C01 (female) (19) and S04 (female) (E) Grounding fault of wiring harness 4 (Contact with grounding circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (19) and S04 (female) (E) and grounding Resistance value Min. 1 M z

Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness S04 (female) (A) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (19) and S04 (female) (B) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Max. 1 V Max. 1 V

a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective C01 Between (22) and (10) Between (19) and (10) Voltage 4.5 – 5.5 V 0.5 – 4.5 V

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E247

Circuit diagram related to arm IN PPC pressure sensor

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E248

Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)
User Code — Failure content Error Code E248 Failure Code DHS4MA Failure phenomenon Bucket CURL PPC pressure sensor abnormality (Pump controller system)

• Signal voltage from the bucket CURL PPC pressure sensor is below 0.3 V or above 4.42 V.

Response from • The controller sets the bucket CURL PPC pressure to 0 MP {0 kg/cm2} for control. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • If auto deceleration is operated, when auto deceleration cannot be released when moving the bucket CURL (The bucket CURL PPC circuit pressure cannot be detected). a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function. (Code No. 07300: Bucket CURL PPC pressure) Cause 1 Sensor power supply system defective Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Bucket CURL PPC pres2 sure sensor defective (Internal defect) S04 Between (1) and (3) Between (2) and (3) Power supply Signal Voltage 4.5 – 5.5 V 0.5 – 4.5 V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Presumed cause and standard value in normalcy Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between C01 (female) (22) and S04 (female) (1) Wiring harness between C01 (female) (10) and S04 (female) (3) Wiring harness between C01 (female) (13) and S04 (female) (2) Grounding fault of wiring harness 4 (Contact with grounding circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (13) and S04 (female) (2) and grounding Resistance value Min. 1 Mz

Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness S04 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (13) and S04 (female) (2) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Max. 1 V Max. 1 V

a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective C01 Between (22) and (10) Between (13) and (10) Voltage 4.5 – 5.5 V 0.5 – 4.5 V

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E248

Circuit diagram related to bucket CURL PPC pressure sensor

PC400/450(LC)-7

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TROUBLESHOOTING

E257

Error Code in Electrical System [E257] (Pump Abnormality)
User Code E0E Failure content Error Code E257 Failure Code DA2RMC Failure phenomenon Pump Abnormality (Pump controller system)

• The pump controller detected communication failure in the CAN communication circuit to the monitor panel or engine controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) Wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) Resistance value Resistance value Below 1 z • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.

Disconnection of wiring harness 1 (Disconnection or defective contact with connector)

Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit) Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding Resistance value Above 1 Mz

Presumed cause and standard value in normalcy

Resistance value

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit) Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding Voltage Below 1 V

Voltage

Below 1 V

4

CAN terminal resistor defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male) Between (1) and (2) Resistance value 40 – 80 z

Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller 5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be carpump controller defective ried out.)

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E257

Electrical circuit diagram related to CAN communication

PC400/450(LC)-7

20-363
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TROUBLESHOOTING

E315

Error Code in Electrical System [E315] (Battery Relay Drive S/C)
User Code — Failure content Error Code E315 Failure Code D110KB Failure phenomenon Battery Relay Drive S/C (Pump controller system)

• When a signal is output to the battery relay drive circuit, abnormal current flowed.

Response from • The controller turns OFF the output to the battery relay drive circuit. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • There may be a trouble in writing data into the ROM (non-volatile memory) of each controller. • Operation of the battery relay (ON or OFF) can be checked in the monitoring function. (Code No. 03700: Controller output 1) Cause Battery relay defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Battery relay (Unit) Between BR and E Between BR and grounding Grounding fault of wiring harness 2 (Contact with grounding circuit) Resistance value Approx. 100 z Min. 1 Mz

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (4), D01, J01, battery relay terminal BR or between C03 (female) (4) and starting switch terminal B or between C03 (female) (4) and D01 (female) (2) and grounding Resistance value Min. 1 Mz

3

Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C03 (female) Between (4) and grounding Starting switch ON o OFF Voltage 20 – 30 V (For 0.5 sec)

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PC400/450(LC)-7

TROUBLESHOOTING

E315

Electrical circuit diagram related to battery relay drive

PC400/450(LC)-7

20-365
(1)

TROUBLESHOOTING

E91B

Error Code in Electrical System [E91B] (Engine Ne sensor problem)
User Code E11 Failure content Error Code E91B Failure Code DLE3LC Failure phenomenon Engine Ne sensor problem (Engine controller system)

• Cranking angle cannot be judged from the engine Ne speed sensor signal.

Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function. (Code No. 01002: Engine speed) • Special adapter (799-601-9410) is necessary for troubleshooting for the engine Ne speed sensor. Cause Engine Ne speed sensor defective 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. NE (male) Between (1) and (2) Between (1), (2) and grounding Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 85 – 210 z Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (36) and NE (female) (2) Wiring harness between CB2 (female) (26) and NE (female) (1) Resistance value Resistance value Below 1 z Below 1 z

Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (36) and NE (female) (2) and grounding Between wiring harness between CB2 (female) (26) and NE (female) (1) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective CB2 (female) Between (36) and (26) Between (36), (26) and grounding Resistance value 85 – 210 z Above 1 Mz

Electrical circuit diagram related to engine Ne speed sensor

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PC400/450(LC)-7

TROUBLESHOOTING

E91C

Error Code in Electrical System [E91C] (Engine G sensor problem)
User Code E11 Failure content Error Code E91C Failure Code DLH1LC Failure phenomenon Engine G sensor problem (Engine controller system)

• Cylinder cannot be judged from the engine G speed sensor signal.

• The machine is driven with limited output. Response from • Control is carried out with the Ne speed sensor signal. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor. Cause Engine G speed sensor defective 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. G (male) Between (1) and (2) Between (1), (2) and grounding Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 1.4 k – 3.5 kz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (35) and G (female) (2) Wiring harness between CB2 (female) (25) and G (female) (1) Resistance value Resistance value Below 1 z Below 1 z

Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (35) and G (female) (2) and grounding Between wiring harness between CB2 (female) (25) and G (female) (1) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective E12 (female) Between (35) and (25) Between (35), (25) and grounding Resistance value 1.4 k – 3.5 kz Above 1 Mz

Electrical circuit diagram related to engine G speed sensor

PC400/450(LC)-7

20-367
(1)

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E920

Error Code in Electrical System [E920] (Engine type selection error)
User Code E11 Failure content Error Code E920 Failure Code DB29KQ Failure phenomenon Engine type selection error (Engine controller system)

• The model selection signal directly taken by the engine controller does not conform to the model in the controller or it is not confirmed.

• Control is carried out with the default model (PC400). Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • The model name (figure) recognized by the controller can be checked in the monitoring function. (Code No. 00201: Controller model code) • Input of the model selection signal (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input state) Cause Model selection connector defective 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB5 (female) Between (2), (3) (4), (5), (6), (7), and (8) Between (1) and (8) Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value Above 1 Mz Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB1 (female) (3) and CB5 (male) (1) Wiring harness between CB2 (female) (1) and CB5 (male) (8) Resistance value Resistance value Below 1 z Below 1 z

Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB1 (female) (23) and CB5 (male) (2) and grounding Between wiring harness between CB1 (female) (17) and CB5 (male) (3) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Engine controller defective CB1, CB2 Between CB1 (23), (17) and CB2 (1) Between CB1 (3) and CB2 (1) Voltage 20 – 30 V Below 1 V

20-368
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PC400/450(LC)-7

TROUBLESHOOTING

E920

Electrical circuit diagram related to model selection connector (for engine controller)

PC400/450(LC)-7

20-369
(1)

TROUBLESHOOTING

E921

Error Code in Electrical System [E921] (Engine type mismatch)
User Code E11 Failure content Error Code E921 Failure Code DB20KQ Failure phenomenon Engine type mismatch (Engine controller system)

• The model information taken by the engine controller through the model selection connector does not conform to the model information taken from the pump controller by communication.

• The normal operation is continued. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • The model name (figure) recognized by the engine controller can be checked in the monitoring function. (Code No. 00201: Controller model code) • The model name (figure) recognized by the pump controller can be checked in the monitoring function. (Code No. 00200: Controller model code) Cause 1 Model selection connector system defective Engine controller defective Standard value in normalcy and references for troubleshooting If error code [E920] is displayed, carry out troubleshooting for it. Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.) Pump controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)

Presumed cause and standard value in normalcy

2

3 Pump controller defective

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TROUBLESHOOTING

E931

Error Code in Electrical System [E931] (Fuel dial sys. error)
User Code E14 Failure content Error Code E931 Failure Code DK10KX Failure phenomenon Fuel dial sys. error (Engine controller system)

• The signal voltage from the fuel control dial is below 0.3 V or above 4.5 V.

• If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or 100% after the engine is started. Response from • If the abnormality is detected while the engine is running, the fuel control dial signal just before the controller abnormality is detected is kept. • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The engine speed cannot be controlled. • Input from the fuel control dial (voltage) can be checked in the monitoring function. (Code No. 03000: Fuel control dial voltage) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Fuel control dial defective 1 (Internal disconnection or short-circuiting) E06 (male) Between (1) and (3) Between (1) and (2) Between (3) and (2) Resistance value 4.0 – 6.0 kz 0.25 – 7.0 kz 0.25 – 7.0 kz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Wiring harness between CB2 (female) (19) and E06 (female) (1) Wiring harness between CB2 (female) (10) and E06 (female) (2) Wiring harness between CB2 (female) (29), (39), and E06 (female) (3) Grounding fault of wiring harness 3 (Contact with grounding circuit) Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (19) and E06 (female) (1) and grounding Between wiring harness between CB2 (female) (10) and E06 (female) (2) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

Short-circuiting of wiring Between wiring harness between CB2 (female) (19) and 4 harness E06 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between CB2 (female) (10) and E06 (female) (2) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Below 1 V Below 1 V

a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5 Engine controller defective CB2 Between (19) and (29), (39) Between (10) and (29), (39) Voltage 4.6 – 5.4 V 0.3 – 4.5 V

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PC400/450(LC)-7

TROUBLESHOOTING

E931

Electrical circuit diagram related to fuel control dial

PC400/450(LC)-7

20-373
(1)

TROUBLESHOOTING

E934

Error Code in Electrical System [E934] (Engine coolant sensor Hi error)
User Code E15 Failure content Error Code E934 Failure Code DGE2KX Failure phenomenon Engine coolant sensor Hi error (Engine controller system)

• The signal voltage from the engine water high temperature sensor is below 0.5 V or above 4.5 V.

Response from • The signal of the engine water high temperature sensor is kept at 90°C. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop. • Input from the engine water high temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No. 04106: Engine water temperature sensor Hi, 04102: Engine water temperature (High temperature)) Cause Engine water high temperature sensor 1 defective (Internal disconnection or short circuit) Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. TWH (male) Between (1) and (2) Between (1), (2) and grounding Resistance value 3.5 k – 90 kz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (27) and TWH (female) (1) Wiring harness between CB2 (female) (29), (39), and TWH (female) (2) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (27) and TWH (female) (1) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective CB2 Between (27), (29) and (39) Between (27), (29), (39) and grounding Resistance value 3.5 k – 90 kz Above 1 Mz

20-374
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E934

Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)

PC400/450(LC)-7

20-375
(1)

TROUBLESHOOTING

E936

Error Code in Electrical System [E936] (Engine oil press. sw. error)
User Code E15 Error Code E936 Failure Code DDE2L6 Failure phenomenon Engine oil press. sw. error (Engine controller system)

Failure content

• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the high-pressure switch is opened (disconnected from grounding) while the engine is running. • The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine is stopped (the starting signal is OFF). • The signal circuit of the high-pressure switch is opened (disconnected from grounding) while the engine is stopped (the starting signal is OFF).

Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop. • Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input) Cause Engine low-oil pressure switch defective 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position and start the engine during the troubleshooting. PSL Between terminal and grounding Engine Stopped Low idling Resistance value Below 1 z Above 1 Mz

Engine high-oil pressure switch defective 2 (Internal disconnection or short-circuiting)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position and start the engine during the troubleshooting. PSH Between terminal and grounding Engine Stopped Running at 1,300 rpm or higher Resistance value Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB1 (female) (21) and PSL Wiring harness between CB1 (female) (15) and PSH Resistance value Resistance value Below 1 z Below 1 z

Grounding fault of wiring harness 4 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB1 (female) (21) and PSL and grounding Between wiring harness between CB1 (female) (15) and PSH and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position and start the engine during the troubleshooting. CB1 Between (21) and grounding (Low-pressure switch signal) Between (15) and grounding (High-pressure switch signal) Engine Stopped Low idling Stopped Running at 1,300 rpm or higher Voltage Below 1 V 20 – 30 V Below 1 V 20 – 30 V

5

Engine controller defective

Carry out troubleshooting while the engine is running 15 seconds after the engine is started.

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PC400/450(LC)-7

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E936

Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)

PC400/450(LC)-7

20-377
(1)

TROUBLESHOOTING

E93C

Error Code in Electrical System [E93C] (Engine boost sensor error)
User Code E11 Failure content Error Code E93C Failure Code DH30KX Failure phenomenon Engine boost sensor error (Engine controller system)

• The signal voltage from the boost pressure sensor is below 0.3 V or above 4.7 V.

Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36501: Boost pressure sensor voltage, 36500: Boost pressure) • Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Boost pressure sensor 1 defective (Internal defect) PIM Between (3) and (1) Between (2) and (1) Power supply Signal Voltage 4.6 – 5.4 V 0.5 – 4.5 V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Wiring harness between CB2 (female) (9) and PIM (female) (3) Wiring harness between CB2 (female) (29), (39), and PIM (female) (1) Wiring harness between CB2 (female) (20) and PIM (female) (2) Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z

Presumed cause and standard value in normalcy

Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (9) and PIM (female) (3), or between CB2 (female) (9) and related circuits and grounding Between wiring harness between CB2 (female) (20) and PIM (female) (2) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring Between wiring harness between CB2 (female) (9), and PIM (female) (3), or between CB2 (female) (9) and 4 harness (Contact with 24 V circuit) related circuits and grounding Between wiring harness between CB2 (female) (20) and PIM (female) (2) and grounding Voltage Voltage Below 1 V Below 1 V

a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5 Engine controller defective CB2 Between (9) and (29), (39) Between (20) and (29), (39) Voltage 4.6 – 5.4 V 0.3 – 4.7 V

20-378
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PC400/450(LC)-7

TROUBLESHOOTING

E93C

Electrical circuit diagram related to boost pressure sensor

PC400/450(LC)-7

20-379
(1)

TROUBLESHOOTING

E93D

Error Code in Electrical System [E93D] (Engine fuel temp. sensor error)
User Code E15 Failure content Error Code E93D Failure Code DGE4KX Failure phenomenon Engine fuel temp. sensor error (Engine controller system)

• The signal voltage from the fuel temperature sensor is above 4.5 V.

Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop. • Input from the fuel temperature sensor (voltage) can be checked in the monitoring function. (Code No. 14201: Fuel temperature sensor voltage) Cause Fuel temperature sensor defective 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. THL (male) Between (1) and (2) Between (1), (2) and grounding Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit) Resistance value 0.3 k – 9 kz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (17) and THL (female) (1) Wiring harness between E12 (female) (29), (39) and THL (female) (2) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (17) and THL (female) (A) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective CB2 Between (17), (29) and (39) Between (17) and (29), (39) and grounding Resistance value 0.3 k – 9 kz Above 1 Mz

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PC400/450(LC)-7

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E93D

Electrical circuit diagram related to fuel temperature sensor

PC400/450(LC)-7

20-381
(1)

TROUBLESHOOTING

E953

Error Code in Electrical System [E953] (Engine Comm. Abnormality)
User Code E0E Failure content Error Code E953 Failure Code DB2RMC Failure phenomenon Engine Comm. Abnormality (Engine controller system)

• The engine controller detected communication failure in the CAN communication circuit to the monitor panel or pump controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) Wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) Resistance value Resistance value Below 1 z • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.

Disconnection of wiring harness 1 (Disconnection or defective contact with connector)

Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit) Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding Resistance value Above 1 Mz

Presumed cause and standard value in normalcy

Resistance value

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit) Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding Voltage Below 1 V

Voltage

Below 1 V

4

CAN terminal resistor defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male) Between (1) and (2) Resistance value 40 – 80 z

Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller 5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be carpump controller defective ried out.)

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E953

Electrical circuit diagram related to CAN communication

PC400/450(LC)-7

20-383
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TROUBLESHOOTING

E954

Error Code in Electrical System [E954] (Short engine starter sw.)
User Code — Failure content Error Code E954 Failure Code DD11KB Failure phenomenon Short engine starter sw. (Engine controller system)

• Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).

Response from • Starting switch signal is recognized to be OFF. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The machine operates normally. • Input of starting switch signal C (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting. 1 Presumed cause and standard value in normalcy Starting switch defective (Internal short-circuiting) Starting switch Between terminal B and terminal C OFF START Resistance value Above 1 Mz Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between starting switch termiShort-circuiting of wiring nal C, J01, and CB1 (female) (20) or between starting 2 harness switch terminal C and C01 (female) (17) or between (Contact with 24 V circuit) starting switch terminal C and P01 (female) (4) or between starting switch terminal C and R11 (female) (5), or between starting switch terminal C or related circuits and grounding

Voltage

Below 1 V

4

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. CB1 Between (20) and grounding Starting switch ON (Engine is running) Voltage Below 1 V

20-384
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PC400/450(LC)-7

TROUBLESHOOTING

E954

Electrical circuit diagram related to engine preheating, starting, charging

PC400/450(LC)-7

20-385
(1)

TROUBLESHOOTING

E955

Error Code in Electrical System [E955] (Engine S-NET error)
User Code E0E Failure content Error Code E955 Failure Code DB2SMC Failure phenomenon Engine S-NET error (Engine controller system)

• The engine controller detected communication failure in the S-NET communication circuit to the monitor panel or pump controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall. • Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector) Grounding fault of wiring harness 2 (Contact with grounding circuit) Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) Resistance value Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding Resistance value Above 1 Mz

Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Below 1 V

4 Monitor panel defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02 Between (9), (10) and (20) Voltage 6–9V

5

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CB2 Between (21), (31) and (11) Voltage 6–9V

6 Pump controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02 Between (21) and (31) Voltage 6–9V

20-386
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E955

Electrical circuit diagram related to S-NET communication

PC400/450(LC)-7

20-387
(1)

TROUBLESHOOTING

E956

Error Code in Electrical System [E956] (Engine power failure (1))
User Code E10 Failure content Error Code E956 Failure Code DB22KK Failure phenomenon Engine power failure (1) (Engine controller system)

• When the starting switch is turned ON, the source voltage of the controller is below 10 V.

Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information Cause Circuit breaker 7 1 defective Standard value in normalcy and references for troubleshooting If circuit breaker is turned OFF, the circuit probably has grounding fault, etc. (See cause 4.) • The engine stalls. • The engine cannot be started.

Engine controller power a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. supply relay defective 2 (Internal disconnection or Replace the power supply relay with another one. If the condition R22 short-circuiting) becomes normal, the relay is defective. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (1), (2), (21) and R22 (female) (5) Presumed cause and standard value in normalcy Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between R22 (female) (3) and B27 Wiring harness between B17 and battery relay B terminal Wiring harness between R22 (female) (1) and J02 (male) (1) Wiring harness between R22 (female) (2) and grounding Resistance value Resistance value Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit) Between wiring harness between CB3 (female) (1), (2), (21) and R22 (female) (5) and grounding Between wiring harness between R22 (female) (3) and B27 Between wiring harness between R22 (female) (1) and J02 (male) (1) or between R22 (female) (1) and related circuits and grounding Resistance value Resistance value Resistance value Above 1 Mz Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting. 5 Engine controller defective E13 Between (1), (2), (21) and (11), (31), (32) Starting switch OFF ON Voltage Below 1 V 20 – 30 V

20-388
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E956

Electrical circuit diagram related to engine controller power supply

PC400/450(LC)-7

20-389
(1)

TROUBLESHOOTING

E957

Error Code in Electrical System [E957] (Engine power failure (2))
User Code E15 Failure content Error Code E957 Failure Code D1D0KB Failure phenomenon Engine power failure (2) (Engine controller system)

• When the starting switch is turned OFF, the source voltage of the controller is above 10 V.

Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information Cause Engine controller power 1 supply relay defective (Internal short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Replace the power supply relay with another one. If the condition becomes normal, the relay is defective. R22 • The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.

Presumed cause and standard value in normalcy

Short-circuiting of wiring Between wiring harness between E13 (female) (1), (2), 2 harness (21) and R22 (female) (3) and grounding (Contact with 24 V circuit) Between wiring harness between R22 (female) (1) and J03, J06 (male) (2), or related circuits and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Below 1 V Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting. 3 Engine controller defective CB3 Between (1), (2), (21) and (11), (31), (32) Starting switch OFF ON Voltage Below 1 V 20 – 30 V

20-390
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E957

Electrical circuit diagram related to engine controller power supply

PC400/450(LC)-7

20-391
(1)

TROUBLESHOOTING

E95A

Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error)
User Code — Failure content Error Code E95A Failure Code DB2AMA Failure phenomenon Engine Q-adj. sw. signal error (Engine controller system)

• The fuel injection amount adjustment switch of the controller is not set to the correct position.

Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information Presumed cause and standard value in normalcy • Setting of the fuel injection amount adjustment switch cannot be changed. • Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring function. (Code No. 36800: Right fuel injection amount adjustment switch, 36801: Left fuel injection amount adjustment switch) Cause Setting of fuel injection amount adjustment 1 switch of engine controller defective Engine controller defective Standard value in normalcy and references for troubleshooting If the fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting is wrong.

2

If the cause is not detected, engine controller may be defective.

20-392
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E96A

Error Code in Electrical System [E96A] (Engine coolant sensor Lo error)
User Code E15 Failure content Response from controller Phenomenon occurring on machine Relative information Error Code E96A Failure Code DGE3L6 Failure phenomenon Engine coolant sensor Lo error (Engine controller system)

• The signal voltage from the engine water low temperature sensor is above 4.5 V. • The signal of the engine water low temperature sensor is kept at 20°C (If the signal of the high temperature sensor is effective, it is used as a substitute). • When the failure cause disappears of itself, the machine operation returns to normalcy. • The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop. • Input from the engine water low temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No. 04105: Engine water temperature sensor voltage Lo, 04107: Engine water temperature (Low temperature)) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. TWL (male) Between (1) and (2) Between (1), (2) and grounding Resistance value 0.3 k – 9 kz Above 1 Mz

Engine water low temperature sensor 1 defective (Internal disconnection or short circuiting) Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (37) and TWL (female) (1) Wiring harness between CB2 (female) (29), (39), and TWL (female) (2) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (37) and TWL (female) (1) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective E12 Between (29), (37) and (39) Between (29), (37), (39) and grounding Resistance value 0.3 k – 9 kz Above 1 Mz

20-394
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E96A

Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)

PC400/450(LC)-7

20-395
(1)

TROUBLESHOOTING

E970

Error Code in Electrical System [E970] (PCV1 over current)
User Code E11 Failure content Error Code E970 Failure Code AD11KB Failure phenomenon PCV1 over current (Engine controller system)

• Abnormal current flowed in the fuel supply pump PCV1 circuit.

• Power to the fuel supply pump PCV1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV1 (male) Between (1) and (2) Between (1) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Fuel supply pump PCV1 defective 1 (Internal short-circuiting or grounding fault) Presumed cause and standard value in normalcy Grounding fault of wiring harness 2 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (12) and PCV1 (female) (1) Resistance value Above 1 Mz

Short-circuiting of wiring Between wiring harness between CB3 (female) (12) and 3 harness PCV1 (female) (1) (Contact with 24 V circuit) Between wiring harness between CB3 (female) (22) and PCV1 (female) (2)

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Below 1 V Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective CB3 (female) Between (12) and (22) Between (12), (22) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Electrical circuit diagram related to fuel supply pump PCV1

20-396
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E971

Error Code in Electrical System [E971] (PCV2 over current)
User Code E11 Failure content Error Code E971 Failure Code AD51KB Failure phenomenon PCV2 over current (Engine controller system)

• Abnormal current flowed in the fuel supply pump PCV2 circuit.

• Power to the fuel supply pump PCV2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV2 (male) Between (1) and (2) Between (1) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Fuel supply pump PCV2 defective 1 (Internal short-circuiting or grounding fault) Presumed cause and standard value in normalcy Grounding fault of wiring harness 2 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (13) and PCV2 (female) (1) Resistance value Above 1 Mz

Short-circuiting of wiring Between wiring harness between CB3 (female) (13) and 3 harness PCV2 (female) (1) (Contact with 24 V circuit) Between wiring harness between CB3 (female) (23) and PCV2 (female) (2)

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Voltage Below 1 V Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective CB3 (female) Between (13) and (23) Between (13), (23) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Electrical circuit diagram related to fuel supply pump PCV2

PC400/450(LC)-7

20-397
(1)

TROUBLESHOOTING

E974

Error Code in Electrical System [E974] (PCV1 line cut)
User Code E11 Failure content Error Code E974 Failure Code AD11KA Failure phenomenon PCV1 line cut (Engine controller system)

• Fuel supply pump PCV1 circuit is disconnected.

• Power to the fuel supply pump PCV1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV1 (male) Between (1) and (2) Between (1) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Fuel supply pump PCV1 1 defective (Internal disconnection)

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (12) and PCV1 (female) (1) Between wiring harness between CB3 (female) (22) and PCV1 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (22) and PCV1 (female) (2) Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective CB3 (female) Between (12) and (22) Between (12), (22) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Electrical circuit diagram related to fuel supply pump PCV1

20-398
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E975

Error Code in Electrical System [E975] (PCV2 line cut)
User Code E11 Failure content Error Code E975 Failure Code AD51KA Failure phenomenon PCV2 line cut (Engine controller system)

• Fuel supply pump PCV2 circuit is disconnected.

• Power to the fuel supply pump PCV2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV2 (male) Between (1) and (2) Between (1) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Fuel supply pump PCV2 1 defective (Internal disconnection)

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (13) and PCV2 (female) (1) Between wiring harness between CB3 (female) (23) and PCV2 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (23) and PCV2 (female) (2) Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Engine controller defective CB3 (female) Between (13) and (23) Between (13), (23) and grounding Resistance value 2.3 – 5.3 z Above 1 Mz

Electrical circuit diagram related to fuel supply pump PCV2

PC400/450(LC)-7

20-399
(1)

TROUBLESHOOTING

E977

Error Code in Electrical System [E977] (Rail press. sensor error)
User Code E11 Failure content Error Code E977 Failure Code DH40KX Failure phenomenon Rail press. sensor error (Engine controller system)

• The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.

Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) • Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. Common rail fuel pressure sensor 1 defective (Internal defect) PFUEL Between (3) and (1) Between (2) and (1) Power supply Signal Voltage 4.6 – 5.4 V 0.7 – 4.5 V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector)

Wiring harness between CB2 (female) (9) and PFUEL (female) (3) Wiring harness between CB2 (female) (39) and PFUEL (female) (1) Wiring harness between CB2 (female) (40) and PFUEL (female) (2)

Resistance value Resistance value Resistance value

Below 1 z Below 1 z Below 1 z

Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (9) and PFUEL (female) (3), or between CB2 (female) (9) and related ciricuits and grounding Between wiring harness between CB2 (female) (40) and PFUEL (female) (2) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring Between wiring harness between CB2 (female) (9) and 4 harness PFUEL (female) (3), or between CB2 (female) (9) and (Contact with 24 V circuit) related ciricuits and grounding Between wiring harness between CB2 (female) (40) and PFUEL (female) (2) and grounding Voltage Voltage Below 1 V Below 1 V

a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5 Engine controller defective CB2 Between (9) and (39) Between (40) and (39) Voltage 4.6 – 5.4 V 0.7 – 4.5 V

20-400
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E977

Electrical circuit diagram related to common rail fuel pressure sensor

PC400/450(LC)-7

20-401
(1)

TROUBLESHOOTING

E979, E97A

Error Code in Electrical System [E979] (Rail press. high)
User Code E11 Failure content Error Code E979 Failure Code AD00L2 Failure phenomenon Rail press. high (Engine controller system)

• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).

Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) Cause Related systems 1 defective Presumed cause and standard value in normalcy 2 Fuel used improper Standard value in normalcy and references for troubleshooting If any other error code or failure code is displayed, carry out troubleshooting for it first. Fuel used may be improper. Check it directly.

Electric system of 3 common rail fuel Carry out troubleshooting for error code [E977]. pressure sensor defective Mechanical system of The common rail fuel pressure sensor may have a mechanical defect. Check it 4 common rail fuel directly. pressure sensor defective 5 Overflow valve defective 6 Overflow piping clogged The overflow valve may have trouble of breakage of spring, wear of seat, or fixing of ball. Check it directly. The overflow piping may be clogged. Check it directly.

7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.

Error Code in Electrical System [E97A] (Rail press. abnormal)
User Code E11 Failure content Error Code E97A Failure Code AD00MA Failure phenomenon Rail press. abnormal (Engine controller system)

• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).

• The machine is driven with limited output. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Presumed cause and standard value in normalcy • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) Cause 1 Common rail related device defective Standard value in normalcy and references for troubleshooting Carry out troubleshooting for error code [E979].

20-402
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E97B

Error Code in Electrical System [E97B] (Rail press. low)
User Code E15 Failure content Error Code E97B Failure Code AD10L3 Failure phenomenon Rail press. low (Engine controller system)

• No-pressure feed by fuel supply pump (level 1) occurred.

• The machine is driven with limited output. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information • The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop. • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) Cause 1 Related systems defective Standard value in normalcy and references for troubleshooting If any other error code or failure code is displayed, carry out troubleshooting for it first. Fuel used may be improper. Check it directly. A low-pressure circuit device may be defective. Referring to Note 1, carry out troubleshooting. The fuel filter/strainer may be clogged. Referring to Note 2, carry out troubleshooting. Carry out troubleshooting for error codes [E970], [E971], [E974], and [E975]. The fuel supply pump may be defective. Check it directly. The common rail fuel pressure sensor may be defective. Check it directly.

2 Fuel used improper Presumed cause and standard value in normalcy Fuel low-pressure circuit 3 device defective 4 Fuel filter/strainer clogged

Electrical system of fuel 5 supply pump PCV1 defective 6 Fuel supply pump defective

Common rail fuel 7 pressure sensor defective 9 Fuel injector defective

8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly. The fuel injector may be defective. Referring to Note 3, check it directly.

Note 1: 1) 2) 3) 4) 5) 6)

Check the low-pressure circuit devices for the following points. Insufficiency of fuel Fixing and wear of feed pump and clogging of filter Leakage from and clogging of low-pressure fuel piping Malfunction of bypass valve and installation of wrong part (See Fig. 1) Clogging of fuel filter Entry of fuel in oil pan (Fuel leakage in head cover) • Fuel low-pressure circuit pressure: 0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}

PC400/450(LC)-7

20-403
(1)

TROUBLESHOOTING

E97B

Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) • Overflow valve (1): Spring is seen through both holes. • Bypass valve (2): Spring is seen through hole on nut side. • Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it. 2) Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter. Note 3: Judge the condition of the fuel injector by measuring the fuel spill rate. k When performing the follow work, take care not to scald yourself with the fuel which becomes hot (up to 90°C). 1) Disconnect the hose connected to the centralized return spill tube adapters (at the rear of the engine). 2) Connect another hose to the spill tube end so that spill fuel can be received in a container. 3) Run the engine and stall at each speed (relieve the arm circuit by moving the arm in). Measure the quantity of the fuel spilling in 1 minute under this condition. a Limit of spill of fuel (Total of spill from 6 cylinders)
Stall speed (rpm) 1,600 1,700 1,800 1,900 2,000 Limit of spill (cc/min) 960 1,020 1,080 1,140 1,200

20-404
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E97C, E97D

Error Code in Electrical System [E97C] (Rail press. too low)
User Code E11 Failure content Error Code E97C Failure Code AD10MB Failure phenomenon Rail press. too low (Engine controller system)

• No-pressure feed by fuel supply pump (level 2) occurred.

• The machine is driven with limited output and speed. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Presumed cause and standard value in normalcy • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) Cause 1 Common rail-related device defective Standard value in normalcy and references for troubleshooting Carry out troubleshooting for error code [E97B].

Error Code in Electrical System [E97D] (Rail press. out of control)
User Code E11 Failure content Error Code E97D Failure Code AD10MA Failure phenomenon Rail press. out of control (Engine controller system)

• Abnormal fuel pressure was generated in the common rail.

• The machine is driven under the normal control. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Presumed cause and standard value in normalcy • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling. • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) Cause 1 Common rail-related device defective Standard value in normalcy and references for troubleshooting Carry out troubleshooting for error code [E97B].

PC400/450(LC)-7

20-405
(1)

TROUBLESHOOTING

E980

Error Code in Electrical System [E980] (Eng. Controller Abnormality)
User Code E10 or E11 Failure content Error Code E980 Failure Code DB20KT Failure phenomenon Eng. Controller Abnormality (Engine controller system)

• The controller has abnormality in it.

• The machine is driven with limited output or all output is turned OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Presumed cause and standard value in normalcy Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector) 2 Engine controller defective Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (11), (31), (32) and grounding Resistance value Below 1 z • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stop and it cannot be started (when user code [E10] is displayed).

If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)

20-406
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E980

Electrical circuit diagram related to engine controller power supply

PC400/450(LC)-7

20-407
(1)

TROUBLESHOOTING

E981

Error Code in Electrical System [E981] (Fuel Injector 1 Disc.)
User Code E11 Failure content Error Code E981 Failure Code ADA1KA Failure phenomenon Fuel Injector 1 Disc. (Engine controller system)

• Fuel injector 1 circuit is disconnected.

• Power to the fuel injector 1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 1 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN1 (male) Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 0.4 – 1.1 z • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

1 Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (14) and CN1 (female) (1) Wiring harness between CB3 (female) (24) and CN1 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

3

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) Between (14) and (24) Resistance value 0.4 – 1.1 z

Electrical circuit diagram related to fuel injector 1

20-408
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E982

Error Code in Electrical System [E982] (Fuel Injector 2 Disc.)
User Code E11 Failure content Error Code E982 Failure Code ADB1KA Failure phenomenon Fuel Injector 2 Disc. (Engine controller system)

• Fuel injector 2 circuit is disconnected.

• Power to the fuel injector 2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 2 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN2 (male) Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 0.4 – 1.1 z • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

1 Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (6) and CN2 (female) (1) Wiring harness between CB3 (female) (16) and CN2 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

3

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) Between (6) and (16) Resistance value 0.4 – 1.1 z

Electrical circuit diagram related to fuel injector 2

PC400/450(LC)-7

20-409
(1)

TROUBLESHOOTING

E983

Error Code in Electrical System [E983] (Fuel Injector 3 Disc.)
User Code E11 Failure content Error Code E983 Failure Code ADC1KA Failure phenomenon Fuel Injector 3 Disc. (Engine controller system)

• Fuel injector 3 circuit is disconnected.

• Power to the fuel injector 3 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 3 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN3 (male) Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 0.4 – 1.1 z • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

1 Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (5) and CN3 (female) (1) Wiring harness between CB3 (female) (15) and CN3 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

3

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) Between (5) and (15) Resistance value 0.4 – 1.1 z

Electrical circuit diagram related to fuel injector 3

20-410
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E984

Error Code in Electrical System [E984] (Fuel Injector 4 Disc.)
User Code E11 Failure content Error Code E984 Failure Code ADD1KA Failure phenomenon Fuel Injector 4 Disc. (Engine controller system)

• Fuel injector 4 circuit is disconnected.

• Power to the fuel injector 4 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 4 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN4 (male) Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 0.4 – 1.1 z • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

1 Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (26) and CN4 (female) (1) Wiring harness between CB3 (female) (36) and CN4 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

3

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) Between (26) and (36) Resistance value 0.4 – 1.1 z

Electrical circuit diagram related to fuel injector 4

PC400/450(LC)-7

20-411
(1)

TROUBLESHOOTING

E985

Error Code in Electrical System [E985] (Fuel Injector 5 Disc.)
User Code E11 Failure content Error Code E985 Failure Code ADF1KA Failure phenomenon Fuel Injector 5 Disc. (Engine controller system)

• Fuel injector 5 circuit is disconnected.

• Power to the fuel injector 5 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 5 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN5 (male) Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 0.4 – 1.1 z • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

1 Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (33) and CN5 (female) (1) Wiring harness between CB3 (female) (34) and CN5 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

3

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) Between (34) and (33) Resistance value 0.4 – 1.1 z

Electrical circuit diagram related to fuel injector 5

20-412
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E986

Error Code in Electrical System [E986] (Fuel Injector 6 Disc.)
User Code E11 Failure content Error Code E986 Failure Code ADF1KA Failure phenomenon Fuel Injector 6 Disc. (Engine controller system)

• Fuel injector 6 circuit is disconnected.

• Power to the fuel injector 6 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 6 defective (Internal disconnection) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN6 (male) Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Resistance value 0.4 – 1.1 z • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

1 Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (25) and CN6 (female) (1) Wiring harness between CB3 (female) (35) and CN6 (female) (2) Resistance value Resistance value Below 1 z Below 1 z

3

Engine controller defective

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) Between (25) and (35) Resistance value 0.4 – 1.1 z

Electrical circuit diagram related to fuel injector 6

PC400/450(LC)-7

20-413
(1)

TROUBLESHOOTING

E98A

Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C)
User Code E11 Failure content Error Code E98A Failure Code ADAZKB Failure phenomenon Fuel Injector 1 – 3 S/C (Engine controller system)

• Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.

• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 1 defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN1 (male) Between (1) and (2) Between (1), (2) and grounding Fuel injector 2 defective 2 (Internal short-circuiting or grounding fault) Presumed cause and standard value in normalcy Resistance value 0.4 – 1.1 z Above 1 Mz • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN2 (male) Between (1) and (2) Between (1), (2) and grounding Resistance value 0.4 – 1.1 z Above 1 Mz

Fuel injector 3 defective 3 (Internal short-circuiting or grounding fault)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN3 (male) Between (1) and (2) Between (1), (2) and grounding Resistance value 0.4 – 1.1 z Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (14) and CN1 (female) (1) and grounding Grounding fault of wiring harness 4 (Contact with grounding circuit) Between wiring harness between CB3 (female) (24) and CN1 (female) (2) and grounding Between wiring harness between CB3 (female) (6) and CN2 (female) (1) and grounding Between wiring harness between CB3 (female) (16) and CN2 (female) (2) and grounding Between wiring harness between CB3 (female) (5) and CN3 (female) (1) and grounding Between wiring harness between CB3 (female) (15) and CN3 (female) (2) and grounding Resistance value Resistance value Resistance value Resistance value Resistance value Resistance value Above 1 Mz Above 1 Mz Above 1 Mz Above 1 Mz Above 1 Mz Above 1 Mz

20-414
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E98A

Cause

Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between CB3 (female) (14) and CN1 (female) (1) and grounding Between wiring harness between CB3 (female) (24) and CN1 (female) (2) and grounding Voltage Voltage Voltage Voltage Voltage Voltage Below 1 V Below 1 V Below 1 V Below 1 V Below 1 V Below 1 V

Presumed cause and standard value in normalcy

Short-circuiting of wiring Between wiring harness between CB3 (female) (6) and 5 harness CN2 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between CB3 (female) (16) and CN2 (female) (2) and grounding Between wiring harness between CB3 (female) (5) and CN3 (female) (1) and grounding Between wiring harness between CB3 (female) (15) and CN3 (female) (2) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) 6 Engine controller defective Between (14) and (24) Between (6) and (16) Between (5) and (15) Between (5), (6), (14), (15), (16), (24) and grounding Resistance value 0.4 – 1.1 z 0.4 – 1.1 z 0.4 – 1.1 z Above 1 Mz

Electrical circuit diagram related to fuel injectors 1, 2, and 3

PC400/450(LC)-7

20-415
(1)

TROUBLESHOOTING

E98B

Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C)
User Code E11 Failure content Error Code E98B Failure Code ADDZKB Failure phenomenon Fuel Injector 4 – 6 S/C (Engine controller system)

• Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.

• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine Relative information Cause Fuel injector 4 defective 1 (Internal short-circuiting or grounding fault) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN4 (male) Between (1) and (2) Between (1), (2) and grounding Fuel injector 5 defective 2 (Internal short-circuiting or grounding fault) Presumed cause and standard value in normalcy Resistance value 0.4 – 1.1 z Above 1 Mz • • • • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN5 (male) Between (1) and (2) Between (1), (2) and grounding Resistance value 0.4 – 1.1 z Above 1 Mz

Fuel injector 6 defective 3 (Internal short-circuiting or grounding fault)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN6 (male) Between (1) and (2) Between (1), (2) and grounding Resistance value 0.4 – 1.1 z Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (26) and CN4 (female) (1) and grounding Grounding fault of wiring harness 4 (Contact with grounding circuit) Between wiring harness between CB3 (female) (36) and CN4 (female) (2) and grounding Between wiring harness between CB3 (female) (34) and CN5 (female) (1) and grounding Between wiring harness between CB3 (female) (33) and CN5 (female) (2) and grounding Between wiring harness between CB3 (female) (25) and CN6 (female) (1) and grounding Between wiring harness between CB3 (female) (35) and CN6 (female) (2) and grounding Resistance value Resistance value Resistance value Resistance value Resistance value Resistance value Above 1 Mz Above 1 Mz Above 1 Mz Above 1 Mz Above 1 Mz Above 1 Mz

20-416
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E98B

Cause

Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between CB3 (female) (26) and CN4 (female) (1) and grounding Between wiring harness between CB3 (female) (36) and CN4 (female) (2) and grounding Voltage Voltage Voltage Voltage Voltage Voltage Below 1 V Below 1 V Below 1 V Below 1 V Below 1 V Below 1 V

Presumed cause and standard value in normalcy

Short-circuiting of wiring Between wiring harness between CB3 (female) (34) and 5 harness CN5 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between CB3 (female) (33) and CN5 (female) (2) and grounding Between wiring harness between CB3 (female) (25) and CN6 (female) (1) and grounding Between wiring harness between CB3 (female) (35) and CN6 (female) (2) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) 6 Engine controller defective Between (26) and (36) Between (34) and (33) Between (25) and (35) Between (25), (26), (33), (34), (35), (36) and grounding Resistance value 0.4 – 1.1 z 0.4 – 1.1 z 0.4 – 1.1 z Above 1 Mz

Electrical circuit diagram related to fuel injectors 4, 5, and 6

PC400/450(LC)-7

20-417
(1)

TROUBLESHOOTING

A000N1, A000N2

Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)
User Code E22 Failure content Error Code E922 Failure Code A000N1 Failure phenomenon Engine high-idling speed out of standard (Mechanical system)

• While the engine is running, its speed above 2,350 rpm is detected.

Response from • None in particular. controller Phenomenon occurring on machine Relative information • If the machine is used as it is, the engine may be damaged. • Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01006: Engine speed) Cause Presumed cause and standard value in normalcy Overrun of engine 1 (While system is normal) 2 Engine speed sensor system abnormal Standard value in normalcy and references for troubleshooting Check for an external or an internal factor which heightens the engine high-idling speed, and then check the mechanical system of the engine. If error code [E227] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch ON for the preparations, and keep the engine running during the troubleshooting. Monitoring 01006 Engine speed Engine High idling Engine speed 1,880 – 1,980 rpm

3

Engine controller defective

Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard)
User Code — Failure content Error Code — Failure Code A000N2 Failure phenomenon Engine low-idling speed out of standard (Mechanical system)

• While the engine is running, its speed below 500 rpm is detected.

Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine Relative information • If the machine is used as it is, the engine may be damaged. • Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01006: Engine speed) Cause Presumed cause and standard value in normalcy 1 2 Engine mechanical system defective Engine speed sensor system abnormal Standard value in normalcy and references for troubleshooting Check for an external or an internal factor which lowers the engine low-idling speed, and then check the mechanical system of the engine. If error code [E227] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch ON for the preparations, and keep the engine running during the troubleshooting. Monitoring 01006 Engine speed Engine Low idling Engine speed 975 – 1,025 rpm

3

Engine controller defective

20-418
(1)

PC400/450(LC)-7

TROUBLESHOOTING

AA10NX

Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging)
User Code — Failure content Error Code — Failure Code AA10NX Failure phenomenon Aircleaner Clogging (Mechanical system)

• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine is running.

Response from • None in particular. controller Phenomenon occurring on machine Relative information • If the machine is used as it is, the engine may be damaged. • If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 1) Cause 1 Air cleaner clogged (While system is normal) Standard value in normalcy and references for troubleshooting Check the air cleaner. If it is clogged, clean or replace it. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position or keep the engine running during the troubleshooting. A31 (male) Between (1) and (2) Air cleaner Normal Clogged Resistance value Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

Air cleaner clogging 2 switch defective (Internal disconnection)

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (5) and A31 (female) (1) Wiring harness between A31 (female) (2) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or keep the engine running during the troubleshooting. 4 Monitor panel defective P02 Between (5) and grounding Air cleaner Normal Clogged Voltage Below 1 V 20 – 30 V

20-420
(1)

PC400/450(LC)-7

TROUBLESHOOTING

AA10NX

Electrical circuit diagram related to air cleaner clogging switch

PC400/450(LC)-7

20-421
(1)

TROUBLESHOOTING

AB00KE

Failure Code in Mechanical System [AB00KE] (Charge Voltage Low)
User Code — Failure content Error Code — Failure Code AB00KE Failure phenomenon Charge Voltage Low (Mechanical system)

• Signal voltage from alternator is below 20 V while the engine is running.

Response from • None in particular. controller Phenomenon occurring on machine Relative information • If the machine is used as it is, the battery may not be charged. • If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function. (Code No. 04300: Charge voltage, 04501: Monitor input 2) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 1 Alternator defective (Internal defect) Alternator Between terminal R and grounding Engine Above low idling Voltage Above 20 V

If the voltage is abnormal, check the belt tension too. Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (11), J02, and alternator terminal R Resistance value Below 1 z

Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (11), J02, and alternator terminal R, or between P02 (female) (11), D01, J01, and starting switch terminal BR, or between P02 (female) (11), battery relay terminal BR and grounding Resistance value

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Monitor panel defective P02 Between (11) and grounding Engine Above low idling Voltage Above 20 V

20-422
(1)

PC400/450(LC)-7

TROUBLESHOOTING

AB00KE

Electrical circuit diagram related to engine preheating, starting, charging

PC400/450(LC)-7

20-423
(1)

TROUBLESHOOTING

B@BAZG

Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)
User Code E11 Error Code E924 Failure Code B@BAZG Failure phenomenon Eng. Oil Press. Low (Mechanical system)

Failure content

• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above 600 rpm. • The signal circuit of the low-pressure switch is opened (disconnected from grounding) and the signal circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above 1,300 rpm.

Response from • None in particular. controller Phenomenon occurring on machine • If the machine is used as it is, the engine may be damaged. • When this failure occurs, the error code is displayed only when the user code is turned ON and the failure code is recorded in only the mechanical system of the failure history. • If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input) Cause Engine oil pressure 1 lowered (While system is normal) 2 Engine oil pressure switch system defective Standard value in normalcy and references for troubleshooting Check the engine oil pressure. If it is abnormal, find out the cause and check the engine for damage, then repair. Carry out troubleshooting for error code [E936]. a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or start the engine during the troubleshooting. CB1 3 Engine controller defective Between (21) and grounding (Low-pressure switch signal) Between (15) and grounding (High-pressure switch signal) Engine Stopped Low idling Stopped Above 1,300 rpm Voltage Below 1 V 20 – 30 V Below 1 V 20 – 30 V

Relative information

Presumed cause and standard value in normalcy

When carrying out troubleshooting while the engine is running, wait for 15 seconds after the engine is started.

20-424
(1)

PC400/450(LC)-7

TROUBLESHOOTING

B@BAZG

Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)

PC400/450(LC)-7

20-425
(1)

TROUBLESHOOTING

B@BAZK

Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)
User Code — Failure content Error Code — Failure Code B@BAZK Failure phenomenon Eng. Oil Level Low (Mechanical system)

• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the engine is stopped.

Response from • None in particular. controller Phenomenon occurring on machine Relative information • If the machine is used as it is, the engine may be damaged. • If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 2) Cause 1 Engine oil level low (While system is normal) Standard value in normalcy and references for troubleshooting Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently, find out the cause.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. OL (male) Between (1) and grounding Engine oil level Normal level Below normal level Resistance value Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

Engine oil level switch 2 defective (Internal disconnection) Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (8) and OL (female) (1) Resistance value Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective P02 Between (8) and grounding Engine oil level Normal level Below normal level Voltage Below 1 V 20 – 30 V

Electrical circuit diagram related to engine oil level switch

20-426
(1)

PC400/450(LC)-7

TROUBLESHOOTING

B@BCNS

Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat)
User Code — Failure content Error Code — Failure Code B@BCNS Failure phenomenon Eng. Water Overheat (Mechanical system)

• The signal circuit of the engine water high temperature sensor detected temperature above 105°C.

Response from • None in particular. controller Phenomenon occurring on machine Relative information • If the machine is used as it is, the engine may be damaged. • If the engine water temperature monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine water high temperature sensor (water temperature and voltage) can be checked in the monitoring function. (Code No. 04102: Engine water temperature (High), 04106: Engine water temperature sensor voltage Hi) Cause Presumed cause and standard value in normalcy 1 Engine overheated (While system is normal) Standard value in normalcy and references for troubleshooting Check the engine for overheating. If it has been overheated, find out the cause and check the engine for damage, then repair. Carry out troubleshooting for “Display of engine water temperature gauge on monitor panel is abnormal” in E mode. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB2 (female) Between (27) and (29), (39) Engine water temperature 105°C Resistance value 3.28 kz

Engine water high 2 temperature sensor system defective Engine controller defective

3

Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)

PC400/450(LC)-7

20-427
(1)

TROUBLESHOOTING

B@BCZK

Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)
User Code — Failure content Error Code — Failure Code B@BCZK Failure phenomenon Eng. Water Lvl Low (Mechanical system)

• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the engine is running.

Response from • None in particular. controller Phenomenon occurring on machine Relative information • If the machine is used as it is, the engine will overheat. • If the radiator water level monitor on the monitor panel lights up in red while the engine is stopped (the starting switch is at the ON position), this failure code is recorded. • Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1) Cause 1 Sub-tank water level low (While system is normal) Standard value in normalcy and references for troubleshooting Check the radiator sub-tank water level. If it is low, add water. (If it is reduced frequently, find out the cause.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A33 (male) Between (1) and (2) Sub-tank water level Within normal level Below LOW level Resistance value Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

Radiator water level 2 switch defective (Internal disconnection)

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (3) and A33 (female) (1) Wiring harness between A33 (female) (2), J08, J12 and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective P02 Between (3) and grounding Sub-tank water level Within normal level Below LOW level Voltage Below 1 V 20 – 30 V

Electrical circuit diagram related to radiator water level switch

20-428
(1)

PC400/450(LC)-7

TROUBLESHOOTING

B@HANS

Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)
User Code — Failure content Error Code — Failure Code B@HANS Failure phenomenon Hydr. Oil Overheat (Mechanical system)

• The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.

Response from • None in particular. controller Phenomenon occurring on machine Relative information • If the machine is used as it is, the hydraulic equipment may be damaged. • If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring function. (Code No. 04401: Hydraulic oil temperature) Cause 1 Hydraulic oil overheated (While system is normal) Standard value in normalcy and references for troubleshooting Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the hydraulic equipment for damage, then repair. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A61 (male) Between (1) and (2) Between (2) and grounding Grounding fault of wiring harness 3 (Contact with grounding circuit) Hydraulic oil temperature 10 – 100°C Resistance value 90 – 3.5 kz Above 1 Mz

Presumed cause and standard value in normalcy

Hydraulic oil temperature 2 sensor defective (Internal short-circuiting)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective P02 Between (12) and (13) Between (12) and grounding 10 – 100°C Hydraulic oil temperature Resistance value 90 – 3.5 kz Above 1 Mz

Electrical circuit diagram related to hydraulic oil temperature sensor

PC400/450(LC)-7

20-429
(1)

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-503 E-1 The engine does not start (The engine does not rotate) ...................................................................... 20-504 E-2 Preheater does not operate.................................................................................................................. 20-508 E-3 Auto engine warm-up device does not work ........................................................................................ 20-510 E-4 Auto-decelerator does not operate ....................................................................................................... 20- 511 E-5 All work equipment, swing and travel do not move .............................................................................. 20-512 E-6 One-touch power max. function does not operate ............................................................................... 20-514 E-7 Machine push-up function does not operate normally.......................................................................... 20-515 E-8 Attachment circuit does not change ..................................................................................................... 20-517 E-9 No display in monitor panel at all ......................................................................................................... 20-519 E-10 Part of display on monitor panel is missing ........................................................................................ 20-520 E-11 Monitor panel displays contents irrelevant to the model..................................................................... 20-520 E-12 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-521 E-13 Engine water temperature gauge does not display correctly ............................................................. 20-522 E-14 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-524 E-15 Fuel gauge does not display correctly ................................................................................................ 20-525 E-16 Swing lock monitor does not display correctly.................................................................................... 20-526 E-17 When monitor switch is operated, nothing is displayed...................................................................... 20-528 E-18 Windshield wiper and window washer do not work ............................................................................ 20-530 E-19 Alarm buzzer cannot be cancelled ..................................................................................................... 20-534 E-20 “Boom RAISE” is not correctly displayed in monitor function ............................................................. 20-535 E-21 “Boom LOWER” is not correctly displayed in monitor function........................................................... 20-536 E-22 “Arm IN” is not displayed normally in monitoring function .................................................................. 20-537 E-23 “Arm DUMPING” is not correctly displayed in monitor function.......................................................... 20-538 E-24 “Bucket CURL” is not displayed normally in monitoring function........................................................ 20-539 E-25 “Bucket DUMPING” is not correctly displayed in monitor function ..................................................... 20-540 E-26 “Swing” is not displayed normally in monitoring function.................................................................... 20-542 E-27 “TRAVEL” is not correctly displayed in monitor function..................................................................... 20-544 E-28 “Travel Differential Pressure” is not correctly displayed in monitor function ....................................... 20-546 E-29 “Service” is not correctly displayed in monitor function ...................................................................... 20-548 E-30 Travel alarm does not sound or does not stop sounding.................................................................... 20-550 E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.............................................................. 20-552

PC400/450(LC)-7

20-501
(1)

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)

Before carrying out troubleshooting for electrical system (E-mode)
Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if the power is supplied normally.
Type of power supply Fuse No. 1 Fuse capacity 10 A Destination of power Pump controller (Controller power supply) Swing holding brake solenoid (When emergency brake is released) PC-EPC solenoid (When emergency pump is driven) Pump controller (Solenoid power supply) Machine push-up solenoid ATT return selector relay & solenoid Starting motor cutout relay (For PPC lock) PPC lock solenoid Cigarette lighter Windshield washer motor Horn (Spare) Rotary lamp Right front working lamp & boom working lamp One-touch power maximizing switch (Input to pump controller input) Radio (Spare) Air conditioner unit Monitor panel Starting motor cutout relay (For personal code) Light relay (For right front working lamp & boom working lamp) Headlamp & additional headlamp Service power supply 1 (M32 connector) Travel alarm Service power supply 2 (DC/DC converter) Radio (For backing up) Monitor panel (For backing up) Starting switch Room lamp (Spare)

Switch power supply (Fusible link: A34)

2 3 4 5 6 7 8 9 10 11 12

20 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A 20 A 20 A 20 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A

Switch power supply (Fusible link: A34)

Switch power supply (Fusible link: A34)

13 14 15 16 17 18 19 20

Constant power supply (Fusible link: A35)

20-502
(1)

PC400/450(LC)-7

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
a The following information are edited and contained in the “Information Contained in Troubleshooting Table”. You are required to proceed with troubleshooting after fully grasping the contents.
Failure information Relative information Phenomena occurring on machine Information on occurred failures and troubleshooting Cause Standard value in normalcy and references for troubleshooting <Contents> • The standard values in normalcy by which to judge “good” or “no good” about presumed causes. • References for making judgement of “good” or “no good” <Phenomena of wiring harness fault> • Failure due to disconnection Defective contact with connector or disconnection of wiring harness has occurred. • Grounding fault A wiring harness that is not originally connected with a grounding circuit is in contact with it. • Failure due to short-circuiting A wiring harness that is not originally connected with a power source circuit (24 V) is in contact with it. <Points to remember in troubleshooting> 1) Connector denotation method and handling of T-adapters Insert or connect T-adapters in the following manner, unless specifically otherwise instructed. • If there is no indication of (male) or (female) in the connector No., pull off a connector and insert a T-adapter into both sides of male and female. • If there is an indication of (male9 and (female) in the connection No., pull off a connector and insert a T-adapter into only one side of (male) or (female). 2) Description sequence of pin No. and handling of circuit tester leads Connect the positive lead (+) and negative lead (–) for troubleshooting in the following manner unless specifically otherwise instructed. • Connect the positive lead (+) to a pin No. marked at the front or wiring harness. • Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.

1

Presumed cause and standard value in normalcy

2

Cause for presumed failure (The attached No. for 3 filing and reference purpose only. It does not stand for any priority)

4

5

Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.

PC400/450(LC)-7

20-503
(1)

TROUBLESHOOTING

E-1

E-1 The engine does not start (The engine does not rotate)
Failure information Relative information • The engine does not start. • The engine starting circuit has the start lock mechanism of the safety lock lever type Cause Insufficient battery capacity Defective fusible link A35 or fuse No. 3 or 17 Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery voltage Min. 24 V 2 Electrolyte specific gravity Min. 1.26

1

If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has a grounding fault (See cause 9). a Prepare with starting switch OFF, then keep starting switch OFF or turn it START and carry out troubleshooting.

3

Defective starting switch (Internal disconnection)

H15 (male) Between (1) and (4)

Starting switch OFF START

Resistance Min. 1 Mz Max. 1 z

4 Presumed cause and standard value in normalcy

Defective safety lock switch (Internal short circuit)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S14 (female) Between (1) and (3) Safety lock lever FREE LOCK Resistance Min. 1 Mz Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Defective starting motor cut-out relay (Internal defect) R11 (female), R13 (female) Between (1) and (2) Between (3) and (5) Between (3) and (6) Resistance 100 – 500 z Min. 1 Mz Max. 1 z

a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to START and carry out troubleshooting. Starting motor Between terminal B and chassis ground Between ST (1) and chassis ground Between ST (2) and chassis ground B (Power supply) S (Start) R (Charge) Voltage 20 – 30 V 20 – 30 V Max. 1 V

6

Defective starting motor (Internal defect)

If the above voltage is normal and the starting motor does not rotate, starting motor has a defect in it or the engine is defective. Defective alternator (Internal short circuit) a Prepare with starting switch OFF (with only wiring harness R disconnected), then turn starting switch ON and carry out troubleshooting. Alternator Between terminal R and chassis ground Voltage Max. 1 V

7

20-504
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-1

Cause

Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery relay B terminal and A35 (male) (1) Wiring harness between A35 (male) (2) and H15 (female) (1) Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z

8

Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)

Wiring harness between H15 (female) (4), J01, and R11 (female) (5) Wiring harness between R11 (female) (3) and ST (female) (1) Wiring harness between FB1-3 and S14 (male) (1) Wiring harness between S14 (male) (3) and R11 (female) (1) Wiring harness between R11 (female) (2) and R13 (female) (6)

Presumed cause and standard value in normalcy

Wiring harness between R13 (female) (3), J04, and chassis ground

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between A35 (male) (2) and H15 (female) (1) and chassis ground Wiring harness between H15 (female) (4), J01, and R11 (female) (5), and other related circuits and chassis ground Short circuit with chassis ground in wiring harness (Contact with ground circuit) Wiring harness between R11 (female) (3) and ST (female) (1) and chassis ground Wiring harness between FB1-3 and S14 (male) (1) and chassis ground Wiring harness between A14 (male) (3) and R11 (female) (1) and chassis ground Wiring harness between R11 (female) (2) and R13 (female) (6) and chassis ground Wiring harness between R13 (female) (2), J05, P02 (female) (14), and other related circuits and chassis ground Short circuit with power source in wiring harness 10 (Contact with 24-V circuit) Resistance Resistance Resistance Resistance Resistance Resistance Resistance Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz Min. 1 Mz

9

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between ST (female) (2), alternator terminal R, J02, D01 (female) (6), and P02 (female) (11) and chassis ground Voltage Max. 1 V

PC400/450(LC)-7

20-505
(1)

TROUBLESHOOTING

E-1

Electrical circuit diagram for engine preheating, starting, charging

20-506
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-1

E-2 Preheater does not operate
Failure information Relative information • The preheater does not operate. (1) When the starting switch is turned to the HEAT position, the preheating monitor does not light up.

• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds). • Input of the preheating signal (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1) Cause Standard value in normalcy and references for troubleshooting If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting (2). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (18) and J02 (male) (7) Resistance value Below 1 z

Presumed cause and standard value in normalcy

Starting switch system 1 defective Disconnection of wiring harness 2 (Disconnection or defective contact with connector)

a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or HEAT position during troubleshooting. 3 Monitor panel defective P02 Between (18) and grounding Starting switch OFF HEAT Voltage Below 1 V 20 – 30 V

Failure information Relative information

• The preheater does not operate.

(2) When the starting switch is turned to the HEAT position, the heater unit is not warmed.

• Check that the starting motor rotates normally. • (If the starting motor does not rotate, carry out troubleshooting in “Engine does not start”.) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or HEAT position during troubleshooting.

1

Starting switch defective (Internal disconnection)

H15 (male) Between (1) and (3)

Starting switch OFF HEAT

Resistance value Above 1 Mz Below 1 z

a Turn the engine starting switch OFF for the preparations (with the wiring harness connected), and hold it in the OFF or HEAT position during troubleshooting. Presumed cause and standard value in normalcy 2 Heater relay defective (Internal disconnection) Heater relay Between coil terminal and grounding Between contact terminals Intake air heater 3 defective (Internal disconnection) Starting switch OFF HEAT Continuity and resistance value Continued Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Intake air heater Between terminals Wiring harness between H15 (female) (3), J02, and heater relay terminal Continuity Continued Resistance value Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z Below 1 z

Disconnection of wiring harness 4 (Disconnection or defective contact with connector)

Wiring harness between starting motor terminal B and heater relay Wiring harness between heater relay and intake air heater Wiring harness between intake air heater and engine

20-508
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-2

Electrical circuit diagram for engine preheating, starting, charging

PC400/450(LC)-7

20-509
(1)

TROUBLESHOOTING

E-3

E-3 Auto engine warm-up device does not work
Failure information • The auto engine warm-up device does not work. • The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C, and raise the engine rotation up to 1,200 rpm. • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more than 3 seconds, when the engine starting switch is in the ON position or after the engine is started. • If the engine water temperature is below 10°C, the turbocharger protection function operates to keep the engine speed below 1,000 rpm for up to 5 seconds after the engine is started. Cause Presumed cause and standard value in normalcy Standard value in normalcy and references for troubleshooting a Turn the starting switch ON for the troubleshooting (monitoring). Monitoring code 1 Engine cooling water temperature signal fault 04107 Item Engine cooling water temperature (low temperature) Normal display Compare the monitor indication with the actual engine cooling water temperature.

Relative information

If the display on the monitor panel is abnormal, carry out troubleshooting in “Engine water thermometer does not display normally”. 2 Engine controller defective If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)

20-510
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-4

E-4 Auto-decelerator does not operate
Failure information Relative information • The auto-decelerator does not operate. • Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above this level. • Check the display on the monitor panel while the engine is running. • If the display on the monitor panel is abnormal, carry out troubleshooting in “ is not displayed normally in monitoring function”. Cause 1 Boom RAISE signal defective Standard value in normalcy and references for troubleshooting Monitoring code 01900 Pressure switch 1 Monitoring code 01900 Pressure switch 1 Monitoring code 3 Arm IN signal defective 01900 Pressure switch 1 Monitoring code 4 Arm OUT signal defective Presumed cause and standard value in normalcy 01900 Pressure switch 1 Monitoring code 01901 Pressure switch 2 Monitoring code 01901 Pressure switch 2 Monitoring code 7 Swing signal defective 01900 Pressure switch 1 Monitoring code 8 Travel signal defective 01900 Pressure switch 1 Monitoring code 9 Service signal defective 01901 Pressure switch 2 Item Boom RAISE Item Boom LOWER Item Arm IN Item Arm OUT Item Bucket CURL Item Bucket DUMP Item Swing Item Travel Item Service Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF Normal display Lever operated: ON Lever in neutral: OFF

Boom LOWER signal 2 defective

5

Bucket CURL signal defective

Bucket DUMP signal 6 defective

10 Pump controller defective 11 Engine controller defective

If causes 1 – 9 are not detected, the pump controller may be defective. (Since trouble is in the pump controller, troubleshooting cannot be carried out.) If causes 1 – 9 are not detected, the engine controller may be defective. (Since trouble is in the pump controller, troubleshooting cannot be carried out.)

PC400/450(LC)-7

20-511
(1)

TROUBLESHOOTING

E-5

E-5 All work equipment, swing and travel do not move
Failure information Relative information • All the work equipment, swing and travel do not move. — Cause 1 Fuse No. 3 fault Standard value in normalcy and references for troubleshooting If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See cause 6.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female) Between (1) and (2) Safety lock lever Free Lock Resistance value Below 1 z Above 1 Mz

Safety lock switch 2 defective (Internal disconnection)

Presumed cause and standard value in normalcy

PPC lock solenoid defective 3 (Internal disconnection, short-circuiting, or grounding fault) Assembled-type diode 4 D01 defective (Internal short-circuiting)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male) Between (1) and (2) Between (1) and grounding Resistance value 20 – 60 z Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male) Between (4) and (8) Resistance value (Continuitiy) Above 1 Mz (No continuitiy)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector) Wiring harness between FB1-3 outlet and S14 (male) (1) Wiring harness from S14 (male) (2) and J02 – V01 (female) (2) Wiring harness between V08 (female) (1) to J13 and grounding Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z

Grounding fault of wiring harness 6 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-3 outlet and S14 (male) (1) and grounding Wiring harness from S14 (male) (2) to J02 – V01 (female) (2), or between wiring harness between S14 (male) (2) and D01 (female) (4) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

20-512
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-5

Electrical circuit diagram for PPC lock solenoid

PC400/450(LC)-7

20-513
(1)

TROUBLESHOOTING

E-6

E-6 One-touch power max. function does not operate
Failure information Relative information • One-touch power max. function does not operate • If the one-touch power max. switch is pressed while the engine is running, the one-touch power max. monitor is displayed on the monitor panel. • Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in the monitoring function. (Code No. 02200: Switch input 1) Cause 1 Fuse No. 9 defective Standard value in normalcy and references for troubleshooting If the fuse is broken, there is a big possibility that grounding fault occurred in the circuit. (See cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. One-touch power max. 2 switch defective (Internal disconnection) Presumed cause and standard value in normalcy M23 (male) Between (1) and (2) Disconnection of wiring harness (Disconnection 3 or defective contact with connector) One-touch power max. switch Released Pressed Resistance value Min. 1 Mz Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between FB1-9 outlet and M23 (female) (1) Resistance value Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring 4 harness (Contact with grounding circuit) Between wiring harness between FB1-9 outlet and M23 (female) (1), or between wiring harness between FB1-9 outlet and other related circuit and grounding Between wiring harness between M23 (female) (2) and C01 (female) (11) and grounding Resistance value Resistance value Min. 1 Mz Min. 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Pump controller defective C01 Between (11) and grounding One-touch power max. switch Released Pressed Voltage Max. 1 V 20 – 30 V

Electrical circuit diagram related to one-touch power max. switch

20-514
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-7

E-7 Machine push-up function does not operate normally
Failure information Relative information • Machine push-up function does not operate normally. (1) The machine push-up function does not operate.

• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M38 (female) Between (1) and (2) Machine push-up switch Low pressure position High pressure position Resistance value Below 1 z Above 1 Mz

Presumed cause and standard value in normalcy

Machine push-up switch 1 defective (Internal short-circuiting)

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during troubleshooting. Short-circuiting of wiring 2 harness Between wiring harness between M38 (female) (2), J07 (Contact with 24 V circuit) and V06 (female) (2) or between M38 (female) (2) and Voltage Below 1 V D02 (female) (3) and grounding

Electrical circuit diagram related to machine push-up solenoid

PC400/450(LC)-7

20-515
(1)

TROUBLESHOOTING

E-7

Failure information Relative information

• Machine push-up function does not operate normally.

(2) The machine push-up function is not turned OFF.

• When the machine push-up function is set in the low pressure position, the solenoid is turned ON. Cause Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has grounding fault (See cause 6). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M38 (female) Between (1) and (2) Machine push-up switch Low pressure position High pressure position Resistance value Below 1 z Above 1 Mz

1 Fuse No. 2 defective Machine push-up switch 2 defective (Internal disconnection)

Presumed cause and standard value in normalcy

Machine push-up solenoid defective 3 (Internal disconnection, short-circuiting or grounding fault) Assembled-type diode 4 D04 defective (Internal short-circuiting)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male) Between (1) and (2) Between (2) and grounding Resistance value 20 – 60 z Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during troubleshooting. D02 (male) Between (3) and (7) Resistance value (Continuitiy) Above 1 Mz (No continuitiy)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector) Wiring harness between FB1-2 outlet and M38 (male) (1) Wiring harness between M38 (male) (2), J07 and V06 (female) (2) Wiring harness between V06 (female) (1) and grounding Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 6 (Contact with grounding circuit) Between wiring harness between FB1-2 outlet and M38 (male) (1) or between FB1-2 outlet and related circuits and grounding Between wiring harness between M38 (male) (2), J07 and V06 (female) (2) or between M38 (male) (2) and D02 (female) (3) and grounding Resistance value Resistance value Above 1 Mz

Above 1 Mz

20-516
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-8

E-8 Attachment circuit does not change
When attachment is installed
Failure information Relative information • Attachment circuit does not change. (1) When working mode A or E is selected, attachment circuit is not switched to crusher circuit (reciprocation circuit). (2) When working mode B is selected, attachment circuit is not switched to breaker circuit (one-way circuit).

• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or disconnection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected, however. Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V12 (male) Between (1) and (2) Between (2) and grounding Resistance value 20 – 60 z Above 1 Mz

Attachment return selector solenoid defective 1 (Internal disconnection or short-circuit)

Presumed cause and standard value in normalcy

Attachment return selector relay defective 2 (Internal disconnection or short-circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male) Between (3) and (5) Between (3) and (6) Resistance value Below 1 z Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between J03 (male) (8) and R20 (female) (3) Wiring harness between R20 (female) (5) and V12 (female) (2) Wiring harness between C03 (female) (3), (13), (23) and V12 (female) (1) Short-circuit of wiring harness 4 (Contact with 24 V circuit) Resistance value Resistance value Resistance value Below 1 z Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness and R20 (female) (5) and V12 (female) (2) and grounding Voltage Below 1 V

PC400/450(LC)-7

20-517
(1)

TROUBLESHOOTING

E-8

Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid

20-518
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-9

E-9 No display in monitor panel at all
Failure information Relative information • No display in monitor panel at all. When the engine starting switch is turned ON, there appears no display at all in the monitor panel. — Cause 1 Fuse No. 12 fault Standard value in normalcy and references for troubleshooting If the fuse No. 12 is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 3.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from P01 (female) (1) (2) to J07 to FB112 Wiring harness from P01 (female) (6) (7) to J04 and grounding Resistance value Resistance value Below 1 z Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defect contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P01 (female) (1) (2) to J07 to FB1-12 outlet or related circuits and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Monitor panel 4 controller defective P01 Between (1) (2) and grounding Between (6) (7) and grounding Starting switch ON OFF Voltage and resistance value Voltage: 20 – 30 V Resistance value: Below 1z

Electrical Circuit Diagram for Power Source in Monitor Panel

PC400/450(LC)-7

20-519
(1)

TROUBLESHOOTING

E-10, E-11

E-10 Part of display on monitor panel is missing
Failure information Relative information Presumed cause and standard value in normalcy • Part of display on monitor panel is missing — Cause Standard value in normalcy and references for troubleshooting a Turn the starting switch ON during the troubleshooting. 1 Monitor panel LCD fault If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen becomes totally white) by the following switching operation, then the monitor panel is normal. • Switching operation: [ ] + [ A ] (push swiches simultaneously.) If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.) Part of the display in the monitor panel is missing during starting switch in ON.

2

Monitor panel defective

E-11 Monitor panel displays contents irrelevant to the model
Failure information Relative information Presumed cause and standard value in normalcy • The monitor panels displays contents that have nothing to do with the model on which it is installed. — Cause Standard value in normalcy and references for troubleshooting a Turn the starting switch in ON during the troubleshooting (monitoring). 1 Model code signal fault (Internal failure) Monitoring code 00200 Item Controller model code Normal display PC400-a

If the display on the monitor panel is normal, troubleshoot Error Code [E217]. 2 Monitor panel defective If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)

20-520
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-10, E-11

E-12 Fuel level monitor red lamp lights up while engine is running
Failure information Relative information • The fuel level monitor red lamp lights up while the engine was running. • If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red. • (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No.: 04200 Fuel level sensor) Cause Fuel level lowered (sys1 tem in normal condition) Fuel level sensor fault 2 (Internal disconnection) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Standard value in normalcy and references for troubleshooting a Check fuel level in fuel tank. If insufficient, refill fuel. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A60 (male) Between (1) and grounding Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 – 110 z

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (2) and A60 (female) (1) Resistance value Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panal defective P02 (female) Between (2) and grounding Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 – 110 z

Electrical Circuit Diagram for Fuel Level Sensor

PC400/450(LC)-7

20-521
(1)

TROUBLESHOOTING

E-13

E-13 Engine water temperature gauge does not display correctly
(1) While the engine water temperature rises normally, the temperature gauge does not rise above the white range (C). (2) While the engine water temperature is stabilized normally, the temperature gauge rises up to the red range (H).

Failure information

• Engine water temperature gauge does not display correctly

Relative information

• The signal of the engine water high temperature sensor for the water temperature gauge is received from the engine controller through the communication line. • If the engine water high temperature sensor system becomes defective, error code [E934] may be displayed. • Input from the engine water high temperature sensor (voltage and temperature) can be checked in the monitoring function. (Code No. 04106: Engine water sensor voltage Hi, 04102: Engine water temperature (High temperature)) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. TWH (male) Between (1) and (2) Between (1), (2) and grounding Resistance value 3.5 k – 90 kz Above 1 Mz

Engine water high temperature sensor defective 1 (Internal disconnection, short-circuiting or grounding fault) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (27) and TWH (female) (1) Wiring harness between CB2 (female) (29), (39) and TWH (female) (2) Resistance value Resistance value Below 1 z Below 1 z

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (27) and TWH (female) (1) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between CB2 (female) (27) and (Contact with 24 V circuit) Voltage Below 1 V TWH (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Engine controller defective CB2 (female) Between (27), (29) and (39) Between (27), (29), (39) and grounding 6 Monitor panel defective Resistance value 3.5 k – 90 kz Above 1 Mz

If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)

20-522
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-13

Electrical circuit diagram related to engine water high temperature sensor

PC400/450(LC)-7

20-523
(1)

TROUBLESHOOTING

E-14

E-14 Hydraulic oil temperature gauge does not display correctly
Failure information Relative information • Hydraulic oil temperature gauge does not display correctly (1) Hydraulic oil temperature rises normally, but the display does not rise from the white range (C). (2) Hydraulic oil temperature remains stable, but the display rises up the red range (H). • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function. (Code No.: 04401 Hydraulic oil temperature) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Hydraulic oil temperature sensor fault 1 (Internal disconnection or short-circuiting) A61 Between (1) and (2) Between (2) and grounding Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit) 10 – 100 °C Engine cooling water temperature Resistance value 90 – 3.5 kz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (12) and A61 (female) (2) Wiring harness between P02 (female) (13) and A61 (female) (1) Resistance value Resistance value Below 1 z Below 1 z

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Monitor panal defective P02 Between (12) and (13) Between (12) and grounding 10 – 100 °C Engine cooling water temperature Resistance value 90 – 3.5 kz 90 – 3.5 kz

Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor

20-524
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-15

E-15 Fuel gauge does not display correctly
Failure information Relative information • Fuel gauge does not display correctly (1) Though fuel was refilled, the display does not exceed the red range (E). (2) Though the remaining fuel level is low, the display does not drop below the green range (F). • Input from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No.: 04200 Fuel sensor voltage) Cause Fuel level sensor fault 1 (Internal disconnection or short-circuiting) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A60 (male) Between (1) and grounding Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 – 110 z

Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (2) and A60 (female) (1) Resistance value Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (2) and A60 (female) (1) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) (2) and A60 (female) (1) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5 Monitor panal defective P01 Between (2) and grounding Fuel level FULL (Upper limit) EMPTY (Lower limit) Resistance value Approx. 12 z 85 – 110 z

Electrical Circuit Diagram for Fuel Level Sensor

PC400/450(LC)-7

20-525
(1)

TROUBLESHOOTING

E-16

E-16 Swing lock monitor does not display correctly
Failure information Relative information (1) Though the swing lock switch was turned ON, the swing lock monitor does not light up. • Swing lock monitor does not display correctly (2) Though the swing lock switch was turned OFF, the swing lock monitor lights up. • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause Swing lock switch defective 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (1) and (2) Swing lock switch OFF ON Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from P02 (female) (17) to J02 and X05 (male) (1) Wiring harness from X05 (male) (2) to J05 and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P02 (female) (17) to J02 and X05 (male) (1), or between P02 (female) (17) to C02 (female) (38) and grounding Resistance value Above 1 Mz

Short-circuiting of wiring 4 harness Between wiring harness from P02 (female) (17) to J02 (Contact with 24 V circuit) and X05 (male) (1), or between P02 (female) (17) to C02 (female) (38) and grounding

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Monitor panel defective P02 Between (17) and grounding Swing lock switch OFF ON Voltage 20 – 30 V Below 1 V

20-526
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-16

Electrical circuit diagram related to swing holding brake solenoid

PC400/450(LC)-7

20-527
(1)

TROUBLESHOOTING

E-17

E-17 When monitor switch is operated, nothing is displayed
Failure information Relative information Presumed cause and standard value in normalcy • When monitor switch is operated, nothing is dis- (1) When mode selector switch is operated, working played. mode monitor is not displayed. — Cause 1 Monitor panel defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information Relative information Presumed cause and standard value in normalcy

• When monitor switch is operated, nothing is displayed. — Cause 1 Monitor panel defective

(2) When LCD monitor adjustment switch is operated, mode selection screen is not displayed.

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information Relative information Presumed cause and standard value in normalcy

• When monitor switch is operated, nothing is displayed. — Cause 1 Monitor panel defective

(3) When selector switch is operated, flow rate adjustment screen or flow rate selection screen is not displayed.

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information Relative information Presumed cause and standard value in normalcy

• When monitor switch is operated, nothing is displayed. — Cause 1 Monitor panel defective

(4) When maintenance switch is operated, item selection screen is not displayed.

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information Relative information Presumed cause and standard value in normalcy

• When monitor switch is operated, nothing is displayed.

(5) When automatic deceleration switch is operated, automatic deceleration monitor is not displayed.

• When the automatic decelerator does not operate either, conduct the troubleshooting for E-4. Cause 1 Monitor panel defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

20-528
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-17

Failure information Relative information Presumed cause and standard value in normalcy

• When monitor switch is operated, nothing is displayed.

(6) When travel speed selector switch is operated, travel speed monitor is not displayed.

• When the travel speed does not change either, conduct the troubleshooting for H-22. Cause 1 Monitor panel defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information Relative information Presumed cause and standard value in normalcy

• When monitor switch is operated, nothing is displayed.

(7) When wiper switch is operated, wiper monitor is not displayed.

• When the wiper does not operate either, conduct the troubleshooting for E-18. Cause 1 Monitor panel defective Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

PC400/450(LC)-7

20-529
(1)

TROUBLESHOOTING

E-18

E-18 Windshield wiper and window washer do not work
Failure information Relative information • Windshield wiper and window washer do not work. (1) The windshield wiper does not work.

• Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W03 (female) Between (1) and (2) Front window When installed at front When retracted at rear Resistance value Above 1 Mz Below 1 z

Window rear limit switch fault 1 (Internal disconnection or short-circuiting)

Windshield wiper motor 2 fault (Internal disconnection)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (male) Between (3) and (1) Continuity and resistance value Continued

Presumed cause and standard value in normalcy

Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (9) and W04 (female) (3) Wiring harness between P01 (female) (10) and W04 (female) (1) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (15) and W03 (2) Resistance value Above 1 Mz

Monitor panel fault (Window rear limit switch system)

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02 Between (15) and grounding Front window When installed at front When retracted at rear Voltage 20 – 30 V Below 1 V

5 Monitor panel fault (Windshield wiper motor system)

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P01 Between (9) and grounding Between (10) and grounding Windshield wiper switch OFF ON Resistance value Below 3 V Below 3 V 20 – 30 V (Constant cycle)

20-530
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-18

Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch

PC400/450(LC)-7

20-531
(1)

TROUBLESHOOTING

E-18

Failure information Relative information

• Windshield wiper and window washer do not work. — Cause

(2) Windshield washer does not operate.

Standard value in normalcy and references for troubleshooting If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A50 (male) Between (1) and (2) Between (1) and grounding Resistance value 5 – 20 z Above 1 Mz

1 Fuse No. 4 defective Washer motor defective 2 (Internal disconnection or grounding fault)

Presumed cause and standard value in normalcy

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1) Wiring harness from A50 (female) (2) to J04 and P01 (female) (3) Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit) Between wiring harness from FB1-4 to J03 to J06 and A50 (female) (1), or FB1-4 to D02 (female) (4), and to other relative circuits and grounding Between wiring harness from A50 (female) (2) to J04 and P01 (female) (3), or A50 (female) (2) to D02 (female) (8) and grounding Resistance value Resistance value Above 1 Mz Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Monitor panel defective P01 Between (3) and grounding Windshield washer switch OFF ON Voltage 20 – 30 V Below 1 V

20-532
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-18

Electrical Circuit Diagram for Window Washer Motor

PC400/450(LC)-7

20-533
(1)

TROUBLESHOOTING

E-19

E-19 Alarm buzzer cannot be cancelled
Failure information Relative information • The alarm buzzer cannot be cancelled. • Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Alarm buzzer stop switch 1 defective (Internal disconnection) P03 (female) Between (1) and (2) Presumed cause and standard value in normalcy Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Alarm buzzer stop switch Release Depress Resistance value Above 1 Mz Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (16) and P03 (male) (1) Wiring harness from P03 (male) (2) to J05 to grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 3 harness Between wiring harness between P02 (female) (16) and (Contact with 24 V circuit) Voltage Below 1 V P03 (male) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective P02 Between (16) and grounding Alarm buzzer stop switch Release Depress Voltage 20 – 30 V Below 1 V

Electrical circuit diagram related to alarm buzzer stop switch

20-534
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-20

E-20 “Boom RAISE” is not correctly displayed in monitor function
Failure information Relative information • “Boom RAISE” is not correctly displayed in monitor function “Boom RAISE” is not correctly displayed in the monitor function on the monitor panel. — Cause Boom RAISE PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S06 (male) Between (1) and (2) R.H. work equipment control lever NEUTRAL Boom RAISE Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (10) and S06 (female) (2) Wiring harness between S06 (female) (1) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (10) and S06 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (10) and S06 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective C03 Between (10) and grounding R.H. work equipment control lever NEUTRAL Boom RAISE Voltage 20 – 30 V Below 1 V

Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch

PC400/450(LC)-7

20-535
(1)

TROUBLESHOOTING

E-21

E-21 “Boom LOWER” is not correctly displayed in monitor function
Failure information Relative information • “Boom LOWER” is not correctly displayed in monitor function “Boom LOWER” is not correctly displayed in the monitor function on the monitor panel. — Cause Boom LOWER PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S02 (male) Between (1) and (2) R.H. work equipment control lever NEUTRAL Boom LOWER Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (20) and S02 (female) (2) Wiring harness between S02 (female) (1) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (20) and S02 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (20) and S02 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective C03 Between (20) and grounding R.H. work equipment control lever NEUTRAL Boom LOWER Voltage 20 – 30 V Below 1 V

Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch

20-536
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-22

E-22 “Arm IN” is not displayed normally in monitoring function
Failure information Relative information Presumed cause and standard value in normalcy Cause Arm IN PPC pressure sensor defective Standard value in normalcy and references for troubleshooting The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for error code [E247]. • “Arm IN” is not displayed normally in monitoring “Arm IN” is not displayed normally in monitoring function. function (special function) of monitor panel.

1

2

Pump controller defective

If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot be carried out since the defect is in the pump controller).

PC400/450(LC)-7

20-537
(1)

TROUBLESHOOTING

E-23

E-23 “Arm DUMPING” is not correctly displayed in monitor function
Failure information Relative information • “Arm DUMPING” is not correctly displayed in monitor function “Arm DUMPING” is not correctly displayed in the monitor function (special function) on the monitor panel. — Cause Arm DUMPING PPC hydraulic switch defect 1 (Internal disconnection and short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S08 (male) Between (1) and (2) L.H. work equipment control lever NEUTRAL Arm DUMPING Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (40) and S08 (female) (2) Wiring harness between S08 (female) (1) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (40) and S08 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (40) and S08 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective C03 Between (40) and grounding L.H. work equipment control lever NEUTRAL Arm DUMPING Voltage 20 – 30 V Below 1 V

Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch

20-538
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-24

E-24 “Bucket CURL” is not displayed normally in monitoring function
Failure information Relative information Presumed cause and standard value in normalcy Cause Bucket CURL PPC pressure sensor defective Standard value in normalcy and references for troubleshooting The bucket CURL PPC pressure sensor may be defective. Carry out troubleshooting for error code [E248]. • “Bucket CURL” is not displayed normally in monitoring function.

“Bucket CURL” is not displayed normally in monitoring function (special function) of monitor panel.

1

2

Pump controller defective

If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot be carried out since the defect is in the pump controller).

PC400/450(LC)-7

20-539
(1)

TROUBLESHOOTING

E-25

E-25 “Bucket DUMPING” is not correctly displayed in monitor function
Failure information Relative information • “Bucket DUMPING” is not correctly displayed in monitor function “Bucket DUMPING” is not correctly displayed in the monitor function (special function) on the monitor panel. — Cause Bucket DUMPING PPC hydraulic switch fault 1 (Internal disconnection and short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S05 (male) Between (1) and (2) R.H. work equipment control lever NEUTRAL Bucket DUMPING Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (19) and S05 (female) (2) Wiring harness between S05 (female) (1) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (19) and S05 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (19) and S05 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective C03 Between (19) and grounding R.H. work equipment control lever NEUTRAL Bucket DUMPING Voltage 20 – 30 V Below 1 V

Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch

20-540
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-26

E-26 “Swing” is not displayed normally in monitoring function
Failure information Relative information Cause Swing left PPC pressure switch defective 1 (Internal disconnection or short-circuit) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S07 (male) Between (1) and (2) Left work equipment control lever Neutral Left swing position Resistance value Min. 1 Mz Max. 1 z • “Swing” is not displayed normally in monitoring function.

“Swing” is not displayed normally in monitoring function (special function) of monitor panel.

Swing right PPC pressure switch defective 2 (Internal disconnection or short-circuit) Presumed cause and standard value in normalcy

a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S03 (male) Between (1) and (2) Left work equipment control lever Neutral Right swing position Resistance value Min. 1 Mz Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Wiring harness between C03 (female) (29) and S07 (female) (2) or S03 (female) (2) Wiring harness between S07 (female) (1) and grounding Wiring harness between S03 (female) (1) and grounding Grounding fault of wiring harness 4 (Contact with grounding circuit) Resistance value Resistance value Resistance value Max. 1 z Max. 1 z Max. 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (29) and S07 (female) (2) or S03 (female) (2) and grounding Resistance value Min. 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 5 harness (Contact with 24 V circuit) Between wiring harness between C03 (female) (29) and Voltage Max. 1 V S07 (female) (2) or S03 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6 Pump controller defective C03 Between (29) and grounding Left work equipment control lever Neutral Left or right swing position Voltage 20 – 30 V Max. 1 V

20-542
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-26

Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches

PC400/450(LC)-7

20-543
(1)

TROUBLESHOOTING

E-27

E-27 “TRAVEL” is not correctly displayed in monitor function
Failure information Relative information • “TRAVEL” is not correctly displayed in monitor function “TRAVEL” is not correctly displayed in the monitor function (special function) on the monitor panel. — Cause Travel PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S30 (male) Between (1) and (2) Travel control lever NEUTRAL Forward or reverse Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (39) to J01 to S30 (female) (2) Wiring harness from S30 (female) (1) to J05 to grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (39) to J01 to S30 (female) (2), or between wiring harness between C03 (female) (39) and A43 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (39) to J01 to S30 (female) (2), or between wiring harness between C03 (female) (39) and A43 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective C03 Between (39) and grounding Travel control lever NEUTRAL Forward or backward Voltage 20 – 30 V Below 1 V

20-544
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-27

Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm

PC400/450(LC)-7

20-545
(1)

TROUBLESHOOTING

E-28

E-28 “Travel Differential Pressure” is not correctly displayed in monitor function
Failure information Relative information • “Travel Differential Pressure” is not correctly displayed in monitor function “Travel Differential Pressure” is not correctly displayed in the monitor function (special function) on the monitor panel. • When pressure difference is created between the right and left travel PPC circuits (in steering), the travel differential mechanism is turned ON. Cause Travel steering PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S31 (male) Between (1) and (2) Travel control lever NEUTRAL One side of right or left only Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (16) and S31 (female) (2) Wiring harness from S31 (female) (1) to J05 to grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (16) and S31 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (16) and S31 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5 Pump controller defective C02 Between (16) and grounding Travel control lever NEUTRAL One side of right or left only Voltage 20 – 30 V Below 1 V

20-546
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-28

Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch

PC400/450(LC)-7

20-547
(1)

TROUBLESHOOTING

E-29

E-29 “Service” is not correctly displayed in monitor function
Failure information Relative information • “Service” is not correctly displayed in monitor function “Service” is not correctly displayed in the monitor function (special function) on the monitor panel. — Cause Service (front) PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting) Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S10 (male) Between (1) and (2) Service pedal NEUTRAL Operated to front Resistance value Above 1 Mz Below 1 z

Service (rear) PPC hydraulic switch fault 2 (Internal disconnection or short-circuiting)

a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S11 (male) Between (1) and (2) Service pedal NEUTRAL Operated to rear Resistance value Above 1 Mz Below 1 z

Presumed cause and standard value in normalcy

Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 5 (Contact with 24 V circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (2), or wiring harness between C02 (female) (35) and S11 (female) (2) Wiring harness between S10 (female) (1) and grounding Resistance value Resistance value Below 1 z Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (2), or between wiring harness between C02 (female) (35) and S11 (female) (2) and grounding Resistance value Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (2), or between wiring harness between C02 (female) (35) and S11 (female) (2) and grounding Voltage Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 6 Pump controller defective C02 Between (35) and grounding Service pedal NEUTRAL Operated to front or rear Voltage 20 – 30 V Below 1 V

20-548
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-29

Electrical Circuit Diagram for Service PPC hydraulic Switch

PC400/450(LC)-7

20-549
(1)

TROUBLESHOOTING

E-30

E-30 Travel alarm does not sound or does not stop sounding
Failure information Relative information • Travel alarm does not sound or does not stop sounding. (1) The travel alarm does not sound while the machine is traveling. (2) The alarm begins to sound when the machine is at a standstill. — Cause 1 Fuse No. 15 fault Standard value in normalcy and references for troubleshooting When fuse No.15 is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 4.) a Start the engine during the troubleshooting (monitoring). Monitoring code 2 Travel signal fault Presumed cause and standard value in normalcy 01900 Item Travel Normal display Control lever operated: ON Control lever NEUTRAL: OFF

If the monitor display is not correct, proceed to No. E-29 Troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between FB1-15 outlet to J03 and A43 (female) (1) Wiring harness between A43 (female) (2) and J01 (19) Resistance value Resistance value Below 1 z Below 1 z

Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-15 outlet to J03 and A43 (female) (1), or between wiring harness between FB1-15 outlet and other related circuit and grounding Resistance value Above 1 Mz

5 Travel alarm fault

As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes listed in Item 1 through 4 above is found, the travel alarm is judged as defective)

20-550
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-30

Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm

PC400/450(LC)-7

20-551
(1)

TROUBLESHOOTING

E-31

E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM
Troubleshooting procedure for air conditioner system a The control panel of the air conditioner constantly monitors the sensors and other devices in the system . When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially. a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to the procedure for “Troubleshooting by self-diagnosis notice”, and then; • If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”. • If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.

Troubleshooting by self-diagnosis notice a Check the “Self-diagnosis notice” on the control panel according to the following procedure. • How to display “Self-diagnosis notice” 1) Turn the starting switch ON. 2) Press OFF switch (1) and check that anything is not displayed on display monitor (2). 3) Hold the UP switch ( ) and DOWN switch ( ) of temperature setting switch (3) simultaneously for 3 seconds or more. 4) Check the “Self-diagnosis notice” displayed on display monitor (2). How to select “Self-diagnosis notice” If multiple “Self-diagnosis notices” are recorded, press the UP switch ( ) or DOWN switch ( ) of temperature setting switch (3) to select another notice. How to delete “Self-diagnosis notice” When reproducing the “Self-diagnosis notices” or after removing the cause of a failure, press the switches on both sides of recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the “Self-diagnosis notices” are deleted. Finishing display of “Self-diagnosis notice” To finish display of the “Self-diagnosis notice”, press OFF switch (1) or turn the starting switch OFF.
Self-diagnosis Failure mode notice E-No failures Disconnection in recirculated air E11 sensor E12 Short-circuit in recirculated air sensor Disconnection in water temperature E15 sensor Short-circuit in water temperature E16 sensor E18 Short-circuit in daylight sensor E43 Abnormality in air outlet damper E44 Abnormality in air mix damper Abnormality in recirculated and fresh E45 air damper

20-552
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-31

Self-diagnosis notice E11 Contents of trouble Action of control panel Related information

Trouble

Disconnection in recirculated air sensor

• Disconnection in the recirculated air sensor system is detected. • Fixes the recirculated air temperature for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Cause Possible causes and standard value in normal state Defective recirculated 1 air sensor (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male) Between (1) and (2) Resistance 300 z – 430 kz

Disconnection of wiring harness (Disconnection 2 or defective contact with connector) Defective air conditioner system

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2) Wiring harness between M29 (female) (11) and TH I (female) (1) Resistance Resistance Max. 1 z Max. 1 z

3

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Self-diagnosis notice E12 Contents of trouble Action of control panel Related information

Trouble

Short circuit in recirculated air sensor

• Short circuit in the recirculated air sensor system is detected. • Fixes the recirculated air temperature for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Cause Possible causes and standard value in normal state Defective recirculated air 1 sensor (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male) Between (1) and (2) Resistance 300 z – 430 kz

Disconnection of wiring harness (Disconnection 2 or defective contact with connector) Defective air conditioner system

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2) Wiring harness between M29 (female) (11) and TH I (female) (1) Resistance Resistance Max. 1 z Max. 1 z

3

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

PC400/450(LC)-7

20-553
(1)

TROUBLESHOOTING

E-31

Self-diagnosis notice E15 Contents of trouble Action of control panel Related information

Trouble

Disconnection in water temperature sensor

• Disconnection in the water temperature sensor system is detected. • Ignores the warm-up control and fixes the engine water temperature at 60°C for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Cause Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning Defective water temperastarting switch ON. 1 ture sensor (Internal disTHW (male) Resistance connection) Between (1) and (2) 95 z – 455 kz Disconnection of wiring harness (Disconnection 2 or defective contact with connector) Defective air conditioner system a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2) Wiring harness between M29 (female) (11) and THW (female) (1) Resistance Resistance Max. 1 z Max. 1 z

3

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Self-diagnosis notice E16 Contents of trouble Action of control panel Related information

Trouble

Short circuit in water temperature sensor

• Short circuit in the water temperature sensor system is detected. • Ignores the warm-up control and fixes the engine water temperature at 60°C for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Cause Possible causes and standard value in normal state Defective water tempera1 ture sensor (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male) Between (1) and (2) Resistance 95 z – 455 kz

Disconnection of wiring harness (Disconnection 2 or defective contact with connector) Defective air conditioner system

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2) Wiring harness between M29 (female) (11) and THW (female) (1) Resistance Resistance Max. 1 z Max. 1 z

3

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

20-554
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-31

Self-diagnosis notice E18 Contents of trouble Action of control panel Related information

Trouble

Short circuit in daylight sensor

• Short circuit in the daylight sensor system is detected. • Assumes that the daylight sensor is not installed for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Cause Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

Defective daylight sen1 The daylight sensor may be defective. Check it directly. sor (Internal short circuit) Disconnection of wiring harness (Disconnection 2 or defective contact with connector) Defective air conditioner system a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (16) and P15 (female) (2) Wiring harness between M30 (female) (3) and P15 (female) (1) Resistance Resistance Max. 1 z Max. 1 z

3

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Self-diagnosis notice E43 Contents of trouble Action of control panel Related information

Trouble

Abnormality in air outlet damper

• Abnormality in air outlet servomotor system is detected. • Stops the air outlet servomotor. • When the following condition is satisfied, the operation returns to normalcy. • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause Standard value in normalcy and references for troubleshooting

Defective air outlet servo1 The air outlet servomotor may be defective. Check it directly. motor (Internal defect) Possible causes and standard value in normal state a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MV1 (female) (1) and M30 (female) (3) Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector) Wiring harness between MV1 (female) (3) and M29 (female) (11) Wiring harness between MV1 (female) (5) and M30 (female) (9) Wiring harness between MV1 (female) (6) and M29 (female) (8) Wiring harness between MV1 (female) (7) and M29 (female) (9) 3 Defective air conditioner system Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z

If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

PC400/450(LC)-7

20-555
(1)

TROUBLESHOOTING

E-31

Self-diagnosis notice E44 Contents of trouble Action of control panel Related information

Trouble

Abnormality in air mix damper

• Abnormality in air mix servomotor system is detected. • Stops the air mix servomotor. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause Standard value in normal state/Remarks on troubleshooting The air mix servomotor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between MAM (female) (1) and M29 (female) (11) Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z

Defective air mix servo1 motor (Internal defect) Possible causes and standard value in normal state

Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)

Wiring harness between MAM (female) (3) and M30 (female) (3) Wiring harness between MAM (female) (5) and M30 (female) (2) Wiring harness between MAM (female) (6) and M29 (female) (4) Wiring harness between MAM (female) (7) and M29 (female) (5)

3

Defective air conditioner system

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

20-556
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-31

Self-diagnosis notice E45 Contents of trouble Action of control panel Related information

Trouble

Abnormality in recirculated and fresh air damper

• Abnormality in recirculated and fresh air servomotor system is detected. • Stops the recirculated and fresh air servomotor. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner> a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause Standard value in normal state/Remarks on troubleshooting The recirculated and fresh air servomotor may be defective. Check it directly. If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Defective recirculated 1 and fresh air servomotor (Internal defect) 2 Defective fuse (in unit)

Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector)

Wiring harness between MRF (female) (1) and M29 (female) (6) Wiring harness between MRF (female) (3) and M29 (female) (7) Wiring harness between MRF (female) (7), fuse in unit, and M33 (female) (3)

Resistance Resistance Resistance

Max. 1 z Max. 1 z Max. 1 z

4

Defective air conditioner system

If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

PC400/450(LC)-7

20-557
(1)

TROUBLESHOOTING

E-31

Electrical Circuit Diagram for Air Conditioner

20-558
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-31

Troubleshooting by failure phenomenon
Trouble Related information Cause 1 Defective fuse No. 11 Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector) Possible causes and standard value in normal state Wiring harness between fuse 11 outlet and M33 (male) (3) Wiring harness between M27 (female) (14) and M30 (female) (6) Wiring harness between M33 (male) (2) and chassis ground Wiring harness between M29 (female) (12) and chassis ground Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit) Resistance Resistance Resistance Resistance Max. 1z Max. 1z Max. 1z Max. 1z • The air conditioner does not operate. (1) The air conditioner does not operate at all.

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between circuit breaker fuse 11 outlet and M33 (male) (3) and chassis ground Between wiring harness between M27 (female) (14) and M30 (female) (6) and chassis ground Resistance Resistance Min. 1 Mz Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective air conditioner unit M33 Between (2) and (3) Voltage 20 V – 30 V

If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective control panel M30, M29 Between M30 (6) and M29 (12) Voltage 20 V – 30 V

If the above voltage is normal and the air conditioner does not operate, the control panel is defective.

PC400/450(LC)-7

20-559
(1)

TROUBLESHOOTING

E-31

Trouble Related information

• The air conditioner does not operate.

(2) Air does not come out (Air flow is insufficient).

Cause 1 Defective fuse (in unit)

Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R30 (male) Between (1) and (3) Resistance 140 – 340 z

2

Defective blower relay (on coil side)

3

Defective blower relay (on contact side)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. R30 Between (4) and chassis ground Fan switch ON (Operated) Voltage 20 – 30 V

Defective power transis4 tor (Internal defect) Possible causes and standard value in normal state

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If air flow can be changed with fan switch, Operate in range of Low, Medium, and High power transistor is normal. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch

5

Defective blower motor (Internal defect)

MB (female) Between (1) and (2)

Fan switch ON (Operated)

Voltage 20 – 30 V

If the above voltage is normal and the blower motor does not rotate, the blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse 11 outlet, fuse in unit, R30 (3), R31 (female) (1), and M30 (female) (6) Wiring harness between M29 (female) (3) and R30 (female) (1) Disconnection in wiring harness (Disconnection 6 in wiring harness or defective contact in connector) Wiring harness between M29 (female) (12) and chassis ground Wiring harness between MB (female) (1) and R30 (female) (4) Wiring harness between MB (female) (2) and PTR (female) (3) Wiring harness between PTR (female) (1) and chassis ground Wiring harness between PTR (female) (2) and M30 (female) (7) Wiring harness between PTR (female) (4) and M30 (female) (8) 7 Defective air conditioner system Resistance Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z

If none of causes 1 – 6 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

20-560
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E-31

Trouble Related information

• The air conditioner does not operate.

(3) Air is not cooled (Cooling capacity is low).

Cause 1 Defective fuse (in unit)

Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R31 (male) Between (1) and (2) Resistance 140 – 340 z

2

Defective compressor relay (on coil side)

3

Defective compressor relay (on contact side)

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position). R31 Between (4) and chassis ground Fan switch ON (Operated) Voltage 20 – 30 V

4

Defective thermostat (Internal defect)

The thermostat may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P17 (male) Between (1) and (2) The compressor clutch may be defective. Check it directly. The compressor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (4) and P17 (female) (1) Wiring harness between P17 (female) (2) and chassis ground Resistance Resistance Resistance Resistance Resistance Resistance Resistance Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Max. 1 z Resistance Max. 1 z

Possible causes and standard value in normal state

Defective high/low pres5 sure switch (Internal disconnection) 6 7 Defective compressor clutch (Internal defect) Defective compressor (Internal defect)

Disconnection in wiring harness (Disconnection 8 in wiring harness or defective contact in connector)

Wiring harness between fuse 11 outlet, R31 (female) (2), fuse in unit, R31 (female) (1), and M30 (female) (6) Wiring harness between ST1 (female) (1) and R31 (female) (3) Wiring harness between M29 (female) (2) and ST1 (female) (2) Wiring harness between M29 (female) (12) and chassis ground Wiring harness between R31 (female) (4) and M34 (female) (1)

9

Defective air conditioner system

If none of causes 1 – 8 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

PC400/450(LC)-7

20-561
(1)

TROUBLESHOOTING

E-31

Electrical Circuit Diagram for Air Conditioner

20-562
(1)

PC400/450(LC)-7

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
system chart for hydraulic and mechanical system .................................................................................... 20-602 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 ........................................... 20-615 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) ...................................................................................... 20-620 H-24 Machine does not swing..................................................................................................................... 20-621 H-25 Swing acceleration is poor, or swing speed is slow ........................................................................... 20-622 H-26 Excessive overrun when stopping swing ........................................................................................... 20-623 H-27 There is big shock when stopping swing............................................................................................ 20-624 H-28 There is big abnormal noise caused when stopping swing ................................................................ 20-624 H-29 Swing natural drift is too big ............................................................................................................... 20-625 H-30 Attachment circuit does not change ................................................................................................... 20-626 H-31 Flow rate in attachment circuit cannot be adjusted ............................................................................ 20-626

PC400/450(LC)-7

20-601
(1)

TROUBLESHOOTING

BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM

20-602
(1)

PC400/450(LC)-7

TROUBLESHOOTING

BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)

a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.

PC400/450(LC)-7

20-603
(1)

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out troubleshooting work after fully grasping their contents.
Failure information Relative information Phenomena occurring on machine Information on occurred failures and troubleshooting Standard value in normalcy and references for troubleshooting

Cause 1 Presumed cause and standard value in normalcy

2 Cause for presumed failure (The attached No. for 3 filing and reference purpose only. It does not stand for any priority) 4 <Contents> • The standard values in normalcy by which to judge “good” or “no good” about presumed causes. • References for making judgement of “good” or “no good”

5

20-604
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-1

H-1 All work equipment lack power, or travel and swing speeds are slow
Failure information Relative information • All the work equipment lack power, or their travel and swing speeds are slow. • Set the working mode at A mode for troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of unload valve Control lever All control levers in NEUTRAL Unload pressure 4.12 ± 1.0 MPa {42 ± 10kg/cm2} Main relief pressure 33.34 – 36.77 MPa {340 – 375kg/cm2}

Cause

a Stop engine for preparations. Start troubleshooting at engine high idling. Control lever Improper adjustment or 2 malfunctioning of main relief valve Arm, DIGGING

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. a Stop engine for preparations. Start troubleshooting at engine high idling. Control lever All control levers in NEUTRAL Control circuit source pressure 2.84 – 3.43 MPa {29 – 35kg/cm2}

Malfunctioning of 3 self pressure decompression valve

a Stop engine for preparations. Start troubleshooting at engine high idling. Presumed cause and standard value in normalcy Oil pressure to be measured Improper adjustment or 4 malfunctioning of PC valve Pump delivery pressure PC valve output pressure Measurement condition Swing lock: ON Arm: Digging relief Oil pressure ratio 1 Approx. 0.6 (Approx. 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. a Stop engine for preparations. Start troubleshooting at engine high idling. 5 Malfunctioning of LS-EPC valve Travel speed Lo Hi Travel control lever NEUTRAL OPERATED LS-EPC output pressure Approx. 1.37 MPa {Approx. 14 kg/cm2} 0 MPa {0 kg/cm2}

a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured Improper adjustment or 6 malfunctioning of LS valve Pump delivery pressure LS valve output pressure Nearly equal pressure All control levers in NEUTRAL Travel without load (control lever held at half stroke) 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of LS valve or its internal failure is suspected. In that case, check the valve itself. 7 Malfunctioning of servo 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, malfunctioning or internal failure.

8 Piston pump defective

PC400/450(LC)-7

20-605
(1)

TROUBLESHOOTING

H-2

H-2 Engine speed sharply drops or engine stalls
Failure information Relative information • The engine speed sharply drops or the engine stalls. • Relative Information Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Control lever Improper adjustment or 1 malfunctioning of main relief valve Arm, DIGGING Main relief pressure 33.34 – 36.77 MPa {340 – 375kg/cm2}

Cause

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. a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure to be measured Measurement condition Swing lock: ON Arm: Digging relief Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)

Presumed cause and standard value in normalcy

Improper adjustment or 2 malfunctioning of PC valve

Pump delivery pressure PC valve output pressure

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the PC valve or its internal failure is suspected. In that case, check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured Improper adjustment or 3 malfunctioning of LS valve Pump delivery pressure LS valve output pressure Nearly equal pressure All control levers in NEUTRAL Travel without load (control lever held at half stroke) 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 4 5 Orifice or filter in servo equipment clogged Malfunction of servo piston The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself. The servo piston is suspected of malfunction. Check the piston itself.

20-606
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-3, H-4

H-3 No work equipment, travel or swing move
Failure information Relative information • No work equipment nor travel and swing functions can be set in motion. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of PPC lock solenoid valve Safety lock lever Locked Released Malfunctioning of 2 self pressure decompression valve Solenoid output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35kg/cm2} Control circuit source pressure 2.84 – 3.43 MPa {29 – 35kg/cm2}

Cause

Presumed cause and standard value in normalcy

a Stop engine for preparations. Start troubleshooting at engine high idling. Control lever All control levers in NEUTRAL position

3 Piston pump defective

The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the following manner. • Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal condition. It is presumed that the pump shaft does not rotate due to some internal failure of the damper. Check the damper itself.

4 Damper defective

H-4 Abnormal noise is heard from around hydraulic pump
Failure information Relative information • An abnormal noise is heard from around the hydraulic pump. — Standard value in normalcy and references for troubleshooting Make a visual check.

Cause 1 Presumed cause and standard value in normalcy Hydraulic oil level lowered Quality of hydraulic oil bad Hydraulic tank cap breather clogged Hydraulic tank strainer clogged

2

Air may have get mixed with the oil. Make a visual check. It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside the tank. Make a visual check. It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction circuit. Make a visual check. The piston pump is suspected of an internal failure. Check the pump itself.

3

4

5 Piston pump defective

PC400/450(LC)-7

20-607
(1)

TROUBLESHOOTING

H-5, H-6

H-5 Auto-decelerator does not work
Failure information Relative information • The auto-decelerator does not work. • This troubleshooting mode is applied when the auto-decelerator does not work, while operating the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch only in the travel circuit -actually located inside PPC valve) • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever Malfunctioning of travel 1 PPC valve (shuttle valve) NEUTRAL PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Presumed cause and standard value in normalcy

Cause

Operation

H-6 Fine control mode does not function
Failure information Relative information • The fine control mode poorly functions or its response is slow. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of LS1 EPC valve Travel speed Lo Hi 2 Orifice in LS circuit clogged Travel control lever NEUTRAL OPERATED LS-EPC valve output pressure Approx. 1.37 MPa {Approx. 14 kg/cm2} 0 MPa {0 kg/cm2}

Cause

Presumed cause and standard value in normalcy

The orifice in the LS circuit is presumed to be clogged. Check the orifice itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured All control levers in NEUTRAL Travel without load (control lever held at half stroke) 1 Nearly equal oil pressure Approx. 0.6 (Approx. 3/5)

Improper adjustment or 3 malfunctioning of LS valve

Pump delivery pressure PC valve output pressure

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 4 Malfunctioning of servo piston Malfunctioning of the servo piston is suspected. Check the piston itself.

20-608
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-7

H-7 Boom moves slowly or lacks power
Failure information Relative information • The boom moves slowly or lacks power • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of right PPC valve (in boom circuit) R.H. work equipment control lever NEUTRAL Boom RAISE Boom LOWER Travel lever Neutral Operated (Note) 3 4 Presumed cause and standard value in normalcy 5 Malfunctioning of merge/ divide valve (main and LS valves) Malfunctioning of boom control valve (spool) Malfunctioning of boom control valve (pressure compensation valve) Malfunctioning of boom control valve (regeneration valve) Malfunctioning of boom control valve (lock valve) PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2} Solenoid output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Cause

a Stop engine for preparations. Start troubleshooting at engine high idling. 2 Malfunction of merge/ divide solenoid valve

The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself. The spool in the boom control valve (Lo • Hi) is presumed to malfunction. Check the valve itself. The pressure compensation valve in the boom control valve (Lo • Hi) is presumed to malfunction. Check the valve itself. The regeneration valve in the boom control valve (Lo) or the seal is presumed to malfunction. Check the valve itself. The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the valve itself.

6 7 8 9

Malfunction of boom con- The check valve in the boom control valve (Hi) is presumed to malfunction. Check trol valve (check valve) the valve itself. Malfunctioning of safety valve for lock valve or seal defective The safety valve for the lock valve is presumed to malfunction, or the seal is suspected to be defective. Check the valve itself. The suction valve (bottom side) in the boom control valve (Lo) is presumed to malfunction, or the seal is suspected to be defective. The safety and suction valves (head side) in the boom control valve (Lo) are presumed to malfunction, or the seal is suspected to be defective. Check those valves themselves. LS shuttle valves in the left travel control valve, bucket control valve and service control valve are presumed to malfunction. Check those valves themselves. a Stop engine for preparations. Start troubleshooting at engine high idling.

Malfunctioning of boom 10 control valve (suction valve) or seal defective Malfunctioning of boom control valve (safety and 11 suction valves) or seal defective Malfunctioning of LS shuttle valve (left travel, 12 bucket and service valves) 13 Boom cylinder defective

Boom cylinder Raise relief

Amount oil leakage from cylinder 20 cc/min

Note:

Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.

PC400/450(LC)-7

20-609
(1)

TROUBLESHOOTING

H-8

H-8 Arm moves slowly or lacks power
Failure information Relative information • The arm moves slowly, or lacks power. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of left PPC valve (arm circuit) L.H. work equipment control lever NEUTRAL Arm DIGGING Arm DUMPING Travel lever Neutral Operated (Note) 3 4 5 Malfunctioning of merge/ divide valve (main and LS valves) Malfunctioning of arm control valve (spool) Malfunctioning of arm control valve (pressure compensation valve) Malfunctioning of arm control valve (regeneration valve) Malfunctioning of arm control valve (safety and suction valves) or seal defective Malfunction of arm control valve (quick return valve) Malfunctioning of LS shuttle valve (right travel, boom, left travel, bucket and service valves) PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2} Solenoid output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Cause

a Stop engine for preparations. Start troubleshooting at engine high idling. 2 Malfunctioning of merge/ divide solenoid valve

Presumed cause and standard value in normalcy

The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself. The spool in the arm control valve (Lo • Hi) is presumed to malfunction. Check the valve itself. The pressure compensation valve in the arm control valve (Lo • Hi) is presumed to malfunction. Check the valve itself. The generation valve in the arm control valve (Lo) is presumed to malfunction, or the seal is suspected to be defective. Check the valve itself. The safety and suction valves in the arm control valve (Lo • Hi) are presumed to malfunction, or the seal is suspected of defect. Check those valves themselves. The quick return valve in the arm control valve (Hi) is presumed to malfunction. Check the valve itself. LS shuttle valves in the right travel control valve, boom control valve, left travel control valve, bucket control valve and service valve are presumed to malfunction. Check those valves themselves. a Stop engine for preparations. Start troubleshooting at engine high idling.

6

7

8

9

10 Arm cylinder defective

Arm cylinder Digging relief

Amount oil leakage from cylinder 20 cc/min

Note:

Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.

20-610
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-9, H-10

H-9 Bucket moves slowly or lacks power
Failure information Relative information • The bucket moves slowly, or lacks power. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of right 1 PPC valve (bucket circuit) Presumed cause and standard value in normalcy Malfunctioning of bucket control valve (spool) R.H. work equipment control lever NEUTRAL Bucket DIGGING Bucket DUMPING PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Cause

2

The spool in the bucket control valve is presumed to malfunction. Check the valve itself. The pressure compensation valve in the bucket control valve is presumed to malfunction. Check the valve itself. The safety and suction valves in the bucket control valve are presumed to malfunction, or the seal is suspected to be defective. Check those valves themselves. The LS shuttle valve in the service control valve is presumed to malfunction. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Bucket cylinder Digging relief Amount oil leakage from cylinder 20 cc/min

Malfunctioning of bucket 3 control valve (pressure compensation valve) Malfunctioning of bucket control valve (safety and 4 suction valves) or seal defective 5 Malfunction of LS shuttle valve (service valve)

6 Bucket cylinder defective

H-10 Work equipment does not move in its single operation
Failure information Relative information Presumed cause and standard value in normalcy • Work equipment does not move in its single operation (1) The boom does not move when operated independently. (2) The arm does not move when operated independently. (3) The bucket does not move when operated independently. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of PPC valve Work equipment control lever NEUTRAL Operated Malfunctioning of work 2 equipment control valve (spool) PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Cause

The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.

PC400/450(LC)-7

20-611
(1)

TROUBLESHOOTING

H-11

H-11 Work equipment has a bit too fast hydraulic drift
Failure information Relative information Presumed cause and standard value in normalcy • Work equipment has a bit too fast hydraulic drift (1) Hydraulic drift of the boom is a bit too fast. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Boom cylinder defective Boom control lever (lock valve) seal defective Seal at safety valve for lock valve defective Boom cylinder Raise relief 2 3 Amount oil leakage from cylinder 20 cc/min

Cause

The seal at lock valve in the boom control lever is suspected to be defective. Check the valve itself. The seal at the safety valve in the lock valve (Lo) is suspected to be defective. Check the valve itself.

Failure information Relative information

• Work equipment has a bit too fast hydraulic drift (2) Hydraulic drift of the arm is a bit too fast. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Arm cylinder Digging relief Amount oil leakage from cylinder 20 cc/min

Cause Presumed cause and standard value in normalcy 1 Arm cylinder defective

Arm control valve (safety 2 and suction valves) seal defective 3 Arm control valve (spool) seal defective

The seal for safety and suction valves (bottom side) in the arm control valve (Lo • Hi) is suspected to be defective. Check the valve itself. (Whether the seal is defective or not may well be determined by changing for other safety and suction valves.) The seal for spool in the arm control valve (Lo • Hi) is suspected to be defective. Check the seal itself. The seal for pressure compensation valve (bottom side) in the arm control valve (Lo • Hi) is suspected to be defective. Check the seal itself.

Arm control valve 4 (pressure compensation valve) seal defective

Failure information Relative information

• Work equipment has a bit too fast hydraulic drift (3) Hydraulic drift of the bucket is a bit too fast. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Bucket cylinder Digging relief Amount oil leakage from cylinder 20 cc/min

Cause Presumed cause and standard value in normalcy 1 Bucket cylinder defective

Bucket control valve 2 (safety and suction valves) seal defective 3 Bucket control valve (spool) seal defective

The seal for the safety and suction valves (bottom side) in the bucket control lever is suspected to be defective. Check the seal itself. (Whether the seal is defective or not may well be determined by changing for other safety and suction valves.) The seal for spool in the bucket control valve is suspected to be defective. Check the seal itself. The seal for pressure compensation valve (bottom side) in the bucket control valve is suspected to be defective. Check the seal itself.

Bucket control valve 4 (pressure compensation valve) seal defective

20-612
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-12, H-13, H-14

H-12 Work equipment has big time lag
Failure information Relative information • The work equipment has a big time lag. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of 1 LS-EPC valve Presumed cause and standard value in normalcy Travel speed Lo Hi Malfunctioning of control valve (regeneration 2 valve) - with boom and arm only Malfunctioning of control 3 valves (safety & suction valve) Malfunctioning of control 4 valve (pressure compensation valve) Travel control lever NEUTRAL Operation LS-EPC valve output pressure Approx. 1.37 MPa {approx. 14 kg/cm2} 0 MPa {0 kg/cm2}

Cause

The regeneration valve in the control valve is presumed to malfunction. Check the valve itself. The safety and suction valves (boom : head side, arm and bucket : bottom side) of the control valve are presumed to malfunction. Check those valves themselves directly. (Whether they are defective or not may well be determined by changing them for other safety and suction valves.) The pressure compensation valve of the control valve is presumed to malfunction. Check the valve itself directly.

H-13 Other work equipment moves when relieving single circuit
Failure information Relative information Presumed cause and standard value in normalcy • Other work equipment moves when relieving the single circuit of specific work equipment. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting

Cause

Control valve (pressure 1 compensation valve) seal defective

The seal for pressure compression valve in the control valve is suspected to be defective. Check the seal itself.

H-14 One-touch power max. function does not work
Failure information Relative information Presumed cause and standard value in normalcy • One-touch power max. function does not work. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of 2-stage solenoid valve Swing lock switch OFF ON 2 Malfunctioning of main relief valve Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35kg/cm2}

Cause

The main relief valve of control valve is presumed to malfunction. Check the valve itself.

PC400/450(LC)-7

20-613
(1)

TROUBLESHOOTING

H-15

H-15 Machine push-up function does not work
Failure information Relative information Presumed cause and standard value in normalcy • The machine push-up function does not work • When carrying out troubleshooting, set the working mode in A-mode. Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then run engine at high idling and carry out troubleshooting. 1 Malfunction of machine push-up solenoid valve Machine push-up switch OFF ON Malfunction of boom 2 control valve (safety-suction valve) Solenoid outlet pressure Min. 2.75 MPa {Min. 28 kg/cm3} 0 MPa {0 kg/cm2}

Cause

The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting side on the head side) may be malfunctioning. Check it directly.

20-614
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-16, H-17, H-18

H-16 In compound operation, work equipment with larger load moves slowly
Failure information Relative information • In a compound operation, work equipment with larger load tends to move slowly. — Standard value in normalcy and references for troubleshooting The pressure compensation valve for the work equipment with larger load is presumed to malfunction. Check the valve itself. Presumed cause and standard value in normalcy Combination of compound operation Malfunctioning of pressure compensation 1 valve for work equipment with larger load Boom RAISE + arm DIGGING Boom RAISE + arm DUMPING Boom RAISE + bucket DIGGING Arm DUMPING + bucket DIGGING Boom LOWER + arm DUMPING Work equipment with larger load Boom Arm Boom Arm Arm Work equipment with smaller load Arm Boom Bucket Bucket Boom

Cause

H-17 In swing + boom RAISE operation, boom moves slowly
Failure information Relative information Presumed cause and standard value in normalcy • In a compound operation of swing + boom RAISE, the boom tends to move slowly. • If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first. Standard value in normalcy and references for troubleshooting

Cause

Malfunctioning of LS 1 select valve or seal defective

The LS select valve of control valve is presumed to malfunction, or the seal is suspected to be defective. Check the valve and seal themselves.

H-18 In swing + travel, travel speed drops sharply
Failure information Relative information Presumed cause and standard value in normalcy • In a compound operation of swing + travel, the travel speed drops sharply. • If the travel speed is slow in the single operation of travel, carry out the H-20 check first. Standard value in normalcy and references for troubleshooting

Cause

Malfunctioning of LS 1 shuttle valve (left travel and swing)

The LS shuttle valve in the left travel control valve or the swing control valve is presumed to malfunction. Check both of them directly.

PC400/450(LC)-7

20-615
(1)

TROUBLESHOOTING

H-19

H-19 Machine swerves in travel
Failure information Relative information • The machine tends to swerve while traveling. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever Malfunctioning of travel 1 PPC valve Operated to Forward Operated to Reverse Differential output between right and left sides Malfunctioning of 2 self-pressure decompression valve Control lever All control levers in NEUTRAL PPC valve output pressure Above 2.75 MPa {Above 28 kg/cm2} 0.4 MPa {4 kg/cm2}

Cause

a Stop engine for preparations. Start troubleshooting at engine high idling. Control circuit source pressure 2.84 – 3.43 MPa {29 – 35 kg/cm2} Oil Pressure ratio

a Stop engine for preparations. Start troubleshooting at engine high idling. Presumed cause and standard value in normalcy Oil pressure to be measured Pump delivery pressure LS valve output pressure Nearly equal pressure Travel without load (control lever held at half stroke) 1 Approx. 0.6 (Approx. 3/5)

Improper adjustment or 3 malfunctioning of LS valve

All control levers in NEUTRAL

a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of travel 4 interlocking solenoid valve Malfunctioning of travel interlocking valve Malfunctioning of travel control valve (spool) Travel control lever NEUTRAL Operating one side only 5 6 PPC valve output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself. The spool in the travel interlocking valve is presumed to malfunction. Check the spool itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever Travel relief Amount of oil leakage from travel motor 40 l/min

Malfunction of travel 7 motor

8 Final drive defective

The final drive is suspected of an internal failure. Check the inside of the final drive directly. (An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or metal chip or dust contained in the drained oil.)

20-616
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-20

H-20 Machine travels slowly
Failure information Relative information a The machine's travel speed is slow. a Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever Malfunctioning of travel 1 PPC valve Operated to Forward Operated to Reverse Output differential between right and left or front and rear Malfunctioning of 2 self-pressure decompression valve Control lever All control levers in NEUTRAL PPC valve output pressure Above 2.75 MPa {Above 28 kg/cm2} Below 0.4 MPa {Below 4 kg/cm2} Control circuit source pressure 2.84 – 3.43 MPa {29 – 35kg/cm2} LS-EPC valve output pressure Approx. 1.37 MPa {approx. 14 kg/cm2} 0 MPa {0 kg/cm2}

Cause

a Stop engine for preparations. Start troubleshooting at engine high idling.

a Stop engine for preparations. Start troubleshooting at engine high idling. Presumed cause and standard value in normalcy Malfunctioning of LS-EPC valve Travel speed Lo Hi 4 Malfunction of travel control valve (spool) Travel control lever NEUTRAL Operated

3

The spool in the travel control valve is presumed to malfunction. Check the spool itself. The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself. The suction valve in the travel control valve is presumed to malfunction. Check the valve itself. The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever Travel relief Amount of oil leakage from travel motor 40 l/min

Malfunctioning of travel 5 control valve (pressure compensation valve) Malfunctioning of travel 6 control valve (suction valve) 7 Malfunctioning of LS shuttle valve (bucket) Malfunction of travel motor

7

8 Final drive defective

The final drive is suspected of an internal failure. Check the inside of the final drive directly. (An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or metal chip or dust contained in the drained oil.)

PC400/450(LC)-7

20-617
(1)

TROUBLESHOOTING

H-21

H-21 Machine cannot be easily steered or lacks power
Failure information Relative information • The machine cannot be easily steered. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of travel PPC valve (steering spool) Travel control lever NEUTRAL on both sides Operating one side only PPC valve output pressure (steering) 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2} Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Cause

a Stop engine for preparations. Start troubleshooting at engine high idling. 2 Malfunctioning of travel interlocking solenoid valve Malfunctioning of travel interlocking valve Travel control lever NEUTRAL Operating one side only 3

The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever NEUTRAL OPERATED Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Presumed cause and standard value in normalcy

4

Malfunctioning of merge/ divide solenoid valve

5 6 7

Malfunctioning of merge/ divide valve Malfunction of travel control valve (spool) Malfunctioning of travel control valve (pressure compensation valve) Malfunctioning of travel control valve (suction valve) Malfunctioning of LS shuttle valve (bucket)

The merge/divide valve of control valve is presumed to malfunction. Check the valve itself. The spool in the travel control valve is presumed to malfunction. Check the spool itself. The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself. The suction valve in the travel control valve is presumed to malfunction. Check the valve itself. The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself. The seal in the check valve of LS oil pressure pick-up port is suspected to be defective. Check the seal itself. The seal in the check valve of the travel motor is suspected to be defective. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the motors between forward and reverse, or right and left.) The seal in the check valve of the travel motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the motors between forward and reverse, or right and left.)

8 9

Check valve seal 10 defective at LS oil pressure pick-up port Malfunctioning of travel 11 motor (safety valve)

Malfunctioning of travel 12 motor (check valve)

20-618
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-22

H-22 Travel speed does not shift, or it is slower or faster than preset speed.
Failure information Relative information • Travel speed does not shift, or it is slower or faster than preset speed. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Travel speed Lo Mi Presumed cause and standard value in normalcy 1 Malfunctioning of LS-EPC valve Hi Travel control lever Fine control (to the extent that the decelerator is released) Monitoring [01500] 690 mA 740 mA 0 mA LS-EPC valve output pressure Approx. 1.37 MPa {approx. 14 kg/cm2} 0 MPa {0 kg/cm2} Solenoid output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Cause

a Stop engine for preparations. Start troubleshooting at engine high idling. Travel speed Lo Hi Travel control lever NEUTRAL Operation

a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of travel 2 speed solenoid valve Travel speed Lo Hi 3 Malfunctioning of travel motor (speed shifting) Travel control lever NEUTRAL Operation

The travel motor is presumed to malfunction when shifting speed. Check the speed shifting portion directly.

PC400/450(LC)-7

20-619
(1)

TROUBLESHOOTING

H-23

H-23 Track shoe does not turn (on one side only)
Failure information Relative information • A track shoe does not turn (only on one side). • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting

Cause 1 Presumed cause and standard value in normalcy 2 3

Travel control valve (suc- The suction valve seat in the travel control valve is suspected of defect. Check the tion valve) seat defective seat itself. Travel motor (safety valve) seat defective Travel motor (check valve) seat defective The safety valve seat in the travel motor is suspected of defect. Check the seat itself. The check valve seat in the travel motor is suspected of defect. Check the seat itself. a Stop engine for preparations. Start troubleshooting at engine high idling.

4 Travel Motor speed

Travel control lever Travel relief

Amount of oil leakage from travel motor 40 l/min

5 Final drive defective

The final drive is suspected of an internal failure. Check the inside of the final drive directly. (A failure inside the final drive may well be determined by an abnormal noise from within, abnormal heat generated or metal dust or chips contained in the drained oil.)

20-620
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-24

H-24 Machine does not swing
Failure information Relative information • Machine does not swing (1) The machine swings neither to the right nor to the left. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of swing 1 holding brake solenoid valve 2 Presumed cause and standard value in normalcy Malfunctioning of swing motor (holding brake) R.H. work equipment control lever NEUTRAL Swing operated Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Cause

The parking brake portion of the swing motor is presumed to malfunction. Check it directly. a Stop engine for preparations. Start troubleshooting at engine high idling. Swing lock switch L.H. work equipment control lever Swing relief Swing relief pressure 27.95 – 32.85 MPa {285 – 335 kg/cm2}

Improper adjustment or 3 malfunctioning of swing motor (safety valve)

ON

If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. 4 Swing motor defective L.H. work equipment control lever Swing relief Swing machinery defective Amount of oil leakage from swing motor Below 11 l/min

5

The swing machinery is suspected of an internal failure. Check the inside of the swing machinery directly. (A failure inside the swing machinery may well be determined by an abnormal noise from within, abnormal heat generated or metal dust or chips contained in the drained oil.)

Failure information Relative information

• Machine does not swing (2) The machine does not swing in one direction. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. L.H. work equipment control lever NEUTRAL Swing operated PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Cause Malfunctioning of swing PPC valve Malfunctioning of swing control valve (spool)

Presumed cause and standard value in normalcy

1

2

The spool in the swing control valve is presumed to malfunction. Check the spool itself. The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching if there is any change.) The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left check valves and watching the result.)

Swing motor (suction 3 valve) seal defective

Swing motor (check 4 valve) seal defective

PC400/450(LC)-7

20-621
(1)

TROUBLESHOOTING

H-25

H-25 Swing acceleration is poor, or swing speed is slow
Failure information Relative information • Swing acceleration is poor, or swing speed is slow (1) Swing acceleration is poor, or swing speed is slow. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting The LS shuttle valves for all the control valves are presumed to malfunction. Check them directly. The swing holding brake portion of the swing motor is presumed to malfunction. Check it directly. a Stop engine for preparations. Start troubleshooting at engine high idling. Swing lock switch Improper adjustment or 3 malfunctioning of swing motor (safety valve) ON L.H. work equipment control lever Swing relief Swing relief pressure 27.95 – 32.85 MPa {285 – 335 kg/cm2}

Cause Malfunctioning of LS 1 shuttle valve (all LS shuttles) 2 Presumed cause and standard value in normalcy Malfunctioning of swing motor (holding brake)

If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. 4 Swing motor defective L.H. work equipment control lever Swing relief 5 Swing machinery defective Amount of oil leakage from swing motor Below 11 l/min

Inside of the swing machinery is presumed to malfunction. Check itself. (Whether it is defective or not may well be determined by abnormal noise, abnormal generation of heat and the mixture of the metal particles in drain oil.)

Failure information Relative information

• Swing acceleration is poor, or swing speed is slow (2) Swing acceleration is poor only on one side, or swing speed is slow. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. L.H. work equipment control lever NEUTRAL Swing operated PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Cause Malfunctioning of swing PPC valve Malfunctioning of swing control valve (spool)

1 Presumed cause and standard value in normalcy

2

The spool in the swing control valve is presumed to malfunction. Check the valve itself. The pressure compensation valve in the swing motor is presumed to malfunction. Check the valve itself. The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching the result.) The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left check valves and watching the result.)

Malfunctioning of swing 3 control valve (pressure compensation valve) Swing motor (suction 4 valve) seal defective

Swing motor (check 5 valve) seal defective

20-622
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-26

H-26 Excessive overrun when stopping swing
Failure information Relative information • Excessive overrun when stopping swing (1) The work equipment overruns excessively when stopping swing. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Presumed cause and standard value in normalcy Swing lock switch Improper adjustment or 1 malfunctioning of swing motor (safety valve) ON L.H. work equipment control lever Swing relief Swing relief pressure 27.95 – 32.85 MPa {285 – 335 kg/cm2}

Cause

If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. 2 Swing motor defective L.H. work equipment control lever Swing relief Amount of oil leakage from swing motor Below 11 l/min

Failure information Relative information

• Excessive overrun when stopping swing (2) Swing acceleration is poor only on one side, or swing speed is slow. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. L.H. work equipment control lever NEUTRAL Swing operated PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Cause Malfunctioning of swing PPC valve

1 Presumed cause and standard value in normalcy

2 3

Swing PPC slow return valve clogged Malfunctioning of swing control valve (spool)

The PPC slow return valve is suspected of clogging. Check the valve itself. (Whether the valve is clogged or not may well be determined by swapping the right and left valves and watching the result.) The spool in the swing control valve is resumed to malfunction. Check the valve itself. The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching the result.) The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left check valves and watching the result.)

Swing motor (suction 4 valve) seal defective

Swing motor (check 5 valve) seal defective

PC400/450(LC)-7

20-623
(1)

TROUBLESHOOTING

H-27, H-28

H-27 There is big shock when stopping swing
Failure information Relative information • There is a big shock caused when stopping a swing motion. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Malfunctioning of swing PPC valve L.H. work equipment control lever NEUTRAL Swing operated 2 3 Malfunctioning of swing PPC slow return valve Malfunctioning of swing motor (shockless valve) PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Cause Presumed cause and standard value in normalcy

The swing PPC slow return valve is presumed to malfunction. Check the valve itself. (Whether the valve malfunctions or not may well be determined by swapping the right and left valves and watching the result.) The swing motor shockless valve is presumed to malfunction. Check the valve itself.

H-28 There is big abnormal noise caused when stopping swing
Failure information Relative information • There is a big abnormal noise caused when stopping a swing motion. • Set the working mode at A mode for the troubleshooting. Standard value in normalcy and references for troubleshooting The backpressure valve is presumed to malfunction. Check the valve itself. The safety valve in the swing motor is presumed to malfunction. Check the valve itself. The seal in suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left valves and watching the result.) The swing machinery is suspected of an internal failure. Check the inside of the machinery itself. (A failure inside the swing machinery may well be determined by monitoring abnormal noise, abnormal heat generated or metal dust or chips contained in the drained oil.)

Cause Presumed cause and standard value in normalcy Malfunctioning of 1 backpressure valve 2 Malfunction of swing motor (safety valve)

Malfunction of swing 3 motor (suction valve)

4

Swing machinery defective

20-624
(1)

PC400/450(LC)-7

TROUBLESHOOTING

H-29

H-29 Swing natural drift is too big
Failure information Relative information • Swing natural drift is too big. (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 swing brake is activated and the swing is fixed with a disc brake. • Set the working mode in A mode for troubleshooting. Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Swing and holding brake 1 solenoid valve malfunctioned Swing motor (parking 2 brake portion) malfunctioned R.H. work equipment control lever NEUTRAL Swing operated Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Presumed cause and standard value in normalcy

Cause

The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that portion directly.

Failure information Relative information

• Swing natural drift is too big. (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 swing is retained only hydraulically. • Set the working mode in A mode for troubleshooting. Standard value in normalcy and references for troubleshooting The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly. The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself directly. The safety valve seal in the swing motor is suspected of defect. Check the valve itself directly. The suction valve seal in the swing motor is suspected of defect. Check the valve itself directly. The check valve seal in the swing motor is suspected of defect. Check the valve itself directly. The shockless valve in the swing motor is suspected of malfunction or the seal is suspected of defect. Check the valve or seal itself directly.

Cause Swing control valve 1 (spool) malfunctioned Presumed cause and standard value in normalcy Swing control valve 2 (pressure compensation valve) malfunctioned 3 4 5 Swing motor (safety valve) defective Swing motor (suction valve) defective Swing motor (check valve) defective

Swing motor (shockless 6 valve) malfunctioned or seal defective

PC400/450(LC)-7

20-625
(1)

TROUBLESHOOTING

H-30, H-31

H-30 Attachment circuit does not change
When attachment is installed
Failure information • The return circuit of the attachment circuit does not change. • If an attachment is installed, the service circuit changes according to the selected working mode as shown below. 1) In mode A or E: The double acting circuit is selected and the safety valve is set to the low pressure. 2) In mode B: The single acting circuit is selected and the safety valve is set to the high pressure. * Setting of the safety valve on only port B side is changed. Port A is always set to the low pressure. Standard value in normalcy and references for troubleshooting a Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. Malfunction of 1 attachment return selector solenoid valve Working mode Mode E or A Mode B Malfunction of 2 attachment return selector valve Malfunction of service 3 control valve (safety valve) Solenoid valve output pressure 0 MPa {0 kg/cm2} 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Relative information

Cause Presumed cause and standard value in normalcy

The attachment return selector valve may have a malfunction. Check it directly. The safety valve of the service control valve (on port B side) may have a malfunction. Check it directly.

H-31 Flow rate in attachment circuit cannot be adjusted
When attachment is installed
Failure information Relative information • 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. • How to adjust the flow rate in modes A and E is different from that in mode B. For details, see OPERATION MANUAL. Standard value in normalcy and references for troubleshooting The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly. a 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 Disconnect connector V30 of attachment flow rate adjustment EPC valve. Service pedal In NEUTRAL Operated PPC valve output pressure 0 MPa {0 kg/cm2} Above 2.75 MPa {Above 28 kg/cm2}

Cause Presumed cause and standard value in normalcy Malfunction of 1 attachment flow rate adjustment EPC valve

20-626
(1)

PC400/450(LC)-7

TROUBLESHOOTING OF ENGINE (S MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-702 METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-703 S-1 Starting performance is poor (starting always takes time).................................................................... 20-706 S-2 Engine does not start ........................................................................................................................... 20-707 S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................................... 20-710 S-4 Engine stops during operations ............................................................................................................ 20- 711 S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-712 S-6 Engine lacks output (or lacks power) ................................................................................................... 20-713 S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 20-714 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-715 S-9 Oil becomes contaminated quickly ....................................................................................................... 20-716 S-10 Fuel consumption is excessive........................................................................................................... 20-717 S-11 Oil is in cooling water (or water spurts back, or water level goes down) ............................................ 20-718 S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-719 S-13 Oil level rises (water, fuel in oil) .......................................................................................................... 20-720 S-14 Water temperature becomes too high (overheating) .......................................................................... 20-721 S-15 Abnormal noise is made..................................................................................................................... 20-722 S-16 Vibration is excessive ......................................................................................................................... 20-723

PC400/450(LC)-7

20-701
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied. k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the water temperature to go down before removing the radiator cap. k Be extremely careful not to touch any hot parts or to get caught in any rotating parts. k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.

k 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.

k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check for any error display on the controller. 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. a When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Us e th e r e s u l ts o f t he i nv e s ti g a ti o n a n d inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) 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.

20-702
(1)

PC400/450(LC)-7

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation.

[Questions]
Sections + in the chart on the right corresponds to the items where answers can be obtained from the user. The items in are items that can be obtained from the user, depending on the user's level.

[Check items]
The serviceman carries out simple inspection to narrow down the causes. The items under in the chart on the right correspond to this. The serviceman narrows down the causes from information that he has obtained from the user and the results of that he has obtained from his own inspection.

[Troubleshooting]
Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with , and of these, causes that have a high probability are marked with . Check each of the [Questions] and [Check items] in turn, and marked the or in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting. Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference.

PC400/450(LC)-7

20-703
(1)

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

<Example of troubleshooting> Exhaust smoke is black
S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

20-704
(1)

PC400/450(LC)-7

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

PC400/450(LC)-7

20-705
(1)

TROUBLESHOOTING

S-1

S-1 Starting performance is poor (starting always takes time)
General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel a With the common rail fuel injection system, the fuel injection timing is recognized electrically, so even when the starting operation is carried out, the engine may not start until the crankshaft has completed two rotations. However, this does not indicate any abnormality.

20-706
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-2

S-2 Engine does not start
a) Engine does not turn General causes why engine does not turn • Internal parts of engine seized a See “Engine stops during operations”. • Defective electrical system • Failure on chassis side

PC400/450(LC)-7

20-707
(1)

TROUBLESHOOTING

S-2

b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter)

20-708
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-2

c) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel

PC400/450(LC)-7

20-709
(1)

TROUBLESHOOTING

S-3

S-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

20-710
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-4

S-4 Engine stops during operations
General causes why engine stops • Internal part of engine seized • Insufficient supply of fuel • Engine overheating a See troubleshooting for [Overheat]. • Failure on chassis side

PC400/450(LC)-7

20-711
(1)

TROUBLESHOOTING

S-5

S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly • Air in fuel system • Speed sensor is not normal (abnormality not big enough to generate error display)

20-712
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-6

S-6 Engine lacks output (or lacks power)
General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

PC400/450(LC)-7

20-713
(1)

TROUBLESHOOTING

S-7

S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

20-714
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive • Abnormal combustion of oil • The engine has been run at low or high idling for a long time continuously (more than 20 minutes continuous operation is not allowed). • External leakage of oil • Wear of lubrication system

PC400/450(LC)-7

20-715
(1)

TROUBLESHOOTING

S-9

S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Improper fuel used • Improper oil used • Operation under excessive load

20-716
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-10

S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection (injection pressure, injection timing) • Excessive injection of fuel

PC400/450(LC)-7

20-717
(1)

TROUBLESHOOTING

S-11

S-11 Oil is in cooling water (or water spurts back, or water level goes down)
General causes why oil is in cooling water • Internal leakage in lubrication system • Internal leakage in cooling system

20-718
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-12

S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure drops • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper oil used (improper viscosity) • Deterioration of oil due to overheating

PC400/450(LC)-7

20-719
(1)

TROUBLESHOOTING

S-13

S-13 Oil level rises (water, fuel in oil)
General causes why oil level rises • Water in oil (cloudy white) • Fuel in oil (diluted, smells of diesel fuel) a If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”.

20-720
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-14

S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Defective cooling circulation system • Rise of hydraulic oil temperature on chassis side

PC400/450(LC)-7

20-721
(1)

TROUBLESHOOTING

S-15

S-15 Abnormal noise is made
General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system a Judge if the noise is an internal noise or an external noise. a If the engine is not thoroughly warmed up, the engine sound becomes slightly louder because it is operated in the low temperature mode, but this is not an abnormality. a When the engine is accelerated, it enters the acceleration mode and the engine noise is higher for 3 seconds, but this is not an abnormality.

20-722
(1)

PC400/450(LC)-7

TROUBLESHOOTING

S-16

S-16 Vibration is excessive
General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment with machine • Abnormal combustion a If there is abnormal noise together with the vibration, carry out troubleshooting also for “Abnormal noise is made”.

PC400/450(LC)-7

20-723
(1)

30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL.................... 30PRECAUTIONS WHEN PERFORMING OPERATION ............................................30SPECIAL TOOL LIST .................................... 30REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY ................ 30REMOVAL AND INSTALLATION OF ENGINE REAR SEAL ............................................. 30REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...........................................30REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY.................... 30REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY ...........................30REMOVAL AND INSTALLATION OF NOZZLE TIP ............................................30REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY ............. 30REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...........................30REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY .30REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY .... 30REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY................................ 30REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY .............................................. 30DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY .............................................. 30REMOVAL AND INSTALLATION OF SPROCKET ............................................. 30REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .............................................. 30DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY ..................................30DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY ............. 30DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...............................30DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY .............................................. 30PC400/450(LC)-7 2 4 6 13 20 24 27 30 33 35 36 38 40 45 46 47 54 55 56 63 65 66 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY................. 30- 69 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY................................... 30- 71 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY .......... 30- 73 REMOVAL AND INSTALLATION OF OPERATOR’S CAB ................................. 30- 75 REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY............................ 30- 78 REMOVAL AND INSTALLATION OF PUMP CONTROLLER ........................................ 30- 79 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ........................................ 30- 80 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY .......... 30- 81 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY............. 30- 84 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.............. 30- 85 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY............. 30- 87 REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT ... 30- 90 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY ............... 30- 91 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY ............... 30- 94 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY .... 30- 98 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY .... 30-100 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VELVE ASSEMBLY... 30-101 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY........... 30-102 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..... 30-103 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY ....................... 30-108 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) ..................................... 30- 111 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY ............................. 30-121

30-1
(2)

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS • Special tools that are deemed necessary for removal or installation of parts are listed. • List of the special tools contains the following kind of information. 1) Necessity t: Special tools which cannot be substituted, should always be used. q:Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. a Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx. REMOVAL OF PARTS • The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the REMOVAL Section are explained and listed below. k This mark indicates safety-related precautions which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts. INSTALLATION OF PARTS • Except where otherwise instructed, install parts is the reverse order of removal. • Instructions and precautions for installing parts are shown with [*1] mark in the INSTALLATION Section, identifying which step the instructions are intended for. • Marks shown in the INSTALLATION Section stand for the following. k This mark indicates safety-related precautions which must be followed when doing the work. a This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5 This mark indicates an amount of oil or water to be added. SKETCHES OF SPECIAL TOOLS • Various special tools are illustrated for the convenience of local manufacture.

a [*1]

6 This mark shows oil or water to be drained.

30-2
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS • Special tools which are deemed necessary for disassembly and assembly are listed in this section. • List of the special tools contains the following kind of information. 1) Necessity t: Special tools which cannot be substituted, should always be used. q: Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. 4) Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx. DISASSEMBLY • The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the DISASSEMBLY Section are explained and listed below. k This mark indicates safety-related precautions which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts. ASSEMBLY • Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil or water to be added. • Various symbols used in the ASSEMBLY Section are explained and listed below. k This mark indicates safety-related precautions which must be followed when doing the work. a This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5 This mark indicates an amount of oil or water to be added. SKETCHES OF SPECIAL TOOLS • Various special tools are illustrated for the convenience of local manufacture.

a [*1]

6 This mark shows oil or water to be drained.

PC400/450(LC)-7

30-3
(2)

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN PERFORMING OPERATION

PRECAUTIONS WHEN PERFORMING OPERATION
Be sure to follow the general precautions given below when performing removal or installation (disassembly or assembly) of units. 1. Precautions when performing removal work • If the engine coolant water contains antifreeze, dispose of it properly. • After disconnecting hoses or tubes, cover them or install 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 during assembly. • To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wiring, hold onto the connectors when disconnecting them. • Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any mistakes when re-installing. • Count and check the number and thickness of the shims, and keep them in a safe place. • When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembly Install the following blind plugs into the piping after disconnecting it during disassembly operations. A. Face seal type hoses and tubes Nominal number 02 03 04 05 06 Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 Nut (elbow end) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628

B. Split flange type hoses and tubes Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500

C. If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D 6 8 10 12 d 5 6.5 8.5 10 L 8 11 12
øD ød
DEW00401

15

Taper 1/8

14 11.5 18 16 13.5 20 18 20 24 15 17 20 22 25 30
L

22 18.5 28 27 22.5 34

30-4
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN PERFORMING OPERATION

2. • • • • • • • • • • • • •

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 installing snap rings, check that the snap ring is installed securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect it securely. When using eye bolts, check that there is no deformation or deterioration. Screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other hydraulic equipment removed for repair, bleed the air as follows: 1) Start the engine and run it at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the cylinders 100 mm from the end of their stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this run the engine at normal speed. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operations • If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified level. Run the engine to circulate the coolant water through the system. Then check the coolant water 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 have been removed for repair, bleed the air from the system after reassembling the parts. a For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.

PC400/450(LC)-7

30-5
(2)

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

SPECIAL TOOL LIST
a Tools with part number 79 Ttured). a Necessity: cannot be supplied (they are items to be locally manufac-

t............Cannot be substituted, must always be installed (used) q............Extremely useful if available or can be substituted with commercially available part a New/Remodel: N............Tools with new part numbers, newly developed for this model R: ...........Tools with upgraded part numbers, remodeled from items already available for other models Blank: ....Tools already available for other models, can be used without any modification a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF SPECIAL TOOLS). New/remodel

Necessity

Symbol

Component

Part No.

Part Name

Sketch Q Q

Q'ty

Nature of work, remarks

1 795-799-1170 2 790-331-1110 3 795-931-1100 795-931-1210

Puller Wrench Seal puller Push tool

t q t t t t t t t t t t t t t t t t t t q q

1 1 1 1 3 3 1 3 1 1 1 3 1 1 1 1 3 1 1 1 1 1 N

Removal, installation of nozzle holder assembly Tightening of cylinder head bolt Removal of engine seal

4 • 01050-31625 • Bolt • 01050-31645 • Bolt 5 Engine assembly A 6 795-931-1220 Push tool • 01050-31645 • Bolt 795T-521-1140 Push tool • 790-101-5221 • Grip • 01010-81225 • Bolt • 01050-31640 • Bolt 795-471-1800 Remover • 795-471-1810 • Plate 7 • 795-471-1820 • Bolt • 795-471-1830 • Bracket • 01435-01035 • Bolt • 01435-01025 • Bolt 8 795T-471-1550 Wrench Engine and hydraulic pump assembly B C 796T-601-1110 Stopper 796-460-1210 796-770-1320 Oil stopper Adapter

Press fitting of engine rear seal

Press fitting of engine front seal

Removal of fuel supply pump

Removal, installation of nozzle tip Removal, installation of engine mounting bolt Stopping of oil

N Q

30-6
(5)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

New/remodel

Necessity

Symbol

Component

Part No.

Part Name

Sketch Q

Q'ty

Nature of work, remarks

1 796T-627-1630 Push tool 2 790-201-2350 3 790-201-2510 790-101-5401 Swing motor and swing machinery assembly 4 D Push tool Push tool Push tool kit

q t t t

1 1 1 1 1 1 1

Q Removal of shaft Removal of bearing Press fitting of bearing

• 790-101-5531 • Plate • 790-101-5421 • Grip • 01010-51240 • Bolt

Press fitting of oil seal

5 790-201-2870 6 790-201-2770

Push tool Push tool

t t t t

1 1 1 1 1 3 3

Press fitting of bearing inner race Press fitting of bearing inner race Q Press fitting of bearing Removal, installation of round nut

7 796T-626-1110 Push tool 796-627-1210 1 Wrench assembly • 796-627-1220 • Wrench • 796-427-1140 • Pin • 01314-20612 • Screw 796T-627-1230 Push tool 790-101-2510 Final drive assemE bly 791-122-1130 790-101-2550 2 790-101-2740 790-101-2570 790-101-2560 790-101-2102 790-101-1102 3 796-627-1020 Carrier roller assembly Track roller assembly Idler assembly F G H 791-430-3230 791-601-1000 791-630-1780 791-601-1000 791-575-1520 791-601-1000 791-685-8006 791-635-3160 1 Recoil spring assembly J 790-101-1600 790-101-1102 790-201-1500 2 Block Plate Leg Adapter Plate Nut Pump Installer Installer Oil pump Installer Oil pump Installer Oil pump Compressor Extension Cylinder (686 kN {70 t}) Pump Push tool kit

t q q q q q q t t t t t t t t t t t t t

1 1 1 2 2 4 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Pressing of bearing inner race

Puller (294 kN {30 t}) t

Installation of floating seal

Supply of oil

Disassembly, assembly of recoil spring assembly

• 790-201-1660 • Plate • 790-101-5021 • Grip • 01010-50816 • Bolt

Installation of dust seal

PC400/450(LC)-7

30-7
(5)

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

New/remodel

Necessity

Symbol

Component

Part No.

Part Name

Sketch

Q'ty

Nature of work, remarks

791-650-3000 Track shoe assembly K 790-101-1300 790-101-1102 796-946-1310 796-946-2110 796-946-2210 796-946-1320 796-946-1420 Control valve assembly 2 L 796-946-2120 796-946-2220 796-946-1330 796-946-1430 3 796-946-2130 796-946-2230 790-101-2501

Remover and installer Cylinder (980 kN {100 t}) Pump Guide Guide Guide Guide Guide Guide Guide Sleeve Sleeve Sleeve Sleeve Push puller 21.6 21.8 20.9 20.6

t t t

1 1 1 1 1 1 1 1 1 1 1 1 1 1 Replacement of pressure compensation valve seal Pulling out of master pin

(For 723-46-40100, 723-46-40601) 1 (For 723-46-44100) (For 723-46-45100, 723-46-45500) (For 723-46-40100, 723-46-40601) (For 723-46-42800) (For 723-46-44100) (For 723-46-45100, 723-46-45500) (For 723-46-40100, 723-46-40601) (For 723-46-42800) (For 723-46-44100) (For 723-46-45100, 723-46-45500) t • 790-101-2510 • Block • 790-101-2520 • Screw Center swivel joint assembly • 791-112-1180 • Nut M • 790-101-2540 • Washer • 790-101-2630 • Leg • 790-101-2570 • Plate • 790-101-2560 • Nut • 790-101-2650 • Adapter

1 1 1 1 1 2 4 2 2 Disassembly, assembly of center swivel joint assembly

30-8
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

New/remodel

Necessity

Symbol

Component

Part No.

Part Name

Sketch

Q'ty

Nature of work, remarks

1 790-502-1003 2 790-102-4300 790-102-4310

Cylinder repair stand t Wrench assembly Pin Expander Ring (For boom and bucket) Clamp (For boom and bucket) Ring (For arm) Clamp (For arm) Push tool kit • Push tool (For bucket) • Push tool (For boom) t t q q q q q t

1 1 2 1 1 1 1 1 1 1 1 1 1 1

Disassembly, assembly of hydraulic cylinder assembly Removal, installation of piston assembly

3 790-720-1000 796-720-1680 4 07281-01589 796-720-1690 07281-01919 790-201-1702 Hydraulic cylinder N assembly 5 • 790-201-1851 • 790-201-1861

Installation of piston ring

Press fitting of bushing

• Push tool (For arm) • 790-201-1871 120 • 790-101-5021 • Grip • 01010-50816 • Bolt 790-201-1500 Push tool kit t • 790-101-5021 • Grip • 01010-50816 • Bolt 6 • 790-201-1660 • Plate (For bucket)

1 1 1 1 1 1 Press fitting of dust seal

• 790-201-1670 • Plate (For boom) • 790-201-1680 • Plate (For arm) 796-670-1100 Remover q • 796-670-1110 • Sleeve • 796-670-1120 • Plate • 796-670-1130 • Screw Work equipment assembly P • 796-870-1110 • Adapter • 01643-33080 • Washer • 01803-13034 • Nut 790-101-4000 790-101-1102 Puller (490 kN {50t}, q long) Pump (294 kN {30t}) q

1 1 1 1 1 1 1 1 1 Removal of foot pin

PC400/450(LC)-7

30-9
(2)

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

New/remodel

Necessity

Symbol

Component

Part No.

Part Name

Sketch

Q'ty

Nature of work, remarks

799-703-1200 799-703-1100 Air conditioner unit assembly Q 799-703-1110 799-703-1120 799-703-1401 Operator’s cab glass Y 1 793-498-1210 2 20Y-54-13180

Service tool kit Vacuum pump (100V) Vacuum pump (220V) Vacuum pump (240V) Gas leak detector Lifter (Suction cup) Adapter

t t t t t t t

1 1 1 1 1 2 2 Removal and Installation of operator’s cab glass Filling with air conditioner refrigerant (gas)

30-10
(5)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

SKETCHES OF SPECIAL TOOLS NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A6. Push tool

A8. Wrench

PC400/450(LC)-7

30-11
(2)

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

B. Stopper

D1. Push tool

30-11-1
(5)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

D7. Push tool

E2. Push tool

30-12
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 7. Remove fuel filter (8) and bracket (9).

Part No.

Part Name

A

1 795-799-1170 Puller 2 790-331-1110 Wrench

t 1 q 1

REMOVAL
k

Disconnect the cable from the negative (–) terminal of the battery.

8. Remove clamp (10), 2 tubes (11), and filter (12). 9. Remove cap (13) and disconnect wire (15). 10. Disconnect heater switch (14). 11. Remove the 2 clips on the back side and remove bracket (16).

1. Remove 2 engine undercovers (1).

2. Drain the coolant. 6 Coolant: Approx. 35 l 12. Disconnect fuel supply pump wiring connectors PCV1 (17) and PCV2 (18) and remove 2 clips (19). 13. Disconnect bracket (20) and connector PIM (21) and remove spacer (22). [*4]

3. Open the engine hood. 4. Remove tube (2). [*1] a Remove the tube and bracket together. 5. Remove clamp (4) and disconnect the bracket and pipe (5) together. [*2] a Fix hose (3) and pipe (5) with cords, etc. apart from the engine. 6. Remove 2 clamps (6) and 2 tubes (7). [*3]

PC400/450(LC)-7

30-13
(2)

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

14. Disconnect clip (23) and bracket (24), and then disconnect 6 fuel injector connectors (25). a Place disconnected wiring harness assembly (26) so that it will not be an obstacle. [*4]

17. Remove 3 high-pressure pipe clamps (31) and 3 brackets (32). [*6] 18. Remove lubrication tube clamp (33).

a To disconnect fuel injector connector "c", insert flat-head screwdriver [1] in stepped part "a" and move it in direction "X", pressing stopper "b".

19. Sling air intake manifold assembly (34) temporarily and remove the air intake manifold mounting bolts. [*7] a Do not remove XX. 20. Lift off air intake manifold assembly (34). 4 Air intake manifold assembly: 45 kg

15. Remove common rail-side high-pressure pipe clamp (28), cover (27), and gate-type bracket (29). [*5] 16. Remove each high-pressure pipe cover (30). [*5] 21. Remove mounting bolts (35) and disconnect lower lubrication tube (36). 22. Remove heat insulation cover (37) and cover (38).

30-14
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

23. Remove clip (39) and lubrication tubes (40) and (36). [*8] a Take care of the spacer. 24. Remove clamp (41). 25. Remove cover (44). 26. Remove clamp (42) and disconnect hose (43). [*10] [*9]

29. Remove coolant tube (48).

[*13]

30. Remove each high-pressure pipe cover (49). [*14]

31. Remove 6 high-pressure pipe sleeve nuts (50) on the common rail side. [*15] 32. Loosen 6 high-pressure pipe sleeve nuts (51) on the head side and remove 6 high-pressure pipes (52). [*16] 27. Sling turbocharger assembly (45) temporarily and remove the mounting bolts of exhaust manifold (46). [*11] 33. Remove spill tube (55). 34. Remove return tube (53). 35. Remove 6 head covers (54). [*17] [*18] [*19]

28. Lift off turbocharger and exhaust manifold assembly (47). 4 Turbocharger and exhaust manifold assembly: 75 kg a When lifting up, remove part A. Note that the center of gravity is off to the left. [*12]

PC400/450(LC)-7

30-15
(2)

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

36. Remove capture nut (56) and disconnect the wiring harness from the injector. [*20] 37. Remove rocker shaft mounting bolts (57) and rocker arm and rocker shaft assembly (58). [*21] 38. Remove injector mounting bolts (59) and injector assembly (60). [*22] a If the injector assembly is not removed easily, use tool A1. a Do not hold the solenoid valve on the top of the injector with pliers, etc.

INSTALLATION
• Carry out installation of all the parts, except the high-pressure pipe, in the reverse order to removal. 3 Hose clamp: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm} 3 Air aftercooler pipe clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} 3 Fuel tube (7): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} Install wiring harness assembly (26) and other wiring harnesses at least 10 mm apart from the high-pressure pipe. [*7] The tightening torque and tightening order of the air intake manifold assembly mounting bolts are not specified. [*8] 3 Joint bolt on engine block side of lubrication tube: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 3 Clamp (41): 68.6 – 98 Nm {7 – 10 kgm}

[*1]

[*2]

[*3]

[*4]

39. Remove cross head (61). 40. Remove 2 push rods (62).

[*23]

[*9]

41. Remove 6 mounting bolts (63) and rocker housing (64). [*24] 42. Remove 7 cylinder head mounting bolts (65) and cylinder head assembly (66). [*25]

[*10] 3 Hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} [*11] Tighten the following 3 exhaust manifold assembly mounting bolts first in the given order, and then tighten the other bolts. 3 Exhaust manifold assembly mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

30-16
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

[*12] 2 All periphery of inserting part of exhaust pipe: Thermosetting sealant (FIREGUM manufactured by HOLTS or equivalent) [*13] 3 Coolant tube (48): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} [*14] a For the installation procedure for high-pressure pipe cover (49), see REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY. [*5] [*6] [*15] [*16] Installation procedure for high-pressure pipe a Do not correct the high-pressure pipe by bending before installing it. 1) Tighten high-pressure pipe (52) permanently. 3 Sleeve nuts (50) and (51): 39.2 – 49.0 Nm {4.0 – 5.0 kgm} 2) Tighten high-pressure pipe clamps (28) and (31) and bracket (32) with your fingers. 3) Tighten high-pressure pipe clamps (28) and (31) permanently. 3 Clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 4) Tighten bracket (32) permanently. 5) Install cover (30). a Set the slit on the cylinder head side. 6) Install gate-type bracket (29) and cover (which is used as the clamp, too) (27) temporarily. 7) Tighten cover (27) permanently. 3 Cover mounting bolt: 11.8 – 14.7 kgm {1.2 – 1.5 kgm} 8) Tighten the gate-type bracket permanently. [*17] 3 Spill tube (55): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} [*18] 3 Return tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} [*19] 3 Head cover mounting bolt: 9.8 ± 1 Nm {1.0 ± 0.1 kgm} [*20] 3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm} [*21] 1) Loosen the locknut and install the rocker arm and rocker shaft assembly. 3 Rocker shaft mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 2) Remove covers (70) and (71) and adjust the valve clearance. The pointer is under cover (70). • Valve clearance Intake: 0.33 mm Exhaust: 0.71 mm a For the adjustment procedure for the valve clearance, see TESTING AND ADJUSTING, Adjusting valve clearance. 3 Rocker arm locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm}

PC400/450(LC)-7

30-17
(2)

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

[*22] a For the installation procedure for the injector and holder, see REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY. [*23] a Apply engine oil (EO30-CD) to the cross head guide and cross head top sufficiently. a Adjust the cross head according to the following procedure. 1) Loosen locknut (73) and return the adjustment screw. 2) Press the cross head top lightly to put it to valve stem (74) and tighten the adjustment screw. 3) After the adjustment screw touches the valve stem, tighten it further by 20°. 4) Tighten the locknut at this position. 3 Locknut: 58.8 – 73.5 Nm {6 – 7.5 kgm}

[*25] a Clean the underside of the head, top of the block, and liner with dry cloths or cloths soaked with solvent. a If a bolt has 5 punch marks on its head, replace it. a Tighten the bolts with your fingers into the block at least 2 turns. 2 Bolt threads and underside of bolt head: LM-P or engine oil (EO30-CD) a Tighten the cylinder head mounting bolts in the following order. 3 Cylinder head mounting bolts 1 – 6: 1st time: 88.3 – 108 Nm {9 – 11 kgm} 2nd time: 157 – 167 Nm {16 – 17 kgm} 3rd time: 1) When using tool A2

Using tool A2, retighten the bolts in the order of 1 – 6 by 90° +30° . 0 [*24] 3 Rocker housing mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

30-18
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

2) When not using tool A2 Make marks on the bolt heads with a marker pen and retighten the bolts in the order of 1 – 6 by 90° +30° . 0 a After tightening bolts 1 – 6, tighten auxiliary bolt 7. 3 Cylinder head auxiliary mounting bolt 7: 66.2 ± 7.4 Nm {6.8 ± 0.8 kgm} a After tightening the bolts, make a punch mark on each bolt head to show the number of tightening time.

Refilling with coolant Add coolant through the coolant filler of the radiator to the specified level. Run the engine to circulate the coolant through the piping. Then, check the coolant level again. 5 Coolant: Approx. 35 l

PC400/450(LC)-7

30-19
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE REAR SEAL

REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 4. Leave 1 mounting bolt (5) and sling flywheel (4) temporarily. [*3] a Sling [2] becomes diagonal because of the muffler. 5. Lift off flywheel assembly (4).
k

Part No.

Part Name

3 795-931-1100 Seal puller 795-931-1210 Push tool A 4 • 01050-31625 • Bolt • 01050-31645 • Bolt 5 795-931-1220 Push tool • 01050-31645 • Bolt

t 1 t 1 t 3 t 3 t 1 t 3

4 Flywheel assembly: 50 kg When the flywheel is hung temporarily, sling [2] becomes diagonal. Accordingly, when flywheel assembly (4) (which has been fitted firmly) is removed, it swings. Take care.

[*3]

REMOVAL
1. Remove they hydraulic pump assembly. For details, see REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY. 2. Using guide bolt [1], remove damper assembly (1). [*1]

6. Rear seal Remove rear seal (6) according to the following procedure. [*4]

3. Disconnect engine speed sensor connector EREV (2), loosen speed sensor locknut (3), and separate the speed sensor from flywheel (4).[*2]

30-20
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

ENGINE REAR SEAL

Removal of original rear seal Set the drill-type tip to tool A3, make a hole on the seal, and pull out the seal with the impact force of the slide hammer (SH). a Remove all the chips.

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 2 Mounting bolt: Adhesive (LT-2)

• Removal of spare rear seal 1) Set the hook-type tip to tool A3, hook it to the metallic ring of seal (6), and pull out the seal with the impact force of the slide hammer (SH). a Drive in the seal a little before pulling it out to separate it from the housing, and you can put it out easily. 2) If sleeve (9) is installed, cut and remove it with a chisel and a hammer. a When cutting sleeve (9), take care extremely not to damage crankshaft (8). a If chips are made, remove all of them.

[*2] Installation procedure for sensor 1) 2 Threads of sensor: Hydraulic sealant manufactured by LOCTITE 2) Screw the sensor into the flywheel housing to touch it to the ring gear. 3) Return the sensor by 1/2 – 2/3 turns. (Clearance between the sensor and ring gear: 0.75 – 1 mm) 4) 3 Sensor locknut: 69 – 74 Nm {7 – 7.5 kgm} [*3] a Apply sufficient amount of clean lubricating oil (EO30-CD) to the threads of the bolt, seat, and washer. a Tighten the 6 flywheel assembly mounting bolts in the order of 1 – 6 shown in the following figure. a Tighten the flywheel assembly mounting bolts 2 times. 3 Mounting bolt: 1st tightening torque: 147 ± 19.6 Nm {15 ± 2.0 kgm} 2nd tightening torque: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}

PC400/450(LC)-7

30-21
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE REAR SEAL

[*4] • Installation procedure for engine rear seal (6) a Rear seal 6151-21-4161: Check the shaft for wear and install "standard seal A" or "sleeved seal B" according to the check result. The part No. of the spare rear seal is 615129-4160 (same as one installed to PC400-6) and its shape is different from that of the seal installed when shipped. a If the shaft is still glossy (If the wear depth felt with a finger cushion is 10 m or less) and it does not have a flaw, install "standard seal A". In other cases, install "sleeved seal B". a Part (7) is the internal plastic cylinder which is also used as a installation guide. a Part (9) is the sleeve. a Wipe off oil from the crankshaft and install the seal while the crankshaft is dry (Do no apply lubricating oil to the lip).

1) Put large inside diameter side "b" of internal plastic cylinder (7) to the end of crankshaft (8). a Take care not to mistake the direction of the plastic internal cylinder.

2) Evenly push in the metallic ring of seal (6) with both hands, getting over the large diameter side of the internal plastic cylinder. 3) After pushing in seal (6), remove internal plastic cylinder (7). a When removing, take care not to damage the seal lip.

Installation procedure for standard seal A a Before installing the seal, check the rims of the crankshaft end, sliding surfaces of the lip, and housing for flaw, burr, rust, etc. a When installing the seal, do not apply oil, grease, etc. to the shaft. Wipe oil thoroughly from the shaft. a Never remove internal plastic cylinder (7) of the spare seal before installing the seal.

4) Tighten the bolt of tool A4 evenly until the end of tool A4 touches the end of crankshaft (8) to press fit seal (6). a When press fitting the seal, take care not to damage the lip on the damper side with the tool, etc. a After press fitting the seal, remove the red sealant layer on its periphery.

30-22
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

ENGINE REAR SEAL

Installation procedure for sleeved seal B a Before installing the seal, check the rims of the crankshaft end, sliding faces of the lip, and housing for flaw, burr, sharp fin, rust, etc. a When installing the seal, do not apply oil, grease, etc. to the shaft. Wipe oil thoroughly from the shaft. a Handle the seal and sleeve as an assembly. Never separate them from each other. 1) Set sleeved seal (6) to tool A5. a Take care not to mistake the direction of the seal. 2 Internal cylinder (C) of sleeve: Gasket sealant (LG-7)

3) Remove tool A5 and install tool A4. 4) Tighten the bolt of tool A4 evenly until the end of tool A4 touches the end of crankshaft (8) to press fit sleeved seal (6). a After press fitting the seal, remove the red sealant layer on its periphery.

2) Put the sleeve of the seal to the end of the crankshaft and tighten the bolt of tool A5 evenly until the end of tool A5 touches the end of crankshaft (8) to press fit sleeved seal (6).

PC400/450(LC)-7

30-23
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE FRONT SEAL

REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 5. Remove covers (5) and (6).

Part No.

Part Name

A3

795-931-1100

Seal puller assembly

t 1 t 1 t 1 t 1 t 3 6. Loosen the air conditioner compressor assembly mounting bolt and adjustment screw (7). [*2] 7. Loosen alternator assembly mounting bolt (11), adjustment bolt nuts (8) and (9), and adjustment bolt guide bolt (10). [*3] Q

795T-521-1140 Push tool A6 • 790-101-5221 • Grip • 01010-81225 • Bolt • 01050-31640 • Bolt

REMOVAL
1. Remove the radiator and hydraulic oil cooler. For details, see REMOVAL AND INSTALLATION OF RADIATOR and REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER. 2. Open the right side cover. 3. Remove reservoir tank bracket (1) and disconnect air aftercooler hoses (2) and (3). [*1] 4. Remove the 4 mounting bolts and air aftercooler (4).

8. Remove fan (12).

30-24
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

ENGINE FRONT SEAL

9. Remove alternator belt (13) and air conditioner compressor belt (14). 10. Remove 6 pulley mounting bolts (15) and (16) in total, and then remove pulley and damper assembly (17). a One mounting bolt (16) is small in diameter. [*4]

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 3 Air aftercooler hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} a Belt tension: 14 – 16 mm (When pressed with finger to about 58.8 N {6 kg}) 3 Mounting bolt: 24.5 – 29.4 Nm {2.5 – 3.0 kgm} • Tense the belt according to the following procedure. 1) Loosen mounting bolt (11), nut (9), and bolt (10). 2) Tense the belt with nut (8). 3) Tighten mounting bolt (11), nut (9), and bolt (10). a Tension of belt: 13 mm (When pressed with finger to about 58.8 N {6 kg}) 3 Bolt: 107.8 – 147 Nm {11 – 15 kgm} [*4] 3 Pulley mounting bolt: (M14): 156.8 – 196 Nm {16 – 20 kgm} (M16): 245 – 308.7 Nm {25 – 31 kgm}

[*2]

[*3]

11. Using the seal pulley assembly and tool A3, remove the front seal. [*5] a Remove all the chips.

PC400/450(LC)-7

30-25
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE FRONT SEAL

[*5] 4) Installation procedure for front seal (18) a Before installing the seal, check the rims of the crankshaft end, sliding surfaces of the lip, and housing for flaw, burr, rust, etc. a When installing the seal, do not apply oil, grease, etc. to the shaft. Wipe oil thoroughly from the shaft. a Never remove internal plastic cylinder of the spare seal before installing the seal.

ii)

Evenly push in the metallic ring of seal (18) with both hands, getting over the large diameter side of the internal plastic cylinder. iii) After pushing in seal (18), remove internal plastic cylinder (19). a When removing, take care not to damage the seal lip.

Put large inside diameter side "b" of internal plastic cylinder (19) to the end of crankshaft (20). a Take care not to mistake the direction of the plastic internal cylinder. 2 Lip: Lithium grease (G2-LI)

i)

iv) Tighten the bolt of tool A5 evenly until the end of tool A6 touches the end of crankshaft (20) to press fit seal (18). a When press fitting the seal, take care not to damage the lip on the pulley side with the tool, etc. a After press fitting the seal, remove the red sealant layer on its periphery. a Seal driving dimension "a": 16 +1 mm 0

30-26
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

FUEL SUPPLY PUMP

REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 4. Open the engine hood. 5. Remove air cleaner tube (2) and bracket together. [*1] 6. Fix hose (3) with cords apart from the engine. 7. Remove cover (4).

Part No.

Part Name

795-471-1800 Remover • 795-471-1810 • Plate A7 • 795-471-1820 • Bolt • 795-471-1830 • Bracket • 01435-01035 • Bolt • 01435-01025 • Bolt

t 1 N 1 1 1 3 1

REMOVAL
k

Disconnect the cable from the negative (–) terminal of the battery.

8. Remove clamp (5). 9. Disconnect fuel supply pump wiring connectors PCV1 (6), PCV2 (7), and G (8). 10. Remove fuel hoses (9) and (10). 11. Remove cover (11). [*2] [*3]

1. Release the residual pressure from the fuel system. For details, see TESTING AND ADJUSTING, Releasing residual pressure from fuel system. 2. Close the fuel supply valve of the fuel tank. 3. Remove two engine undercovers (1).

PC400/450(LC)-7

30-27
(2)

DISASSEMBLY AND ASSEMBLY

FUEL SUPPLY PUMP

12. Remove 4 high-pressure pipe clamps (12). [*4] 13. Remove 2 clamps (13) and fuel tubes (14) and (15). [*5] 14. Remove 2 covers (16). 15. Remove 2 high-pressure pipes (17). 16. Remove lubrication tube (18). [*3] [*6] [*7]

4) Install plate (23) of tool A7 to installation hole B and install bracket (24) of tool A7 to C. 5) Set bolt (25) of tool A7. a Keep tool A7 installed until the pump is installed so that meshing point of the fuel supply pump drive gear and camshaft will change.

17. Setting tool to remove fuel supply pump drive gear 1) Remove 2 mounting bolts (19) and cover (20). [*8]

18. Remove bracket (26) and mounting bolts of fuel supply pump assembly (27) and install guide bolt [1]. [*10] a The proper length of the guide bolt is a half of the length shown in the photo. 19. Remove the remaining 3 mounting bolts.

2) Remove mounting nut (22) and the washer of fuel supply pump drive gear (21). [*9] 3) Rotate the crankshaft so that key way A of the shaft will be in the 11 o'clock direction.

20. Tighten bolt (25) of tool A7 to remove fuel supply pump assembly (27).

30-28
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

FUEL SUPPLY PUMP

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 3 Air cleaner hose clamp: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm} 3 Fuel hoses (9) and (10): 14.8 – 19.6 Nm {1.5 – 2.0 kgm}

3) Tighten the fuel supply pump mounting bolts. 4) Tighten the mounting bolts of bracket (26). 5) Tighten 4 high-pressure pipe clamps (12) temporarily with your fingers. 6) Tighten 4 high-pressure pipe clamps (12) to the following torque. 3 High-pressure pipe clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}

[*2]

[*3] a Install cover (11) with the slit on the cylinder block side and install cover (16) with the slit directed down. [*4], [*6], [*10] k Do not correct the high-pressure pipe by bending before installing it. k Be sure to use the genuine high-pressure pipe clamps and tighten them to the specified torque. k Install the wiring harnesses at least 10 mm apart from the high-pressure pipe. a When installing each high-pressure pipe, check the taper seal of its joint (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and spot "c" and check part "d" (End of taper seal: Part of 2 mm from the end) for stepped-type wear caused by fatigue which your nail can feel. If there is any of those defects, it can cause fuel leakage. In this case, replace the high-pressure pipe.

[*5]

3 Fuel tubes (14) and (15): 24.5 – 34.3 {2.5 – 3.5 kgm} 3 Lubrication tube (20) Fuel supply pump side: 7.9 – 12.7 Nm {0.8 – 1.3 kgm} Cylinder block side: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm} 3 Cover: 14.7 – 17.6 Nm {1.5 – 1.8 kgm} 3 Fuel supply pump drive gear: 127 – 147 Nm {13 – 15 kgm} Checking for fuel leakage a Check the fuel system for leakage. For details, see TESTING AND ADJUSTING, Checking fuel system for leakage. Bleeding air a Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.

[*7]

[*8] [*9]

• 1) Tighten fuel supply pump (27), bracket (26), and 2 high-pressure pipes (17) temporarily with your fingers. 2 Fuel supply pump mounting bolt: LOCTITE (LT-7) 2) Tighten 2 high-pressure pipes (17) to the following torque. 3 Common rail-side sleeve nut: 39.2 – 58.8 Nm {4.0 – 6.0 kgm} Supply pump-side sleeve nut: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}

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(2)

DISASSEMBLY AND ASSEMBLY

FUEL INJECTOR

REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
SPECIAL TOOL
Necessity Q’ty New/Remodel Sketch Symbol 5. Remove gate-type bracket (4). [*4] 6. Remove injector-side covers (6) and common rail-side covers (5) from the high-pressure pipe joints according to the fuel injectors to be removed and installed. [*5] 7. Remove high-pressure pipe clamp cover (7) and its clamp (77) according to the fuel injectors to be removed and installed. [*6] a Do not remove bracket X. If it is removed, tighten it permanently after tightening the high-pressure pipe and all the high-pressure pipe clamps in the assembly procedure.

Part No.

Part Name

A1

795-799-1170 Puller

t 1

REMOVAL
k

Disconnect the cable from the negative (–) terminal of the battery.

1. Open the engine hood. 2. Remove air cleaner tube (1) and the bracket together. [*1]

8. Loosen common rail-side sleeve nuts (8) and fuel injector-side sleeve nut (10) and remove high-pressure pipe (9). [*7] 3. Remove common rail cover (2). [*2] 9. Remove head cover (11). [*8]

4. Remove high-pressure pipe clamps (3) according to the fuel injectors to be removed and installed. [*3]

30-30
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

FUEL INJECTOR

10. Remove capture nuts (12) and disconnect wiring harness (13) from the fuel injector. [*9] 11. Remove holder mounting bolt (14), and then remove the holder and fuel injector assembly (16) together. [*10] a Do not grip the solenoid valve at the top of the injector with pliers, etc.

a Install high-pressure pipe (9) between the common rail and fuel injector according to the following procedure. 1) Tighten sleeve nuts (8) and (10) of highpressure pipe (9). 3 High-pressure pipe sleeve nut: 39.2 – 49.0 Nm {4.0 – 5.0 kgm} a If the fuel injector is not removed easily, use tool A1. 2) Tighten high-pressure pipe clamps (3) and (77) temporarily with your fingers, and then tighten them permanently. 3) Install common rail cover (2) and gate-type bracket (4) temporarily. 4) Tighten common rail cover (2) (which is also used as a high-pressure pipe clamp) permanently first, then tighten gate-type bracket (4) permanently. 3 Common rail cover: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 3 Air cleaner tube band: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}

[*2] [*3] [*4] [*6] [*7] k Do not correct the high-pressure pipe by bending before installing it. k Be sure to use the genuine high-pressure pipe clamps and tighten them to the specified torque. k Install the wiring harnesses at least 10 mm apart from the high-pressure pipe. a When installing each high-pressure pipe, check the taper seal of its joint (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and spot "c" and check part "d" (End of taper seal: Part of 2 mm from the end) for stepped-type wear caused by fatigue which your nail can feel. If there is any of those defects, it can cause fuel leakage. In this case, replace the high-pressure pipe.

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(2)

DISASSEMBLY AND ASSEMBLY

FUEL INJECTOR

[*5]

a Install common rail-side cover (5) with the slit on the cylinder block side. a Set the slit on fuel injector-side cover (6) at position "a" in the figure and match it to the center of the clip.

Checking for fuel leakage Check the fuel system for leakage. For details, see TESTING AND ADJUSTING, Checking fuel system for leakage. Bleeding air Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.

[*8]

3 Head cover mounting bolt: 9.8 ± 1 Nm {1.0 ± 0.1 kgm} 3 Wiring harness mounting nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}

[*9]

[*10] a Install fuel injector assembly (16) according to the following procedure. 1) Insert gasket (b) and O-ring (c) in fuel injector (a). 2) Put holder (d) in injector (a) and install them to the rocker housing temporarily. a Matching key (g) of the injector to key way (h) of the rocker housing, insert the holder securely until the sealing surface of the injector touches the sealing surface on the cylinder head side. 3) Apply engine oil to the spherical part of spherical washer (e). 4) Tighten holder mounting bolt (f). 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}

30-32
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

NOZZLE TIP

REMOVAL AND INSTALLATION OF NOZZLE TIP
a [ERA Regulation] In a country where EPA Regulation is applied, replace the nozzle of the common rail engine by the assembly. In a country where EPA Regulation is not applied, however, only the nozzle tip can be replaced according to the following procedure. (EPA: Environmental Protection Agency) 3. Using 19-mm deep socket [3], loosen retaining nut (4).

SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol

Part No.

Part Name

A8 795T-471-1550 Wrench

q 1

4. Remove retaining nut (4) from injector assembly (3). 5. Lift up and remove nozzle assembly (5) vertically. a Do not remove tip guide (6). (The tip guide cannot be disassembled.) a Take care that dirt will not stick to the parts.

REMOVAL
1. Grip tool A8 with vise [1]. a Do not grip the injector directly with the vice.

2. Set injector assembly (3) to tool A8.

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(2)

DISASSEMBLY AND ASSEMBLY

NOZZLE TIP

INSTALLATION
1. Grip tool A8 with vise [1]. a Do not hold the injector directly with the vice.

5. Install nozzle assembly (3) and tighten retaining nut (2) with the fingers.

2. Set injector assembly (1) to tool A8. 3. Clean the lower body and the threads of retaining nut (2) throughly with parts cleaner and blow air against them.

6. Set 19-mm deep socket [2] to a torque wrench and tighten the retaining nut according to the following procedure. a Apply rust-preventive oil to the nozzle body. 1) Tighten the retaining nut to 88.3 Nm {9.0 kgm}. 2) Make match marks (6) on retaining nut (2) and lower body (5). 3) Tighten the retaining nut by 45° (Angle tightening).

4. Install new nozzle assembly (3), matching it to the dowel pin of tip guide (4). a Take care not to drop the tip.

30-34
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

STARTING MOTOR

REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL
k

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 3 Mounting nut of starting motor terminal B: 19.6 – 25.5 Nm {2 – 2.6 kgm}

Disconnect the cable from the negative (–) terminal of the battery.

1. Open the engine hood. 2. Disconnect the following 2 starting motor wires. [*1] • (1) and (2): Terminal B 3. Remove 3 mounting bolts (3) and starting motor assembly (4).

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

RADIATOR

REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL
1. Remove cover (1).

4. Disconnect reservoir tank hose (6). a Disconnect the hose from the radiator. 2. Drain the coolant. 6 Coolant: Approx. 35 l 5. Disconnect radiator hoses (7), (8), and (9). [*1] 6. Remove covers (10) and (11).

3. Erect the engine hood according to the following procedure. 1) Open engine hood (2) and sling it temporarily. a When slinging the engine hood, take care not to damage the rubber seal. 2) Prepare M10 bolt [1]. • When removing the radiator, L = 50 or longer. • When removing the oil cooler, L = 70 or longer. 3) Remove bolt (4). 4) Remove pin (5) from the lower part of stay (3). 5) Adjust the engine hood so that center hole A of stay (3) will be at the bolt (4). 6) Install stay (3) with bolt [1] and fix engine hood (2) vertically.

7. Remove cover (12). 8. Disconnect radiator hose (13). [*1]

30-36
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

RADIATOR

9. Remove 2 mounting bolts (14).

INSTALLATION
• • Carry out installation in the reverse order to removal. Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 [*1] Coolant: Approx. 35 l

10. Lift off radiator assembly (15). 4 Radiator assembly: 30 kg

3 Radiator hose clamps (7): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm} (8): 4.4 ± 0.49 Nm {0.49 ± 0.05 kgm} (9), (13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC OIL COOLER

REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL
1. Remove cover (1).

4. Remove covers (3) and (4). 2. Remove plug (2) of the hydraulic oil cooler drain hose to drain the hydraulic oil. a Before draining, open the hydraulic tank cap to release the pressure in the tank. Then, drain the oil through the cooler hose.

5. Remove hydraulic oil cooler tube mounting bolts (5) and (6). 6. Remove right and left hydraulic oil cooler mounting bolts (7). 3. Erect the engine hood according to the following procedure. 1) Open engine hood (100) and sling it temporarily. a When slinging the engine hood, take care not to damage the rubber seal. 2) Prepare M10 bolt [1]. 3) Remove bolt (102). 4) Remove pin (103) from the lower part of stay (101). 5) Adjust the engine hood so that center hole A of stay (101) will be at the bolt (102). 6) Install stay (101) with bolt [1] and fix engine hood (100) vertically.

30-38
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC OIL COOLER

7. Remove 3 hydraulic oil cooler-side mounting bolts (8). a When removing 1 of the 3 bolts which is hidden behind cover B, pull cover B lightly. a Bolt [1] is used to fix the engine hood vertically.

INSTALLATION
• • Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

8. Remove the net on the outside of the hydraulic oil cooler. 9. Lift off hydraulic oil cooler assembly (9). 4 Hydraulic oil cooler: 50 kg

PC400/450(LC)-7

30-39
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 3. Drain the coolant. 6 Coolant: Approx. 35 l

Part No.

Part Name

4. Close the fuel stop valve of the fuel tank. 5. Erect the engine hood according to the following procedure. 1) Open engine hood (100) and sling it temporarily. a When slinging the engine hood, take care not to damage the rubber seal. 2) Prepare M10 bolt [1]. 3) Remove bolt (102). 4) Remove pin (103) from the lower part of stay (101). 5) Adjust the engine hood so that center hole A of stay (101) will be at the bolt (102). 6) Install stay (101) with bolt [1] and fix engine hood (100) vertically.

B C

796-601-1110 Stopper 796-460-1210 Oil stopper 796-770-1320 Adapter

t 1 N t 1 t 1

REMOVAL
Disconnect the cable from the negative (–) terminal of the battery. k 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. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Remove the 4 engine undercovers. 2. Remove the hydraulic tank strainer. Using tool C, stop the oil. a When not using tool C, remove the drain plug to drain the oil from the hydraulic tank and piping. 6 Hydraulic tank: Approx. 335 l
k

6. Remove tube (1). [*1] a Remove the tube and bracket together. 7. Disconnect clamp (2) and pipe (3). [*2] a Remove the clamp, pipe, and bracket (4) together.

30-40
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

8. Disconnect fuel inlet hose (5) and fuel return hoses (6) and (7). [*3]

15. Disconnect aftercooler hose (21) and heater hose (22). [*6] 9. Disconnect clamp (8) and radiator hoses (9), (10), and (11). [*4] 10. Remove covers (12) and (13). 11. Remove fan guard (14). a Bolt [1] is used to fix the engine hood vertically.

16. Remove cover (23). 17. Disconnect radiator hose (24). [*4]

12. Loosen adjustment bolt (15) and remove belt (16). [*5] 13. Remove air conditioner compressor assembly (17). a Move the air conditioner compressor assembly toward the control valve top cover. 14. Disconnect fan (18). a Insert your hand through clearance A between the fan and the radiator and remove the 6 fan mounting bolts in order, turning the fan with your foot.

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

18. Disconnect heater hose (25).

19. Disconnect the following 2 wiring connectors. • (26): ERO2 (Various sensors) • (27): ERO3 (Each injector and fuel supply pump) 20. Remove mounting bolts (28) and bracket (29).

24. Disconnect the following 2 pump wiring connectors. • (34): V22 (PC-EPC solenoid valve) Band color: Red • (35): V21 (LS-EPC solenoid valve) Band color: White 25. Disconnect the following 10 hoses and 1 tube. • (36): EPC basic pressure port hose (Band color: Yellow) • (37): Rear pressure port hose (Band color: Yellow) • (38): Rear pump discharge port hose • (39): Front pump discharge port hose • (40): Drain port hose • (41): Front load pressure input port hose • (42): Rear load pressure input port hose (Band color: Red) • (43): Front pressure input port hose • (44): Pump suction port tube

21. Open the main pump side cover. 22. Lift off covers (30) and (31) together. 23. Remove cover (32) and stay (33).

30-42
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

28. Lift off engine and hydraulic pump assembly (48). a Check that all the wires and pipes have been disconnected. 4 Engine and hydraulic pump assembly: 1,700 kg

26. Disconnect engine ground cable (46) from the rear of the hydraulic pump. 27. Using tool B, remove 4 front and rear engine mounting bolts (47). [*7]

PC400/450(LC)-7

30-43
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 3 Hose clamp: 9.8 ± 0.5 Nm {0.1 ± 0.05 kgm} 3 Clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} 3 Fuel hoses (5), (6), and (7): 14.8 – 19.6 Nm {1.5 – 2.0 kgm} 3 Radiator hoses: (9): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm} (10): 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm} (11), (24): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} a See TESTING AND ADJUSTING, Testing and adjusting air conditioner compressor belt tension or REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL. 3 Air aftercooler hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 3 Engine mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 • Coolant: Approx. 35 l

[*2]

[*3]

[*4]

[*5]

[*6]

[*7]

Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5 Hydraulic oil: Approx. 335 l

Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.

30-44
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SWING CIRCLE

REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY
REMOVAL
1. Remove the revolving frame assembly. For d e t a i l s , s e e R E M O VA L O F R E V O LV I N G FRAME ASSEMBLY. 2. Sling swing circle assembly (1) by 3 points temporarily, remove 40 mounting bolts, and lift off the swing circle assembly. [*1] 4 Swing circle assembly: 600 kg

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 2 Mating face of swing circle: Gasket sealant (LG-6) 2 Threads of swing circle mounting bolt: Adhesive (LT-2) 3 Swing circle mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} Target: 927 Nm {94.5 kgm} a 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. 2 Quantity of grease in grease bath: Grease (G2-LI), 33 l (Use GLT2-LI for 50°C specification)

PC400/450(LC)-7

30-45
(2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
REMOVAL
k

Release the residual pressure in the hydraulic circuit. Refer to the Releasing of Residual Pressure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this manual. k Lower the work equipment to the ground for oil filler cap on the fuel tank to release the residual pressure inside the tank and move the safty lock lever to the LOCK position. 1. Disconnect five swing motor hoses (1) through (5). • (1): Between swing motor and control valve (MA port) • (2): Between swing motor and control valve (MB port) • (3): Suction hose (S port) • (4): Drain hose (T port) • (5): Swing brake releasing pilot hose (B port)

3. Lift and remove swing motor and swing machinery assembly (6). a When lifting the swing motor and swing machinery assembly for removal, do so slowly so that the hoses and other parts will not be damaged. a Take good care, when lifting the assembly, until the spigot joint portion is pulled out. 4 Swing motor and swing machinery assembly: 550 kg

INSTALLATION
• [*1] Install in reverse order of removal. 3 Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} Refilling hydraulic oil Refill hydraulic oil through the oil filler port to the specfied level. Let the oil cirdulate in the hydraulic system by starting the engine. Then check the oil level again. Air bleeding Refer to the Air Bleeding of Various Parts section in the TESTING AND ADJUSTING chapter of this manual.

• 2. Detach the swing motor and swing machinery assembly (6), using forcing screw [1] after removing the mounting bolts. [*1] •

30-46
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 3. No. 1 sun gear Remove No. 1 sun gear (2).

Part No.

Part Name

1 796T-627-1630 Push tool 2 790-201-2350 Push tool 3 790-201-2510 Push tool 790-101-5401 Push tool kit D 4 • 790-101-5531 • Plate • 790-101-5421 • Grip • 01010-51240 • Bolt 5 790-201-2870 Push tool 6 790-201-2770 Push tool 7 796T-626-1110 Push tool

q 1 t 1 t 1 t 1 1 1 1 N t t t Q 4. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3).

DISASSEMBLY
1. Draining oil Loosen the drain plug and drain the oil from the swing machinery case. 6 Swing machinery case: Approx. 21 l 2) Disassemble the No. 1 carrier assembly according to the following procedure. Remove snap ring (4), and then remove shaft (5), gear (6), bearing (7), thrust washer (8), and plate (9).

2. Swing motor assembly 1) Set the swing motor and swing machinery assembly on block [1]. 2) Remove 10 mounting bolts and lift off swing motor assembly (1). 4 Swing motor assembly: 115 kg

PC400/450(LC)-7

30-47
(2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

5. Ring gear Remove the mounting bolts and ring gear (10).

8. No. 2 carrier assembly 1) Lift of No. 2 carrier assembly (13).

6. No. 2 sun gear Remove No. 2 sun gear (11).

2) Disassemble the No. 2 carrier assembly according to the following procedure. i) Push in pin (14) and drive out shaft (15) from carrier (16). a After removing the shaft, remove pin (14). ii) Remove thrust washer (17), gear (18), bearing (19), and thrust washer (20). iii) Remove plate (21).

7. Bolt Remove holder mounting bolt (12).

9. Shaft assembly 1) Turn over case and pinion assembly (24) and remove 12 mounting bolts (23) of cover assembly (22).

30-48
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

2) 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). a Set a wood block under the press so that the pinion shaft will not be damaged when it comes off. a A rough standard pressing force is 20 odd tons.

11. Bearing Using multiple push tools [3], remove bearing (30) from case (31). a Push tool to be set contact with bearing: D2

ASSEMBLY
a 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 A rough standard pressing force is several tons.

10. Disassemble the pinion shaft assembly (25) according to the following procedure. 1) Using the push tool, remove cover assembly (22) and bearing (26) from shaft (27). a A rough standard pressing force is 30 tons. 2) Remove oil seal (28) from cover (29).

PC400/450(LC)-7

30-49
(2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

2. Cover assembly 1) Using push tool D4, press fit oil seal (28) to cover (29).

2 Periphery of oil seal: Gasket sealant (LG-6) a Take care that the gasket sealant (LG-6) will not stick to the oil seal lip and shaft assembly (22).

3. Case assembly 1) Turn over case assembly (32) and set it to shaft (27). Using push tools D5 and D6 [5], press fit the bearing inner race. a When setting the case assembly to the shaft, take care extremely not to damage the oil seal. a A rough standard pressing force is 30 tons.

2) Install cover assembly (22) to case (31) and tighten mounting bolts (23). a Match the oil path of cover (22) to the drilled hole of case (31). 2 Cover fitting face: Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 2 Oil seal lip: Grease (G2-LI)

2) Bearing Using too D7, press fit bearing (30). a Press both inner race and outer race of the bearing simultaneously. Do not press only the inner race. a A rough standard pressing force is 20 odd tons. a After press fitting the bearing, check that the case turns smoothly.

30-50
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

4. No. 2 carrier assembly 1) Assemble the No. 2 carrier assembly according to the following procedure. a There is a caulking mark made when the pin was inserted at the end of carrier side hole "a" and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i) Install plate (21) to carrier (16). ii) Install bearing (19) to gear (18) and fit top and bottom thrust washers (17) and (20), and then set the gear assembly to carrier (16).

a When inserting the pin, do not set the 3 claws (parts "a") on the periphery to the thin part of the carrier (part "b"). The thin part may be on the opposite side, however. Check each carrier and avoid setting a claw to the thin part.

a After inserting the pin, caulk the pin part of the carrier. 2) Install No. 2 carrier assembly (13). 5. Bolt and O-ring 1) Tighten bolt (12). 2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 343 – 427 Nm {34 – 43.5 kgm}

iii) Aligning the pin holes of shaft (15) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iv) Insert pin (14).

2) Fit the O-ring to case (31). 6. No. 2 sun gear Install No. 2 sun gear (11).

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

7. Ring gear Using the eyebolt (M12 x 1.75), install ring gear (10).

8. No. 1 carrier assembly 1) 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.

a When installing ring gear (10), set its match mark (part "d") and the projection of the case flange (part "c") as shown in the following figure.

iii) After installing plate (9), install thrust washer (8), bearing (7), gear (6), and snap ring (4).

2) Install No. 1 carrier assembly (3).

a Degrease the mating faces of ring gear (10) and case (29). a Never stick gasket sealant to the mating faces of ring gear (10) and case (29). 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} a Add engine oil (EO30-CD) at this time.

30-52
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

9. No. 1 sun gear assembly Install No. 1 sun gear (2).

a Take care not to install the No. 1 sun gear upside down. a Install the No. 1 sun gear with the tooth (part "e") down.

Refilling with oil Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-30K for extremely cold district) through the oil filler to the specified level. 5 Swing machinery case: Approx. 21 l

10. Swing motor assembly Install swing motor assembly (1) to ring gear (10). a When installing the swing motor assembly, set the relief valve (part f) and the projection of the case (part c) as shown in the following figure. a Degrease the mating faces of swing motor assembly (1) and ring gear (10). 2 Mating faces of swing motor assembly (1) and ring gear (10): Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 4 Swing motor assembly: 115 kg

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(2)

DISASSEMBLY AND ASSEMBLY

SPROCKET

REMOVAL AND INSTALLATION OF SPROCKET
REMOVAL
1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Swing work equipment 90°, push up chassis with work equipment and place block [1] between track frame and track shoe.

INSTALLATION
• [*1] Install in reverse order of removal. 2 Thread of sprocket mounting bolt: Gasket sealant (LG-6) 3 Sprocket mounting bolt: 640 – 785 Nm {65 – 80 kgm}

3. Remove mounting bolts and lift off sprocket (1). [*1] 4 Sprocket: 70 kg

30-54
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR AND FINAL DRIVE

REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
REMOVAL
1. Remove the sprocket. For details, see Removal of sprocket. k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. 2. Remove cover (1). 4. Remove the 24 mounting bolts and lift off the final drive assembly (6). [*1] a Take care extremely not to damage the nipple sealing faces of the hose joints. a When slinging the final drive assembly, do not use the tap hole for the cover. 4 Final drive assembly: 700 kg

3. Disconnect drain hose (2), travel speed selector hose (3), and motor hoses (4) and (5). a Remove the nipples, too.

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm} Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.

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(2)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 2) Using eyebolt [2], remove cover (1).

Part No.

Part Name

796-627-1210 1

Wrench assembly

t 1 1 3 3 t 1 q 1 q 1 q 2 q 2 q 4 q 2 t 1 t 1 t 1 4. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3). Q 3. Spacer Remove spacer (2).

• 796-627-1220 • Wrench • 796-427-1140 • Pin • 01314-20612 • Screw 796T-627-1230 Push tool 790-101-2510 Block

E

791-122-1130 Plate 790-101-2550 Leg 2 790-101-2740 Adapter 790-101-2570 Plate 790-101-2560 Nut 790-101-2102 Puller (30 tons) 790-101-1102 Pump 3 796-627-1020 Installer

DISASSEMBLY
1. Draining oil Remove the drain plug to drain the oil from the final drive case. 6 Final drive case: Approx. 11 l

2. Cover 1) Place the final drive on block [1] and remove the mounting bolts and cover (1).

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(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

2) Disassemble the No. 1 carrier assembly according to the following procedure. i) Push in pin (5) to drive out shaft (6) from carrier (7). a After removing the shaft, remove pin (5). ii) Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11).

7. No. 2 carrier assembly 1) Sling No. 2 carrier assembly (15) with wires, etc. and remove it.

5. No. 1 sun gear shaft Remove spacer (4), No. 1 sun gear (12), and No. 2 sun gear (13).

2) Disassemble No. 2 carrier assembly according to the following procedure. i) Push in pin (16) to drive out shaft (17) from carrier (18). a After removing the shaft, remove pin (16). ii) Remove thrust washer (19), gear (20), bearing (21), and thrust washer (22).

6. Thrust washer Remove thrust washer (14).

8. Nut 1) Remove lock plate (23).

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DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

2) Using tool E1, remove nut (24).

ii)

Remove floating seal (27) from hub (32).

9. Hub assembly 1) Using eyebolts [3], remove hub assembly (25) from the travel motor.

iii) Remove bearings (28) and (29) from hub (32).

2) Disassemble hub assembly (25) according to the following procedure. i) Remove bearing (26) from hub (32).

3) Remove floating seal (30) from travel motor (31).

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

4) Using puller [4], remove bearing (34) and collar (33) together. a You can remove bearing (34) and collar (33) without using puller [4] in some cases.

3) Install collar (33) and bearing (34) to travel motor (31).

ASSEMBLY
a Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1. Hub assembly 1) Using the push tool, press fit bearings (28) and (29) to hub (32).

4) Using tool E3, install floating seal (30) (which is hidden and not seen behind tool E3) to travel motor (31). a Thoroughly degrease and dry the O-ring and O-ring fitting surface of the floating seal before installing. a After installing the floating seal, check that its slant is less than 1 mm. a After installing the floating seal, thinly apply engine oil to the sliding surfaces. 2) Using tool E3, install floating seal (27) to hub (32). a Thoroughly degrease and dry the O-ring and O-ring fitting surface of the floating seal before installing. a After installing the floating seal, check that its slant is less than 1 mm. a After installing the floating seal, thinly apply engine oil to the sliding surfaces.

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(2)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

5) Using eyebolts [3], set hub assembly (25) to the travel motor. Using the push tool, lightly hit the bearing to press fit it.

7) Measure thickness "b" of nut (24). 8) Obtain a – b = c. 9) Using tool D1, tighten nut (24) until dimension "c" is as follows. a Dimension "c": c +0.07 mm –0.03

2. Nut Install the nut according to the following procedure. 1) Rotate the hub 2 – 3 turns. 2) Using tool E2, press the bearing inner race. a Pressing force: 29.4 – 38.3 kN {3.0 – 3.9 tons} 3) While the bearing is pressed, rotate the hub at least 5 turns in 1 direction. 4) Release the pressing force. 5) Press the bearing again. a Pressing force: 14.7 – 18.6 kN {1.5 – 1.9 tons}

10) Using push-pull gauge [5], measure the tangential force of the hub in its revolving direction on the motor case. a Tangential force: Max. 765 N {78 kg} a The tangential force means the maximum force at the beginning of rotation.

11) Install lock plate (23), fitting it to the motor spline.

6) Under the condition in 5) above, measure dimension "a".

2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

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(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

3. No. 2 carrier assembly 1) Assemble the No. 2 carrier assembly according to the following procedure. a There is a caulking mark made when the pin was inserted at the end of carrier side hole "h" and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i) Install bearing (21) to gear (20) and fit top and bottom thrust washers (19) and (22), and then set the gear assembly to carrier (18).

4. Thrust washer Install thrust washer (14).

Aligning the pin holes of shaft (17) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iii) Insert pin (16). a After inserting the pin, caulk the pin part of the carrier. a After assembling the carrier assembly, check that the gear (20) turns smoothly.

ii)

5. No. 2 sun gear Install spacer (4) and No. 2 sun gear (13).

2) Install No. 2 carrier assembly (15). a Install No. 2 carrier assembly (15) so that the 4 gear shaft ends will be in the 4 hollows at the motor case end.

6. No. 1 carrier assembly 1) Assemble the No. 1 carrier assembly according to the following procedure. a There is a caulking mark made when the pin was inserted at the end of carrier side hole "h" and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance.

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DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

i)

Install bearing (10) to gear (9) and fit top and bottom thrust washers (8) and (11), and then set the gear assembly to carrier (7).

7. No. 1 sun gear shaft Install No. 1 sun gear shaft (12). 8. Spacer Install spacer (2).

Aligning the pin holes of shaft (6) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iii) Insert pin (5). a After inserting the pin, caulk the pin part of the carrier. a After assembling the carrier assembly, check that the gear (9) turns smoothly.

ii)

9. Cover Using eyebolts [2], install cover (1) and tighten the mounting bolts.

2 Cover mounting face: Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

• 2) Install No. 1 carrier assembly (4).

Refilling with oil a Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-30K for extremely cold district) through the oil filler. 5 Final drive case: Approx. 11 l

a After installing the final drive assembly to the chassis, check the oil level again at the specified position.

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
a Only precautions for assembling the carrier roller assembly are explained below. • Floating seal a 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. a Be sure to use the installer F to insert the floating seal assembly in the housing. a After installing the floating seal, check that its slant is less than 1 mm and its projection "a" is 5 – 7 mm.

SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch t 1 t 1 Symbol

Part No.

Part Name

F

1 791-430-3230 Installer 2 791-601-1000 Oil pump

4

Carrier roller assembly: 35 kg

ASSEMBLY
• Press fitting of support (2) 1) The threads of shaft (1) must be in the range of the following figure. 2) Press fitting dimension of shaft: (Shown in the following figure) 3) Using push tool [1], press fit support (2) to shaft (1). At this time, apply press fitting force of at least 79 kN {8.1 tons}.

Carrier roller a Using tool F, apply the standard pressure to the oil filler to check the seal for air leakage. a Keep the following standard pressure for 10 seconds and check that the pointer of the gauge does not lower. Standard pressure: 0.1 MPa {1 kg/cm2}

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

a Using tool F, fill the carrier roller assembly with oil and tighten the plug. 5 Carrier roller: 170 – 180 cc (EO30-CD)

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(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
a Only precautions for assembling the track roller assembly are explained below. • Track roller a Using tool G, apply the standard pressure to the oil filler to check the seal for air leakage. a Keep the following standard pressure for 10 seconds and check that the pointer of the gauge does not lower. Standard pressure: 0.1 MPa {1 kg/cm2}

SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch t 1 t 1 Symbol

Part No.

Part Name

G

1 791-630-1780 Installer 2 791-601-1000 Oil pump

4

Track roller assembly: 80 kg

ASSEMBLY
• Floating seal a 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. a Be sure to use the installer G to insert the floating seal assembly in the housing. a After installing the floating seal, check that its slant is less than 1 mm and its projection "a" is 5 – 7 mm. a Using tool G, fill the track roller assembly with oil and tighten the plug.

5 Track roller: 280 – 310 cc (EO30-CD) 3 Plug: 10 – 20 Nm {1 – 2 kgm}

PC400/450(LC)-7

30-65
(2)

DISASSEMBLY AND ASSEMBLY

IDLER

DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 4. Remove floating seal (7) on the opposite side from idler (5) and shaft and support assembly (6).

Part No.

Part Name

H

791-575-1520 Installer 791-601-1000 Oil pump

t 1 t 1

4

Idler assembly: 250 kg

DISASSEMBLY
5. Remove nut (8), pull out bolt (9), and then remove support (10) from shaft (11).

6. Remove bushing (12) from idler (5).

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). a Idler is filled with oil of 345 ± 10 cc. Drain it or spread cloths to soak it at this time.

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(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

IDLER

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).

a 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. a Be sure to use the installer H to insert the floating seal assembly in the housing. a After installing the floating seal, check that its slant is less than 1 mm and its projection "a" is 9 – 11 mm.

a Install the shaft with the UP mark up.

4. Install shaft and support assembly (6) to idler (5).

3. Using tool H, install floating seal (7) to idler (5) and shaft and support assembly (6).

5. Similarly, using too H, install floating seal (4) to idler (5) and support (3).

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

IDLER

a Coat the sliding surface of the floating seal with oil and take care that dirt will not stick to it. a Degrease the floating seal and the O-ring contact surfaces. 6. Fit the O-ring, set support (3), install bolt (2), and tighten nut (1). 7. Add oil and tighten the plug. 5 Quantity of oil: Approx. 345 ± 10 cc (EO-30CD) 3 Plug: 130 – 180 Nm {13 – 18 kgm}

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(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 1. Remove piston assembly (2) from recoil spring assembly (1). 2. Disassembly of recoil spring assembly 1) Set tool J1 to recoil spring assembly (1). k Since the installed load of the spring is large and dangerous, set the tool securely. a Installed load of spring: 239.037 kN {24,375 kg}

Part No.

Part Name

791-685-8006 Compressor 791-635-3160 Extension 1 790-101-1600 Cylinder (686 kN {70 t})

t 1 t 1 t 3 t 3 1

J

790-101-1102 Pump 790-201-1500 Push tool kit 2 • 790-201-1660 • Plate • 790-101-5021 • Grip • 01010-50816 • Bolt

4

Recoil spring (Excluding idler): 900 kg

DISSASSEMBLY

2) Apply oil pressure gradually to compress the spring and remove lock plate (3) and nut (4). a Compress the spring to a degree that you can loosen the nut. a Release the oil pressure gradually to reduce the spring tension to 0 (zero). a Free length of spring: 845.3 mm 3) Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from spring (5). 3. Disassembly of piston assembly 1) Remove lock plate (11) from piston (10), and then remove valve (12). 2) Remove snap ring (13), U-packing (14), and ring (15).

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

ASSEMBLY

2) Install cylinder (7), collar (8), and yoke (6) to spring (5), and then set them to tool J1. 2 Sliding parts of cylinder: Grease (G2-LI)

3) Apply oil pressure gradually to compress the spring and tighten nut (4) so that installed length of the spring will be "a", and then secure it with lock plate (3). a Installed length of spring "a": Approx. 690 mm

1. Assembly of piston assembly 1) Install ring (15) and U-packing (14) to piston (10) and secure them with snap ring (13). 2) Tighten valve (12) temporarily and secure it with lock plate (11). 2. Assembly of recoil spring assembly 1) Using tool J2, install dust seal (9) to cylinder (7).

4) Remove recoil spring assembly (1) from tool J1. 3. Install piston assembly (2) to recoil spring assembly (1). 2 Sliding parts of piston: Grease (G2-LI) 2 Wear ring: Grease (G2-LI) a Install the piston assembly so that the position of the valve will be on outside. a Supply 320 cc of grease (G2-LI) to the cylinder, bleed air, and check that the grease flows out of the grease hole.

30-70
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 4. Using tool K, remove master pin (1). [*3]

Part No.

Part Name

791-650-3000 K 790-101-1300

Remover and installer Cylinder (980 kN {100 t})

t 1 t 1 t 1 5. Move the master pin forward and set block [1] under the track shoe in front of the idler. 6. Pull out pusher K.

790-101-1102 Pump

EXPANSION OF TRACK SHOE
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] k 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.

7. Move the machine in reverse slowly to expand the track shoe. [*4]

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

INSTALLATION OF TRACK SHOE
• [*1] Carry out installation in the reverse order to expansion. 2 Mounting bolt: Anti-seizure compound (MARUZEN MOLYMAX No. 2 or equivalent) 3 Mounting bolt: Tighten the 4 bolts first to 392 ± 39 Nm {40 ± 4 kgm}. Check that the mating faces are fitted, then retighten each bolt by 120° ± 10°. a Adjust the tension of the track shoe. For detail, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension. 3 Tightening torque for lubricator: 58.8 – 88.3 Nm {6 – 9 kgm} [*3]

2 Apply grease to the contact faces of dust seal (5) and bushing (4) (all over the end face of the dust seal or bushing) (parts marked Q). Do not apply grease to the pars marked X, however. R: Detail of regular pin position M: Detail of master pin position (Pins are not inserted, however)

[*2]

a Using the tool, press fit the master pin so that its projection "a" will be as follows. • Dimension "a": 4.4 ± 2 mm

[*4] Set the track shoe and sprocket (4) as shown in the following figure (on both right and left sides).

2 Supply grease to the space between the bushing and pin so that filling rate will be 100%. Grease: NIGUTAITE LYK-2 manufactured by NIPPON GREASE CO., LTD. or equivalent

30-72
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
SPECIAL TOOLS
New/Remodel Necessity Q’ty Symbol Sketch 4. Remove rear covers (1), (2), (3), and (4).

Part No.

Part Name

799-703-1200 Service tool kit 799-703-1100 Q 799-703-1110 799-703-1120 799-703-1401 Vacuum pump (100V) Vacuum pump (220V) Vacuum pump (240V)

t 1 t 1 t 1 t 1 5. Remove duct (5), cover (6), and plate (7). 6. Remove plate (8) and duct (9). a Remove the duct lock clip. 7. Remove ducts (10) and (11).

Gas leak detect 1 tor

REMOVAL
k

Disconnect the cable from the negative (–) terminal of the battery.

1. Swing the upper structure by 90°. 2. Open the engine hood. 3. Connect tool Q to cap [1] and collect the air conditioner refrigerant.

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).

PC400/450(LC)-7

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(5)

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

12. Remove the air conditioner unit undercover. a Part A

INSTALLATION
• Carry out installation in the reverse order to removal. a When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them. a When connecting each air conditioner hose, check that the O-ring is fitted to the joint. a Check that each O-ring is free from flaw and deterioration. a Apply compressor oil (ND-OIL8) to the threads of the refrigerant pipe joints and tighten each nut with double spanner.

[*1]

13. Remove mounting bolt (24) and connector (25). [*1] 14. Disconnect heater hoses (22) and (23) and air conditioner tube (26). [*1] a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.

3 Hose clamp (M6 bolt): 8 – 12 Nm {0.8 – 1.2 kgm} 3 Hose screw of M16 x 1.5: 12 – 15 Nm {1.2 – 1.5 kgm} 3 Hose screw of M22 x 1.5: 20 – 25 Nm {2.0 – 2.5 kgm} 3 Hose screw of M24 x 1.5: 30 – 35 Nm {3.0 – 3.5 kgm} • Charging air conditioner with refrigerant gas Using tool Q, charge the air conditioner circuit with refrigerant (HFC R134a) from the compressor. a Quantity of refrigerant: 950 ± 50 g

15. Remove the 7 mounting bolts and air conditioner unit assembly (27).

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(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

OPERATOR’S CAB

REMOVAL AND INSTALLATION OF OPERATOR’S CAB
REMOVAL
k

Disconnect the cable from the negative (–) terminal of the battery.

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.

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. a Remove the duct lock clip. 9. Remove cover (22) and floor mat (23).

4. Remove clip (10) and disconnect cab wiring connectors M45 (11), H08 (12), and H09 (13). 5. Remove air conditioner connector plate (14).

10. Move right console (24) into the cab. 11. Remove monitor panel undercover (25).

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

OPERATOR’S CAB

12. Disconnect cab wiring connector W04 (26) (Wiper motor). 13. Remove ducts (27) and (28). a Both (27) and (28) are 2 in number. a Cut the tie-wrap on the monitor wiring harness. 14. Remove cover (29) and monitor assembly (30).

20. Using lever block [1], lift off operator's cab assembly (39). 4 Operator's cab assembly: 300 kg

15. Disconnect radio antenna (31). 16. Remove clip (32) and take wiring harness (33) out of grommet (34).

21. When starting the engine while the operator's cab is removed (for transportation, etc.), use the following brackets. 1) Bracket (41) for controller (40) Part No.: 208-53-13920

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). a Check the types of the bolts. a In the initial period, 7 mounting bolts (38) are used.

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

OPERATOR’S CAB

2) Bracket (42) for monitor panel assembly (30) Part No.: 208-53-13910

INSTALLATION
• Carry out installation in the reverse order to removal.

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

MONITOR

REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY
REMOVAL
k

INSTALLATION
• Carry out installation in the reverse order to removal.

Disconnect the cable from the negative (–) terminal of the battery.

1. Remove cover (1) and disconnect wiring connector P15 of air conditioner sunlight sensor (2). a Raise and remove the cover. 2. Remove the 3 mounting screws and monitor assembly (3). a Disconnect monitor panel wiring connectors P01, P02, and P70 before removing the monitor assembly.

30-78
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

PUMP CONTROLLER

REMOVAL AND INSTALLATION OF PUMP CONTROLLER
REMOVAL
k

INSTALLATION
• Carry out installation in the reverse order to removal.

Disconnect the cable from the negative (–) terminal of the battery.

1. Remove covers (1), (2), and (3).

2. Disconnect pump controller wiring connectors C01 (4), C02 (5), and C03 (6). 3. Remove the 4 mounting bolts and pump controller assembly (7).

PC400/450(LC)-7

30-79
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE CONTROLLER

REMOVAL AND INSTALLATION OF ENGINE CONTROLLER
REMOVAL
k

INSTALLATION
• Carry out installation in the reverse order to removal.

Disconnect the cable from the negative (–) terminal of the battery.

1. Open the right side cover (cooler). 2. Remove bracket (1). 3. Remove the 4 mounting bolts and engine controller assembly (2).

4. Disconnect engine controller wiring connectors CB1 (3), CB2 (4), and CB3 (5).

30-80
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY
REMOVAL
k

Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position.

1. Remove the work equipment assembly. For details, see REMOVAL AND INSTALLATION OF WORK EQUIPMENT. 2. Remove the counterweight assembly. For details, see REMOVAL AND INSTALLATION OF COUNTERWEIGHT. 3. Disconnect 4 boom cylinder hoses (1). a Plug the hoses to stop oil.

4. Sling boom cylinder assembly (2) temporarily. 5. Remove plate (3) and pin (4) and lift off boom cylinder assembly (2). a Remove the boom cylinder on the opposite side similarly. 4 Boom cylinder assembly: 360 kg

6. Disconnect 7 hoses (5) – (11). • (5): Center swivel joint (Port D) – Swing motor (Port T) • (6): Center swivel joint (Port D) – Hydraulic tank • (7): Center swivel joint (Port E) – Solenoid valve • (8): Center swivel joint (Port B) – Control valve left travel (Port B2) • (9): Center swivel joint (Port D) – Control valve right travel (Port B5) • (10): Center swivel joint (Port A) – Control valve left travel (Port A2) • (11): Center swivel joint (Port C) – Control valve right travel (Port A5) 7. Pull out pin (12) on the center swivel joint side and disconnect the lock plate from the center swivel joint.

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DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

8. Remove 29 mounting bolts (13), leaving 3 each at the front and rear sides.

INSTALLATION
• [*1] • Match the soft zone point (P) of the outer race and the soft zone point (S) of the inner race. 2 Mating face of swing circle: Gasket sealant (LG-6) 2 Threads of revolving frame mounting bolt: Adhesive (LT-2) Carry out installation in the reverse order to removal.

9. Using a lever block, sling the revolving frame assembly temporarily, balancing it in each direction. a Put wood liners to the rear side of the frame. • Rough standard length of sling: Front: 8 m in total Rear: 6 m a 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] k When removing the revolving frame assembly, take care that it will not interfere with the center swivel joint assembly. 4 Revolving frame assembly: 10,000 kg

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY 3 Revolving frame mounting bolt 1. Tighten the bolts marked with A (at 4 places) according to the following steps 1) – 3). 1) Tighten each bolt to 392 Nm {40 kgm} first. 2) Then, tighten the bolt by 90° ± 5°. • Make a mark on the bolt head with a marker pen (to check the angle). 3) The tightening torque of the bolt tighten in 2) above must be 1,176 Nm {120 kgm} or larger.

REVOLVING FRAME

2. Tighten each bolt 208-25-71230 which is not marked with A according to above steps 1) – 3). If the tightening torque reaches 2,254 Nm {230 kgm} before completing the above steps and the tightening angle is 35° – 95°, however, stop tightening.

a Marks P and S are the soft zone points. • Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air Bleed air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

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DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT

REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
REMOVAL
1. Set eyebolt [1] to counterweight assembly (1). 2. Remove 4 mounting bolts (2). a Check where shims have been used. [*1]

INSTALLATION
• Carry out installation in the reverse order to removal. a If heat insulation cover (3) of the engine compartment is flattened, replace it.

3. Lift off counterweight assembly (1). [*2] a When lifting off the counterweight, take care not to strike it against the engine, radiator and cooler assembly, etc. 4 Counterweight assembly: 9,500 kg

[*1]

2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 3,430 – 4,212 Nm {350 – 430 kgm} a Installation and adjustment of counterweight 1) Adjust the level difference from the exterior parts (horizontal clearance) with shims. • Kinds of shim thickness: 0.5 mm, 1 mm 2) Insert the shims so that the clearance between the door and counterweight and that between the revolving frame and counterweight will be 10 ± 5 mm evenly.

[*2]

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL
1. Remove 3 lower covers (1). 7. Disconnect drain hoses (8), (9), and (10). 8. Disconnect 2 clamps (11). 9. Remove side cover (12).

2. Drain the oil from the hydraulic tank. 6 Capacity of hydraulic tank: Approx. 335 l 10. Remove sensor (13). 11. Disconnect suction tube (14). 12. Sling the hydraulic tank assembly temporarily and remove 6 mounting bolts (15).

3. Open engine hood (2) and remove control valve top cover (3).

4. Remove cover (4). 5. Disconnect drain hoses (5) and (6). 6. Disconnect block (7). 13. Lift off hydraulic tank assembly (16). 4 Hydraulic tank assembly: 200 kg

PC400/450(LC)-7

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DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

INSTALLATION
• • Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5 Capacity of hydraulic tank: Approx. 335 l Quantity of oil in tank (Center of oil level gauge): 248 l

Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch q 1 q 1 Symbol

Part No.

Part Name

C

796-460-1210 Oil stopper 796-770-1320 Adapter

REMOVAL
Disconnect the cable from the negative (–) terminal of the battery. k 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. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Remove 2 lower covers (1).
k

3. Drain the oil from the flywheel housing. 4. Open the main pump side cover. 5. Open the engine hood. 6. Lift off covers (2) and (3) together. 7. Remove cover (4). 8. Remove stay (5).

2. Remove the hydraulic tank strainer. Using tool C, stop the oil. a When not using tool C, remove the drain plug to drain the oil from the hydraulic tank and piping. 6 Hydraulic tank: Approx. 335 l

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DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

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). 4 Hydraulic pump assembly: 255 kg

[*1]

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. 2 Hydraulic pump involute spline: Anti-friction compound (LM-G) 2 Mating face of hydraulic pump case: Gasket sealant (LG-6) Refilling with oil 3 Flywheel housing drain plug: 42.1 – 70.6 Nm {4.3 – 7.2 kgm} Add oil through the oil filler to the specified level. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5 Capacity of hydraulic tank: Approx. 335 l Quantity of oil in tank (Center of oil level gauge): 248 l

Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.

PC400/450(LC)-7

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DISASSEMBLY AND ASSEMBLY

OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT

REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
REMOVAL
1. Remove the hydraulic pump assembly. Refer to t h e R E M O VA L O F H Y D R A U L I C P U M P ASSEMBLY section. 2. Remove snap ring (1) and then remove spacer (2). 3. Pry off oil seal (3) with a screwdriver. [*1] a When attempting to pry off the seal, do not damage the shaft.

INSTALLATION
• [*1] Install in reverse order of removal. 2 Oil seal lip portion: Grease (G2-LI) 2 Oil seal outer circumference: Grease (G2-LI) a Coat the oil seal outer circumference thinly with grease. a Press-fit oil seal (3), using tool .

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
REMOVAL
Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank and set the safety lock lever to the LOCK position.. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Open engine hood (1). 2. Remove control valve top cover (2). 6. Disconnect the following 4 control valve hoses: • (16): Port PPS1 hose (Front pump) • (17): Port PLS2 hose (Hose band: Red) • (18): Port PLS1 hose • (19): Port PX1 hose (Hose band: Blue) 7. Remove relay bracket (20) and clamp (21). 8. Disconnect drain hose (22). (To tank) 9. Disconnect the following 6 left PPC hoses. • (23): In order from top Bucket CURL (Hose band: White) Left travel REVERSE Boom RAISE (Hose band: Green) Left SWING (Hose band: Red) Right travel REVERSE (Hose band: Blue) Arm DUMP (Hose band: Yellow)
k

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)

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DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

10. Disconnect 4 boom hoses (24). 11. Remove boom tube clamps (25) and (26).

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)

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).

16. Disconnect the following 3 control valve hoses. a Do not disconnect hose C. • (36): Port BP5 hose (To solenoid) • (37): Port PX2 hose • (38): Port TS hose

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

17. Sling control valve assembly (40) temporarily and remove 3 mounting bolts (39).

INSTALLATION
• • Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.

18. Lift off control valve assembly (40). 4 Control valve assembly: 250 kg

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DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
a Only precautions for assembling the pressure compensation valve assembly and control valve assembly are explained below. a Since there many types of the pressure compensation valves, make a mark on each valve to indicate from where it was removed. 1. Remove piston (2), plug (3), and spring (4) from pressure compensation valve (1). 2. Remove seal (5) and O-ring (6) from piston (2).

REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL

SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch 1 1 1 1 1 1 1 1 1 1 1 Symbol

Part No.

Part Name

796-946-1310 Guide 796-946-2110 Guide (For 723-46-44100) 796-946-2210 Guide 796-946-1320 Guide

21.8 20.9 20.6

(For 723-46-40100, 723-46-40601) 1

(For 723-46-45100, 723-46-45500) (For 723-46-40100, 723-46-40601) 796-946-1420 Guide 2 L (For 723-46-42800) 796-946-2120 Guide (For 723-46-44100) 796-946-2220 Guide (For 723-46-45100, 723-46-45500) 796-946-1330 Sleeve (For 723-46-40100, 723-46-40601) 796-946-1430 Sleeve 3 (For 723-46-42800) 796-946-2130 Sleeve (For 723-46-44100) 796-946-2230 Sleeve (For 723-46-45100, 723-46-45500) 21.6

a There many types of the pistons. a 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. a 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.

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

5. Set tool L2 to piston (1) for other seal (3) and push it in with your hand slowly so that seal (3) will expand evenly. a 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.

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).

6. Install correcting tool L3 to piston (1) for about 1 minute to fit seals (2) and (3). a Check that the seal are not projected or broken.

Install filters (13) to the bottom of ports PLS1 and PLS2 as shown below.

7. Fit plug (3) and spring (4) to piston (2) and assemble pressure compensation valve (1). a If these parts are difficult to install, do not push them in forcibly, but install them to correcting tool L3 to fit the seals, and then install them to the piston. a After assembling, push the piston with your hand and check that it is returned by only the spring force.

PC400/450(LC)-7

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DISASSEMBLY AND ASSEMBLY

CONTROL VALVE 3 Mounting bolt of boom Hi check valve, quick return valve, lock valve, and arm plate: 58.8 – 73.6 Nm {6 – 7.5 kgm}

3 Mounting bolt of control valve top and bottom covers: 156.9 – 176.5 Nm {16 – 18 kgm}

Control valve top and bottom covers 2 Mating faces of control valve top and bottom covers: SEALEND 242 or equivalent a Use 2 washers (W2) each for only 2 places of the control valve top cover. Tighten the mounting bolts of the control valve top and bottom covers in the following order. (A o D o C o B)

2 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. 3 Mounting bolt of merge-divider valve: 156.9 – 176.5 Nm {16 – 18 kgm}

Merge-divider valve

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.

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY 3 Mounting bolts of back-pressure valve, boom Hi check valve, quick return valve, lock valve and arm plate: 58.8 – 73.6 Nm {6 – 7.5 kgm} • Pressure compensation valve a When installing each pressure compensation valve, check the mark made when it was removed. Main relief valve assembly After installing the main relief valve to the control valve, see TESTING AND ADJUSTING, Testing and adjusting oil pressures in work equipment, swing, and travel circuits.

CONTROL VALVE

PC400/450(LC)-7

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DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
REMOVAL
Replace the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, release of remaining pressure in hydraulic circuit. a Mark all the piping with tags to prevent mistakes in the mounting position when installing. 1. Disconnect six hoses (1) through (6) between travel motor and center swivel joint. • (1): Center swivel joint (T port) – Left travel motor (T port) • (2): Center swivel joint (T port) – Right travel motor (T port) • (3): Center swivel joint (B port) – Left travel motor (PA port) • (4): Center swivel joint (D port) – Right travel motor (PB port) • (5): Center swivel joint (A port) – Left travel motor (PB port) • (6): Center swivel joint (C port) – Right travel motor (PA port)
k

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).

5. Remove center swivel joint assembly (18). 4 Center swivel joint assembly: 40 kg

[*1]

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)

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

INSTALLATION
• [*1] Install the center swivel joint facing in the direction shown in the diagram. (The diagram shows the machine as seen from above) Install in reverse order of removal.

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air Bleed the air from the travel motor. For details see TESTING AND ADUSTING, Air Bleeding of Various Parts.

PC400/450(LC)-7

30-99
(2)

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 1. Remove cover (1). 2. Remove snap ring (2). 3. Using tool M, pull out swivel rotor (4) and ring (3) from swivel shaft (5). 4. Remove seal (6) from swivel shaft (5). 5. Remove O-ring (7) and slipper seal (8) from swivel rotor (4).

Part No.

Part Name

790-101-2501 Push puller • 790-101-2510 • Block • 790-101-2520 • Screw • 791-112-1180 • Nut M • 790-101-2540 • Washer • 790-101-2630 • Leg • 790-101-2570 • Plate • 790-101-2560 • Nut • 790-101-2650 • Adapter

q 1 1 1 1 1 2 4 2 2

DISASSEMBLY 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. 2 Contact surface of rotor, shaft: Grease (G0-LI or G2-LI) a When installing the rotor, be extremely careful not to damage the slipper seal and the Oring. 4. Install ring (3) ans secure with snap ring (2). 5. Install O-ring and cover (1). 3 Mounting bolt: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}

30-100
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT PPC VELVE

DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VELVE ASSEMBLY
a Only precautions for assembling the work equipment PPC valve assembly are explained below. a When installing pistons (8), apply grease to their outside and the inside of the valve body holes. 3 Mounting bolt of plate (5): 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 2 Sliding parts of joint (4): 2 – 4 cc of Grease (G2-LI) 2 Female threads of body (A): Adhesive (LT-2) a 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). 3 Joint (4): 39 – 49 Nm {4 – 5 kgm} a Observe the tightening torque of the joint.

ASSEMBLY
• Work equipment PPC valve assembly a Install springs (11 ) with the small-diameter (inside diameter) end on the shim (12) side. a Springs (10 ) having different number of turns are used for the following hydraulic ports. Take care when installing them. Installed height: 31.9 mm (Common to all springs) Installed load: P1, P2: 35.3 N {3.6 kg} P3, P4: 21.6 N {2.2 kg} a The position of each port is stamped on the underside of valve body. 2 Piston (8): Grease (G2-LI)

2 Contact parts of piston and disc (2): Grease 0.3 – 0.8 cc (G2-LI) 3 Nut (1): 69 – 88 Nm {7 – 9 kgm} a When installing disc (2), adjust the play to 0.5 – 3mm at 200 mm from the turning center of the lever.

PC400/450(LC)-7

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DISASSEMBLY AND ASSEMBLY

TRAVEL PPC VALVE

DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
DISASSEMBLY
a Only precautions for assembling the travel PPC valve assembly are explained below.

ASSEMBLY
• Travel PPC valve assembly a Insert shim (3) of the thickness and quantity checked when disassembled. Standard shim thickness: 0.3 mm a Since spring (4) is not symmetric vertically, install it with the small-diameter (inside diameter) end on the shim side.

2 Periphery of piston (7) and inside of hole of body (1): Grease (G2-LI) 2 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) in in

a Use the inserting jig described KES.D.07177 to insert bushing (19). a Use the inserting jig described KES.D.04025 to insert spring pin (25).

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PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol

DISASSEMBLY

Part No.

Part Name

1 790-502-1003 790-102-4300

Cylinder repair stand

t 1

1. Piston rod assembly 1) Remove the piping from the cylinder assembly. 2) Remove the mounting bolts and disconnect cylinder head assembly (1). 3) Pull out piston rod assembly (2). a Put a container under the cylinder to receive oil.

2

Wrench assemt 1 bly t 2 q 1

790-102-4310 Pin 3 790-720-1000 Expander 796-720-1680

Ring (For boom q 1 and bucket) q 1 q 1

4

Clamp (For 07281-01589 boom and bucket) 796-720-1690 Ring (For arm)

07281-01919 Clamp (For arm) q 1 790-201-1702 Push tool kit N 5 • 790-201-1851 • 790-201-1861 • 790-201-1871 • Push tool (For bucket) • Push tool (For boom) • Push tool (For arm) t 1 1 1 1 1 1 1 1 1 1 1 1

4) Disassemble the piston rod assembly according to the following procedure. i) Set piston rod assembly (2) to tool N1.

• 790-101-5021 • Grip • 01010-50816 • Bolt 790-201-1500 Push tool kit • 790-101-5021 • Grip • 01010-50816 • Bolt 6 • 790-201-1660 • Plate (For bucket) • 790-201-1670 • 790-201-1680 • Plate (For boom) • Plate (For arm)

ii)

Remove piston assembly lock screw (3). a This work is common to the boom, arm, and bucket cylinders. Screw size: M12 x Pitch 1.75

PC400/450(LC)-7

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(2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

a If screw (3) is so caulked that you cannot remove it, tighten it temporarily and tap the threads on it, and then remove it.

vii) Remove cap (8), 11 balls (9), and plunger (10). • Perform this work for only the arm cylinder. a Since cap (8) is made of nylon, tighten a screw into it and pull it with pliers.

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).

2. Disassembly of piston assembly 1) Remove rings (11). 2) Remove wear rings (12). 3) Remove piston ring (13). 4) Remove the O-ring and backup rings (14).

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).

3. Disassembly of cylinder head assembly 1) Remove the O-ring and backup ring (15). 2) Remove snap ring (16) and dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove snap ring (21). 6) Remove bushing (20).

30-104
(2)

PC400/450(LC)-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

ASSEMBLY
a Take care not to damage the packings, dust seals, O-rings, etc. a Clean the all parts. After installing them, cover the piping ports and pin holes to prevent dirt from entering. a Do not insert each backup ring forcibly, but warm it in water at 50 – 60°C and then insert it.

2. Assembly of piston assembly 1) Using tool N3, expand piston ring (13). a Set piston ring (13) to tool N3 and turn the handle 8 – 10 times to expand the piston ring. 2) Set tool N4 and contract piston ring (13).

1. Assembly of cylinder head assembly 1) Using tool N5, press fit bushing (20). 2) Install buffer ring (19). 3) Install rod packing (18). 4) Using tool N6, install dust seal (17) and secure it with snap ring (16). 5) Install backup ring and O-ring (15). 6) Install snap ring (21).

3) Install backup ring and O-ring (14). 4) Install wear ring (12). 5) Install ring (11). a Do not increase the closed gap of the ring too much. 2 Ring groove: Grease (G2-LI)

PC400/450(LC)-7

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HYDRAULIC CYLINDER

3. Piston rod assembly 1) Set the piston rod to tool N1. 2) Install cylinder head assembly (7) to the piston rod. 3) Fit the O-ring and backup ring to collar (6), and then install them. • Perform this work for only the boom and arm cylinders. 4) Install plunger (5). • Perform this work for only the boom and arm cylinders.

6) 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. a Remove the burrs from the threads with a file. Go to iv).

5) Set plunger (10) to the piston rod. Install 11 balls (9) and secure them with cap (8). a After installing the plunger, check that it has a little play at its end. • Perform this work for only the arm cylinder.

When replacing either or both of the rod and piston assembly (4) with new ones a Make a mark of the cushion plug position on the end of the rod having the bottom cushion. • Perform this work for only the arm cylinder. ii) Using the tool, tighten piston assembly (4) until it reaches the end of the rod. 3 Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} a After tightening the piston, check that plunger (5) has some play. • Perform this work for only the boom and arm cylinders.

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HYDRAULIC CYLINDER

iii) Make a screw hole to install screw (3). a Apply a drill to the V-groove of the threaded parts of piston (4) and rod (2) and make a hole. a 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 10.3 Tap drill hole depth Bucket/Boom Arm 27 36 Tap to be used 12 x 1.75 Tapping depth 20 29

7) Install piston rod assembly (2). a Set the abutment joint of the ring at a side and insert the piston rod, aligning it with the cylinder tube. a After inserting the piston rod, check that the ring is not broken or removed, and then insert to the end.

2 Threads of screw: Adhesive (LOCTITE No. 262) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} v) Caulk the threaded part by 4 places with a punch.

iv) Tighten screw (3). a Clean the parts thoroughly and remove metal chips, dirt, etc.

8) Tighten the mounting bolts of cylinder head assembly (7). 3 Mounting bolt: Cylinder name Bucket Arm Boom

Tightening torque 530 ± 78.5 Nm {54.0 ± 8 kgm} 892 ± 137 Nm {91.0 ± 14 kgm} 530 ± 78.5 Nm {54.0 ± 8 kgm}

9) Install the piping.

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WORK EQUIPMENT

REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
SPECIAL TOOLS
Necessity Q’ty New/Remodel Sketch Symbol 4. Start the engine and retract the piston rod. a 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. a Disconnect the boom cylinder on the opposite side similarly. a 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). a Put oil stopper plugs and secure the hoses to the valve side with ropes.

Part No.

Part Name

796-670-1100 Remover • 796-670-1110 • Sleeve • 796-670-1120 • Plate • 796-670-1130 • Screw P • 796-870-1110 • Adapter • 01643-33080 • Washer • 01803-13034 • Nut 790-101-4000 790-101-1102 Puller (490 kN {50t}, long) Pump (294 kN {30t})

q 1 1 1 1 1 1 1 q 1 q 1

REMOVAL
k

Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position. k See TESTING AND ADJUSTING, Releasing residual pressure in hydraulic circuit. 1. Disconnect grease hose (1). 2. Sling boom cylinder assembly (2) temporarily and remove lock bolt and nut (3). [*1] 3. Remove plate (4) and head pin (5). [*2] a Check the quantity and positions of the inserted shims. 7. Sling work equipment assembly (12) temporarily. 8. Remove cover (9), plate (10), and foot pin (11) to disconnect work equipment assembly (12). [*3]

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WORK EQUIPMENT

When removing with tool P Remove plate (10). Sling and set tool P and remove foot pin (11) to disconnect work equipment assembly (12). a Check the quantity and positions of the inserted shims.

INSTALLATION
• [*1] Carry out installation in the reverse order to removal. a Tighten the locknut so that clearance "a" between the plate and nut will be 0.5 – 1.5 mm.

9. Move the machine in reverse to remove work equipment assembly (12). 4 Work equipment assembly: PC400-7, PC400LC-7: 7,400 kg PC450-7, PC450LC-7: 8,400 kg

[*2]

2 Inside wall of bushing before assembling pin: Anti-friction composition (LM-P) 2 Greasing after assembling pin: Grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a 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

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WORK EQUIPMENT

[*3]

2 Inside wall of bushing before assembling pin: Anti-friction composition (LM-P) 2 Greasing after assembling pin: Grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a Adjust the shim thickness so that clearance "c" between boom (13) and bracket (14) will be 1 mm or less. Standard shim: 2.0, 2.5, 3.0, 3.5 mm

Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

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DISASSEMBLY AND ASSEMBLY

OPERATOR’S CAB GLASS (STUCK GLASS)

REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)

a Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) – (4) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) For the procedure for replacing the front window assembly, see REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.

Right side window glass Left side rear window glass Door lower window glass Front window glass Front window assembly (Front window glass + Front frame) (6) : Both-sided adhesive tape (16): Center trim seal

(1) : (2) : (3) : (4) : (5) :

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OPERATOR’S CAB GLASS (STUCK GLASS)

SPECI