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SEBM033007

MACHINE MODEL

SERIAL No.

PC400-7
PC400LC-7
PC450-7
PC450LC-7

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)

00-1
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GENERAL

CONTENTS
No. of page

01 GENERAL ............................................................................................................................

01-1

10 STRUCTURE, FUNCTION AND


MAINTENANCE STANDARD............................................

10-1

20 TESTING AND ADJUSTING ......................................................................... 20-1


30 DISASSEMBLY AND ASSEMBLY

..................................................... 30-1

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

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90-1

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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.

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.

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.

00-3

SAFETY

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.

00-4

SAFETY NOTICE

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.

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.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:

When a manual is revised, an edition mark


((1)(2)(3)....) is recorded on the bottom of the pages.

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

REVISIONS

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.

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

00-6

Revised pages are shown in the LIST OF REVISED


PAGES next to the CONTENTS page.

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

Remarks

Safety

Special safety precautions


are necessary when performing the work.

Caution

Special technical precautions or other precautions


for preserving standards
are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary


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

Tightening
torque

Places that require special


attention for the tightening
torque during assembly.

Coat

Places to be coated with


adhesives and lubricants,
etc.

Oil, water

Places where oil, water or


fuel must be added, and
the capacity.

Drain

Places where oil or water


must be drained, and
quantity to be drained.

3
2

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.

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

Allowable load

mm

kN

tons

10
11.5
12.5
14
16
18
20
22.4
30
40
50
60

9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2

1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0

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%

88%

79%

71%

41%
SAD00479

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.

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

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

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.

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).

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.

Disassembly

Type 2

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

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.

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.

Category

Komatsu code

Part No.

LT-1A

790-129-9030

LT-1B

790-129-9050

LT-2

09940-00030

LT-3

790-129-9060
(Set of adhesive
and hardening
agent)

LT-4

790-129-9040

Holtz
MH 705

790-126-9120

Three bond
1735

790-129-9140

Aron-alpha
201

790-129-9130

Loctite
648-50

79A-129-9110

LG-1

790-129-9010

LG-5

790-129-9080

LG-6

790-129-9020

LG-7

790-129-9070

Three bond
1211

790-129-9090

Three bond
1207B

419-15-18131

Adhesives

Gasket
sealant

00-10

Qty

Container

Main applications, features

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
(max. strength after 30 minutes)
2g
container
Used mainly for adhesion of rubbers,
plastics and metals.
Resistance to heat, chemicals
Polyethylene
Used at joint portions subject to high
50 cc
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
Used as sealant for flange surface, tread.
200 g
Tube
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
150 g

Tube

FOREWORD

Molybdenum
disulphide
lubricant

Komatsu code

Part No.

Qty

Container

LM-G

09940-00051

60 g

Can

LM-P

09940-00040

200 g

Tube

Various

Various

G2-LI

G2-CA

Grease

Primer

Adhesive

Caulking
material

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA

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

SYG2-400B
SYGA-16CNB
SYG2-400BT (*)
SYGA-16CNBT (*)

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

SYG2-400M
SYG2-400M-A
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)

Various

Various

400 g 10 Bellows type


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

400 g
16 kg

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

Used for normal temperature, light load


bearing at places in contact with water or
steam.
Used for heavy load portion

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

20 ml

Glass
container

20 ml

Glass
container

22M-54-27230

20 ml

Glass
container

22M-54-27240

150 ml

Can

22M-54-27250

20 ml

Glass
container

22M-54-27210

320 ml

Ecocart
(Special
container)

Used as primer for cab side


(Using limit: 4 months)

417-926-3910

417-926-3910

320 ml

Polyethylene
container

20Y-54-39850

310 ml

Polyethylene
container

417-926-3920

320 ml

Polyethylene
container

20Y-54-55130

333 ml

Polyethylene
container

22M-54-27220

333 ml

Cartridge

Used as primer for glass side


(Using limit: 4 months)

Adhesive for cab glass

Category

COATING MATERIALS

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)

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

Width across
flats

mm

mm

Nm

kgm

6
8
10
12
14

10
13
17
19
22

11.8 14.7
27 34
59 74
98 123
153 190

1.2 1.5
2.8 3.5
6 7.5
10 12.5
15.5 19.5

16
18
20
22
24

24
27
30
32
36

235 285
320 400
455 565
610 765
785 980

23.5 29.5
33 41
46.5 58
62.5 78
80 100

27
30
33
36
39

41
46
50
55
60

1150 1440
1520 1910
1960 2450
2450 3040
2890 3630

118 147
155 195
200 250
250 310
295 370

Thread diameter
of bolt

Width across
flats

mm

mm

Nm

kgm

6
8
10
12

10
13
14
27

5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2

0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2

Tightening torque

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.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14
18
22
24
30
33
36
42

19
24
27
32
36
41
46
55

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

2.5 0.5
52
82
14 3
18 3
20 5
25 5
30 5

00-12

Tightening torque

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

Width across flat

Tightening torque

mm

mm

Nm

kgm

10
12
16

14
17
22

59 74
98 123
235 285

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

Width across flat

mm

mm

14
20
24
33
42

Varies depending
on type of
connector.

Tightening torque (Nm {kgm})

Norminal No.

02
03, 04
05, 06
10, 12
14

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}

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

Width across flat

mm

mm

08
10
12
14
16
18
20
24
30
33
36
42
52

14
17
19
22
24
27
30
32
32

36

Tightening torque (Nm {kgm})

Norminal No.

08
10
12
14
16
18
20
24
30
33
36
42
52

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

Tightening torque

mm

Nm

kgm

10 0 2
24 0 4
43 0 6
77 0 12

6
8
10
12

1.02 0 0.20
2.45 0 0.41
4.38 0 0.61
7.85 0 1.22

2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter

Tightening torque

mm

Nm

kgm

802
10 0 2
12 0 2
24 0 4
36 0 5

6
8
10
12
14

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

3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter

Tightening torque

inch

Nm

kgm

301
802
12 0 2
15 0 2
24 0 4
36 0 5
60 0 9

1 / 16
1/8
1/4
3/8
1/2
3/4
1

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

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

Taper seal
type

Face seal type

Nominal thread
Thread size size
Root diameter
- Threads per
(mm)
inch, Thread series (mm) (Reference)

Range

Target

34 54 {3.5 5.5}

44 {4.5}

9
18UN
16

14.3

34 63 {3.5 6.5}

44 {4.5}

14

22

54 93 {5.5 9.5}

74 {7.5}

11
16UN
16

17.5

24

59 98 {6.0 10.0}

78 {8.0}

18

04

27

84 132 {8.5 13.5}

103 {10.5}

22

13
16UN
16

20.6

05

32

128 186 {13.0 19.0}

157 {16.0}

24

1 14UNS

25.4

06

36

177 245 {18.0 25.0}

216 {22.0}

30

3
1 12UN
16

30.2

(10)

41

177 245 {18.0 25.0}

216 {22.0}

33

(12)

46

197 294 {20.0 30.0}

245 {25.0}

36

(14)

55

246 343 {25.0 35.0}

294 {30.0}

42

02

03

00-14

19

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
Cable O.D.
(mm)

Current
rating
(A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal


etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal
number

Number of
strands

Dia. of
strands
(mm2)

Cross
section
(mm2)

0.85

11

0.32

26

CLASSIFICATION BY COLOR AND CODE


Circuits
Priority
Classification

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

BW

RW

YR

GW

LW

2
Color White & Red

Code

WB

White & Black Red & White Rellow & Red Green & White Blue & White
BY

RB

YB

GR

LR

Auxiliary

Color White & Black

Code

WL

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR

Color White & Blue

Code

Color White & Green

Code

Color

WG

RY

Black & Red Red & Yellow


RG

YG

GY

LY

Yellow &
Green

Green &
Yellow

Blue & Yellow

YL

GB

LB

5
Red & Green Yellow & Blue Green & Black Blue & Black
RL

YW

GL

6
Red & Blue Yellow & White Green & Blue

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

(A)

00-16

0
10
20
30
40

0
0.394
0.787
1.181
1.575

0.039
0.433
0.827
1.220
1.614

0.079
0.472
0.866
1.260
1.654

0.118
0.512
0.906
1.299
1.693

0.157
0.551
0.945
1.339
1.732

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

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

0.236
0.630
1.024
1.417
1.811

0.276
0.669
1.063
1.457
1.850

0.315
0.709
1.102
1.496
1.890

0.354
0.748
1.142
1.536
1.929

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

Kilogram to Pound
1 kg = 2.2046 lb

0
0

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon


1l = 0.2642 U.S. Gal

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Liter to U.K. Gallon


1l = 0.21997 U.K. Gal

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-18

FOREWORD

CONVERSION TABLE

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

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

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

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

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.
1C = 33.8F

40.4
37.2
34.4
31.7
28.9

40
35
30
25
20

40.0
31.0
22.0
13.0
4.0

11.7
11.1
10.6
10.0
9.4

11
12
13
14
15

51.8
53.6
55.4
57.2
59.0

7.8
8.3
8.9
9.4
10.0

46
47
48
49
50

114.8
116.6
118.4
120.2
122.0

27.2
27.8
28.3
28.9
29.4

81
82
83
84
85

117.8
179.6
181.4
183.2
185.0

28.3
27.8
27.2
26.7
26.1

19
18
17
16
15

2.2
0.4
1.4
3.2
5.0

8.9
8.3
7.8
7.2
6.7

16
17
18
19
20

60.8
62.6
64.4
66.2
68.0

10.6
11.1
11.7
12.2
12.8

51
52
53
54
55

123.8
125.6
127.4
129.2
131.0

30.0
30.6
31.1
31.7
32.2

86
87
88
89
90

186.8
188.6
190.4
192.2
194.0

25.6
25.0
24.4
23.9
23.3

14
13
12
11
10

6.8
8.6
10.4
12.2
14.0

6.1
5.6
5.0
4.4
3.9

21
22
23
24
25

69.8
71.6
73.4
75.2
77.0

13.3
13.9
14.4
15.0
15.6

56
57
58
59
0

132.8
134.6
136.4
138.2
140.0

32.8
33.3
33.9
34.4
35.0

91
92
93
94
95

195.8
197.6
199.4
201.2
203.0

22.8
22.2
21.7
21.1
20.6

9
8
7
6
5

15.8
17.6
19.4
21.2
23.0

3.3
2.8
2.2
1.7
1.1

26
27
28
29
30

78.8
80.6
82.4
84.2
86.0

16.1
16.7
17.2
17.8
18.3

61
62
63
64
65

141.8
143.6
145.4
147.2
149.0

35.6
36.1
36.7
37.2
37.8

96
97
98
99
100

204.8
206.6
208.4
210.2
212.0

20.0
19.4
18.9
18.3
17.8

4
3
2
1
0

24.8
26.6
28.4
30.2
32.0

0.6
0
0.6
1.1
1.7

31
32
33
34
35

87.8
89.6
91.4
93.2
95.0

18.9
19.4
20.0
20.6
21.1

66
67
68
69
70

150.8
152.6
154.4
156.2
158.0

40.6
43.3
46.1
48.9
51.7

105
110
115
120
125

221.0
230.0
239.0
248.0
257.0

17.2
16.7
16.1
15.6
15.0

1
2
3
4
5

33.8
35.6
37.4
39.2
41.0

2.2
2.8
3.3
3.9
4.4

36
37
38
39
40

96.8
98.6
100.4
102.2
104.0

21.7
22.2
22.8
23.3
23.9

71
72
73
74
75

159.8
161.6
163.4
165.2
167.0

54.4
57.2
60.0
62.7
65.6

130
135
140
145
150

266.0
275.0
284.0
293.0
302.0

14.4
13.9
13.3
12.8
12.2

6
7
8
9
10

42.8
44.6
46.4
48.2
50.0

5.0
5.6
6.1
6.7
7.2

41
42
43
44
45

105.8
107.6
109.4
111.2
113.0

24.4
25.0
25.6
26.1
26.7

76
77
78
79
80

168.8
170.6
172.4
174.2
176.0

68.3
71.1
73.9
76.7
79.4

155
160
165
170
175

311.0
320.0
329.0
338.0
347.0

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

Unit

PC400-7

PC400LC-7

PC450-7

PC450LC-7

Overall length

mm

11,940

11,940

12,040

12,040

Overall height

mm

3,635

3,635

3,660

3,660

Overall width

mm

3,340

3,440

3,340

3,340

Track shoe width

mm

600

700

600

600

Height of machine cab

mm

3,265

3,265

3,265

3,265

Tail swing radius

mm

3,645

3,645

3,645

3,645

Track overall length

mm

5,055

5,355

5,055

5,355

Length of track on ground

mm

4,020

4,350

4,020

4,350

Min. ground clearance

mm

555

550

555

550

Unit

PC400-7

PC400LC-7

PC450-7

PC450LC-7

Variable gauge specification


Item
A

Overall length

mm

11,940

11,940

12,040

12,040

Overall height

mm

3,635

3,635

3,660

3,660

Overall width

mm

3,490

3,490

3,490

3,490

Track shoe width

mm

600

600

600

600

Height of machine cab

mm

3,265

3,265

3,265

3,265

Tail swing radius

mm

3,645

3,645

3,645

3,645

Track overall length

mm

5,055

5,355

5,055

5,355

Length of track on ground

mm

4,020

4,350

4,020

4,350

Min. ground clearance

mm

685

685

685

685

Unit

PC400-7

PC400LC-7

PC450-7

PC450LC-7

WORKING RANGES
Working range
A

Max. digging reach

mm

12,025

12,025

12,005

12,005

Max. digging depth

mm

7,820

7,820

7,790

7,790

Max. digging height

mm

10,915

10,915

10,925

10,925

Max. vertical wall depth

mm

6,870

6,870

6,600

6,600

Max. dumping height

mm

7,565

7,565

7,625

7,625

Min. dumping height

mm

Max. reach at ground


level

mm

11,820

11,820

11,800

11,800

PC400/450(LC)-7

01-3

GENERAL

SPECIFICATIONS

SPECIFICATIONS
PC400-7, PC400LC-7
PC400-7
Machine model

PC400LC-7

Variable
gauge spec.

Fixed gauge
spec.

Serial Number
m3

Weight of machine

kg

1.4

1.4

41,200

42,400

42,200

43,500

Max. digging depth

mm

7,820

7,820

Max. vertical wall depth

mm

6,870

6,870

Max. digging reach

mm

12,025

12,025

Max. reach at ground level

mm

11,820

11,820

Max. digging height

mm

10,915

10,915

Max. dumping height

mm

7,565

7,565

Max. digging force

kN {kg}

256.0 {26,100}

256.0 {26,100}

(using power max. function)

kN {kg}

(274.6 {28,000})

(274.6 {28,000})

Swing speed

rpm

9.1

9.1

Swing max. slope angle

deg.

20

20

Travel speed

km/h

Lo: 3.0, Mi: 4.4, Hi: 5.5

Lo: 3.0, Mi: 4.4, Hi: 5.5

Gradeability

deg.

35

35

Working ranges
Performance

Variable
gauge spec.

50001 and up

Bucket capacity

kPa {kg/cm }

77.7{0.79}

79.9 {0.82}

73.9 {0.75}

65.3 {0.67}

[mm]

[600]

[600]

[700]

[700]

Overall length (for transport)

mm

11,940

11,940

11,940

11,940

Overall width

mm

3,340

3,490

3,440

3,490

Overall width of track

mm

3,340

2,990

3,440

2,990

Overall width of track when extended

mm

3,490

3,490

Overall height (for transport)

mm

3,635

3,635

3,635

3,635

Overall height to top of machine

mm

3,265

3,265

3,265

3,265

Ground clearance of upper structure

mm

1,320

1,320

1,320

1,320

Min. ground clearance

mm

555

685

555

685

Tail swing radius

mm

3,645

3,645

3,645

3,645

Min. swing radius of work equipment

mm

4,735

4,735

4,735

4,735

Height of work equipment

mm

9,210

9,210

9,210

9,210

Length of track on ground

mm

4,020

4,020

4,020

4,020

Track gauge

mm

2,740

2,890

2,740

2,890

Height of machine cab

mm

3,265

3,265

3,265

3,265

Ground pressure
[standard shoe width]

Dimensions

Fixed gauge
spec.

at min. swing radius

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

01-4

PC400/450(LC)-7

GENERAL

SPECIFICATIONS

Machine model

PC400-7

PC400LC-7

Serial Number

50001 and up

mm
l {cc}

SAA6D125E-3
4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler
6 125 150
11.045 {11,045}

kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}

246.4/1,850 {330/1,850}
1,334/1,400 {136/1,400}
1,930
1,000
203 {151}

Model
Type

Performance

Engine

No. of cylinders bore stroke


Piston displacement
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption

Starting motor
Alternator
Battery

24V, 7.5 kW
24V, 35A
12V, 110 Ah 2
ALW-4

Carrier roller

2 on each side
7 on each side

8 on each side

Track shoe

Assembly-type triple grouser,


45 on each side

Assembly-type triple grouser,


48 on each side

Hydraulic motor Control valve Hydraulic pump

Track roller

Hydraulic cylinder

Hydraulic system

Undercarriage

Radiator core type

Type No.
Delivery
Set pressure

HPV190+190, variable displacement, piston type x2


l /min

345 2

MPa {kg/cm2}

37.8 {380}

Type No.

6-spool type + 1-spool type 1

Control method

Hydraulic

Travel motor

KMV200ADT-2, Variable displacement, piston type


(with brake valve, parking brake): 2

Swing motor

KMF230ABE-5, Fixed displacement piston type


(with safety valve, holding brake, reverse rotation preventive valve): 1

Type

Boom

Arm

Bucket

Double-acting
piston

Double-acting
piston

Double-acting
piston

Inside diameter of cylinder

mm

160

185

160

Diameter of piston rod

mm

110

120

110

Stroke

mm

1,570

1,820

1,270

Max. distance between pins

mm

3,830

4,325

3,140

Min. distance between pins

mm

2,260

2,505

1,870

Hydraulic tank
Hydraulic filter
Hydraulic cooler

PC400/450(LC)-7

Closed box type


Tank return side
CF40-1 (Air cooled)

01-5

GENERAL

SPECIFICATIONS

PC450-7, PC450LC-7
PC450LC-7
Machine model

PC450LC-7

Variable
gauge spec.

Fixed gauge
spec.

Performance

Working ranges

Serial Number

20001 and up

Bucket capacity

m3

Operating weight

kg

1.4

1.4

42,700

44,000

43,700

44,600

Max. digging depth

mm

7,790

7,790

Max. vertical wall depth

mm

6,600

6,600

Max. digging reach

mm

12,005

12,005

Max. reach at ground level

mm

11,800

11,800

Max. digging height

mm

10,925

10,925

Max. dumping height

mm

7,625

7,625

kN {kg}

258.9 {26,400}

258.9 {26,400}

(275.5 {28,300})

(275.5 {28,300})

Max. digging force


(using power max. function)
Swing speed

rpm

9.1

9.1

Swing max. slope angle

deg.

17

17

Travel speed

km/h

Lo: 3.0, Mi: 4.4, Hi: 5.5

Lo: 3.0, Mi: 4.4, Hi: 5.5

Gradeability

deg.

35

35

Ground pressure
[standard shoe width]

kPa {kg/cm2}
[mm]

80.5 {0.82}
[600]

82.9 {0.85}
[600]

76.5 {0.78}
[600]

78.1 {0.80}
[600]

Overall length (for transport)

mm

12,040

12,040

12,040

12,040

Overall width

mm

3,340

3,490

3,340

3,490

Overall width of track

mm

3,340

2,990

3,340

2,990

3,490

3,490

Overall width of track when extended

Dimensions

Variable
gauge spec.

Fixed gauge
spec.

Overall height (for transport)

mm

3,660

3,660

3,660

3,660

Overall height to top of machine

mm

3,265

3,265

3,265

3,265

Ground clearance of upper structure

mm

1,320

1,320

1,320

1,320

Min. ground clearance

mm

555

685

555

685

Tail swing radius

mm

3,645

3,645

3,645

3,645

Min. swing radius of work equipment

mm

4,805

4,805

4,805

4,805

Height of work equipment

mm

9,230

9,230

9,230

9,230

Length of track on ground

mm

4,020

4,020

4,350

4,350

Track gauge

mm

2,740

2,890

2,740

2,890

Height of machine cab

mm

3,265

3,265

3,265

3,265

at min. swing radius

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

01-6

PC400/450(LC)-7

GENERAL

SPECIFICATIONS

Machine model

PC450-7

PC450LC-7

Serial Number

20001 and up

Model

SAA6D125E-3

Type

4-cycle, water-cooled, in-line, vertical, direct injection,


with turbocharger and aftercooler

No. of cylinders bore stroke

mm

6 125 150

l {cc}

11.045 {11,045}

Flywheel horsepower

kW/rpm {HP/rpm}

246.4/1,850 {330/1,850}

Max. torque

Nm/rpm {kgm/rpm}

1,334/1,400 {136/1,400}

Max. speed at no load

rpm

1,930

Min. speed at no load

rpm

4,000

Min. fuel consumption

g/kWh {g/HPh}

203 {151}

Performance

Engine

Piston displacement

Starting motor

24V, 7.5 kW

Alternator

24 V, 35 A

Battery

12V, 110 Ah 2
ALW-4

Carrier roller

2 on each side

Track roller

Hydraulic pump

Type No.

Control valve

Type No.

Hydraulic motor

Track shoe

Travel motor

Hydraulic cylinder

Hydraulic system

Undercarriage

Radiator core type

Delivery
Set pressure

7 on each side

8 on each side

Assembly-type triple grouser,

Assembly-type triple grouser,

45 on each side

48 on each side

HPV190+190, ariable displacement, piston type 2


l /min

345 2

MPa {kg/cm2}

37.8 {380}
6-spool type + 1-spool type 1

Control method

Hydraulic

KMV200ADT-2, Variable displacement, piston type


(with brake valve, parking brake): 2

Swing motor

KMF230ABE-5, Fixed displacement piston type 2


(with safety valve, holding brake, reverse rotation preventive valve): 1

Cylinder type

Boom

Arm

Bucket

Double-acting piston

Double-acting piston

Double-acting piston

Inside diameter of cylinder

mm

160

185

160

Outside diameter of piston rod

mm

110

130

110

Stroke

mm

1,570

1,985

1,270

Max. distance between pins

mm

3,830

4,740

3,140

Min. distance between pins

mm

2,260

2,755

1,870

Hydraulic tank
Hydraulic filter
Hydraulic cooler

PC400/450(LC)-7

Closed box type


Tank return side
CF40-1 (Air cooled)

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

PC400-7

Serial Number

PC400LC-7
50001 and up

Engine assembly

1,500

1,500

Engine

1,150

1,150

Damper

14.7

14.7

Hydraulic pump

210

210

Radiator, oil cooler assembly

195

195

Hydraulic tank, filter assembly (excluding hydraulic oil)

198

198

Fuel tank (excluding fuel)

251

251

3,297

3,297

Operator's cab

279

279

Operator's seat

35

35

Counterweight

9,220

9,500

Swing machinery (including swing motor)

526

526

Control valve (with service valve)

257

257

Swing motor

105

105

Travel motor

208 2

208 2

40

40

Revolving frame

Center swivel joint


Fixed gauge
specification

Variable gauge
specification

Fixed gauge
specification

Variable gauge
specification

Track frame assembly

10,173

11,367

10,965

11,934

Track frame

5,506

6,766

6,077

7,096

Center frame

3,229

3,229

Crawler frame

1,754 2

1,921 2

Swing circle

605 2

605 2

Idler

230 2

230 2

Idler cushion

338 2

338 2

Carrier roller

32 4

32 4

Track roller

72 14

72 16

Final drive (including travel motor)

722 2

722 2

01-8
(4)

PC400/450(LC)-7

GENERAL

WEIGHT TABLE

Unit: kg
Machine model

PC400-7

Serial Number

PC400LC-7
50001 and up

Track shoe assembly


Standard triple grouser shoe (600 mm)

4,470

4,760

Standard triple grouser shoe (700 mm)

4,890

5,210

Wide triple grouser shoe (800 mm)

5,320

5,670

Wide triple grouser shoe (900 mm)

6,130

Boom assembly

3,290

3,290

Arm assembly

1,374

1,374

Bucket assembly

1,366

1,366

355 2

355 2

Arm cylinder assembly

510

510

Bucket cylinder assembly

280

280

Link assembly

258

258

92 + 20 2 + 73 + 27 + 54

92 + 20 2 + 73 + 27 + 54

Arm pin

17 + 23

17 + 23

Bucket pin

38 2

38 2

Link pin

34 2

34 2

Boom cylinder assembly

Boom pin

PC400/450(LC)-7

01-9

GENERAL

WEIGHT TABLE

PC450-7, PC450LC-7
Unit: kg
Machine model

PC450-7

PC450LC-7

Serial Number

20001 and up

Engine assembly

1,500

1,500

Engine

1,150

1,150

Damper

14.7

14.7

Hydraulic pump

210

210

Radiator oil cooler assembly

195

195

Hydraulic tank, filter assembly (excluding hydraulic oil)

198

198

Fuel tank (excluding fuel)

251

251

3,402

3,402

Operators cab

279

279

Operators seat

35

35

Counterweight

9,220

9,220

Swing machinery

526

526

Control valve

257

257

Swing motor

105

105

Travel motor

208 2

208 2

40

40

Revolving frame

Center swivel joint


Fixed gauge
specification

Variable gauge
specification

Fixed gauge
specification

Variable gauge
specification

Track frame assembly

10,462

11,697

11,269

12,244

Track frame

5,506

6,766

6,077

7,096

Center frame

3,229

3,229

Crawler frame

1,754 2

1,921 2

Swing circle

605

605

Idler

230 2

230 2

Idler cushion

338 2

338 2

Carrier roller

32 4

32 4

Track roller

81 6, 72 8

81 8, 72 8

722 2

722 2

Final drive (including travel motor)

01-10

PC400/450(LC)-7

GENERAL

WEIGHT TABLE

Unit: kg
Machine model

PC450-7

Serial Number

PC450LC-7
20001 and up

Track shoe assembly


Standard triple grouser shoe (600 mm)

4,470

4,760

Standard triple grouser shoe (700 mm)

4,890

5,210

Boom assembly

3,380

3,380

Arm assembly

1,622

1,622

Bucket assembly

1,941

1,941

355 2

355 2

Arm cylinder assembly

580

580

Bucket cylinder assembly

280

280

Link assembly

258

258

92 + 20 2 + 73 + 27 + 54

92 + 20 2 + 73 + 27 + 54

Arm pin

17 + 23

17 + 23

Bucket pin

38 2

38 2

Link pin

34 2

34 2

Wide triple grouser shoe (800 mm)

Boom cylinder assembly

Boom pin

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

10-2

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

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

PC400/450(LC)-7

10. Condenser
11. Fuel cooler

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

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)

10-4

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

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.

Check item

14

Backlash between No. 1 sun


gear and No. 1 planetary gear

15

Criteria

Remedy

Standard clearance

Clearance limit

0.15 0.54

1.10

Backlash between No. 1


planetary gear and ring gear

0.18 0.66

1.30

16

Backlash between No. 2


planetary carrier and motor

0.06 0.24

17

Backlash between No. 2 sun


gear and No. 2 planetary
gear

0.15 0.51

1.00

18

Backlash between No. 2 planetary gear and ring gear

0.17 0.60

1.20

19

Backlash between No. 2


planetary carrier and No. 2
sun gear

0.15 0.54

20

Amount of wear on sprocket


tooth

21

Width of sprocket tooth

PC400/450(LC)-7

Replace

Repair limit: 6
Standard size

Repair limit

90

87

Rebuild or
replace

10-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SPROCKET

SPROCKET

Unit: mm
No.

Check item

Wear of tooth tip

Thickness of tooth root

Width of tooth

Wear of tooth shape

10-7-1
(6)

Criteria

Remedy

Standard size

Repair limit

355

343

20.8

14.8

90

87

Build-up welding
or replace

Repair limit: 6 (measure with sprocket tooth shape)

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.

Check item

14

Backlash between swing


motor shaft and No. 1 sun gear

15

Criteria

Remedy

Standard clearance

Clearance limit

0.18 0.28

Backlash between No. 1 sun


gear and No. 1 planetary
gear

0.15 0.51

1.00

16

Backlash between No. 1


planetary gear and ring gear

0.17 0.60

1.10

17

Backlash between No. 1


planetary carrier and No. 2
sun gear

0.40 0.75

1.20

18

Backlash between No. 2 sun


gear and No. 2 planetary gear

0.16 0.55

1.00

19

Backlash between No. 2


planetary gear and ring gear

0.17 0.60

1.10

20

Backlash between coupling


and swing pinion

0.08 0.25

21

Backlash between swing pinion and swing circle

0.00 1.21

2.00

22

Clearance between plate


and coupling

0.57 1.09

Standard size

Repair limit

23

Wear of swing pinion surface


contacting with oil seal

PC400/450(LC)-7

Replace

150 0.100

Apply hard
chrome plating, recondition, or
replace

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

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

a. Inner race soft zone S position


b. Outer race soft zone S position

Unit: mm
No.

Check item
Axial clearance of bearing
(when mounted on chassis)

10-10

Criteria

Remedy

Standard clearance

Repair limit

0.5 1.6

3.2

Replace

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

10-12

The dimensions and the number of track rollers


depend on the model, but the basic structure is
not different.

Number of track rollers


Model

Qty

PC400-7, 450-7

PC400LC-7, 450LC-7

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK FRAME AND RECOIL SPRING

Standard shoe
Model

PC400-7

PC400LC-7

PC450-7

PC450LC-7

Shoe width

600 mm

700 mm

600 mm

600 mm

Link pitch

228 mm

228 mm

228 mm

228 mm

46 (Pieces)

46 (Pieces)

49 (Pieces)

49 (Pieces)

Item

No. on track (one side)

Unit: mm
No.

10

11

Check item

Vertical width of idler guide

Criteria

Remedy

Standard
size

Tolerance

Repair limit

Track frame

123

+2
1

127

Idler support

120

0.5

118

Track frame

266

+3
1

271

Idler support

261

259

Horizontal width of idler guide

Standard size
12

Rebuild or
replace

Recoil spring

PC400/450(LC)-7

Repair limit

Free length
OD

Installation
length

Installation
load

Free length

Installation
load

795 241

648

173.3 kN
{17,680 kg}

138.56 kN
{14,140 kg}

Replace

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

Criteria

Remedy
Repair limit

Standard size
704

Outside diameter of tread

660

648

Depth of tread

22

28

Total width

202

Width of tread

48.5

Clearance between shaft and


bushing

Standard size
95

Interference between idler


and bushing

Standard size
102.6

PC400/450(LC)-7

Tolerance
Shaft

Hole

0.120
0.207

+0.360
+0.220

Tolerance
Shaft

Hole

+0.087
+0.037

0.027
0.079

Rebuild or
replace

Standard
clearance
0.340 0.507
Replace bushing
Standard
interference
0.064 0.149

10-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CARRIER ROLLER

CARRIER ROLLER

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

175

Outside diameter of tread

148

134

Width of tread

50.3

Thickness of tread

32

25

Width of flange

19

Outside diameter of flange

Interference between shaft


and bushing

Interference between roller


and bushing

Axial clearance of roller

10-16

Standard
size

Tolerance

Standard Interference Replace


interference
limit

Shaft

Hole

50

0.250
0.270

+0.099
0.032

0.218
0.369

57

+0.117
+0.087

+0.040
0

0.047
0.177

Standard clearance

Clearance limit

0.5 0.7

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK ROLLER

TRACK ROLLER

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

240

Outside diameter of inner flange


(double flange)

237

Outside diameter of tread

200

188

Thickness of tread

56.2

50.2

Overall width

278

Singe flange

54.6

Double flange

51.6

Singe flange

32.6

Double flange

32.6

23.0

0.4 1.0

Outside diameter of outer


flange

Width of tread

Width of outer
flange

Width of inner flange


(Double flange)

Axial play

10

Clearance between shaft and


bushing

Standard
size
80

11

Interference between roller


and bushing

Standard
size
87.6

PC400/450(LC)-7

Tolerance
Shaft

Hole

Standard
clearance

0.250
0.350

+0.174
+0.029

0.279
0.524

Tolerance
Shaft

Hole

+0.108
+0.008

0.006
0.036

Rebuild or
replace

Clearance
limit
1.5

Standard Interference
interference
limit
0.014
0.144

Replace
bushing

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

Criteria

Link pitch

Bushing outside diameter

Thickness of bushing metal

Link height

Thickness of link metal


(bushing press-fitting portion)

6
7

Standard size

Repair limit

228.9

231.9

Standard size

When turned

71.5

66.5

12

Standard size

Repair limit

129

119

34.5

24.5

Shoe bolt pitch

144

Adjust or
replace

Repair or
replace

Replace

76.2

9
Link

11

Inside
width

106

Overall
width

51.6

Tread
width

44.8

12

Protrusion of pin

4.4

13

Protrusion of regular bushing

5.25

14

Overall length of pin

252

15

Overall length of bushing

16

Thickness of spacer

17
18

Reverse or
replace

184

10

Remedy

Press-fitting
force

19

Repair or
replace

Adjust or
replace

164.5

Bushing

118 304 kN {12 31 ton}

Regular
pin

176 451 kN {18 46 ton}

Master
pin

137 284 kN {14 29 ton}

: Dry type track link


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

Criteria
Tightening torque
(Nm {kgm})
Triple shoe

22

23

Interference between
bushing and link

Interference between regular


pin and link

Clearance between regular


pin and bushing

Interference between master


pin and bushing

25

PC400-7, PC450-7: 46
PC400LC-7, PC450LC-7: 49
Standard size

Tolerance

Standard
interference

Hole

71

+0.494
+0.454

+0.074
0

0.380 0.494

47

+0.235
+0.085

0.218
0.280

0.303 0.515

Standard size

Standard size

Standard size

Tolerance
Shaft

Hole

+0.235
+0.085

+0.915
+0.415
Tolerance

Shaft

Hole

+0.03
0

0.218
0.280
Tolerance

Shaft

Hole

0.2
0.4

+0.915
+0.415

Retighten

Shaft

47

10-20

12010
Lower limit torque
(Nm {kgm})

47

Clearance between master


pin and bushing

39339 {404}
Additinal tightening
angle (deg.)

47

24

Additinal tightening
angle (deg.)

Tightening torque
(Nm {kgm})

No. of shoes (each side)

21

Remedy

Standard
clearance
0.180 0.830

Adjust or
replace

Standard
interference
0.218 0.310
Standard
clearance
0.615 1.315

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK SHOE

TRIPLE GROUSER SHOE

Unit: mm
No.

Check item

Height

Thickness

3
4

Length at of base

5
6

Criteria

Remedy

Standard size

Repair limit

37

22
13
33
27

Rebuild or
replace

25.5
Length at tip

PC400/450(LC)-7

17.5
23.5

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

PC400/450(LC)-7

HYDRAULIC PIPING DRAWING

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

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

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

PC400/450(LC)-7

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

HYDRAULIC PUMP

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

10-27

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Function

Structure

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.

10-28

HYDRAULIC PUMP

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).

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

PA
PA2
PDP
PM
PPL

:
:
:
:
:

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

PC VALVE

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

Servo piston assembly


Plug
Pin
Spool
Retainer
Seat
Cover
Wiring

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.)

of the piston, so the swash plate is moved to the


minimum angle by the difference in the area of
the piston (12).

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

10-33

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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).

10-34

HYDRAULIC PUMP

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.

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

PC400/450(LC)-7

HYDRAULIC PUMP

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.

10-35

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.)

10-36
(1)

HYDRAULIC PUMP

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}.

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

(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.

PC400/450(LC)-7

HYDRAULIC PUMP

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

10-37

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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).

10-38

HYDRAULIC PUMP

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.

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

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.

10-40

HYDRAULIC PUMP

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.

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

HYDRAULIC PUMP

10-41

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

10-42

HYDRAULIC PUMP

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.

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

HYDRAULIC PUMP

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

10-44

5. Coil
6. Plunger
7. Connector

PSIG : To LS(PC) valve


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

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

PC400/450(LC)-7

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

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
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

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

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

10-50

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

CONTROL 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.

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

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)

PC400/450(LC)-7

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

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

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

11

Spool return spring

Remedy

Criteria
Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

54.2 34.8

51.2

416.5 N
{42.5 kg}

333.2 N
{34 kg}

12

Spool return spring

54.6 34.8

51.2

429.9 N
{42.9 kg}

336.1 N
{34.3 kg}

13

Spool return spring

54.5 34.8

51.2

393 N
{40.1 kg}

314.6 N
{32.1 kg}

14

Spool return spring

54.9 24.2

51.2

251 N
{25.1 kg}

201.0 N
{20.5 kg}

15

Spool return spring

57.2 32.8

51

416 N
{42.5 kg}

333.2 N
{34.0 kg}

10-54

If damaged or
deformed,
replace spring

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

Remedy

Criteria
Standard size

17

Check valve spring

PC400/450(LC)-7

Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

11.5 4.6

8.5

1.5 N
{0.15 kg}

1.2 N
{0.12 kg}

If damaged or
deformed,
replace spring

10-55

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(6/9)

1.
2.
3.
4.

Unload valve
Main relief valve
Safety valve (Boom RAISE)
Lift check valve

10-56

ARM CONTROL VALVE

R. H. TRAVEL CONTROL 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

12. Suction valve


13. Spool
14. Pressure compensation valve
(Reverse)
15. LS shuttle valve
16. Pressure compensation valve
(Forward)
17. Suction valve

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No.

Check item

Remedy

Criteria
Standard size

18

Regeneration valve spring

Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

31.5 10.3

19.5

6.2 N
{0.6 kg}

4.9 N
{0.5 kg}

19

Piston return spring

36.9 11.1

28

29.4 N
{3 kg}

23.5 N
{2.4 kg}

20

Piston return spring

36.9 11.1

28

29.4 N
{3 kg}

23.5 N
{2.4 kg}

PC400/450(LC)-7

If damaged or
deformed,
replace spring

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)

10-58

ARM CONTROL VALVE

L. H. TRAVEL 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

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

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No.

Check item

Remedy

Criteria
Standard size

21

Regeneration valve spring

Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

31.5 10.3

19.5

6.2 N
{0.6 kg}

4.9 N
{0.5 kg}

14.0 N
{1.4 kg}

22

Piston return spring

48.1 10.8

28

17.5 N
{1.8 kg}

23

Piston return spring

36.9 11.1

28

29.4 N
{3 kg}

23.5 N
{2.4 kg}

24

Spool return spring

30.7 20.5

23

50.0 N
{5.1 kg}

40.0 N
{4.1 kg}

PC400/450(LC)-7

If damaged or
deformed,
replace spring

10-59

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

(8/9)

BOOM, ARM HI VALVE

BUCKET CONTROL VALVE


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

7.
8.
9.
10.
11.
12.
13.

Safety-suction valve
Spool
Pressure compensation valve (CURL)
LS shuttle valve
Pressure compensation valve (DUMP)
Safety-suction valve

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

14

15

Piston return spring

Piston return spring

10-60

Remedy

Criteria
Repair limit

Installed
length

Installed
load

48.1 10.8
36.9 11.1

Free length
OD

Free
length

Installed
load

28

17.5 N
{1.8 kg}

14.0 N
{1.4 kg}

28

29.4 N
{3 kg}

23.5 N
{2.4 kg}

If damaged or
deformed,
replace spring

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)

10-62

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

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

Unit: mm
No.

Check item

Remedy

Criteria
Standard size

17

Check valve spring

Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

11.5 4.6

8.5

1.5 N
{0.15 kg}

1.2 N
{0.12 kg}

125.5 N
{12.8 kg}

18

Spool return spring

46.6 21.8

3.3

156.8 N
{16.0 kg}

19

Spool return spring

64.5 32.3

63

177.5 N
{18.1 kg}

142.0 N
{14.5 kg}

20

Sequence valve spring

70.9 18.0

59

199.8 N
{20.4 kg}

160.0 N
{16.3 kg}

PC400/450(LC)-7

If damaged or
deformed,
replace spring

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

Structure

CLSS stands for Closed Center Load Sensing


System, and has the following features.

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)

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.

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

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).

10-68

CLSS

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.

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 d 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
d PR pressure, and then valve (7) moves to
the right stroke end.
As a result, the area of the pass between ports
P2 and A2 increases and the pass resistance
lowers and the loss of the engine power is reduced.
If the PR pressure rises above the set pressure,
poppet (11) opens and the hydraulic oil flows
from the PR port through orifice a in spool (14)
and open part of poppet (11) to seal drain port
TS.
Accordingly, differential pressure is generated
between before and after orifice a in spool (14)
and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area
of the oil pass at this time and supplied as the PR
pressure.

10-70
(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

KMF230ABE-5

Theoretical displacement

229.4 cm/rev

Safety valve set


pressure
Rated revolving
speed
Brake release
pressure

10-72

27.9 +0.5
+0 MPa
{285 +0.5
kg/cm2}
+0
1,413 rpm
1.9 0.4 MPa {19 4 kg/cm2}

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

Brake spring
Drive shaft
Spacer
Case
Disc
Plate
Brake piston

10-74

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

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

SWING MOTOR

15. Safety valve


16. Check valve
17. Shuttle valve

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

Unit: mm
No.

Check item

Criteria

Remedy

Standard size
18

19

Check valve spring

Shuttle valve spring

PC400/450(LC)-7

Free length
OD

Repair limit

Installed
length

Installed
load

66.5 25.6
24.5 11.6

Free length

Installed
load

45

6.96 N
{0.71 kg}

5.59 N
{0.57 kg}

14.5

7.45 N
{0.76 kg}

5.98 N
{0.61 kg}

If damaged or
deformed,
replace spring

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

10-80

Criteria

Remedy

Standard Size

Standard clearance

Repair limit

80

If damaged or
deformed,
replace spring

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)

10-82

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:
2
+4
0.8 +0.4
0.1 MPa {8 1 kg/cm }
(Differentical pressure)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

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

PC400/450(LC)-7

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

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

TRAVEL MOTOR

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

Safety valve
Rgegulator valve
Spring
Brake spring
Brake piston
Check valve

10-83

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

Unit: mm
No.

Check item

Criteria

Remedy

Standard size
21

Spool return spring

22

Check valve spring

23

Regulator piston spring

10-84

Repair limit

Free length
OD

Installed
length

Installed
load

Free length

Installed
load

62.52 32.0

42.0

426.6N
{43.5 kg}

341.3 N
{32.2 kg}

62.5 20.0

39.0

3.04 N
{0.31 kg}

2.45 N
{0.25 kg}

55.0 9.0

50.0

98.1 N
{10 kg}

78.5 N
{8 kg}

Replace
spring if damaged or
deformed

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.

PC400/450(LC)-7

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.

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

10-88

valve (7) when the brake piston returns, and this


ensures that the brake is applied after the machine stops.

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}

PC400/450(LC)-7

27.5 MPa {27.5 kg/cm2}

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.

PC400/450(LC)-7

Operation
When pilot pressure is turned ON
If the pilot pressure from the travel junction solenoid valve becomes higher than the force of
spring (14), travel junction spool (13) moves to
the left stroke end and the junction circuit between port PTL (Left travel circuit) and PTR
(Right travel circuit) is closed.

10-93

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

10-94

TRAVEL JUNCTION VALVE

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.

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

PC400/450(LC)-7

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

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

PC400/450(LC)-7

TRAVEL PPC SHUTTLE VALVE

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

PC400/450(LC)-7

TRAVEL PPC SHUTTLE VALVE

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

10-100

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

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

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

7.
8.
9.
10.
11.

WORK EQUIPMENT SWING PPC VALVE

Joint
Plate
Retainer
Body
Filter

Unit: mm
No.

Check item

Criteria

Remedy

Standard size
12

Centering spring
(For P3 and P4)

Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

42.4 15.5

34

17.1 N {1.8
kg}

13.7 N {1.4
kg}

13

Centering spring
(For P1 and P2)

44.4 15.5

34

29.4 N
{3.0 kg}

23.5 N
{2.4 kg}

14

Metering spring

26.5 8.2

24.9

16.7 N
{1.7 kg}

13.7 N
{1.4 kg}

PC400/450(LC)-7

If damaged or
deformed,
replace spring

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

10-104

P3
P4
P5
P6

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

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1.
2.
3.
4.
5.

Plate
Body
Piston
Collar
Metering spring

PC400/450(LC)-7

6.
7.
8.
9.
10.

TRAVEL PPC VALVE

Centering spring
Valve
Damper
Steering signal
Steering signal valve spring

10-105

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

Unit: mm
No.

Check item

Criteria
Standard size

Metering spring

Remedy
Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

26.5 8.15

24.7

16.7 N
{1.7 kg}

13.7 N
{1.4 kg}

Centering spring

48.1 15.5

32.5

108 N
{11 kg}

86.3 N
{8.8 kg}

Steering signal spring

12.8 7.3

8.5

8.8 N
{0.9 kg}

7.1 N
{0.72 kg}

10-106

If damaged or
deformed,
replace spring

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

Criteria

Remedy

Standard size
9

10

Centering spring

Metering spring

PC400/450(LC)-7

Free length
OD

Repair limit

Installed
length

Installed
load

33.9 15.3
22.7 8.1

Free
length

Installed
load

28.4

124.5 N
{12.7 kg}

100 N
{10.2 kg}

22

16.7 N
{1.7 kg}

13.7 N
{1.4 kg}

If damaged or
deformed,
replace spring

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

10-112

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

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

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

Gas plug
Shell
Poppet
Holder
Bladder
Oil port

Specifications
Gas capacity: 300 cc (for PPC)
4

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

PC400/450(LC)-7

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 m
Filtering area
: 4,570 cm2

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

10-116

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC400/450(LC)-7

BOOM HYDRAULIC DRIFT PREVENTION

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 d1 Area
of d2) because of the difference in the outside
diameter d1 of poppet (5) and seat diameter d2.
Poppet (5) is closed by the total of this force and
the force of spring (4), so the main pressure oil
and hold pressure at the bottom of the boom cylinder are shut off.
In addition, the hold pressure at the bottom of the
boom cylinder acts in the left direction on outside
diameter d4 of valve (6).
Valve (6) is closed by the total of this force and
the force of spring (4), so the main pressure oil
and hold pressure at the bottom of the boom cylinder are shut off. As a result, the boom is held in
position.

10-118

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC400/450(LC)-7

BOOM HYDRAULIC DRIFT PREVENTION

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 d1 Area of d2)
because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When
it overcomes the force of spring (4), poppet (5)
moves to the left.
As a result, the main pressure oil prom the control valve passes through the opening of poppet
(5) and flows to the bottom end of the boom cylinder.

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 d1 Area
of d2) because of the difference in the outside
diameter d1 of poppet (5) and seat diameter d2.
Poppet (5) is closed by the total of this force and
the force of spring (4), so the main pressure oil
and hold pressure at the head of the arm cylinder
are shut off.
In addition, the hold pressure at the bottom of the
boom cylinder acts in the left direction on outside
diameter d4 of valve (6).
As a result, the arm is held in position.

10-122

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.

PC400/450(LC)-7

10-123

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

10-124

ARM HYDRAULIC DRIFT PREVENTION

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.

PC400/450(LC)-7

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 d1
Area of d2) because of the difference in the outside diameter d1 of valve (2) and seat diameter
d2. Valve (2) moves to the left and the pressure
oil from port A goes to port B. From port B, the oil
is drained directly to the tank.

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 d1 Area of d2) because
of the difference in the outside diameter d1 of
valve (2) and seat diameter d2. Valve (2) is
closed by the total of this force and the force of
spring (3), so port A and port B are shut off.

10-126

PC400/450(LC)-7

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

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

Criteria
Standard size

Spool return spring

10-128

Remedy
Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

132.0 29

114.5

833 N
{85.0 kg}

666 N
{68.0 kg}

Replace
spring if any
damages or
deformations
are found

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

10-129

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

10-130

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

HOLDING VALVE

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

Unit: mm
No.

Check item

Criteria

Remedy

Standard size
7

Check valve spring

Repair limit

Free length
OD

Installed
length

Installed
load

Free
length

Installed
load

20.8 12.2

13.5

12.7 N
{1.3 kg}

9.8 N
{1.0 kg}

47.0 N
{4.8 kg}

Spool return spring

41.1 9.6

35

58.8 N
{6.0 kg}

Spool return spring

41.9 25.8

41

78.4 N
{8.0 kg}

62.7 N
{6.4 kg}

10

Spool return spring

43.2 25.4

41

125.4 N
{12.8 kg}

100.4 N
{10.2 kg}

PC400/450(LC)-7

If damaged of
deformed,
replace spring

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.

10-132
(1)

PC400/450(LC)-7

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

10-133
(1)

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 d), spool (1) moves to
the right standby position (1st-stage stroke).
At this time, chambers a and b are not
connected to each other.
If the pilot pressure rises higher than the
force of spring (3) (area of d), spool (1)
moves further to the right and chambers a
and b connected to each other (2nd-stage
stroke).
Accordingly, the oil is returned from the work
equipment cylinder to the main valve.

[When piping bursts]


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

10-134

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-136

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC CYLINDER

Unit: mm
No.

Check item
Cylinder

Clearance
between
piston rod and
bushing

Clearance
between
piston rod
support pin
and bushing

Clearance
between
cylinder
bottom support pin and
bushing

PC400/450(LC)-7

Criteria
Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

Boom

110

0.036
0.090

+0.261
+0.047

0.083
0.351

0.412

Arm

120

0.036
0.090

+0.263
+0.048

0.084
0.353

0.412

Bucket

100

0.036
0.090

+0.257
+0.047

0.083
0.347

0.447

Boom

110

0.036
0.090

+0.169
+0.100

0.136
0.259

Arm

110

0.036
0.090

+0.169
+0.100

0.136
0.259

Bucket

100

0.036
0.090

+0.187
+0.097

0.133
0.277

Boom

100

0.036
0.090

+0.190
+0.070

0.106
0.280

Arm

110

0.036
0.090

+0.195
+0.099

0.135
0.285

Bucket

100

0.036
0.090

+0.187
+0.097

0.133
0.277

Replace
bushing

Replace pin
or bushing

10-137

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

WORK EQUIPMENT

10-138

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm
No.

Check item

Clearance between
connecting pin and bushing
of revolving frame and boom

Criteria
Standard
size

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

120

0.036
0.090

+0.173
+0.101

0.137
0.263

1.0

Clearance between
connecting pin and bushing
of boom and arm

120

0.036
0.090

+0.180
+0.112

0.148
0.270

1.0

Clearance between
connecting pin and bushing
of arm and link

100

0.036
0.090

+0.172
+0.081

0.117
0.262

1.0

Clearance between connecting pin and bushing of arm


and bucket

100

0.036
0.090

+0.138
+0.077

0.113
0.228

1.0

Clearance between connecting pin and bushing of link


and bucket

100

0.036
0.090

+0.172
+0.081

0.117
0.262

1.0

Clearance between connecting pin and bushing of link


and link

100

0.036
0.090

+0.190
+0.097

0.133
0.280

1.0

Bucket clearance (a)

0.5 1.0

Bucket clearance (b)

2.0

PC400/450(LC)-7

Replace

Adjust shims

10-139

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

1. Dimension of arm

10-140

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm
Model
PC400-7

PC450-7

No.
1

0.036
0.090

110 +0.1
+0 /

0.036
0.090

129.3 +1.5
+0 / 126 1.2

129.3 +1.5
+0 / 126 1.2

0.3
355 +0.5
+0 / 351 0.8

0.3
355 +0.5
+0 / 351 0.8

120 +0.1
+0 /

0.036
0.090

120 +0.1
+0 /

0.036
0.090

514.8

570.6

195

208.2

1,038

1,132.2

3,375

3,375

2,977.5

2,975.1

10

502

506.8

11

720

720

12

719

719

13

537.1

537.1

14

1,850

1,817

15
16
17

18

110 +0.1
+0 /

100 +0.1
+0 /

0.036
0.090

371 +1
+0 / 370 0.5
100 +0.1
+0 /

0.036
0.090

100 +0.1
+0 /

0.036
0.090

371 +1
+0 / 370 0.5
100 +0.1
+0 /

0.036
0.090

Arm as
individual part

355 0.5

355 0.5

When pressfitting bushing

370

370

Min.

1,870

1,870

Max.

3,140

3,140

19

PC400/450(LC)-7

10-141

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

2. Dimension of bucket

10-142

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm
Model
PC400-7

PC450-7

534.1 0.5

534.1 0.5

56.3 0.5

56.3 0.5

96 1

94 14

537.1

537.1

1,839

1,806

190

198

62 1

46 1

140.1 +0.1
+0

140.1 +0.1
+0

130 +0.063
0

130 +0.063
0

100 +0.1
+0

100 +0.1
+0

371 +1
+0

371 +1
+0

No.

10
A

57

58

72

72

12

144

144

13

562.5 +0.5
2.5

562.5 +0.5
2.5

14

26

26

165

165

16

230

230

17

146.1

135.5

18

137.6

142.0

19

R115

R115

20

R85

R85

21

410 1

410 1

22

64

64

11

15

PC400/450(LC)-7

10-143
(3)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AIR CONDITIONER

AIR CONDITIONER
AIR CONDITIONER PIPING

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

Hot water pickup piping


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

10-144

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

PC400/450(LC)-7

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.

PC400/450(LC)-7

10-145
(1)

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

PC400/450(LC)-7

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

CN1 [CN-E11]
Pin No.

ENGINE CONTROL

CN2 [CN-E12]
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

Pin No.
CN2-1 GND

Input

CN2-2 NC
CN2-3 NC

Input

CN2-4 RS232C_1RX
CN2-5 NC

Output

Input

CN2-8 NC
CN2-9 Sensor 5V power supply 2

CN1-10 GND
CN1-11 NC

Input

CN2-10 Fuel control dial


CN2-11 S_NET_SHIELD GND

CN1-14 NC
CN1-15

Engine oil pressure switch (For high


pressure)

CN1-16 Memory clear

Output
Input
Input
Input
Input

CN1-17 Model selection 3


CN1-18 NC

Input
Output

CN1-19 Key switch (ACC)


CN1-20 Starting switch (C)

Input
Input

Engine oil pressure switch (For low


CN1-21
pressure)

Input

CN1-22 Auto deceleration signal


CN1-23 Model selection 2

Input
Input

CN1-24 NC

Output

Input
Input

CN2-6 NC
CN2-7 NC

CN1-8 GND
CN1-9 NC

CN1-12 NC
CN1-13 Key switch (ACC)

Input/
Output

Signal name

Input
Input
Output
Input

CN2-12 CAN_SHIELD
CN2-13 NC

Output

CN2-14 RS232C_1TX
CN2-15 G_SHIELD (GND)

Output

CN2-16 Ne_SHIELD (GND)


CN2-17 Fuel temperature sensor

Input

CN2-18 NC
CN2-19 Sensor 5V power supply 1

Input
Output

CN2-20 Boost pressure sensor

Input

CN2-21 S_NET (+)

Input/
Output

CN2-22 CAN0_L

Input/
Output

CN2-23 NC
CN2-24 FWE_switch
CN2-25 G pulse ()

Input
Input

CN2-26 Ne pulse ()
CN2-27 Coolant temperature sensor (High)

Input
Input

CN2-28 NC
CN2-29 Analog GND

Input

CN2-30 NC

Input

CN2-31 S_NET (+)

Input/
Output

CN2-32 CAN0_H

Input/
Output

CN2-33 NC

10-148
(1)

CN2-34 GND (232C_GND)


CN2-35 G pulse (+)

Input

CN2-36 Ne pulse (+)


CN2-37 Coolant temperature sensor (Low)

Input
Input

CN2-38 NC

Input

CN2-39 Analog GND


CN2-40 Common rail pressure sensor

Input

PC400/450(LC)-7

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 (+)

Output

CN3-6 Injector #2 (+)


CN3-7 NC

Output
Input

CN3-8 Output mode selection 1 (Test mode)


CN3-9 Lever neutral flag (Test mode)

Input
Input

CN3-10 Engine rotation pulse output


CN3-11 Power GND

Output
Input

CN3-12 Supply pump 1 (+)


CN3-13 Supply pump 2 (+)

Output
Output

CN3-14 Injector #1 (+)


CN3-15 Injector #3 ()

Output
Output

CN3-16 Injector #2 ()
CN3-17 NC

Output
Input

CN3-18 Output mode selection 2 (Test mode)


CN3-19 NC

Input
Input

CN3-20 Q command output


CN3-21 Power supply for power

Output

CN3-22 Supply pump 1 ()


CN3-23 Supply pump 2 ()

Output
Output

CN3-24 Injector #1 ()
CN3-25 Injector #6 (+)

Output
Output

CN3-26 Injector #4 (+)


CN3-27 NC

Output
Output

CN3-28 Auto deceleration flag (Test mode)


CN3-29 NC

Input
Input

CN3-30 GND
CN3-31 Power GND
CN3-32 Power GND
CN3-33 Injector #5 ()

Output

CN3-34 Injector #5 (+)


CN3-35 Injector #6 ()

Output
Output

CN3-36 Injector #4 ()
CN3-37 NC

Output
Output

CN3-38 Auto deceleration control (Test mode)


CN3-39 NC

Input
Input

CN3-40 GND

PC400/450(LC)-7

10-149

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

10-151

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

TOTAL SYSTEM DIAGRAM

10-152
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC400/450(LC)-7

ELECTRONIC CONTROL SYSTEM

10-153

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1. Engine and Pump control function

10-154

PC400/450(LC)-7

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

10-155

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

246.3 kW/1,850 rpm


{331 HP/1,850 rpm}

Mode E

213.3. kW/1,720 rpm


{286 HP/1,720 rpm}

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

10-156

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Mode B / (Mode
Mode

L)
Mode B

Mode

Partial output point

82%

Mode B

194.9 kW/1,730 rpm


{261 HP / 1,730 rpm}

Mode

ELECTRONIC CONTROL SYSTEM

61%

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

10-157

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

10-158

PC400/450(LC)-7

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

10-159

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

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

Relief pressure
34.8 MPa
{355 kg/cm2}
37.2 MPa
{380 kg/cm2}

: The L mode is on the multi-monitor specification


machine only.

10-160

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

10-161

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

Software cut-off
function

Automatically reset at
8.5 sec

Cancel

2) Machine push-up function


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

Switch

OFF

ON

10-162

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}

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

PC400/450(LC)-7

10-163
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

10-164

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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.

PC400/450(LC)-7

10-165
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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)

Operated

Coolant temperature: Below 30C.


Engine speed: Max. 1,200 rpm

Engine speed: Max. 1,200 rpm

Resetting condition (Any one)


Auto
Manual

Reset

Coolant temperature: Above 30C


Auto-warm-up operation time: Min. 10 minutes

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.

Operating condition

Coolant temperature: Above 105C

Operating condition
Coolant temperature: Above 102C

Operating condition
Coolant temperature: Above 100C

Operating condition
Coolant temperature: Above 95C

10-166
(1)

Engine speed: Any level

Fuel control dial: Kept at 70% of full level for


3 sec. or longer

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

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.

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

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

Resetting condition
Coolant temperature: Below 105C
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 102C
Under above condition, controller is
set to condition before operation of
function. (Automatic reset)
Resetting condition
Coolant temperature: Below 100C
Under above condition, controller is
set to condition before operation of
function. (Automatic reset)
Resetting condition
Coolant temperature: Below 95C
Under above condition, controller is
set to condition before operation of
function. (Automatic reset)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

6. Swing control function

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

PC400/450(LC)-7

10-167

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1) Swing lock and swing holding brake functions


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

Lock
lamp

Function

OFF

OFF

Swing
holding
brake

ON

ON

Swing
lock

ELECTRONIC CONTROL SYSTEM

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.

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.

: 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

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

OFF
Swing
holding
brake is
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.

10-168

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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.

PC400/450(LC)-7

10-169

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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)

( Mi)
(Middle
Speed)

Hi
(High
speed)

90

82

100

Max.

Max.

Min.

3.2

4.5

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.

10-170

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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.

PC400/450(LC)-7

10-171
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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.

10-172

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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.

PC400/450(LC)-7

10-173

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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

10-174
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

Pump controller

PC400/450(LC)-7

10-175

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

Input and output signals


CN-1

CN-2

Pin No.

Signal name

Input/
Output

NC

2
3

R pump pressure sensor


NC

4
5

NC
NC

6
7

NC
NC

Input

8
9

F boom pressure sensor


NC

Input

10
11

Signal GND
Knob SW

12
13

NC
Buchet CURL PPC pressure sensor

14
15

NC
NC

16
17

NC
Starting switch (Terminal C)

18
19

NC
Arm IN PPC pressure sensor

20
21

NC
NC

22
23

POT_PWR
Starting switch (terminal ACC)

24

NC

10-176
(1)

Input

Pin No.

Input/
Output

Signal name

NC

2
3

Swing emergency switch


NC

Input
Input

4
5

232C_RxD
NC

Input

6
7

NC
Model selection 4

8
9

Attachment circuit selector signal


NC

Input
Output

Input

10
11

NC
NC

Input

12
13

CAN shield
Model selection 5

Input

14
15

232C_TxD
NC

Input

16
17

Travel steering signal pressure SW


Model selection 3

Input

18
19

NC
Auto deceleration signal

20

NC

21

S_NET

Input/
output

22

CAN0_L

Input/
output

Output
Input

Input
Output
Input
Input
Output

23

NC

24
25

FWE_SW
NC

26
27

NC
Model selection 2

28
29

NC
GND (pulse GND)

30
31

NC
GND (S_NET GND)

32

CAN0_H

33

NC

34

GND (232C GND)

35

Service valve pressure switch

Input

36
37

NC
Model selection switch 1

Input

38
39

Swing lock switch


GND (pulse GND)

Input

40

Engine speed sensor

Input

Input

Input

Input/
output

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

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

PC400/450(LC)-7

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

10-177

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.)

10-178

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

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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). The switches are flat sheet
switches.

PC400/450(LC)-7

10-179

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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)

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

Input/
output
Input
Input
Output
Input
Input

Input
Output
Output
Input
Input

Input/
output
Input
Input
Input
Input
Input
Input
Input
Input

9 N/W signal

Input/
Output

10 N/W signal

Input/
Output

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

10-180
(1)

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

9 RS230C RXD

Input/
Output

10 RS230C RXD

Input/
Output

11 BOOTSW
12 NC
13 GND

Input
Input

14 CAN (SHIELD)

Input

15 CAN (+)
16 CAN (-)

Input
Input

Input
Input
Input
Input
Input
Input
Input
Input

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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

PC400/450(LC)-7

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

10-181
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

MONITOR ITEMS AND DISPLAY


Symbol

Display item

Swing lock

Preheating

Power Max

Display method

Swing lock switch

Swing holding brake


release switch

Swing lock monitor

OFF

OFF

OFF

ON

OFF

ON

OFF

ON

Flashes

ON

ON

ON

Continuous set time

Preheating monitor status

Up to 30 sec.

ON

From 30 sec. to 40 sec.

Flashes

More than 40 sec.

OFF

Power Max. switch status

Power Max. monitor status

Being pressed

Lights up but goes out after


approx. 9 sec when kept pressed

Not being pressed

Flashes

Engine coolant
temperature
Hydraulic oil
temperature

See gauge display on the next page

Fuel level

10-182
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Gauge

Engine coolant
temperature (C)

Hydraulic oil temperature (C)

Fuel level (l)

PC400/450(LC)-7

MONITOR SYSTEM

Range

Temperature, volume

Indicator

A1

105

Red

A2

102

Red

A3

100

Green

A4

80

Green

A5

60

Green

A6

30

White

B1

105

Red

B2

102

Red

B3

100

Green

B4

80

Green

B5

40

Green

B6

20

White

C1

467

Green

C2

381

Green

C3

295

Green

C4

147.5

Green

C5

114

Green

C6

80.5

Red

Buzzer sound

10-183
(1)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

Symbol

Display item

Check before starting


item

When engine is
stopped

When engine is
running

Engine oil pressure

When abnormal,
lights up and buzzer
sounds

Battery charge

Lights up when
abnormal

Radiator coolant level

Lights up when
abnormal

When abnormal,
lights up and buzzer
sounds

Engine oil level

Lights up when
abnormal

Air cleaner clogging

Lights up when
abnormal

Maintenance

Lights up when there is a warning. Lights up for


only 30 sec. after key is turned ON, then goes
out.

The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed.
Condition of hydraulic oil

Color of symbol

Low temperature (below B6 or equivalent)

Black on white background

Normal (B6 B2)

No display

High temperature (below B2)

White on red background

10-184
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Display category

Symbol

Display item

Wiper

MONITOR SYSTEM

Display range

INT

ON

Display method

OFF

Displays set condition

Working mode

Displays set mode

Travel speed

Displays set speed

Monitor

Auto-deceleration

Service meter

PC400/450(LC)-7

Service meter
indicator

ON

OFF

When service meter is working

Displays actuation
status

Lights up when service


meter is working

10-185

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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

10-186

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

PC400/450(LC)-7

MONITOR SYSTEM

Switch that is
pressed

Display

Working mode status


after setting

[A]

A mode (default)

[E]

E mode

[L]

Heavy-lift mode

[B]

Swing priority mode

Display

Setting

Crawler symbol + Lo

Low speed (default)

Crawler symbol + Mi

Medium speed

Crawler symbol + Hi

High speed

Display

Setting

Wiper actuation
status

None

OFF

Stowing stopped or
now stowing

Wiper symbol + INT

INT

Intermittent actuation

Wiper symbol + ON

ON

Continuous actuation

10-187

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.)

10-188

MONITOR SYSTEM

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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

Monitor display

A mode

[A] + crusher symbol

E mode

[E] + crusher symbol

B mode

[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.

PC400/450(LC)-7

Flow level

Flow (L/min.)

530

430

370

300

230

165

100

30

Remarks
Default

10-189

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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.

10-key pad operation

01

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

No.

Flow level (L/min.)

01

230

02

190

03

150

Remarks
Default

Actuation
Flow level bar graph
extends to the right

Flow level bar graph


retracts to the left

10-190

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

PC400/450(LC)-7

MONITOR SYSTEM

Flow
level

When
flow is
140 l/
min.

When
flow is
220 l/
min.

When
flow is
300 l/
min.

200

280

360

180

260

340

160

240

320

140

220

300

120

200

280

100

180

260

80

160

240

Remarks

Default

Display level

Set value (l/min.)

220 or 360

200 or 340

180 or 320

160 or 300

140 or 280

120 or 260

100 or 240

80

10-191

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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.

Item

Replacement interval
(hours)

01

Engine oil

500

02

Engine oil filter

500

03

Fuel filter

500

04

Hydraulic filter

1000

05

Hydraulic tank breather

500

06

Corrosion resistor

1000

07

Damper case oil

1000

08

Final case oil

2000

09

Machinery case oil

1000

10

Hydraulic oil

5000

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

Condition

None

Remaining time for maintenance for all items is more


than 30 hours

Notice display (black symbol displayed on yellow


background)

There is one or more items


with less than 30 hours
remaining time for maintenance

Warning display (wiper


symbol displayed on red
background)

There is one or more items


with less than 0 hours
remaining time for maintenance

10-192
(1)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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.

PC400/450(LC)-7

10-193

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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.

Symbol

Content

01

Return mark

Return

02

Contrast

03

Brightness

2. Press control switch (2), or use the 10-key pad


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

Actuation
Flow level bar graph
extends to the right

Flow level bar graph


retracts to the left

10-194

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR SYSTEM

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.

PC400/450(LC)-7

10-195

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

10-196

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.

PC400/450(LC)-7

MONITOR SYSTEM

10-197
(4)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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.)

10-197-1
(4)

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

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.

CN-P02
Signal name

Pin
No.

Signal name

Key switch (Battery)

Engine water temperature

Key switch (Battery)

Fuel

Washer motor output

Radiator water level

Key switch (Terminal C)

NC

Wiper contact W

Air cleaner clogging sensor

GND

NC

GND

Engine oil pressure sensor

VB + (24 V)

Engine oil level sensor

Wiper motor (+)

Network signal

10 Wiper motor ()

10 Network signal

11 (Buzzer ON signal input)

11 Charge level

12 Wiper contact P

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
(4)

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
(4)

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Monitored items and display


Symbol

PC400/450(LC)-7

Displayed item

Display range

When engine is
stopped

While engine is running

Engine oil pressure

Max. 1,500 rpm


Max. 0.05 MPa
{0.5 kg/cm}
Min. 1,500 rpm
Max. 0.15 MPa
{1.5 kg/cm}

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.

Engine oil level

Below low level

Flashes when
abnormal.

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

Coolant temperature

Flashes at 102C or higher. Flashes and


buzzer sounds at 105C or higher.

Fuel level

Flashes when below low level.

Lights up for 30 sec. when starting switch is set to


HEAT. Then, flashes for 10 sec. to indicated
completion of preheating.

10-197-4
(4)

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
(4)

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
(4)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Mode selector switches


1.
2.
3.
4.

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.

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.

10-197-7
(4)

Travel speed switch


Auto-deceleration switch
Wiper switch
Work mode selector switch
(Including setting 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

Operation

Work mode

AEB

Auto-deceleration

ON OFF

Wiper
Travel speed

OFF Intermittent ON
Hi Lo

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

Type of sensor

When normal

When abnormal

Engine oil level

Contact

ON (closed)

OFF (open)

Engine oil pressure

Contact

OFF (open)

ON (closed)

Hydraulic oil temperature

Resistance

Coolant temperature

Resistance

Fuel level

Resistance

Contact type

OFF (open)

ON (closed)

Air cleaner clogging

10-198

PC400/450(LC)-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SENSOR

Engine oil level sensor


1.
2.
3.
4.

Connector
Bracket
Float
Switch

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

Plug
Contact ring
Contact
Diaphragm
Spring
Terminal

Engine oil pressure sensor (For low pressure)

Coolant temperature sensor


Hydraulic oil temperature sensor

1. Thermistor
2. Body
3. Tube

PC400/450(LC)-7

4. Tube
5. Wire
6. Connector

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

Item

Machine model

PC400, 400LC-7
PC450, 450LC-7

Engine

SAA6D125E-3

Measurement condition

Unit

Standard value

Permissible value

1,930 50

1,930 50

1,000 25

1,000 25

1,850

1,850

kPa
{mmHg}

Min 107 {Min. 800}

87 {650}

Max. 700

Max. 700

Max. 4.0

6.0

Max. 1.0

2.0

0.33

0.71

Min. 2.9 {Min. 30}


(150 200)

2.0 {20}
(150 200)

Max. 1.18 {Max. 120}

1.96 {200}

0.39 0.69 {4.0 7.0}

0.21 {2.1}

0.34 0.64 {3.5 6.5}

0.18 {1.8}

High idling
Engine speed

Low idling

rpm

Rated speed
Intake air pressure

At rated output

Exhaust gas
pressure

All speed range


(intake air temp: 20C)
At sudden acceleration

Bosch
index

Exhaust gas color


At high idling
Valve clearance
(normal temperature)

Intake valve
mm
Exhaust valve

Compression
pressure

Oil temperature: 40 60C


(Engine speed)

Blow-by pressure

(Coolant temperature:
within operating range)
At rated output

MPa {kg/cm2}

(rpm)
kPa
{mmH2O}

(Coolant temperature:
within operating range)
At high idling
Oil pressure

At high idling

(SAE30)
(SAE10W)

MPa
{kg/cm2}

At low idling

(SAE30)

Min. 0.15 {Min. 1.5}

0.08 {0.8}

At low idling

(SAE10W)

Min. 0.1 {Min. 1.0}

0.07 {0.7}

Oil temperature

All speed range (inside oil pan)

90 120

120

Fan, alternator belt


tension

Deflection when pressed with finger force of approx. 58.8 N {6 kg}

mm

Approx. 13

Approx. 13

Air conditioner
compressor belt
tension

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


PC400, 400LC-7
PC450, 450LC-7

Applicable model

Engine speed

Category

Item

Measurement conditions

Standard value

Permissible value

1,930 100

1,930 100

1,830 100

1,830 100

1,300 100

1,300 100

9.5 0.5

9.5 0.5

85 10

85 10

85 10

85 10

85 10

85 10

85 10

85 10

115 12

115 12

Max. 10

Max. 15

Boom control lever

15.7 4.9
{1.6 0.4}

Max. 24.5
{Max. 2.5}

Arm control lever

15.7 4.9
{1.6 0.4}

Max. 24.5
{Max. 2.5}

12.7 2.9
{1.3 0.3}

Max. 21.6
{Max. 2.2}

12.7 2.9
{1.3 0.3}

Max. 21.6
{Max. 2.2}

24.5 5.9
{2.5 0.6}

Max. 39.2
{Max. 4.0}

74.5 18.6
{7.6 1.9}

Max. 107.6
{Max. 11}

2 pumps at relief

Engine coolant temperature:


Within operating range
Hydraulic oil temperature:
Within operating range
Engine at high idling
Arm in relief condition

At 2-pump relief + one


touch power up

Engine coolant temperature:


Within operating range
Hydraulic oil temperature:
Within operating range
Engine at high idling
Arm relief + One-touch power
max. switch in ON condition

Speed when autodeceleration is operated

Engine at high idling


Auto-deceleration switch in ON
condition
All control levers in NEUTRAL
condition

Unit

rpm

Spool stroke

Boom control valve


Arm control valve
Bucket control valve

mm

Swing control valve

Operating effort of control levers

Travel of control levers

Travel control valve


Boom control lever
Arm control lever
Bucket control lever
Swing control lever
Travel control lever

Engine stopped
At center of control lever grip
Max. reading up to stroke end
(excepting lever play in NEUTRAL position)

mm

Play of control levers

Bucket control lever


Swing control lever

Travel
control

PC400/450(LC)-7

Lever
Pedal

Hydraulic oil temperature:


Within operation range
Engine at high idling
Hydraulic oil temperature:
Within operating range
At center of control lever grip
Max. reading up to stroke end

N {kg}

20-3
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

Applicable model
Category

Item

Unload pressure

Measurement conditions

Unit

Hydraulic oil temperature:


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

Hydraulic pressure

Arm

Bucket

LOWER

Hydraulic oil
temperature:
Within operation range
Engine at high
idling

(1)

{42 10}

{42 10}

34.81 +1.47
0.98

33.34 36.77
(35.79 39.23)

At lowpressure
setting

18.14 0.98

16.67 19.61

{185 10}

{170 200}

At highpressure
setting

31.38 1.47

29.2 33.34

{320 15}

{300 340}

34.81 +1.47
0.98

33.34 36.77

Travel

20-4

4.2 1.0

{340 375 (365 400)}

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)

Hydraulic oil temperature:


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

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

+15
{355 +15
10 (380 10 )}

Swing

Control circuit source


pressure

Permissible value

(37.27 +1.47
0.98 )

RAISE

Boom

Standard value

MPa
{kg/cm2}

(37.27 +1.47
0.98 )
+15
{355 +15
(380
10
10 )}
34.81 +1.47
0.98
(37.27 +1.47
0.98 )
+15
{355 10 (380 +15
10 )}
+1.47
30.89 2.45
{315 +15
25 }
37.27 +2.94
0.98
{380 +30
10 }

(35.79 39.23)
{340 375 (365 400)}

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

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

3.24 0.2
{33 2}

2.84 3.43
{29 35}

When all
control
levers in
NEUTRAL
position

4.2 1.0
{42 10}

4.2 1.0
{42 10}

When traveling at half


stroke
(without
load)

2.65 0.1
{27 1}

2.65 0.1
{27 1}

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

Applicable model
Category

Item

Swing brake angle

Measurement conditions

Unit

Standard value

Permissible value

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

3.7 0.4

Max. 4.6

5.4 0.5

Max. 6.4

sec.

33.0 3.3

Max. 38

mm

90
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

sec.

180

Swing

Time taken to start


swing

Time taken to swing

Hydraulic drift of swing

PC400/450(LC)-7

Hydraulic oil temperature:


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

Hydraulic 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

20-5
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

Applicable model

Swing

Category

Item

Leakage from swing


motor

Measurement conditions

Unit

Standard value

Permissible value

l/min

Max. 5.5

Max. 11

STD: 63.2 12.6


LC: 67.3 13.5

STD: 42.0 80.0


LC: 45.0 84.5

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

17.1 2.6

14.4 21.0

13.1 1.3

11.7 15.1

Max. 200

Max. 300

Hydraulic oil temperature: Within


operation range
Engine at high idling
Swing lock switch: ON
Leakage amount for one minute
during swing relief

Lo

Travel speed
(Idle travel)

Travel

Travel speed
(Actual travel)

Travel deviation

20-6
(1)

Hydraulic oil temperature:


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

Hydraulic oil temperature:


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

Mi

Mi

sec.

sec.

Hi

Hydraulic oil temperature: Within


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

mm

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

Applicable model
Category

Measurement conditions

Unit

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

mm

l/min

Max. 20

Max. 40

Whole work
equipment (tooth
tip fall amount)

PC400: Max. 600


PC450: Max. 700

PC400: Max. 900


PC450: Max. 1,050

Boom cylinder
(cylinder retraction amount)

PC400: Max. 25
PC450: Max. 29

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

Travel

Item

Hydraulic drift of work equipment

Work equipment

Leakage of travel
motor

Arm cylinder (cylinder extension


amount)

Bucket cylinder
(cylinder retraction amount)

PC400/450(LC)-7

Hydraulic oil temperature:


Within operating range
Engine at high idling
Travel: Lock sprocket.
Oil leakage amount for one
minute with traveling in relief condition

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

mm

20-7
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

20-8
(1)

RAISE
Bucket

PC400: 4.0 0.4


PC450: 4.2 0.4

PC400: Max. 4.8


PC450: Max. 5.0

LOWER

Arm

Service limit value

PC400: 2.9 0.3


PC450: 2.8 0.3

PC400: Max. 3.4


PC450: Max. 3.3

CURL

Work equipment speed

Work equipment

Boom

Standard value for


new machine

PC400: 4.3 0.4


PC450: 4.7 0.5

PC400: Max. 5.0


PC450: Max. 5.4

DUMP

Item

3.6 0.4

Max. 4.3

CURL

Category

3.6 0.4

Max. 4.3

DUMP

Applicable model

2.9 0.3

Max. 3.5

Measurement conditions

Hydraulic oil temperature:


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

Hydraulic oil temperature:


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

Hydraulic oil temperature:


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

Unit

sec.

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

Applicable model
Category

Item

Time lag

Work equipment

Boom

Arm

Internal leackage

Bucket

Cylinders

Center swivel
joint

PC400/450(LC)-7

Measurement Condition

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

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

Unit

Standard value

Permissible value

sec.

Max. 3.0

Max. 3.6

PC400: Max. 3.0


PC450: Max. 4.0

PC400: Max. 3.6


PC450: Max. 4.6

Max. 3.0

Max. 5.0

4.5

20

10

50

sec.

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

cc/min

20-9
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

Applicable model

Performance of
hydraulic pump

Performance in compound operation

Category

20-10
(1)

Item

Swerving amount in
simultaneous operation of work equipment and travel

Hydraulic pump
delivery

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

See next page

Unit

Standard value

Permissible value

mm

Max. 400

Max. 440

l/min

See next page

PC400/450(LC)-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

PC400, 400LC-7
PC450, 450LC-7

Applicable model
Category

Item

Measurement Condition

Unit

Standard value

Permissible
value

Performance of hydraulic pump

Discharge amount of hydraulic pump (A mode)

Pump speed: At 1,950 rpm, PC current 280 mA

Check point

As desired
a
a

Test pump
discharge
pressure
(MPa {kg/cm2})

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

P1

P2

Average
pressure
(MPa {kg/cm2})
P1+P2
2

Standard value
for discharge
amount Q
(l/min)

Judgement
standard lower
limit Q
(l/min)

See graph

See graph

As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point
of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.

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

Measuring intake air pressure (boost pressure)

799-201-2202 Boost gauge kit

101 200 kPa {760 1,500 mmHg}

Measuring exhaust
temperature

799-101-1502 Digital thermometer

99.9 1,299C

1 799-201-1502 Handy smoke meter

Measuring exhaust gas


color

Part No.

Part name

C
2

Adjusting valve clearance

E 2
3

Measuring blow-by pressure

Measuring engine oil


pressure

Measuring fuel pressure

Smoke meter

Commercially
available

Feeler gauge

Air intake side: 0.35 mm, Exhaust side:


0.57 mm

0 6.9 MPa {0 70 kg/cm2}

795-471-1410 Adapter

6217-71-6112

Gasket

795-799-1170

Puller

799-101-5002 Hydraulic tester

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


{25, 60, 400, 600 kg/cm2}

790-261-1203 Digital hydraulic tester

(Pressure gauge): 58.8 MPa {600 kg/cm2}

2 799-401-2320 Hydraulic tester

(Pressure gauge): 0.98MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

2 799-401-2320 Hydraulic tester


Measuring clearance of
swing circle bearing
Measuring and adjusting oil
pressures in work equipment, swing, and travel circuits

Commercially
available

J
1
k
2

1
Measuring basic pressure
in control circuit

L
2

Testing and adjusting oil


pressure in pump PC
control circuit

20-102
(1)

For 125E-3 engine

Pollution level: 0 70 % (With standard


color)
(Pollution level 1/10 Bosch index)

799-201-1504 Blow-by checker

Remarks

Commercially
available

1 795-502-1590 Compression gauge


Measuring compression
pressure

Qty

Testing/Adjusting item

symbol

TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE

1
M
2

Dial gauge

1
1

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

799-101-5220 Nipple

07002-11023

O-ring

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

799-101-5220 Nipple

07002-11023

O-ring

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

799-101-5220 Nipple

07002-11023

O-ring

Same as G

with magnet
Same as G

(Size): 10 1.25 mm

Same as G1

Same as K2

Same as G

PC400/450(LC)-7

1
Testing and adjusting
pressure in pump LS
control circuit

N 2

Part No.

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

799-101-5220 Nipple

07002-11023

O-ring

Differential pressure
gauge

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

P
2

Measuring PPC valve


output pressure

Part name

Qty

Testing/Adjusting item

TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE

symbol

TESTING AND ADJUSTING

Remarks

Same as G1

Same as M2

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

799-401-3100 Adapter

(Size): 02

799-401-3200 Adapter

(Size): 03

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

2 970-301-1740 Joint

Same as G1

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

Measuring oil leakage

Commercially
available

Testing wear of sprocket

799-627-1120 Wear gauge

Measuring coolant and oil


temperatures

799-101-1502 Digital thermometer

Measuring operating effort


and pressing force

79A-264-0021 Push-pull scale

0 294 N {0 30 kg}

79A-264-0091 Push-pull scale

0 490 N {0 50 kg}

Measuring stroke and


hydraulic drift

Commercially
available

Scale

Measuring work equipment speed

Commercially
available

Stopwatch

Measuring voltage and


resistance

Commercially
available

Tester

Measuring cylinder

Same as B

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.

PC400/450(LC)-7

20-103
(1)

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.

20-104
(1)

PC400/450(LC)-7

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

Part No.

799-201-2202

Part Name
Boost gauge kit

a When installing and removing the measuring


instruments, take care not to touch a hot part of
the engine.

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).

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.

PC400/450(LC)-7

20-105
(1)

TESTING AND ADJUSTING

MEASURING EXHAUST TEMPERATURE

MEASURING EXHAUST TEMPERATURE


a Measuring instrument of exhaust gas temperature
Symbol

Part No.

799-101-1502

Part Name
Digital thermometer

k Install and remove the measuring instrument after the exhaust manifold is cooled.

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.

1. Open the engine hood and remove exhaust


temperature pick-up plug (1).

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.

20-106
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

MEASURING EXHAUST GAS COLOR


a Measuring instrument of exhaust gas color
Symbol
C

Part No.

Part Name

799-101-9000

Handy smoke checker

Commercially
available

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.

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.

PC400/450(LC)-7

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.

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.

20-107
(1)

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE


a Adjusting instrument for valve clearance
Symbol

Part No.

Commercially
available

the compression top dead center. In this


case, rotate the crankshaft one more turn.

Part Name
Feeler gauge

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

20-108
(1)

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

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

20-109
(1)

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE


a Measuring instruments for compression pressure
Symbol
1
E

2
3

Part No.

Part Name

795-502-1590

Compression gauge

795-471-1410

Adapter

6217-71-6112

Gasket

795-799-1170

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 60C.

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}

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.
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.

20-110
(1)

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.

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}

PC400/450(LC)-7

20-111
(1)

TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE


a Measuring instrument for blow-by pressure
Symbol

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.

20-112
(1)

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.

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-401-2320

Hydraulic tester

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.

PC400/450(LC)-7

20-113
(1)

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.

20-114
(1)

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.)

PC400/450(LC)-7

TESTING AND ADJUSTING

MEASURING FUEL PRESSURE

MEASURING FUEL PRESSURE


a Measuring instruments for fuel pressure
Symbol

1
2

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-401-2320

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}

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.

PC400/450(LC)-7

20-115
(1)

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.

20-116
(1)

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}

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

20-117
(1)

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.

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.

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.

20-118
(1)

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)

PC400/450(LC)-7

20-119
(1)

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).

Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.

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

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.

20-120
(1)

PC400/450(LC)-7

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).

Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.

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

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.

PC400/450(LC)-7

20-121
(1)

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

Part No.

Commercially
available

Part Name

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.

Dial gauge

a When measuring the clearance of the swing circle bearing on the actual machine, observe the
following procedure.

5.

Under this condition, read dial gauge J.


a Dial gauge J indicates the clearance of the
bearing.

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.

20-122
(1)

PC400/450(LC)-7

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

PC400/450(LC)-7

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.

20-123
(1)

TESTING AND ADJUSTING OIL PRESSURE IN WORK


EQUIPMENT, SWING, AND TRAVEL CIRCUITS

TESTING AND ADJUSTING

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.

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 1.25 mm)

07002-11023

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

20-124
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING OIL PRESSURE IN WORK


EQUIPMENT, SWING, AND TRAVEL CIRCUITS

TESTING AND ADJUSTING

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

(F unload valve) (F main relief valve)

Front

Service

Safety valve for service

Boom Hi
Arm Hi

F main relief valve

Bucket

F main relief valve

Left
travel

F main relief valve

Boom

RAISE: F main relief valve


LOWER: Safety-suction
valve

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.

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)

Rear

Swing

Swing motor safety valve

Right
travel

R main relief valve

Arm Lo

R main relief valve

(R unload valve) (R main relief valve)


(Centralized safety valve) (Back pressure valve)

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.

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.

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.

PC400/450(LC)-7

20-125
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK


EQUIPMENT, SWING, AND TRAVEL CIRCUITS

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.

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}

20-126
(1)

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 (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}

PC400/450(LC)-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK


EQUIPMENT, SWING, AND TRAVEL CIRCUITS

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.

PC400/450(LC)-7

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.

20-127
(1)

TESTING AND ADJUSTING

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.

Part Name

799-101-1502

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 1.25 mm)

07002-11023

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}.

20-128
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING OIL PRESSURE IN PUMP


PC CONTROL CIRCUIT

TESTING AND ADJUSTING

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.

Part Name

799-101-1502

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 1.25 mm)

07002-11023

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.

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

PC400/450(LC)-7

The figure shows the PC valve output


pressure side.

3) Run the engine and raise the hydraulic oil


temperature to the operating range.

20-129
(1)

TESTING AND ADJUSTING OIL PRESSURE IN PUMP


PC CONTROL CIRCUIT

TESTING AND ADJUSTING

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

2. Measuring PC-EPC valve output pressure


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

Pressure ratio
1
Approx. 0.6
(Approx. 3/5)

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.

20-130
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING OIL PRESSURE IN PUMP


PC CONTROL CIRCUIT

TESTING AND ADJUSTING

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

Control lever

Low idling
Neutral
High idling

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).

PC400/450(LC)-7

20-131
(1)

TESTING AND ADJUSTING OIL PRESSURE IN PUMP


LS CONTROL CIRCUIT

TESTING AND ADJUSTING

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

2
3

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 1.25 mm)

07002-11023

O-ring

799-401-2701

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.

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.

20-132
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS


CONTROL CIRCUIT

TESTING AND ADJUSTING

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

(5): Front LS valve output pressure pickup plug


(6): Rear LS valve output pressure pickup plug

Pressure ratio
Travel lever
All levers
operated
in neutral
halfway
Almost
same

1
Approx. 0.6
(Approx. 3/5)

5) After finishing measurement, remove the


measuring instruments and return the
removed parts.

PC400/450(LC)-7

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.

20-133
(1)

TESTING AND ADJUSTING

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.

20-134
(1)

5) After finishing measurement, remove the


measuring instruments and return the
removed parts.

PC400/450(LC)-7

TESTING AND ADJUSTING

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

Travel lever

Lo

Netral

Hi

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}

PC400/450(LC)-7

20-135
(1)

TESTING AND ADJUSTING

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.

20-136
(1)

PC400/450(LC)-7

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.

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-401-3100

Adapter (Size 02)

799-401-3200

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 operators 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

PC400/450(LC)-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).

20-137
(1)

TESTING AND ADJUSTING

MEASURING SOLENOID VALVE OUTPUT PRESSURE

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


Solenoid valve

Output pressure

OFF (Deenergized)

0 MPa {0 kg/cm2}

ON (Energized)

Almost same as control


basic pressure
(See standard values
table)

6. After finishing measurement, remove the measuring instruments and return the removed parts.
Operation table of 2nd-stage relief solenoid valve
Operating condition
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

Operation
OFF

When travel signal is turned ON


When in L-mode
ON

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

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
When all are
turned OFF

Work equipment,
swing, travel signal When one of them
is turned ON

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 speed switch is set to Mi or Hi

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

ON

When not under above condition

20-138
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

MEASURING SOLENOID VALVE OUTPUT PRESSURE

Operation table of merge-divider solenoid valve


When in B-mode

Operating condition
When service signal is turned ON

Operation

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 travel signal is When swing signal is


turned OFF
turned OFF

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}

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}

ON

OFF
ON
OFF
ON
OFF

When not under above condition

Operation table of travel junction solenoid valve


Operating condition

Operation

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 table of PPC lock solenoid valve


Operating condition
Lock
Safety lock lever
Free

PC400/450(LC)-7

OFF
ON

20-139
(1)

TESTING AND ADJUSTING

MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE OUTPUT PRESSURE


a Measuring instruments for PPC valve output
pressure
Symbol
1

Part No.

Part Name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

790-301-1740

Joint (PF 1/4 + PT 1/8)

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 operators 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.

Circuit to be
measured

No.

Boom RAISE (S06)

Swing LEFT (S07)

Boom LOWER (S02)

Swing RIGHT (S03)

Arm IN (S04)

Travel (S30)

Arm OUT (S08)

10 Steering (S31)

Bucket CURL (S01)

Bucket DUMP (S05)

20-140
(1)

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

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

PC400/450(LC)-7

TESTING AND ADJUSTING

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

Output pressure

In neutral

0 MPa {0 kg/cm2}

Operated to
stroke end

Almost same as control


basic pressure
(See standard values
table)

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

PC400/450(LC)-7

20-141
(1)

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.

20-142
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

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.

2. Testing arm cylinder


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

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) 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.

PC400/450(LC)-7

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.

20-143
(1)

TESTING AND ADJUSTING

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).

20-144
(1)

PC400/450(LC)-7

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.

PC400/450(LC)-7

20-145
(1)

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE


a Measuring device for oil leakage
Symbol

Part No.

Commercially
available

Part Name
Measuring cylinder

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.

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.

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 disconnect the hose on


the cylinder bottom side.
a Use the following part to block the hose
side.
07379-01044 (Flange #10)

4) Run the engine at high idling and relieve the


arm circuit by moving the arm IN.

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.

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.

20-146
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

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.

MEASURING OIL LEAKAGE

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)

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)

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.

PC400/450(LC)-7

20-147
(1)

TESTING AND ADJUSTING

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)

4) Run the engine at high idling and relieve the


travel circuit.

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.

20-148
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

BLEEDING AIR FROM EACH PART

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

Note:

1
Bleeding
air from
hydraulic
pump
q

2
Starting
engine
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

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.

PC400/450(LC)-7

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.)

20-149
(1)

TESTING AND ADJUSTING

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.

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.

20-150
(1)

BLEEDING AIR FROM EACH PART

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}

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.

PC400/450(LC)-7

TESTING AND ADJUSTING

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.

PC400/450(LC)-7

20-151
(1)

TESTING AND ADJUSTING

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.

20-152
(1)

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)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

SPECIAL FUNCTIONS OF MONITOR PANEL

[1] Numeral input switch 1

[6] Numeral input switch 6

] Return switch

[2] Numeral input switch 2

[7] Numeral input switch 7

] Move-up switch

[3] Numeral input switch 3

[8] Numeral input switch 8

] Move-down switch

[4] Numeral input switch 4

[9] Numeral input switch 9

] Input check switch

[5] Numeral input switch 5

[0] Numeral input switch 0

PC400/450(LC)-7

20-153
(1)

TESTING AND ADJUSTING

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.
Operators Menu
1

Function of inputting and setting password

Screen to display KOMATSU logo

Service Menu
16

Function of monitoring [01]

17

Function of
abnormality
record [02]

Electrical system

Function of check before starting

Function of displaying maintenance items

18

Function of maintenance record [03]

Function of displaying caution items

19

Function of maintenance mode change [04]

Function of checking working mode and


travel speed

20

Function of phone No. entry [05]

Function of displaying ordinary screen

Function of adjusting brightness and contrast


of display

Function of adjusting flow rate for breaker


and attachments

10

Function of checking maintenance information

With/Without service circuit

11

Function of displaying service meter

Pump absorption torque

12

Function of checking display LCD

13

Function of displaying cautions

14

Function of displaying user code

15

Function of displaying error code and failure


code

20-154
(1)

Mechanical system

Mode in which key is ON

21

Function of
initial setting
and default [06]

Language
Unit

22

Function of
adjustment [07]

23

Function of cylinder cut out mode operation


[09]

Adjustment of flow for


attachment during compound operation

PC400/450(LC)-7

TESTING AND ADJUSTING

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.

PC400/450(LC)-7

20-155
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

20-156
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

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.

PC400/450(LC)-7

20-157
(1)

TESTING AND ADJUSTING

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

Failure mode

Instructions given to operator

Error in pump control system

If the emergency pump drive switch is set in the upper (emergency) position,
the machine can operate normally. Have the machine inspected immediately,
however.

E03

Error in swing brake system

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.

E10

Error in engine controller power


supply or abnormality in engine
controller drive system circuit
(Engine stops)

Have the machine inspected immediately.

E11

Error in engine controller system


Set the machine in a safe position and have the machine inspected immedi(Engine protection output is down) ately.

E14

Error in throttle system

Set the machine in a safe position and have the machine inspected immediately.

E15

Error in engine sensor (coolant


temperature, fuel temperature, or
oil pressure)

Although the machine can operate normally, have the machine inspected
immediately.

E0E

Error in network

Set the machine in a safe position and have the machine inspected immediately.

E02

20-158
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

PC400/450(LC)-7

20-159
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Code

Contents

Failure code
Code

Component

Trouble

E112 Wiper Drive (For) S/C

DY2DKB Wiper motor (Forward)

Short Circuit

E113 Wiper Drive (Rev) S/C

DYDEKB Wiper Motor (Reverse)

Short Circuit

E114 Washer Drive S/C

Windshield Washer
DY2CKB
Motor

Short Circuit

E115 Wiper Working Abnormality

DY20KA Wiper Motor

Disconnection

E116 Wiper Parking Abnormality

DY20MA Wiper Motor

Malfunction

E117 Eng. Controller S-NET Comm Err.

DAC0KR Engine Controller

Defective communication (Abnormality in


related component)

E118 Pump Controller S-NET Comm Err.

DAB0KR Pump Controller

Defective communication (Abnormality in


related component)

E0E E128 Monitor Comm. Abnormality

E201 Travel Junction Sol. S/C

E03 E203 Swing Brake Sol. S/C

DAFRMC

Monitor CAN CommuniDefective Operation


cation

DW91KB

Travel Neutral Solenoid


Valve

Short Circuit

DW45KB

Swing Holding Brake


Solenoid Valve

Short Circuit

E204 Merge-divider Sol. S/C

DWJ0KB

Pump Merge-divider
Solenoid Valve

Short Circuit

E205 2-stage Relief Sol. S/C

DWK0KB

2-stage Relief Solenoid


Valve

Short Circuit

E206 Travel Speed Sol. S/C

DW43KB

Travel Speed Hi/Lo


Short Circuit
Selector Solenoid Valve

E211 Travel Junction Sol. Disc.

DW91KA

Travel Neutral Solenoid


Valve

Disconnection

DW45KA

Swing Holding Brake


Solenoid Valve

Disconnection

E03 E213 Swing Brake Sol. Disc.

E214 Merge-divider Sol. Disc.

DWJ0KA

Pump Merge-divider
Solenoid Valve

Disconnection

E215 2-stage Relief Sol. Disc.

DWK0KA

2-stage Relief Solenoid


Valve

Disconnection

E216 Travel Speed Sol. Disc.

DW43KA

Travel Speed Hi/Lo


Disconnection
Selector Solenoid Valve

E217 Model Selection Abnormality

Pump Controller Model


DA2SKQ Selection Wiring Harness

E0E E218 S-Net Comm. Disc.

DA2SKA

Pump Controller S-NET


Communication

Disagreement of Model
Selection Signals
Disconnection

E222 LS-EPC Sol. S/C

DXE0KB LS-EPC Solenoid Valve

Short Circuit

E223 LS-EPC Sol. Disc.

DXE0KA LS-EPC Solenoid Valve

Disconnection

E224 F Pump P. Sensor Abnormality

F Pump Pressure SenDHPAMA


sor

Malfunction

E225 R Pump P. Sensor Abnormality

DHPBMA

R Pump Pressure Sensor

Malfunction

E226 Press. Sensor Power Abnormality

DA25KP

Pump Controller Power


Supply Output

Lowering of Output Voltage

E227 Engine Speed Sensor Abnormality

DLE2MA Engine Speed Sensor

Malfunction

E228 Service Return Relay S/C

D196KB

ATT Selector Relay

Short Circuit

DXA0KB TVC Solenoid Valve

Short Circuit

E02 E232 PC-EPC Sol. S/C

20-160
(1)

History
division

Error code

Electrical system

User
code

Table for Error and Failure Code Nos.

PC400/450(LC)-7

SPECIAL FUNCTIONS OF MONITOR PANEL

Code

Contents

E02 E233 PC-EPC Sol. Disc.

Failure code
Code

Component

History
division

Error code

Trouble

DXA0KA TVC Solenoid Valve

Disconnection

E238 Service Return Relay Disc.

D196KA

ATT Selector Relay

Disconnection

E245 Service Current EPC S/C

DXE4KB

ATT Flow Throttle EPC


Valve

Short Circuit

E246 Service Current EPC Disc.

DXE4KA

ATT Flow Throttle EPC


Valve

Disconnection

E247 Arm Curl PPC Sen. Abnormality

DHS3MA

Arm IN PPC Pressure


Sensor

Malfunction

E248 Bucket Curl PPC Sen. Abnormality

DHS4MA

Bucket CURL PPC


Pressure Sensor

Malfunction

E251 Overload Sensor Abnormality

DHX1MA

Malfunction

Pump Controller CAN


DA2RMC
Communication

Defective Operation

D110KB

Battery Relay

Short Circuit

E11 E91B Engine Ne Sensor Problem

DLE3LC

NE Speed Sensor

Disagreement of Speed
Signal

E11 E91C Engine G Sensor Problem

DLH1LC G Speed Sensor

E11 E920 Engine Type Selection Error

Engine Controller Model


Disagreement of Model
DB29KQ Selection Wiring HarSelection Signals
ness

E11 E921 Engine Type Mismatch

DB20KQ Engine Controller

Disagreement of Model
Selection Signals

E14 E931 Fuel Dial sys. error

DK10KX Throttle Angle Sensor

Out of input signal range

E15 E934 Engine Coolant Sensor Hi Error

Engine Coolant TemperDGE2KX


Out of input signal range
ature Sensor

E15 E936 Engine Oil Press. Sw. Error

DDE2L6

E11 E93C Engine Boost Sensor Error

DH30KX Boost Pressure Sensor

Out of input signal range

E15 E93D Engine Fuel Temp. Sensor Error

Fuel Temperature SenDGE4KX


sor

Out of input signal range

E0E E953 Engine Comm. Abnormality

DB2RMC

E0E E257 Pump Comm. Abnormality

E315 Battery Relay Drive S/C

E954 Short Engine Starter SW.

Engine Oil Pressure


Switch

Engine Controller CAN


Communication

Disagreement of Speed
Signal

Disagreement of signal
with operation of engine

Defective Operation

DD11KB Starter SW

Short Circuit

E0E E955 Engine S-NET error

Engine Controller SDB2SMC


NET Communication

Defective Operation

E10 E956 Engine Power Failure (1)

DB22KK

Engine Controller Load


Power Supply Line

Lowering of source voltage (Input)

E15 E957 Engine Power Failure (2)

D1D0KB

Engine Controller Load


Power Supply Relay

Short Circuit

DB2AMA

Rotary Switch in Engine


Malfunction
Controller

E15 E96A Engine Coolant Sensor Lo Error

DGE3L6

Engine Coolant Temper- Disagreement of signal


ature Sensor
with operation of engine

E11 E970 PCV1 Over Current

AD11KB

Supply Pump (1) Solenoid Valve

Short Circuit

E11 E971 PCV2 Over Current

AD51KB

Supply Pump (2) Solenoid Valve

Short Circuit

E11 E974 PCV1 Line Cut

AD11KA

Supply Pump (1) Solenoid Valve

Disconnection

E11 E975 PCV2 Line Cut

AD51KA

Supply Pump (2) Solenoid Valve

Disconnection

E11 E977 Rail Press. Sensor Error

DH40KX

Common Rail Pressure


Sensor

Out of input signal range

E95A Engine Q-adj. Sw. Signal Error

PC400/450(LC)-7

Electrical system

User
code

TESTING AND ADJUSTING

20-161
(1)

Code

Contents

Failure code
Code

Component

E11 E979 Rail Press. High 1

AD00L2

Common Rail

E11 E97A Rail Press. High 2

AD00MA Common Rail


Supply Pump

Trouble
Abnormally High Fuel
Pressure
Malfunction

E15 E97B Rail press. low

AD10L3

E11 E97C Rail press. too low

AD10MB Supply Pump

Lowering of Function

E11 E97D Rail Press. Out of Control

AD10MA Supply Pump

Malfunction

E11 E980 Eng. Controller Abnormality

DB20KT

Abnormality in Controller

E11 E981 Fuel Injector 1 Disc.

ADA1KA Injector 1 Solenoid Valve Disconnection

E11 E982 Fuel Injector 2 Disc.

ADB1KA Injector 2 Solenoid Valve Disconnection

E11 E983 Fuel Injector 3 Disc.

ADC1KA Injector 3 Solenoid Valve Disconnection

E11 E984 Fuel Injector 4 Disc.

ADD1KA Injector 4 Solenoid Valve Disconnection

E11 E985 Fuel Injector 5 Disc.

ADE1KA Injector 5 Solenoid Valve Disconnection

E11 E986 Fuel Injector 6 Disc.

ADF1KA Injector 6 Solenoid Valve Disconnection

E11 E98A Fuel Injector 1 3 S/C

ADAZKB

Injector 1, 2, 3 Solenoid
Valve

Short Circuit

E11 E98B Fuel Injector 4 6 S/C

ADDZKB

Injector 4, 5, 6 Solenoid
Valve

Short Circuit

E22 E922 Eng. Hi Out of Std

A000N1

Engine

Overrun

Engine

Engine Controller

Out of control

Eng. Lo Out of Std

A000N2

Aircleaner Clogging

AA10NX Air Cleaner Element

Out of input signal range

Charge Voltage Low

AB00KE Alternator

Eng. Oil Press. Low

B@BAZG Engine Oil

Eng. Oil LvI. Low

B@BAZK Engine Oil

Lowering of level

Eng. Coolant Overheat

B@BCNS Coolant

Overheating

Eng. Coolant Lvl Low

B@BCZK Coolant

Lowering of level

Hydr. Oil Overheat

B@HANS Hydraulic Oil

Overheating

Clogging
Defective Charge
Lowering of Oil Pressure

Electrical system

Error code

History
division

SPECIAL FUNCTIONS OF MONITOR PANEL

Mechanical system

User
code

TESTING AND ADJUSTING

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.

20-162
(1)

PC400/450(LC)-7

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.

Service menu

00
01

Return (Finish service menu)


Monitoring

02
03

Abnormality record
Maintenance record

04
05

Maintenance mode change


Phone number entry

06
07

Initial setting/Default
Adjust

09

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.

PC400/450(LC)-7

20-163
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

20-164
(1)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

PC400/450(LC)-7

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TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Monitoring items list


Code
No.

Monitoring item

Unit (Default: ISO)


SI

meter

inch

Remarks

00000 Return

(Not displayed)

Finish Menu

99999 To Display Screen

(Not displayed)

Display and Execution Menu

00200 Controller Model Select

Numerals

00201 Controller Model Select

Numerals

01002 Engine Speed

r/min

rpm

rpm

01601 2nd Eng. Speed Command

r/min

rpm

rpm

01100 F Pump Pressure

MPa

kg/cm2

psi

01101 R Pump Pressure

MPa

kg/cm

psi

07200 Arm Curl PPC Pressure

MPa

kg/cm

psi

07300 Bucket Curl PPC Pressure

MPa

kg/cm2

psi

04102 Engine Coolant Temp. Hi

14200 Fuel Temperature

04401 Hydr. Oil Temperature

01300 PC-EPC Sol. Curr.

mA

mA

mA

01500 LS-EPC Sol. Curr.

mA

mA

mA

01700 Service Sol. Curr.

mA

mA

mA

03200 Battery Voltage

03500 Battery Relay O/P Vol.

04300 Battery Charge Vol.

r/min

rpm

rpm

36400 Rail Pressure

MPa

kg/cm2

psi

36500 Boost Pressure

kPa

kg/cm2

psi

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.

CA

CA

CA

01006 Engine Speed


04107 Engine Coolant Temp. Low

17200 PCV Close Angle


17300 Eng. Control Mode
31701 Throttle Level

Numeral
%

36100 Fuel Delivery Command

mm3/st

mm3/st

mm3/st

36200 Rail Pressure Command

MPa

kg/cm2

psi

CA

CA

CA

36300 Injection Timing Angle

20-166
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PC400/450(LC)-7

TESTING AND ADJUSTING

Code
No.

Monitoring item

01900 Pressure Switch 1

01901 Pressure Switch 2

02300 Solenoid 1

02301 Solenoid 2

02200 Switch Input 1

02201 Switch Input 2

02202 Switch Input 3

04501 Monitor Input 2

04502 Monitor Input 3

PC400/450(LC)-7

Unit (Default: ISO)


SI

meter

Swing

ON/OFF

Travel

ON/OFF

Boom Lower

ON/OFF

Boom Raise

ON/OFF

Arm Curl

ON/OFF

Arm Dump

ON/OFF

Bucket Curl

ON/OFF

Bucket Dump

ON/OFF

Service

ON/OFF

Travel Steering

ON/OFF

Travel Junction

ON/OFF

Swing Brake

ON/OFF

Merge-divider

ON/OFF

2-stage Relief

ON/OFF

Travel Speed

ON/OFF

Service Return

ON/OFF

Lever Sw.

ON/OFF

Swing Release Sw.

ON/OFF

Swing Brake Sw.

ON/OFF

Model Select 1

ON/OFF

Model Select 2

ON/OFF

Model Select 3

ON/OFF

Model Select 4

ON/OFF

Model Select 5

ON/OFF

Key Switch (ACC)

ON/OFF

03700 Controller Output 1 Batt. Relay Dr.

04500 Monitor Input 1

SPECIAL FUNCTIONS OF MONITOR PANEL

inch

Remarks

ON/OFF

Key Switch

ON/OFF

Start

ON/OFF

Preheat

ON/OFF

Light

ON/OFF

Rad. Level

ON/OFF

Aircleaner

ON/OFF

Eng. Oil Level

ON/OFF

Battery Charge

ON/OFF

Swing Brake Sw.

ON/OFF

Bzzr Cancel Sw.

ON/OFF

Window Limit Sw.

ON/OFF

W Limit Sw.

ON/OFF

P Limit Sw.

ON/OFF

20-167
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TESTING AND ADJUSTING

Code
No.

17400

Monitoring item

Eng. Controller
Input

SPECIAL FUNCTIONS OF MONITOR PANEL

Unit (Default: ISO)


SI

meter

Key SW (C)

ON/OFF

Eng. Oil Press. Lo

ON/OFF

Eng. Oil Press. Hi

ON/OFF

Machine Sel. 1

ON/OFF

Machine Sel. 2

ON/OFF

Machine Sel. 3

ON/OFF

36800 Q Adjust Switch R (ROT-SW1)

Alphanumerals

36801 Q Adjust Switch L (ROT-SW2)

Alphanumerals

05100 S-NET Connection

Pump Controller

ON/OFF

Eng. Controller

ON/OFF

20200 Monitor Prog. Version

Numerals

20212 Pump Con. Prog. Version

Numerals

20209 Eng. Con. Prog. Version

Numerals

inch

Remarks

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.

20-168
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PC400/450(LC)-7

TESTING AND ADJUSTING

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.

Sub-menu of abnormality record

00
01

Return (Finish sub-menu)


Electrical systems

02

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.

PC400/450(LC)-7

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TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

20-170
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PC400/450(LC)-7

TESTING AND ADJUSTING

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

PC400/450(LC)-7

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TESTING AND ADJUSTING

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.

Item of maintenance mode change

00
01

Return
Use/Disuse maintenance mode

02
03

Replacement interval of engine oil


Replacement interval of engine oil filter

04
05

Replacement interval of fuel filter


Replacement interval of hydraulic oil filter

06

Replacement interval of hydraulic tank


breather

07

Replacement interval of corrosion resistor


(if equipped)

08
09

Check and refill interval of damper case oil


Replacement interval of final drive case oil

10
11

Replacement interval of machinery case oil


Replacement interval of hydraulic oil

12

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).

20-172
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TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

PC400/450(LC)-7

20-173
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TESTING AND ADJUSTING

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.

20-174
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PC400/450(LC)-7

TESTING AND ADJUSTING

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.

PC400/450(LC)-7

20-175
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

20-176
(1)

PC400/450(LC)-7

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

Sub-menu of adjustment
Return (Finish adjustment)

01

Pump absorption torque


Adjustment of oil flow for attachment in
compound operation

02

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

+8.0 kgm

225

2.0 kgm

221
222

+6.0 kgm
+4.0 kgm

226
227

4.0 kgm
6.0 kgm

223
224

+2.0 kgm
0.0 kgm

228

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

Oil flow for attachment


0.5 times

371
372

0.7 times
1.0 times

373

0.4 times

PC400/450(LC)-7

20-177
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

20-178
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PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

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.

PC400/450(LC)-7

20-179
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TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Section to display
special functions

Section to operate special


function 1 (Basic operation)

Section to operate special function 2


(Selecting operation and special operation)

1. Display section

3. Caution buzzer stop switch

7. Working mode selector (UP) switch

2. Service meter
section

4. Auto-decelerator switch

8. Working mode selector (DOWN) switch

5. Setting switch (Black switch)


6. Travel speed shifting switch

PC400/450(LC)-7

20-179-2
(7)

TESTING AND ADJUSTING

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

1 Function of displaying service meter


O <Automatic>
2 Function of displaying user code

Special functions (Service menu)


<Operation of switch> O

Ordinary functions (Operator 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

20-179-3
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

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

E03

Remedy (shown to operator)

Caution
buzzer

Error in pump
control system

If the emergency pump drive switch is set in the upper position,


the machine can operate normally. Have the machine inspected
immediately, however.

Error in swing
brake system

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.

Error mode

Error in engine controller


power supply
E10 Abnormality in engine con- Have the machine inspected immediately.
troller drive system circuit
(Engine is stopped)
Error in engine controller
system
(Engine output is reduced
for protection)

Move the machine to safe place and have it inspected immediately.

E14 Error in throttle system

Move the machine to safe place and have it inspected immediately.

Error in engine sensor


E15 (coolant temperature, fuel
temperature, oil pressure)

Have the machine inspected, although it can be operated normally.

E0E Error in network

Move the machine to safe place and have it inspected immediately.

E11

PC400/450(LC)-7

20-179-4
(7)

TESTING AND ADJUSTING

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.)

20-179-5
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

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.

PC400/450(LC)-7

20-179-6
(7)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

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.

20-179-7
(7)

PC400/450(LC)-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Service codes table


User code

Service code

Trouble

E112

Short circuit in wiper motor drive forward system

E113

Short circuit in wiper motor drive reverse system

E114

Short circuit in windshield washer drive system

E115

Trouble in operation of windshield wiper

E116

Trouble in storage of windshield wiper

E117

Abnormality in engine controller S-NET

E118

Abnormality in pump controller S-NET

E0E

E128

Abnormality in communication (monitor)

E201

Short circuit in travel junction solenoid

E03

E203

Short circuit in swing holding brake solenoid

E204

Short circuit in merge-divider solenoid

E205

Short circuit in 2-stage relief solenoid

E206

Short circuit in travel speed shifting solenoid

E211

Disconnection in travel junction solenoid

E03

E213

Disconnection in swing holding brake solenoid

E214

Disconnection in merge-divider solenoid

E215

Disconnection in 2-stage relief solenoid

E216

Disconnection in travel speed shifting solenoid

E217

Abnormality in input model code

E218

Disconnection in S-NET signal line

E222

Short circuit in LS-EPC solenoid

E223

Disconnection in LS-EPC solenoid

E224

Abnormality in F pump pressure sensor

E225

Abnormality in R pump pressure sensor

E226

Abnormality in pressure sensor power supply

E227

Abnormality in engine speed sensor

E228

Short circuit in ATT return selector relay

E02

E232

Short circuit in PC-EPC solenoid

E02

E233

Disconnection in PC-EPC solenoid

E238

Disconnection in ATT return selector relay

E245

Short circuit in ATT flow adjustment EPC

E246

Disconnection in ATT flow adjustment EPC

E247

Abnormality in arm IN PPC pressure sensor

E248

Abnormality in bucket CURL PPC pressure sensor

E251

Abnormality in overload sensor

E0E

E257

Abnormality in communication (pump)

E315

Short circuit in battery relay output line

E11

E91B

Abnormality in engine Ne speed sensor system

E11

E91C

Abnormality in engine G speed sensor system

E11

E920

Abnormality in model selection system

E11

E921

Abnormality in model checking

E14

E931

Abnormality in fuel control dial system

E15

E934

Abnormality in coolant high temperature sensor

E15

E936

Abnormality in engine oil pressure switch system

PC400/450(LC)-7

20-179-8
(7)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

User code

Service code

Trouble

E11

E93C

Abnormality in boost pressure sensor system

E15

E93D

Abnormality in fuel temperature sensor system

E0E

E953

Abnormality in communication (engine)

E954

Short circuit in starting switch C terminal system

E0E

E955

Abnormality in network system

E10

E956

Abnormality in power supply system 1

E15

E957

Abnormality in power supply system 2

E95A

Abnormality in Q-adjustment switch signal

E15

E96A

Abnormality in coolant low temperature sensor system

E11

E970

Overcurrent in fuel supply pump PCV1 system

E11

E971

Overcurrent in fuel supply pump PCV2 system

E11

E974

Disconnection in fuel supply pump PCV1 system

E11

E975

Disconnection in fuel supply pump PCV2 system

E11

E977

Abnormality in common rail fuel pressure sensor system

E11

E979

Abnormality in common rail fuel high pressure 1

E11

E97A

Abnormality in common rail fuel high pressure 2

E15

E97B

No-pressure feed by supply pump 1

E11

E97C

No-pressure feed by supply pump 2

E11

E97D

Abnormality in common rail fuel pressure

E11

E980

Abnormality in controller

E11

E981

Disconnection in fuel injector 1 system

E11

E982

Disconnection in fuel injector 2 system

E11

E983

Disconnection in fuel injector 3 system

E11

E984

Disconnection in fuel injector 4 system

E11

E985

Disconnection in fuel injector 5 system

E11

E986

Disconnection in fuel injector 6 system

E11

E98A

Short circuit in fuel injector 1 3 systems

E11

E98B

Short circuit in fuel injector 4 6 systems

E22

E922

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

Monitoring item

Unit

Remarks

00200

Controller model code

Numeral

00201

Controller model code

Numeral

01002

Engine speed

rpm

01601

2nd throttle command

rpm

01100

F pump pressure

kg/cm2

01101

R pump pressure

kg/cm2

07200

Arm IN PPC pressure

kg/cm2

07300

Bucket curl PPC pressure

kg/cm2

04102

Engine coolant temperature (high)

14200

Fuel temperature

04401

Hydraulic oil temperature

01300

PC-EPC solenoid current

mA

01500

LS-EPC solenoid current

mA

01700

Service solenoid current

mA

03200

Power supply voltage

03500

Battery relay output voltage

04300

Charge voltage

01006

Engine speed

rpm

04107

Engine coolant temperature (low)

36400

Common rail fuel pressure

kg/cm2

36500

Boost pressure

kg/cm2

36700

Converted torque

03000

Fuel control dial voltage

04200

Fuel sensor voltage

04106

Engine coolant temperature sensor voltage high

04105

Engine coolant temperature sensor voltage low

14201

Fuel temperature sensor voltage

36501

Boost pressure sensor voltage

36401

Common rail pressure sensor voltage

17200

PCV valve closing timing

17300

Engine control mode

31701

Throttle angle

36100

Fuel injection rate command

mm3/st

36200

Common rail pressure command

kg/cm2

36300

Fuel injection timing command

20-179-11
(7)

CA
Numeral
%

CA

PC400/450(LC)-7

TESTING AND ADJUSTING

Code

01900

01901

02300

02301
02200

02201

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Monitoring item

Pressure switch 1

Pressure switch 2

Solenoid 1

Swing

(6 bit)

Travel

(6 bit)

Boom LOWER

(6 bit)

Boom RAISE

(6 bit)

Arm IN

(6 bit)

Arm OUT

(6 bit)

Bucket CURL

(6 bit)

Bucket DUMP

(6 bit)

Service

(6 bit)

Travel differential pressure

(6 bit)

Travel junction

(6 bit)

Swing holding brake

(6 bit)

Pump merge-divider

(6 bit)

2-stage relief

(6 bit)

Travel speed shifting

(6 bit)

ATT return selection

(6 bit)

Knob switch

(6 bit)

Swing brake release switch

(6 bit)

Swing holding brake switch

(6 bit)

Model selection 1

(6 bit)

Model selection 2

(6 bit)

Model selection 3

(6 bit)

Model selection 4

(6 bit)

Model selection 5

(6 bit)

Solenoid 2
Switch input 1

Switch input 2

Unit

02202

Switch input 3

Key switch (ACC)

(6 bit)

03700

Controller output 1

Battery relay drive

(6 bit)

Key switch

(6 bit)

Start

(6 bit)

Preheating

(6 bit)

Light

(6 bit)

Radiator coolant level

(6 bit)

Air cleaner

(6 bit)

Engine oil level

(6 bit)

Charge voltage

(6 bit)

04500

04501

Monitor input 1

Monitor input 2

PC400/450(LC)-7

Remarks

20-179-12
(7)

TESTING AND ADJUSTING

Code

04502

17400

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Monitoring item

Monitor input 3

Engine controller input state

Unit

Swing holding brake switch

(6 bit)

Buzzer cancel switch

(6 bit)

Window limit switch

(6 bit)

W limit switch

(6 bit)

P limit switch

(6 bit)

Key switch (C)

(6 bit)

Engine oil pressure low

(6 bit)

Engine oil pressure high

(6 bit)

Model selection 1

(6 bit)

Model selection 2

(6 bit)

Model selection 3

(6 bit)

Remarks

36800

Right Q-adjustment switch (ROT-SW1)

Numeral and
alphabet

36801

Left Q-adjustment switch (ROT-SW2)

Numeral and
alphabet

05100

S-NET connection state

20200

Program version (monitor)

Numeral

20212

Program version (pump controller)

Numeral

20209

Program version (engine controller)

Numeral

Pump controller

(6 bit)

Engine controller

(6 bit)

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

20-179-13
(7)

Display of 6-bit code

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

Display mode/
Maintenance period

Maintenance function is reset.

125

125-hour interval

250

250-hour interval

500

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.

2. Engine controller
1) Open the right side cover and remove radiator sub tank (3) and bracket together.

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) 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.

PC400/450(LC)-7

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}

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 operators 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

20-188
(1)

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

PC400/450(LC)-7

UNDERCARRIAGE INSPECTION
Komatsu
Undercarriage Inspection

T20606

(Program form No.: SELA195001)

Customer name:
Address:

PC400/450-7

Model

Serial#

Location
Soil condition
Working condition

Equip#

Work Order No

SMR

Wet,AR,HD or Dry

Dealer

Shoe width (mm)

nspector

LH

Insp.Date(yyyy/mm/dd)
New 100% Measured
Wear
mm
915.6 927.6

Shoe type
(yyyy/m/d)

Wear
%

New

SMR
Hours on
Rebuilt Parts:

DRY

TRIPLE

NORMAL
Wear type
Comments/Observation

R
RH

915.6

LH

228.90 231.90

927.6

RH

228.90 231.90

LH

129.0

119.0

RH

129.0

119.0

LH

71.5

66.5

RH

71.5

66.5

LH

37.0

22.0

RH

37.0

22.0

LH

148.0

134.0

RH

148.0

134.0

LH

148.0

134.0

RH

148.0

134.0

LH

22.0

28.0

RH

22.0

28.0

LH

22.0

28.0

New

Turned

New

Turned

Front

Rear

Front

Rear

1.3

RH

22.0

28.0

LH

200.0

188.0

LH

200.0

188.0

LH

200.0

188.0

LH

200.0

188.0

LH

200.0

188.0

LH

200.0

188.0

LH

200.0

188.0

LH

200.0

188.0

LH

200.0

188.0

10

LH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

RH

200.0

188.0

10

RH

200.0

188.0

LH

0.0

6.0

RH

0.0

6.0

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

allow any unauthorized person to come near.

k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for

the engine to cool down before starting troubleshooting.

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 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.

20-202
(1)

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.

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.

PC400/450(LC)-7

20-209
(1)

TROUBLESHOOTING

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.

20-210
(1)

PC400/450(LC)-7

TROUBLESHOOTING

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 3) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.

PC400/450(LC)-7

20-211
(1)

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

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

Electrics, electrical equipment

Hydraulic,
Electrical
mechanical
equipment
equipment

Lubricating oil,
coolant

Item

20-212
(1)

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

Action
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add water
Clean or replace
Replace
Add oil

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

Tighten or replace
Tighten or replace
Tighten or replace

1. Check for abnormal noise, smell


2. Check for oil leakage
3. Carry out air bleeding

Repair
Repair
Bleed air

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)

20 30V

Replace
Add or replace
Replace
Repair
Disconnect
connector and dry
Replace
Replace

After
running for
several
minutes :
27.5 29.5V

Replace

PC400/450(LC)-7

TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING


Classification of troubleshooting
Mode
Code display

Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
displayed.

E mode

Troubleshooting of electrical system

H mode

Troubleshooting of hydraulic and mechanical systems

S mode

Troubleshooting of engine

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.

PC400/450(LC)-7

20-213
(1)

TROUBLESHOOTING

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

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

Engine does not start easily (It always takes time to start)

Engine does not crank

S-1
E-1

S-2 a)

Engine cranks but exhaust smoke


does not come out

S-2 b)

Exhaust smoke comes out but engine


does not start

S-2 c)

Engine speed does not rise sharply (Follow-up performance is low)

S-3

Engine stops during operation

S-4

10

Engine rotation is abnormal (Engine hunts)

S-5

11

Output is insufficient (Power is low)

S-6

12

Exhaust gas color is bad (Incomplete combustion)

S-7

13

Oil is consumed much or exhaust gas color is bad

S-8

14

Oil becomes dirty quickly

S-9

15

Fuel is consumed much

S-10

16

Coolant contains oil (or it blows back or reduces)

S-11

17

Engine oil pressure caution lamp lights up (Oil pressure lowers)

S-12

18

Oil level rises (Water or fuel is mixed in oil)

S-13

19

Water temperature rises too high (Overheating)

S-14

20

Abnormal sound comes out

S-15

21

Vibration is excessive

S-16

22

Engine is not preheated normally

E-2

23

Automatic warm-up function does not work

E-3

24

Automatic decelerator does not work

E-4

Engine does not start

H-5

Possible faults related to work equipment, swing, and travel


25

Speed or power of whole work equipment, travel, and swing is low

H-1

S-6

26

Engine speed lowers extremely or engine stalls

H-2

S-4

27

Work equipment, travel, and swing systems do not work

28

Abnormal sound comes out from around hydraulic pump

H-4

29

Fine control performance or response is low

H-6

20-214
(1)

E-5

H-3

PC400/450(LC)-7

TROUBLESHOOTING

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

Speed or power of boom is low

H-7

31

Speed or power of arm is low

H-8

32

Speed or power of bucket is low

H-9

33

Work equipment does not move singly

H-10

34

Hydraulic drift of work equipment is large

H-11

35

Time lag of work equipment is large

H-12

36

When a work equipment device is relieved singly, other work equipment device moves

H-13

37

One-touch power maximizing function does not work

E-6

H-14

38

Machine push-up function does not work normally

E-7

H-15

39

Attachment circuit is not selected (when attachment is installed)

E-8

H-30

40

Oil flow in attachment circuit cannot be adjusted (when attachment is


installed)

H-31

Possible faults related to compound operation


41

In compound operation of work equipment, speed of part loaded


more is low

H-16

42

When machine swings and raises boom simultaneously, boom rising


speed is low

H-17

43

When machine swings and travels simultaneously, travel speed lowers largely

H-18

Possible faults related to travel


44

Machine deviates during travel

H-19

45

Travel speed is low

H-20

46

Machine is not steered well or steering power is low

H-21

47

Travel speed does not change or it is lower or higher than set speed

H-22

48

Travel motor does not work (only 1 side)

H-23

49

Travel alarm does not sound or does not stop sounding

E-31

Possible faults related to swing


47

Machine does not swing

H-24

48

Swing acceleration or swing speed is low

H-25

50

Upper structure overruns remarkably when it stops swinging

H-26

51

Large shock is made when upper structure stops swinging

H-27

52

Large sound is made when upper structure stops swinging

H-28

53

Hydraulic drift of swing is large

H-29

Possible faults related to monitor panel (Operator menu: Ordinary screen)


54

No items are displayed on monitor panel

E-9

55

Some items are not displayed on monitor panel

E-10

56

Items displayed on monitor panel are not matched to machine model

E-11

57

Fuel level monitor lights red while engine is running

E-12

PC400/450(LC)-7

20-215
(1)

TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Troubleshooting
No.

Phenomena considered to be failures

Display of
code

E-mode

58

Engine coolant temperature gauge does not indicate normally

E-13

59

Hydraulic oil temperature gauge does not indicate normally

E-14

60

Fuel level gauge does not indicate normally

E-15

61

Swing lock monitor does not indicate normally

E-16

62

When monitor switches are operated, no items are displayed

E-17

63

Windshield wiper or windshield washer does not operate

E-18

64

Alarm buzzer cannot be cancelled

E-19

H-mode

S-mode

Possible faults related to monitor panel (Service menu: Special function screen)
65

Monitoring function does not indicate Boom RAISE normally.

E-20

66

Monitoring function does not indicate Boom LOWER normally.

E-21

67

Monitoring function does not indicate Arm IN normally.

E-22

68

Monitoring function does not indicate Arm OUT normally.

E-23

69

Monitoring function does not indicate Bucket CURL normally.

E-24

70

Monitoring function does not indicate Bucket DUMP normally.

E-25

71

Monitoring function does not indicate Swing normally.

E-26

72

Monitoring function does not indicate Travel normally.

E-27

73

Monitoring function does not indicate Travel differential pressure


normally.

E-28

74

Monitoring function does not indicate Service normally.

E-29

Other failure
75

Air conditioner does not operate


(Troubleshooting for air conditioner system)

20-216
(1)

E-31

PC400/450(LC)-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

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.

Type

No. of
pins

A01
A02
A03
A04
A05
A06
A07
A09
A10
A11
A12
A13
A14
A15
A16
A20
A21
A22
A23
A31
A33
A34
A35
A40
A41
A42
A43
A44
A50
A51
A52
A60
A61

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

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

A70

A73
A80
AL/B
AL/E
AL/R
C01
C02
C03
C09
CB1

D
DT
Terminal
Terminal
Terminal
DRC
DRC
DRC
S
DRC

2
8
1
1
1
24
40
40
8
24

PC400/450(LC)-7

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

Address
M
E
circuit circuit
H-6
D-7
H-6
H-6
D-7
H-5
H-5
A-4
I-1
I-1
I-1
I-1
I-1
I-1
L-5
J-6
J-5
J-6
K-4
K-5
K-6
K-6

D-7
F-1
F-1

D-8

D-9

J-8
J-8
J-8
K-8
K-9
K-9
K-9
K-9

K-9
K-9

J-7
K-5
K-7
K-5
L-5
L-5
K-4
K-5

H-1
G-9
S-1
AE-6
AE-6
AE-6
U-9
U-9
W-9
W-9
I-9

P
circuit
G-7
G-7
G-7
G-6
G-6
G-5
G-5
G-5
J-8

K-3
H-3

D-6

G-4

A-3
A-3
A-2

A-8
A-8

K-1

A-6

A-8
A-7
A-6
B-1
L-8

20-217
(4)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector
No.

Type

No. of
pins

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

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

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

20-218
(4)

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

P
circuit
L-8

A-4
A-4

J-3

I-5
I-3

K-6

I-9

E-7
K-3

G-8

I-7

E-2
E-2
E-2
A-2

J-8
J-8
D-6
D-6
D-5
C-2

I-6
I-7

C-9
D-9
D-9
E-9
E-9
F-9
F-9

H-9

A-2
A-4
C-1
K-7

A-9
K-6

H-9
H-9
I-9
I-9
I-9

B-9
C-1
C-9
C-9
D-9
D-9
D-9
E-9
B-1
A-9
E-1

F-9

PC400/450(LC)-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

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

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

PC400/450(LC)-7

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

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

20-219
(4)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector
No.

Type

No. of
pins

S21
S22
S25
S30
S31
ST
ST/B
T05
T06
T06A
T11
THL

Terminal
Terminal
S090
X
X
DT
Terminal
Terminal
Terminal
M
Terminal
DT

6
6
16
2
2
2
1
1
1
1
1
3

TWH

DT

TWL

DT

V01
V02
V03
V04
V05
V06
V08
V12
V21
V22
V30
W03
W04
X05

DT
DT
D
D
D
D
D
D
D
D
X
M
M
M

2
2
2
2
2
2
2
2
2
2
2
2
6
4

20-220
(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

Address
M
E
circuit circuit

K-3

P
circuit
C-1
D-1
C-2
A-9
A-9
K-6

J-8

K-8
AJ-4

K-3

AE-7

K-5

AG-8

K-5

J-3
J-2
J-2
J-2
J-2
J-2
J-1
J-1
L-6
L-6
P-1
AB-9
Y-5
Q-8

K-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

PC400/450(LC)-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector type
D or DT

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)

PA

Product of Yazaki PA type connector

SWP

Product of Yazaki SWP type connector (08055-1XXXX)

DRC

Japanese and German makes DRC type connector

040

Product of Japan AMP 040 type connector

070

Product of Japan AMP 070 type connector

Y050

Product of Yazaki 050 type connector

S090

Product of Sumitomo 090 type connector

Y090

Product of Yazaki 090 type connector

YAZAKI
SUMITOMO
KES0

Yazaki-made connector
Product of Sumitomo Wiring Systems 6098 type connector
KESO type connector (08027-0XXXX)

Terminal

Round pin type single terminal connector

Terminal

Round terminal

PC400/450(LC)-7

20-221
(1)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

Connector Location Stereogram

20-222
(1)

PC400/450(LC)-7

TROUBLESHOOTING

PC400/450(LC)-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

20-223
(4)

TROUBLESHOOTING

20-224
(1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

PC400/450(LC)-7

TROUBLESHOOTING

PC400/450(LC)-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

20-225
(1)

TROUBLESHOOTING

20-226
(1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

PC400/450(LC)-7

TROUBLESHOOTING

PC400/450(LC)-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

20-227
(1)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

Monitor Panel System Circuit Diagram (M Circuit)

20-228
(1)

PC400/450(LC)-7

TROUBLESHOOTING

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

20-229
(1)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

Engine Control System Circuit Diagram (E Ciruit)

20-230
(1)

PC400/450(LC)-7

TROUBLESHOOTING

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.

PC400/450(LC)-7

20-231
(1)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

Pump Controller System Circuit Diagram (P Circuit)

20-232
(4)

PC400/450(LC)-7

TROUBLESHOOTING

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.

PC400/450(LC)-7

20-233
(4)

TROUBLESHOOTING

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.

X type connector

No.of
pins

Male (female housing)

Female (male housing)

T-adapter
Part No.

Part No.: 08055-00181

Part No.: 08055-00191

799-601-7010

799-601-7020

Part No.: 08055-00282

Part No.: 08055-00292

799-601-7030

Part No.: 08055-00381

Part No.: 08055-00391

799-601-7040

Part No.: 08055-00481

Part No.: 08055-00491

Terminal part No.: 79A-222-3370


Electric wire size: 0.85
Grommet: Black
Qty: 20

Terminal part No.: 79A-222-3390


Electric wire size: 0.85
Grommet: Black
Qty : 20

Terminal part No.: 79A-222-3380


Electric wire size: 2.0
Grommet: Red
Qty: 20

Terminal part No.: 79A-222-3410


Electric wire size: 2.0
Grommet: Red
Qty: 20

20-234
(1)

PC400/450(LC)-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector


Male (female housing)

Female (male housing)

T-adapter
Part No.

799-601-7050

Part No.: 08055-10681

Part No.: 08055-10691

799-601-7060

Part No.: 08055-10881

Part No.: 08055-10891

12

799-601-7310

Part No.: 08055-11281

Part No.: 08055-11291

14

799-601-7070

Part No.: 08055-11481

PC400/450(LC)-7

Part No.: 08055-11491

20-235
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No. of
pins

Male (female housing)

Female (male housing)

16

T-adapter
Part No.

799-601-7320

Part No.: 08055-11681

Part No.: 08055-11691

Terminal part No.:


Electric wire size: 0.85
Grommet: Black
Qty: 20

Terminal part No.:


Electric wire size: 0.85
Grommet: Black
Qty: 20

Terminal part No.:


Electric wire size: 1.25
Grommet: Red
Qty: 20

Terminal part No.:


Electric wire size: 1.25
Grommet: Red
Qty: 20

20-236
(1)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector

No.of
pins

Male (female housing)

Female (male housing)

T-adapter Part
No.

Part No.: 08056-00171

Part No.: 08056-00181

799-601-7080

799-601-7090

Part No.: 08056-00271

Part No.: 08056-00281

799-601-7110

Part No.: 08056-00371

Part No.: 08056-00381

799-601-7120

Part No.: 08056-00471

Part No.: 08056-00481

799-601-7130

Part No.: 08056-00671

Part No.: 08056-00681

799-601-7340

Part No.: 08056-00871

PC400/450(LC)-7

Part No.: 08056-00881

20-237
(1)

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
Male (female housing)

Female (male housing)

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10
(White)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12
(White)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16
(White)

799-601-7330

Part No.: 08056-11671

20-238
(1)

T-adapter
Part No.

Part No.: 08056-11681

PC400/450(LC)-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
Male (female housing)

Female (male housing)

10
(Blue)

12
(Blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16
(Blue)

799-601-7170

Part No.: 08056-11672

PC400/450(LC)-7

T-adapter
Part No.

Part No.: 08056-11682

20-239
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins

Male (female housing)

Female (male housing)

T-adapter Part
No.

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

Body part No.: 79A-222-2630 (Qty: 5)

11

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

Body part No.: 79A-222-2670 (Qty: 5)

799-601-2710

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

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

799-601-2950

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

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

13

799-601-2720

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

20-240
(1)

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

PC400/450(LC)-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector


Male (female housing)

Female (male housing)

17

T-adapter Part
No.

799-601-2730

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

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

21

799-601-2740

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

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

Terminal part No.: 79A-222-2770


(Qty: 50)

Terminal part No.: 79A-222-2760


(Qty: 50)

PC400/450(LC)-7

20-241
(1)

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector


Male (female housing)

Female (male housing)

T-adapter Part
No.

799-601-7180

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

12

799-601-7190

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

16

799-601-7210

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

20

799-601-7220

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

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

20-242
(1)

PC400/450(LC)-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector


Male (female housing)

Female (male housing)

10

799-601-7510

Part No.: 08195-10210

12

799-601-7520

Part No.: 08195-12210

14

799-601-7530

Part No.: 08195-14210

18

799-601-7540

Part No.: 08195-18210

20

799-601-7550

PC400/450(LC)-7

T-adapter Part
No.

Part No.: 08195-20210

20-243
(1)

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector
Male (female housing)

Female (male housing)

No.of
pins

Connector for PA
Male (female housing)

Female (male housing)

Bendix MS connector
Male (female housing)

Female (male housing)

10

(1)

T-adapter Part
No.

799-601-3460

20-244

T-adapter Part
No.

No.of
pins

T-adapter Part
No.

PC400/450(LC)-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector


Male (female housing)

Female (male housing)

T-adapter Part
No.

Part No.: 08027-10210 (Natural color)


08027-10220 (Black)

Part No.: 08027-10260 (Natural color)


08027-10270 (Black)

Part No.:08027-10310

Part No.:08027-10360

Part No.: 08027-10410 (Natural color)


08027-10420 (Black)

Part No.: 08027-10460 (Natural color)


08027-10470 (Black)

Part No.: 08027-10610 (Natural color)


08027-10620 (Black)

PC400/450(LC)-7

Part No.: 08027-10660 (Natural color)


08027-10670 (Black)

20-245
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins

Male (female housing)

Female (male housing)

Part No.: 08027-10810 (Natural color)


08027-10820 (Black)

No.of
pins

Part No.: 08027-10860 (Natural color)


08027-10870 (Black)

Connector for relay (Socket type)


Male (female housing)

Female (male housing)

799-601-7370

20-246

T-adapter Part
No.

799-601-7360

(1)

T-adapter Part
No.

PC400/450(LC)-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

F type connector
Male (female housing)

Female (male housing)

PC400/450(LC)-7

T-adapter
Part No.

20-247
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

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

20-248
(1)

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


08191-23105, 08191-23106

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter
Part No.

799-601-9230

18-20
(3)

Part No.:08191-31201, 08191-31202

Part No.:08191-34101, 08191-34102

Pin (female terminal)

Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202

Part No.:08191-33101, 08191-33102

Pin (male terminal)

Pin (female termial)

799-601-9240

18-21
(4)

Part No.:08191-41201, 08191-42202

Part No.:08191-44101, 08191-44102

Pin (female terminal)

Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202

PC400/450(LC)-7

Part No.:08191-43101, 08191-43102

20-249
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter
Part No.

799-601-9250

24-9
(5)

Part No.:08191-51201, 08191-51202

Part No.:08191-54101, 08191-54102

Pin (female terminal)

Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202

Part No.:08191-53101, 08191-53102

Pin (male terminal)

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

20-250
(1)

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


08191-63105, 08191-63106

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

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,

PC400/450(LC)-7

08191-82202
08191-82204
08191-82206

Part No.: 08191-83101,


08191-83103,
08191-83105,

08191-83102
08191-83104
08191-83106

20-251
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male termial)

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

20-252
(1)

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


08191-93105, 08191-93106

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector

No.of
pins

Body (plug)

Body (receptacle)

T-adapter
Part No.

799-601-9020

Part No.: 08192-12200 (normal type)


08192-22200 (fine wire type)

Part No.: 08192-12100 (normal type)


08192-22100 (fine wire type)

799-601-9030

Part No.: 08192-13200 (normal type)


08192-23200 (fine wire type)

Part No.: 08192-13100 (normal type)


08192-23100 (fine wire type)

799-601-9040

Part No.: 08192-14200 (normal type)


08192-24200 (fine wire type)

Part No.: 08192-14100 (normal type)


08192-24100 (fine wire type)

799-601-9050

Part No.: 08192-16200 (normal type)


08192-26200 (fine wire type)

PC400/450(LC)-7

Part No.: 08192-16100 (normal type)


08192-26100 (fine wire type)

20-253
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector

No.of
pins

Body (plug)

Body (receptacle)

8GR:
8B:
8G:
8BR:

Part No.: 08192-1820


08192-2820

(normal type) Part No.: 08192-1810


(fine wire type)
08192-2810

799-601-9060
799-601-9070
799-601-9080
799-601-9090

(normal type)
(fine wire type)

12GR:
12B:
12G:
12BR:

12

Part No.: 08192-1920


08192-2920

20-254
(1)

T-adapter Part No.

(normal type) Part No.: 08192-1910


(fine wire type)
08192-2910

799-601-9110
799-601-9120
799-601-9130
799-601-9140

(normal type)
(fine wire type)

PC400/450(LC)-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DTM Series connector

No.of
pins

Body (plug)

Body (receptacle)

T-adapter Part
No.

799-601-9010

Part No.: 08192-02200

Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)]
DTHD Series connector

No.of
pins

Body (plug)

Body (receptacle)

T-adapter Part
No.

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

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

20-256
(1)

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

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

Connector type or
No. of pins
part name

799-601-2700

Part No.

799-601-2500

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.

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

PC400/450(LC)-7

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

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

PC400/450(LC)-7

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

Connector type or
No. of pins
part name

799-601-2700

Part No.

T-BRANCH BOX AND T-BRANCH TABLE

799-601-2500

TROUBLESHOOTING

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

20-257
(1)

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

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Constant
power supply
(Fusible link: A35)

20-258
(1)

Fuse No.

Fuse capacity

10 A

20 A

10 A

10 A

5
6
7
8

10 A
10 A
10 A
10 A

10 A

10
11

10 A
20 A

12

20 A

13

20 A

14

10 A

15

10 A

16
17
18
19
20

10 A
10 A
10 A
10 A
10 A

Destination of powerDestination of power


Pump controller (Controller power supply)
Swing holding brake solenoid
(When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
Pump controller (Solenoid power supply)
Machine push-up solenoid
ATT return selector relay & solenoid
Starting motor cutout relay (For PPC lock)
PPC lock solenoid
Cigarette lighter
Windshield washer motor
Horn
(Spare)
Rotary lamp
Right front working lamp & boom working lamp
One-touch power maximizing switch
(Input to pump controller input)
Radio
(Spare)
Air conditioner unit
Monitor panel
Starting motor cutout relay (For personal code)
Light relay (For right front working lamp & boom working lamp)
Headlamp & additional headlamp
Service power supply 1 (M32 connector)
Travel alarm
Service power supply 2 (DC/DC converter)
Radio (For backing up)
Monitor panel (For backing up)
Starting switch
Room lamp
(Spare)

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
(1)

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) ....................................................... 20-422
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

Error Code

Failure Code

Display in
monitor panel

Display in
monitor panel

Display in
monitor panel

Failure
phenomenon

Title of failure phenomenon shown in failure history

Failure content

Failure status as detected by monitor panel or controller

Response from
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
occurring on
machine

Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
controller

Relative
information

Information on the failure occurred as well as the troubleshooting


Cause

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

20-304
(1)

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.

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

Error Code

Failure Code

E112

DY2DKB

Failure
phenomenon

Short-circuiting in normal rotation system of windshield wiper motor drive (in monitor panel system)

Failure content

Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.

Response from
Monitor Panel

Power supply to the windshield wiper motor normal rotation circuit is turned OFF.

Phenomenon
occurring on
machine

The windshield wiper stops moving.

Relative
information

Presumed cause and


standard value in normalcy

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)

Continuity and resistance value

Between (3) and (1)

Continued

Between (3) and grounding

Above 1 Mz

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

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

20-306
(1)

Resistance
value

Windshield wiper switch

Voltage

OFF

Below 3 V

ON

Below 3 V
20 30 V
(at constant cycle)

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

Error Code

Failure Code

E113

DY2EKB

Failure content

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

The windshield wiper stopped moving.

Relative
information

Presumed cause and


standard value in normalcy

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)

Continued

Between (1) and grounding

Above 1 Mz

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

20-308
(1)

Continuity and resistance value

Windshield wiper switch

Voltage

OFF

Below 3 V

ON

Below 3 V
20 30 V
(at constant cycle)

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

Error Code

Failure Code

E114

DY2CKB

Failure content

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

The window washer stopped moving.

Relative
information

Presumed cause and


standard value in normalcy

Cause
Window washer drive
1 motor defective
(Internal short-circuiting)

Short-circuiting of wiring
harness
2
(Contact with 24 V
circuit)

A50 (male)

Resistance value

Between (1) and (2)

5 20 z

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

20-310
(1)

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.

P01

Window washer switch

Voltage

Between (3) and


grounding

OFF

20 30 V

ON

Below 1 V

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

Error Code

Failure Code

E115

DY20KA

Failure content

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

The windshield wiper motor does not work.

Relative
information

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.

Presumed cause and


standard value in normalcy

Windshield wiper motor


1 defective
(Internal disconnection)

Disconnection of wiring
harness
2
(Disconnection or faulty
contact with connector)

W04 (female)

Between (6) and (5)

Resistance value
Below 1 z

Outside upper end of


operation range

Above 1 Mz

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)

Resistance
value

Below 1 z

Wiring harness between W04 (male) (5) and grounding

Resistance
value

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

20-312
(1)

Windshield wiper blade


At upper end of operation
range

Windshield wiper blade

Voltage

At upper end of operation


range

Below 1 V

Outside upper end of


operation range

20 30 V

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

Error Code

Failure Code

E116

DY20MA

Failure content

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

The windshield wiper cannot be retracted completely.

Relative
information

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)

Presumed cause and


standard value in normalcy

Cause
Windshield wiper motor
1 defective
(Internal disconnection)

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 for the troubleshooting.
W04 (female)
Between (4) and (5)

Windshield wiper blade

Resistance value

Retraction range

Below 1 z

Operation range

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 P01 (female) (12) and W04
(male) (4)

Resistance
value

Below 1 z

Between wiring harness W04 (male) (5) and grounding

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.
3 Monitor panel defective

20-314
(1)

Standard value in normalcy and references for troubleshooting

P01

Windshield wiper blade

Voltage

Between (12) and


grounding

Retraction range

Below 1V

Operation range

20 30 V

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

Error Code

Failure Code

E117

DAC0KR

Failure content

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.
The output lowers (The pump absorption torque is reduced).
If the working load increases, the engine may stall.

Relative
information

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

Presumed cause and


standard value in normalcy

Phenomenon
occurring on
machine

Cause

Standard value in normalcy and references for troubleshooting

Disconnection of wiring
harness
1 (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.

Grounding fault of wiring


harness
2
(Contact with grounding
circuit)

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

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 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

5 Monitor panel defective

20-316
(1)

Wiring harness between P02 (female) (9), (10) and CB2


(female) (21), (31) or between P02 (female) (9), (10)
and C02 (female) (21)

Voltage

Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
CB2

Voltage

Between (21), (31) and (11)

69V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02

Voltage

Between (9), (10) and (20)

69V

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

Error Code

Failure Code

E118

DAB0KR

Failure content

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.
The output lowers (The pump absorption torque is reduced).
If the working load increases, the engine may stall.

Relative
information

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

Presumed cause and


standard value in normalcy

Phenomenon
occurring on
machine

Cause

Standard value in normalcy and references for troubleshooting

Disconnection of wiring
harness
1 (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.

Grounding fault of wiring


harness
2
(Contact with grounding
circuit)

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

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 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

5 Monitor panel defective

20-318
(1)

Wiring harness between P02 (female) (9), (10) and CB2


(female) (21), (31) or between P02 (female) (9), (10)
and C02 (female) (21)

Voltage

Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C02

Voltage

Between (21) and (31)

69V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02

Voltage

Between (9), (10) and (20)

69V

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

Error Code

Failure Code

E0E

E128

DAF0MC

Failure content

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

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


If the working load increases, the engine may stall.

Relative
information
Cause

Disconnection of wiring
harness
1 (Disconnection or defective contact with connector)

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)

Resistance
value

Below 1 z

Wiring harness between P70 (female) (15) and CB2


(female) (32) or between P70 (female) (15) and C02
(female) (32)

Resistance
value

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.
Grounding fault of wiring
harness
2
(Contact with grounding
circuit)

Resistance
value

Above 1 Mz

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

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)

CAN terminal resistor


defective

Monitor panel, engine


5 controller, or pump
controller defective

20-320
(1)

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) (16) and


CB2 (female) (22) or between P70 (female) (16) and
C02 (female) (22) or between P70 (female) (16) and
related circuits and grounding

Voltage

Below 1 V

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

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
K30 (male), K31 (male)

Voltage

Between (1) and (2)

40 80 z

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.)

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

Error Code

Failure Code

E201

DW91KB

Failure content

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

It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits connot be disconnected)

Relative
information

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

Presumed cause and


standard value in normalcy

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)

Resistance value

Between (1) and (2)

20 60 z

Between (2) and grounding

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) (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

Voltage

Neutral

Below 1 V

Steering

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

Error Code

Failure Code

E03

E203

DW45KB

Failure content

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

The upper structure cannot swing. (The swing holding brake cannot be released.)

Relative
information

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)

Presumed cause and


standard value in normalcy

Cause
Swing holding brake
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.
V05 (male)
Between (1) and (2)

20 60 z

Between (2) and grounding

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 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

20-324
(1)

Resistance value

L.H. work equipment


control lever

Voltage

NEUTRAL

Below 1 V

Swing operated

20 30 V

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

Error Code

Failure Code

E204

DWJ0KB

Failure content

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

In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
(FR pumps cannot be disconnected.)

Relative
information

Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)

Presumed cause and


standard value in normalcy

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)

Resistance value

Between (1) and (2)

20 60 z

Between (2) and grounding

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 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

Voltage

NEUTRAL

Below 1 V

When operating one side


only

20 30 V

Electrical Circuit Diagram for Merge/Divide Solenoid

20-326
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E205

Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid)


User Code

Error Code

Failure Code

E205

DWK0KB

Failure content

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

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


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

Relative
information

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

Presumed cause and


standard value in normalcy

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)

Resistance value

Between (1) and (2)

20 60 z

Between (2) and grounding

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 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

Working mode

Voltage

Between (28) and


grounding

Other than L mode

Below 1 V

L mode

20 30 V

Electric Circuit Diagram for 2-stage Relief Solenoid

PC400/450(LC)-7

20-327
(1)

TROUBLESHOOTING

E206

Error Code in Electrical System [E206]


(Short-circuiting in travel speed shifting solenoid)
User Code

Error Code

Failure Code

E206

DW43KB

Failure content

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

The travel speed does not turn to Hi.


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

Relative
information

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

Presumed cause and


standard value in normalcy

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)

Resistance value

Between (1) and (2)

20 60 z

Between (2) and grounding

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 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

Travel speed + travel lever

Voltage

Between (27) and


grounding

Lo + Neutral

Below 1 V

Hi + Travel operation

20 30 V

Electrical Circuit Diagram for Travel Speed Shifting Solenoid

20-328
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E211

Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid)


User Code

Error Code

Failure Code

E211

DW91KA

Failure content

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

It is difficult to steer the machine while traveling. (L.H. and R.H. travel circuits cannot be disconnected.)

Relative
information

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

Presumed cause and


standard value in normalcy

Travel interlocking
1 solenoid defective
(Internal disconnection)

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.
V02 (male)

Resistance value

Between (1) and (2)

20 60 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) (7) to V02 (female)
(2)

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3), (13), (23)


and V02 (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.
Wiring harness from C03 (female) (7) to V02 (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.
C03 (female)

Resistance value

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

20 60 z

Electrical Circuit Diagram for Travel Interlocking Solenoid

PC400/450(LC)-7

20-329
(1)

TROUBLESHOOTING

E213

Error Code in Electrical System [E213]


(Disconnection in swing holding brake solenoid)
User Code

Error Code

Failure Code

E03

E213

DW45KA

Failure content

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.)

Relative
information

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)

Presumed cause and


standard value in normalcy

Swing lock switch


2 defective
(Internal disconnection)

Assembled-type diode
3 D01 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)

Resistance value

Between (1) and (2)

20 60 z

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

Resistance value

OFF

Below 1 z

ON

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)

Digital type circuit tester

Continuity

Between (7) and (3)

Diode mode

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)

Resistance
value

Below 1 z

Wiring harness from D01 (female) (3) to J02 to X05


(male) (3)

Resistance
value

Below 1 z

Wiring harness from X05 (male) (4) to V05 (female) (2)

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3), (13), (23)


and V05 (female) (1)

Resistance
value

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

20-330
(1)

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 (37) and
(3), (13), (23)

Disconnect D01 and


connect pins (3) and (7) of
the female side.

Resistance value
20 60 z

PC400/450(LC)-7

TROUBLESHOOTING

E213

Electrical Circuit Diagram for Swing Holding Brake Solenoid

PC400/450(LC)-7

20-331
(1)

TROUBLESHOOTING

E214

Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)


User Code

Error Code

Failure Code

E214

DWJ0KA

Failure content

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

In L mode, speeds of the work equipment and swing in its single operation are too fast.
(FR pumps cannot be disconnected.)

Relative
information

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

Presumed cause and


standard value in normalcy

Merge/divide solenoid
1 defective
(Internal disconnection)

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.
V03 (male)

Resistance value

Between (1) and (2)

20 60 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) (17) to V03 (female)
(2)

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3), (13), (23)


and V03 (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.
Wiring harness from C03 (female) (17) to V03 (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.
C03 (female)

Resistance value

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

20 60 z

Electrical Circuit Diagram for Merge/Divide Solenoid

20-332
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E215

Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)


User Code

Error Code

Failure Code

E215

DWK0KA

Failure content

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

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


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

Relative
information

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

Presumed cause and


standard value in normalcy

2-stage relief solenoid


1 defective
(Internal disconnection)

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.
V08 (male)

Resistance value

Between (1) and (2)

20 60 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) (28) to V08 (female)
(2)

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3), (13), (23)


and V08 (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.
Wiring harness from C03 (female) (28) to V08 (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.
C03 (female)

Resistance value

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

20 60 z

Electrical Circuit Diagram for 2-stage Relief Solenoid

PC400/450(LC)-7

20-333
(1)

TROUBLESHOOTING

E216

Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid)
User Code

Error Code

Failure Code

E216

DW43KA

Failure content

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

The travel speed does not shift to Hi.


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

Relative
information

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

Presumed cause and


standard value in normalcy

Travel speed shifting


1 solenoid defective
(Internal disconnection)

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.
V04 (male)

Resistance value

Between (1) and (2)

20 60 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) (27) to V04 (female)
(2)

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3), (13), (23)


and V04 (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.
Wiring harness from C03 (female) (27) to V04 (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.
C03 (female)

Resistance value

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

20 60 z

Electrical Circuit Diagram for Travel Speed Shifting Solenoid

20-334
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E217

Error Code in Electrical System [E217] (Abnormal input model code)


User Code

Error Code

Failure Code

E217

DA2SKQ

Failure content

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

Since the controller controls the machine as PC750/800, the working speed changes and operation
becomes difficult.

Relative
information

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)

Resistance value

Between (4), (5), (6) and (8)

Min. 1 Mz

Between (1), (2), (3), (7) and (8)

Max. 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.

Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)

Grounding fault of wiring


harness
3
(Contact with grounding
circuit)

Wiring harness between C02 (female) (37) and C09


(male) (1)

Resistance
value

Max, 1 z

Wiring harness between C02 (female) (27) and C09


(male) (2)

Resistance
value

Max, 1 z

Wiring harness between C02 (female) (17) and C09


(male) (3)

Resistance
value

Max, 1 z

Wiring harness between C02 (female) (13) and C09


(male) (7)

Resistance
value

Max, 1 z

Wiring harness between C09 (male) (8), J05, and


grounding

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 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

20-336
(1)

C02

Voltage

Between (7) and grounding

5 30 V

Between (37), (27), (17), (13) and grounding

Max. 1 V

PC400/450(LC)-7

TROUBLESHOOTING

E217

Electrical circuit diagram related to model selection connector (for pump controller)

PC400/450(LC)-7

20-337
(1)

TROUBLESHOOTING

E218

Error Code in Electrical System [E218] (S-Net Comm. Disc.)


User Code

Error Code

Failure Code

E0E

E218

DA2SKA

Failure content

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

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


If the working load increases, the engine may stall.

Relative
information

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)

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.
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

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 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

4 Monitor panel defective

Engine controller
defective

6 Pump controller defective

20-338
(1)

Standard value in normalcy and references for troubleshooting

Voltage

Max. 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02

Voltage

Between (9), (10) and (20)

69V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
CB2

Voltage

Between (21), (31) and (11)

69V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C02

Voltage

Between (21) and (31)

69V

PC400/450(LC)-7

TROUBLESHOOTING

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

Error Code

Failure Code

E222

DXE0KB

Failure content

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

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.)

Relative
information

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


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

Presumed cause and


standard value in normalcy

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)

Resistance value

Between (1) and (2)

7 14 z

Between (1) and grounding

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 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)

Resistance value

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

7 14 z

Between (6) and grounding

Above 1 Mz

Electrical Circuit Diagram for LS-EPC Solenoid

20-340
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E223

Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system)


User Code

Error Code

Failure Code

E223

DXE0KA

Failure content

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

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.)

Relative
information

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


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

Presumed cause and


standard value in normalcy

LS-EPC solenoid
1 defective
(Internal short-circuiting)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)
Short-circuiting of wiring
harness
3
(Contact with 24 V
circuit)

4 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.
V22 (male)

Resistance value

Between (1) and (2)

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) (6) and
V22 (female) (1) and grounding

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3) (13) (23) and


V22 (female) (2)

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.
Between wiring harness between C03 (female) (6) and
V22 (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.
C03 (female)

Resistance value

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

7 14 z

Electrical Circuit Diagram for LS-EPC Solenoid

PC400/450(LC)-7

20-341
(1)

TROUBLESHOOTING

E224

Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality)


User Code

Error Code

Failure Code

E224

DHPAMA

Failure content

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

The travel speed does not shift automatically (The travel load pressure cannot be detected).

Relative
information

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

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

Voltage

Between (B) and (A)

Power supply

4.5 5.5 V

Between (C) and (A)

Signal

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.

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)

Grounding fault of wiring


harness
4
(Contact with grounding
circuit)

Wiring harness between C01 (female) (22) and A51


(female) (B)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (10) and A51


(female) (A)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (8) and P30


(female) (C)

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 C01 (female) (8) and
A51 (female) (C) 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.

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

Voltage

Max. 1 V

Voltage

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

20-342
(1)

C01

Voltage

Between (22) and (10)

4.5 5.5 V

Between (8) and (10)

0.5 4.5 V

PC400/450(LC)-7

TROUBLESHOOTING

E224

Electrical circuit diagram related to front pump pressure sensor

PC400/450(LC)-7

20-343
(1)

TROUBLESHOOTING

E225

Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality)


User Code

Error Code

Failure Code

E225

DHPBMA

Failure content

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

The travel speed does not shift automatically (The travel load pressure cannot be detected).

Relative
information

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

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

Voltage

Between (B) and (A)

Power supply

4.5 5.5 V

Between (C) and (A)

Signal

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.

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)

Grounding fault of wiring


harness
4
(Contact with grounding
circuit)

Wiring harness between C01 (female) (22) and A52


(female) (B)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (10) and A52


(female) (A)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (2) and A52


(female) (C)

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 C01 (female) (2) and
A52 (female) (C) 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.

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

Voltage

Max. 1 V

Voltage

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

20-344
(1)

C01

Voltage

Between (22) and (10)

4.5 5.5 V

Between (2) and (10)

0.5 4.5 V

PC400/450(LC)-7

TROUBLESHOOTING

E225

Electrical circuit diagram related to rear pump pressure sensor

PC400/450(LC)-7

20-345
(1)

TROUBLESHOOTING

E226

Error Code in Electrical System [E226] (Press. Sensor Power Abnormality)


User Code

Error Code

Failure Code

E226

DA25KP

Failure content

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

The pressure sensor signal is not input normally.


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

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.

Presumed cause and


standard value in normalcy

Pressure sensor
1 defective
(Internal short-circuiting)

Connector A51

Rear pump
pressure sensor

Connector A52

Arm IN PPC
pressure sensor

Connector S04

Bucket CURL PPC


pressure sensor

Connector S01

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)

3 Pump controller defective

20-346
(1)

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

Between wiring harness between C01 (female) (22),


A51 (female) (B) and grounding
[Front pump pressure sensor system]

Resistance
value

Min. 1 Mz

Between wiring harness between C01 (female) (22),


A51 (female) (B) and grounding
[Rear pump pressure sensor system]

Resistance
value

Min. 1 Mz

Between wiring harness between C01 (female) (22),


S04 (female) (A) and grounding
[Arm IN PPC pressure sensor system]

Resistance
value

Min. 1 Mz

Between wiring harness between C01 (female) (22),


S01 (female) (A) and grounding
[Bucket CURL PPC pressure sensor system]

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.
C01

Voltage

Between (22) and (10)

4.5 5.5 V

PC400/450(LC)-7

TROUBLESHOOTING

E226

Electrical circuit diagram related to pressure sensor power supply

PC400/450(LC)-7

20-347
(1)

TROUBLESHOOTING

E227

Error Code in Electrical System [E227] (Abnormality in engine rotation sensor)


User Code

Error Code

Failure Code

E227

DLE2MA

Failure content

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

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.

Relative
information

Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
(Code No.: 01006 Engine RPM)
Cause

Presumed cause and


standard value in normalcy

Engine rotation sensor


fault
1
(Internal short-circuiting
or disconnection)
2

Engine rotation sensor


adjustment improper

Disconnection of wiring
harness
3 (Disconnection or
defective contact with
connector)
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.
ENE (male)

Resistance value

Between (1) and (2)

500 1,000 z

Between (1) and grounding

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)

Resistance
value

Below 1 z

Wiring harness between C02 (female) (29) (39) and


ENE (female) (2)

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.
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)

Resistance value

Between (40) and (29) (39)

500 1,000 z

Between (40) and grounding

Above 1 Mz

Electrical Circuit Diagram for Engine Rotation Sensor

20-348
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E228

Error Code in Electrical System [E228]


(Short-circuiting in attachment return switching relay)
User Code

Error Code

Failure Code

E228

D196KB

Failure content

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

The hydraulic circuit for attachments is not switched to the single operation circuit.
(The switching valve is not switched to the tank circuit.)

Relative
information

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).

Presumed cause and


standard value in normalcy

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)

Resistance value

Between (1) and (2)

100 500 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 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

Working mode

Voltage

Between (8) and


grounding

Other than B mode

20 30 V

B mode

Below 1 V

Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid

PC400/450(LC)-7

20-349
(1)

TROUBLESHOOTING

E232

Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid)


User Code

Error Code

Failure Code

E02

E232

DXA0KB

Failure content

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.)

Relative
information

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)

Resistance value

Between (1) and (2)

7 14 z

Between (1) and grounding

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.
Emergency pump driving
switch defective
2
(Internal short-circuiting
or grounding fault)

S25 (male)

Emergency pump drive


switch

Between (3) and (4)


Between (3) and
grounding

Grounding fault of wiring


harness
3
(Contact with grounding
circuit)

Resistance value
Above 1 Mz

Normal

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

Resistance
value

Above
1 Mz

Between wiring harness from S25 (female) (2) to V21


(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

20-350
(1)

Pump controller
defective

C03 (female)

Resistance value

Between (16) and (3) (13) (23)

7 14 z

Between (16) and grounding

Above 1 Mz

PC400/450(LC)-7

TROUBLESHOOTING

E232

Electrical Circuit Diagram for PC-EPC Solenoid

PC400/450(LC)-7

20-351
(1)

TROUBLESHOOTING

E233

Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)


User Code

Error Code

Failure Code

E02

E233

DXA0KA

Failure content

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

As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
(The pump absorption torque cannot be controlled.)

Relative
information

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)

Resistance value

Between (1) and (2)

7 14 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

Emergency pump driving


2 switch defective
(Internal disconnection)

Emergency pump driving


switch

Resistance value

Normal

Below 1 z

Emergency

Above 1 Mz

Normal

Below 1 z

Emergency

Above 1 Mz

Between (2) and (3)


Between (5) and (6)

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)

Short-circuiting of wiring
harness
4
(Contact with 24 V
circuit)

20-352
(1)

S25 (male)

Pump controller
defective

Wiring harness between C03 (female) (16) and S25


(female) (3)

Resistance
value

Below 1 z

Wiring harness between S25 (female) (2) and V21


(female) (1)

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3) (13) (23) and


S25 (female) (6)

Resistance
value

Below 1 z

Wiring harness between S25 (female) (5) and V21


(female) (2)

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.
Between wiring harness between C03 (female) (16) and
S25 (female) (3) and grounding

Voltage

Below 1 V

Between wiring harness between S25 (female) (2) and


V21 (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.
C03 (female)

Resistance value

Between (16) and (3) (13) (23)

7 14 z

PC400/450(LC)-7

TROUBLESHOOTING

E233

Electrical Circuit Diagram for PC-EPC Solenoid

PC400/450(LC)-7

20-353
(1)

TROUBLESHOOTING

E238

Error Code in Electrical System [E238] (Disconnection in attachment return switching relay)
User Code

Error Code

Failure Code

E238

D196KA

Failure content

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

The hydraulic circuit for attachments cannot be switched to the single operation.
(The switching valve cannot be switched to the tank circuit.)

Relative
information

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

Presumed cause and


standard value in normalcy

Attachment return
2 switching relay defective
(Internal disconnection)

Disconnection in wiring
harness (Disconnection
3
in wiring or defective
contact in connector)

Grounding fault of wiring


harness
4
(Contact with grounding
circuit)

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)

Resistance value

Between (1) and (2)

100 500 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) (8) and R20
(female) (2)

Resistance
value

Below 1 z

Wiring harness from R20 (female) (1) to J03 to FB1-2


outlet

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 C02 (female) (8) and
R20 (female) (2) and grounding

Resistance
value

Above
1 Mz

Between wiring harness from R20 (female) (1) to J03 to


FB1-2 outlet 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.
5

20-354
(1)

Pump controller
defective

C02

Working mode

Voltage

Between (8) and


grounding

Other than B mode

20 30 V

B mode

Below 1 V

PC400/450(LC)-7

TROUBLESHOOTING

E238

Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid

PC400/450(LC)-7

20-355
(1)

TROUBLESHOOTING

E245

Error Code in Electrical System [E245]


(Short-circuiting in attachment oil flow rate adjusting EPC)
User Code

Error Code

Failure Code

E245

DXE4KB

Failure content

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

The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)

Relative
information

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)

Presumed cause and


standard value in normalcy

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)

Resistance value

Between (1) and (2)

7 14 z

Between (1) and grounding

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 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)

Resistance value

Between (26) and (3) (13) (23)

7 14 z

Between (26) and grounding

Above 1 Mz

Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid

20-356
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E246

Error Code in Electrical System [E246]


(Disconnection in attachment oil flow rate adjusting EPC)
User Code

Error Code

Failure Code

E246

DXE4KA

Failure content

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

The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)

Relative
information

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

Presumed cause and


standard value in normalcy

Attachment oil flow rate


adjusting EPC defective
1
(Internal short-circuiting
or grounding fault)
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)

Resistance value

Between (1) and (2)

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

Resistance
value

Below 1 z

Between wiring harness between C03 (female) (3) (13)


(23) and V30 (male) (2) and grounding

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.
Between wiring harness between C03 (female) (26) and
V30 (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.
C03 (female)

Resistance value

Between (26) and (3) (13) (23)

7 14 z

Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid

PC400/450(LC)-7

20-357
(1)

TROUBLESHOOTING

E247

Error Code in Electrical System [E247]


(Arm IN PPC pressure sensor abnormality)
User Code

Error Code

Failure Code

E247

DHS3MA

Failure content

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

If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The
arm IN PPC circuit pressure cannot be detected).

Relative
information

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

Voltage

Between (A) and (C)

Power supply

4.5 5.5 V

Between (B) and (C)

Signal

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.

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)

Grounding fault of wiring


harness
4
(Contact with grounding
circuit)

Wiring harness between C01 (female) (22) and S04


(female) (A)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (10) and S04


(female) (C)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (19) and S04


(female) (E)

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 C01 (female) (19) and
S04 (female) (E) and grounding

Resistance
value

Min. 1 M z

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 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

Voltage

Max. 1 V

Voltage

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

20-358
(1)

C01

Voltage

Between (22) and (10)

4.5 5.5 V

Between (19) and (10)

0.5 4.5 V

PC400/450(LC)-7

TROUBLESHOOTING

E247

Circuit diagram related to arm IN PPC pressure sensor

PC400/450(LC)-7

20-359
(1)

TROUBLESHOOTING

E248

Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)
User Code

Error Code

Failure Code

E248

DHS4MA

Failure content

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

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).

Relative
information

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

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

Voltage

Between (1) and (3)

Power supply

4.5 5.5 V

Between (2) and (3)

Signal

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.

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)

Grounding fault of wiring


harness
4
(Contact with grounding
circuit)

Wiring harness between C01 (female) (22) and S04


(female) (1)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (10) and S04


(female) (3)

Resistance
value

Max. 1 z

Wiring harness between C01 (female) (13) and S04


(female) (2)

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 C01 (female) (13) and
S04 (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
position during the troubleshooting.

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

Voltage

Max. 1 V

Voltage

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

20-360
(1)

C01

Voltage

Between (22) and (10)

4.5 5.5 V

Between (13) and (10)

0.5 4.5 V

PC400/450(LC)-7

TROUBLESHOOTING

E248

Circuit diagram related to bucket CURL PPC pressure sensor

PC400/450(LC)-7

20-361
(1)

TROUBLESHOOTING

E257

Error Code in Electrical System [E257] (Pump Abnormality)


User Code

Error Code

Failure Code

E0E

E257

DA2RMC

Failure content

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

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


If the working load increases, the engine may stall.

Relative
information
Cause

Disconnection of wiring
harness
1 (Disconnection or defective contact with connector)

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)

Resistance
value

Below 1 z

Wiring harness between P70 (female) (15) and CB2


(female) (32) or between P70 (female) (15) and C02
(female) (32)

Resistance
value

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.
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

Resistance
value

Above 1 Mz

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

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)

CAN terminal resistor


defective

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

Voltage

Below 1 V

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

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
K30 (male), K31 (male)

Resistance value

Between (1) and (2)

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.)

20-362
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E257

Electrical circuit diagram related to CAN communication

PC400/450(LC)-7

20-363
(1)

TROUBLESHOOTING

E315

Error Code in Electrical System [E315] (Battery Relay Drive S/C)


User Code

Error Code

Failure Code

E315

D110KB

Failure content

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

There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.

Relative
information

Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
(Code No. 03700: Controller output 1)

Presumed cause and


standard value in normalcy

Cause
Battery relay defective
1 (Internal short-circuiting
or grounding fault)

Grounding fault of wiring


harness
2
(Contact with grounding
circuit)

20-364
(1)

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.
Battery relay (Unit)

Resistance value

Between BR and E

Approx. 100 z

Between BR and grounding

Min. 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 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

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C03 (female)

Starting switch

Voltage

Between (4) and grounding

ON o OFF

20 30 V
(For 0.5 sec)

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

Error Code

Failure Code

E11

E91B

DLE3LC

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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

Presumed cause and


standard value in normalcy

Engine Ne speed sensor


defective
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
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.
NE (male)

Resistance value

Between (1) and (2)

85 210 z

Between (1), (2) and grounding

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)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (26) and NE


(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 CB2 (female) (36) and
NE (female) (2) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB2 (female) (26) and


NE (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 (female)

Resistance value

Between (36) and (26)

85 210 z

Between (36), (26) and grounding

Above 1 Mz

Electrical circuit diagram related to engine Ne speed sensor

20-366
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E91C

Error Code in Electrical System [E91C] (Engine G sensor problem)


User Code

Error Code

Failure Code

E11

E91C

DLH1LC

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.
Cause

Presumed cause and


standard value in normalcy

Engine G speed sensor


defective
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
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.
G (male)

Resistance value

Between (1) and (2)

1.4 k 3.5 kz

Between (1), (2) and grounding

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)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (25) and G


(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 CB2 (female) (35) and
G (female) (2) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB2 (female) (25) and


G (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 (female)

Resistance value

Between (35) and (25)

1.4 k 3.5 kz

Between (35), (25) and grounding

Above 1 Mz

Electrical circuit diagram related to engine G speed sensor

PC400/450(LC)-7

20-367
(1)

TROUBLESHOOTING

E920

Error Code in Electrical System [E920] (Engine type selection error)


User Code

Error Code

Failure Code

E11

E920

DB29KQ

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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

Presumed cause and


standard value in normalcy

Model selection
connector defective
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
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.
CB5 (female)

Resistance value

Between (2), (3) (4), (5), (6), (7), and


(8)

Above 1 Mz

Between (1) and (8)

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)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (1) and CB5


(male) (8)

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 CB1 (female) (23) and
CB5 (male) (2) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB1 (female) (17) and


CB5 (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 during the troubleshooting.
4

20-368
(1)

Engine controller
defective

CB1, CB2

Voltage

Between CB1 (23), (17) and CB2 (1)

20 30 V

Between CB1 (3) and CB2 (1)

Below 1 V

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

Error Code

Failure Code

E11

E921

DB20KQ

Failure content

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.
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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)

Presumed cause and


standard value in normalcy

Phenomenon
occurring on
machine

Cause
1

Model selection connector system defective

If error code [E920] is displayed, carry out troubleshooting for it.

Engine controller
defective

Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)

3 Pump controller defective

20-370
(1)

Standard value in normalcy and references for troubleshooting

Pump controller may be defective. (Since trouble is in the controller, troubleshooting


cannot be carried out.)

PC400/450(LC)-7

TROUBLESHOOTING

E931

Error Code in Electrical System [E931] (Fuel dial sys. error)


User Code

Error Code

Failure Code

E14

E931

DK10KX

Failure content

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

The engine speed cannot be controlled.

Relative
information

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)

Resistance value

Between (1) and (3)

4.0 6.0 kz

Between (1) and (2)

0.25 7.0 kz

Between (3) and (2)

0.25 7.0 kz

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
2 (Disconnection or
defective contact with
connector)

Grounding fault of wiring


harness
3
(Contact with grounding
circuit)

Wiring harness between CB2 (female) (19) and E06


(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (10) and E06


(female) (2)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (29), (39), and


E06 (female) (3)

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 CB2 (female) (19) and
E06 (female) (1) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB2 (female) (10) and


E06 (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.

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

Voltage

Below 1 V

Voltage

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

20-372
(1)

Engine controller
defective

CB2

Voltage

Between (19) and (29), (39)

4.6 5.4 V

Between (10) and (29), (39)

0.3 4.5 V

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

Error Code

Failure Code

E15

E934

DGE2KX

Failure content

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 90C.
controller
When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine

The engine does not start easily when temperature is low.


The overheat protection function does not operate.
If the controller is also defective, the engine does not stop.

Relative
information

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

Presumed cause and


standard value in normalcy

Engine water high


temperature sensor
1 defective
(Internal disconnection or
short circuit)
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)

Resistance value

Between (1) and (2)

3.5 k 90 kz

Between (1), (2) and grounding

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)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (29), (39), and


TWH (female) (2)

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 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

20-374
(1)

Engine controller
defective

CB2

Resistance value

Between (27), (29) and (39)

3.5 k 90 kz

Between (27), (29), (39) and grounding

Above 1 Mz

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

Error Code

Failure Code

E15

E936

DDE2L6

Failure content

Failure
phenomenon

Engine oil press. sw. error


(Engine controller system)

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

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.

Relative
information

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)

Presumed cause and


standard value in normalcy

Engine high-oil pressure


switch defective
2
(Internal disconnection or
short-circuiting)

Disconnection of wiring
harness
3 (Disconnection or
defective contact with
connector)

Grounding fault of wiring


harness
4
(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 and start the engine during the troubleshooting.
PSL

Engine

Resistance value

Between terminal
and grounding

Stopped

Below 1 z

Low idling

Above 1 Mz

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

Resistance value

Stopped

Below 1 z

Running at 1,300 rpm


or higher

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 CB1 (female) (21) and PSL

Resistance
value

Below 1 z

Wiring harness between CB1 (female) (15) and PSH

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 CB1 (female) (21) and
PSL and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB1 (female) (15) and


PSH and grounding

Resistance
value

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.

Engine controller
defective

CB1

Engine

Voltage

Between (21) and grounding (Low-pressure switch


signal)

Stopped

Below 1 V

Low idling

20 30 V

Stopped

Below 1 V

Running at 1,300 rpm


or higher

20 30 V

Between (15) and grounding (High-pressure switch


signal)

Carry out troubleshooting while the engine is running 15 seconds after the engine is
started.

20-376
(1)

PC400/450(LC)-7

TROUBLESHOOTING

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

Error Code

Failure Code

E11

E93C

DH30KX

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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

Voltage

Between (3) and (1)

Power supply

4.6 5.4 V

Between (2) and (1)

Signal

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.

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
2 (Disconnection or
defective contact with
connector)

Grounding fault of wiring


harness
3
(Contact with grounding
circuit)

Wiring harness between CB2 (female) (9) and PIM


(female) (3)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (29), (39), and


PIM (female) (1)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (20) and PIM


(female) (2)

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 CB2 (female) (9) and
PIM (female) (3), or between CB2 (female) (9) and
related circuits and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB2 (female) (20) and


PIM (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.
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

Voltage

Below 1 V

Between wiring harness between CB2 (female) (20) and


PIM (female) (2) and grounding

Voltage

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

20-378
(1)

Engine controller
defective

CB2

Voltage

Between (9) and (29), (39)

4.6 5.4 V

Between (20) and (29), (39)

0.3 4.7 V

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

Error Code

Failure Code

E15

E93D

DGE4KX

Failure content

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

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.

Relative
information

Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
(Code No. 14201: Fuel temperature sensor voltage)
Cause

Presumed cause and


standard value in normalcy

Fuel temperature sensor


defective
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
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.
THL (male)

Resistance value

Between (1) and (2)

0.3 k 9 kz

Between (1), (2) and grounding

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)

Resistance
value

Below 1 z

Wiring harness between E12 (female) (29), (39) and


THL (female) (2)

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 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

20-380
(1)

Engine controller
defective

CB2

Resistance value

Between (17), (29) and (39)

0.3 k 9 kz

Between (17) and (29), (39) and


grounding

Above 1 Mz

PC400/450(LC)-7

TROUBLESHOOTING

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

Error Code

Failure Code

E0E

E953

DB2RMC

Failure content

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

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


If the working load increases, the engine may stall.

Relative
information
Cause

Disconnection of wiring
harness
1 (Disconnection or
defective contact with
connector)

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)

Resistance
value

Below 1 z

Wiring harness between P70 (female) (15) and CB2


(female) (32) or between P70 (female) (15) and C02
(female) (32)

Resistance
value

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.
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

Resistance
value

Above 1 Mz

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

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)

CAN terminal resistor


defective

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

Voltage

Below 1 V

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

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
K30 (male), K31 (male)

Resistance value

Between (1) and (2)

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.)

20-382
(1)

PC400/450(LC)-7

TROUBLESHOOTING

E953

Electrical circuit diagram related to CAN communication

PC400/450(LC)-7

20-383
(1)

TROUBLESHOOTING

E954

Error Code in Electrical System [E954] (Short engine starter sw.)


User Code

Error Code

Failure Code

E954

DD11KB

Failure content

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

The machine operates normally.

Relative
information

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.

Presumed cause and


standard value in normalcy

Starting switch
Between terminal B
and terminal C

Resistance value
OFF

Above 1 Mz

START

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

20-384
(1)

Starting switch defective


(Internal short-circuiting)

Engine controller
defective

Voltage

Below 1 V

a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
CB1

Starting switch

Voltage

Between (20) and


grounding

ON
(Engine is running)

Below 1 V

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

Error Code

Failure Code

E0E

E955

DB2SMC

Failure content

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

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


If the working load increases, the engine may stall.

Relative
information

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)

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.
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

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 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

4 Monitor panel defective

Engine controller
defective

6 Pump controller defective

20-386
(1)

Standard value in normalcy and references for 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.
P02

Voltage

Between (9), (10) and (20)

69V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
CB2

Voltage

Between (21), (31) and (11)

69V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C02

Voltage

Between (21) and (31)

69V

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

Error Code

Failure Code

E10

E956

DB22KK

Failure content

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

The engine stalls.


The engine cannot be started.

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.)

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.

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 CB3 (female) (1), (2), (21) and


R22 (female) (5)

Resistance
value

Below 1 z

Wiring harness between R22 (female) (3) and B27

Resistance
value

Below 1 z

Wiring harness between B17 and battery relay B terminal

Resistance
value

Below 1 z

Wiring harness between R22 (female) (1) and J02


(male) (1)

Resistance
value

Below 1 z

Wiring harness between R22 (female) (2) and grounding

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.
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

Resistance
value

Above 1 Mz

Between wiring harness between R22 (female) (3) and


B27

Resistance
value

Above 1 Mz

Between wiring harness between R22 (female) (1) and


J02 (male) (1) or between R22 (female) (1) and related
circuits and grounding

Resistance
value

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

20-388
(1)

Engine controller
defective

E13

Starting switch

Voltage

Between (1), (2), (21)


and (11), (31), (32)

OFF

Below 1 V

ON

20 30 V

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

Error Code

Failure Code

E15

E957

D1D0KB

Failure content

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

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.

Relative
information

Presumed cause and


standard value in normalcy

Cause
Engine controller power
1 supply relay defective
(Internal short-circuiting)

Replace the power supply relay with another one. If the condition
becomes normal, the relay is defective.

R22

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 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

Voltage

Below 1 V

Voltage

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

20-390
(1)

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.

Engine controller
defective

CB3

Starting switch

Voltage

Between (1), (2), (21)


and (11), (31), (32)

OFF

Below 1 V

ON

20 30 V

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

Error Code

Failure Code

E95A

DB2AMA

Failure content

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.
Setting of the fuel injection amount adjustment switch cannot be changed.

Relative
information

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)

Presumed cause and


standard value in normalcy

Phenomenon
occurring on
machine

Cause
Setting of fuel injection
amount adjustment
1
switch of engine
controller defective

20-392
(1)

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.

If the cause is not detected, engine controller may be defective.

PC400/450(LC)-7

TROUBLESHOOTING

E96A

Error Code in Electrical System [E96A] (Engine coolant sensor Lo error)


User Code

Error Code

Failure Code

E15

E96A

DGE3L6

Failure
phenomenon

Engine coolant sensor Lo error


(Engine controller system)

Failure content

The signal voltage from the engine water low temperature sensor is above 4.5 V.

Response from
controller

The signal of the engine water low temperature sensor is kept at 20C (If the signal of the high temperature sensor is effective, it is used as a substitute).
When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon
occurring on
machine

The engine does not start easily when temperature is low.


The overheat protection function does not operate.
If the controller is also defective, the engine does not stop.

Relative
information

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

Presumed cause and


standard value in normalcy

Engine water low


temperature sensor
1 defective
(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
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.
TWL (male)

Resistance value

Between (1) and (2)

0.3 k 9 kz

Between (1), (2) and grounding

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) (37) and TWL
(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (29), (39), and


TWL (female) (2)

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 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

20-394
(1)

Engine controller
defective

E12

Resistance value

Between (29), (37) and (39)

0.3 k 9 kz

Between (29), (37), (39) and grounding

Above 1 Mz

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

Error Code

Failure Code

E11

E970

AD11KB

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
Cause

Presumed cause and


standard value in normalcy

Fuel supply pump PCV1


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.
PCV1 (male)

Resistance value

Between (1) and (2)

2.3 5.3 z

Between (1) and grounding

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) (12) and
PCV1 (female) (1)

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
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)

Voltage

Below 1 V

Voltage

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)

Resistance value

Between (12) and (22)

2.3 5.3 z

Between (12), (22) and grounding

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

Error Code

Failure Code

E11

E971

AD51KB

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
Cause

Presumed cause and


standard value in normalcy

Fuel supply pump PCV2


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.
PCV2 (male)

Resistance value

Between (1) and (2)

2.3 5.3 z

Between (1) and grounding

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) (13) and
PCV2 (female) (1)

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
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)

Voltage

Below 1 V

Voltage

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)

Resistance value

Between (13) and (23)

2.3 5.3 z

Between (13), (23) and grounding

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

Error Code

Failure Code

E11

E974

AD11KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
Cause

Presumed cause and


standard value in normalcy

Fuel supply pump PCV1


1 defective
(Internal disconnection)

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.
PCV1 (male)

Resistance value

Between (1) and (2)

2.3 5.3 z

Between (1) and grounding

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) (12) and
PCV1 (female) (1)

Resistance
value

Below 1 z

Between wiring harness between CB3 (female) (22) and


PCV1 (female) (2)

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 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)

Resistance value

Between (12) and (22)

2.3 5.3 z

Between (12), (22) and grounding

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

Error Code

Failure Code

E11

E975

AD51KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
Cause

Presumed cause and


standard value in normalcy

Fuel supply pump PCV2


1 defective
(Internal disconnection)

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.
PCV2 (male)

Resistance value

Between (1) and (2)

2.3 5.3 z

Between (1) and grounding

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) (13) and
PCV2 (female) (1)

Resistance
value

Below 1 z

Between wiring harness between CB3 (female) (23) and


PCV2 (female) (2)

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 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)

Resistance value

Between (13) and (23)

2.3 5.3 z

Between (13), (23) and grounding

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

Error Code

Failure Code

E11

E977

DH40KX

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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

Voltage

Between (3) and (1)

Power supply

4.6 5.4 V

Between (2) and (1)

Signal

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.

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
2 (Disconnection or
defective contact with
connector)

Grounding fault of wiring


harness
3
(Contact with grounding
circuit)

Wiring harness between CB2 (female) (9) and PFUEL


(female) (3)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (39) and PFUEL


(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (40) and PFUEL


(female) (2)

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 CB2 (female) (9) and
PFUEL (female) (3), or between CB2 (female) (9) and
related ciricuits and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB2 (female) (40) and


PFUEL (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.
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

Voltage

Below 1 V

Between wiring harness between CB2 (female) (40) and


PFUEL (female) (2) and grounding

Voltage

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

20-400
(1)

Engine controller
defective

CB2

Voltage

Between (9) and (39)

4.6 5.4 V

Between (40) and (39)

0.7 4.5 V

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

Error Code

Failure Code

E11

E979

AD00L2

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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)

Presumed cause and


standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Related systems
1
defective

If any other error code or failure code is displayed, carry out troubleshooting for it
first.

2 Fuel used improper

Fuel used may be improper. Check it directly.

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

The overflow valve may have trouble of breakage of spring, wear of seat, or fixing of
ball. Check it directly.

6 Overflow piping clogged

The overflow piping may be clogged. Check it directly.

7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.

Error Code in Electrical System [E97A] (Rail press. abnormal)


User Code
E11
Failure content

Error Code

Failure Code

E97A

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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)

Presumed
cause and
standard value
in normalcy

20-402
(1)

Cause
1

Common rail related


device defective

Standard value in normalcy and references for troubleshooting


Carry out troubleshooting for error code [E979].

PC400/450(LC)-7

TROUBLESHOOTING

E97B

Error Code in Electrical System [E97B] (Rail press. low)


User Code

Error Code

Failure Code

E15

E97B

AD10L3

Failure content

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

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.

Relative
information

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

Presumed cause and


standard value in normalcy

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.

2 Fuel used improper

Fuel used may be improper. Check it directly.

Fuel low-pressure circuit


3
device defective

A low-pressure circuit device may be defective. Referring to Note 1, carry out


troubleshooting.

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

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.

8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
9 Fuel injector defective

Note 1:
1)
2)
3)
4)
5)
6)

The fuel injector may be defective. Referring to Note 3, check it directly.

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 90C).
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.

20-404
(1)

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)

Limit of spill (cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1,200

PC400/450(LC)-7

TROUBLESHOOTING

E97C, E97D

Error Code in Electrical System [E97C] (Rail press. too low)


User Code

Error Code

Failure Code

E11

E97C

AD10MB

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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)

Presumed
cause and
standard value
in normalcy

Cause
1

Standard value in normalcy and references for troubleshooting

Common rail-related
device defective

Carry out troubleshooting for error code [E97B].

Error Code in Electrical System [E97D] (Rail press. out of control)


User Code

Error Code

Failure Code

E11

E97D

AD10MA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.

Relative
information

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)

Presumed
cause and
standard value
in normalcy

Cause
1

PC400/450(LC)-7

Common rail-related
device defective

Standard value in normalcy and references for troubleshooting


Carry out troubleshooting for error code [E97B].

20-405
(1)

TROUBLESHOOTING

E980

Error Code in Electrical System [E980] (Eng. Controller Abnormality)


User Code

Error Code

Failure Code

E10 or E11

E980

DB20KT

Failure content

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

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).

Presumed cause and


standard value in normalcy

Relative
information
Cause
Disconnection of wiring
harness
1 (Disconnection or
defective contact with
connector)
2

20-406
(1)

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

If cause 1 is not detected, the engine controller may be defective.


(Since trouble is in the engine controller, troubleshooting cannot be carried out.)

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

Error Code

Failure Code

E11

E981

ADA1KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause

Presumed cause and


standard value in normalcy

Fuel injector 1 defective


(Internal disconnection)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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.
CN1 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (14) and CN1
(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB3 (female) (24) and CN1


(female) (2)

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.
CB3 (female)

Resistance value

Between (14) and (24)

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

Error Code

Failure Code

E11

E982

ADB1KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause

Presumed cause and


standard value in normalcy

Fuel injector 2 defective


(Internal disconnection)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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.
CN2 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (6) and CN2
(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB3 (female) (16) and CN2


(female) (2)

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.
CB3 (female)

Resistance value

Between (6) and (16)

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

Error Code

Failure Code

E11

E983

ADC1KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause

Presumed cause and


standard value in normalcy

Fuel injector 3 defective


(Internal disconnection)

Disconnection of wiring
harness
2 (Disconnection or defective contact with connector)

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.
CN3 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (5) and CN3
(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB3 (female) (15) and CN3


(female) (2)

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.
CB3 (female)

Resistance value

Between (5) and (15)

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

Error Code

Failure Code

E11

E984

ADD1KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause

Presumed cause and


standard value in normalcy

Fuel injector 4 defective


(Internal disconnection)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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.
CN4 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (26) and CN4
(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB3 (female) (36) and CN4


(female) (2)

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.
CB3 (female)

Resistance value

Between (26) and (36)

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

Error Code

Failure Code

E11

E985

ADF1KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause

Presumed cause and


standard value in normalcy

Fuel injector 5 defective


(Internal disconnection)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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.
CN5 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (33) and CN5
(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB3 (female) (34) and CN5


(female) (2)

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.
CB3 (female)

Resistance value

Between (34) and (33)

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

Error Code

Failure Code

E11

E986

ADF1KA

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause

Presumed cause and


standard value in normalcy

Fuel injector 6 defective


(Internal disconnection)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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.
CN6 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (25) and CN6
(female) (1)

Resistance
value

Below 1 z

Wiring harness between CB3 (female) (35) and CN6


(female) (2)

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.
CB3 (female)

Resistance value

Between (25) and (35)

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

Error Code

Failure Code

E11

E98A

ADAZKB

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause
Fuel injector 1 defective
1 (Internal short-circuiting
or grounding fault)

Presumed cause and


standard value in normalcy

Fuel injector 2 defective


2 (Internal short-circuiting
or grounding fault)

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.
CN1 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

Between (1), (2) and grounding

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN2 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

Between (1), (2) and grounding

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN3 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

Between (1), (2) and grounding

Above 1 Mz

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)

20-414
(1)

Standard value in normalcy and references for troubleshooting

Between wiring harness between CB3 (female) (14) and


CN1 (female) (1) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (24) and


CN1 (female) (2) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (6) and


CN2 (female) (1) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (16) and


CN2 (female) (2) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (5) and


CN3 (female) (1) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (15) and


CN3 (female) (2) and grounding

Resistance
value

Above 1 Mz

PC400/450(LC)-7

TROUBLESHOOTING

Cause

E98A

Standard value in normalcy and references for troubleshooting

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 CB3 (female) (14) and
CN1 (female) (1) and grounding

Voltage

Below 1 V

Between wiring harness between CB3 (female) (24) and


CN1 (female) (2) and grounding

Voltage

Below 1 V

Voltage

Below 1 V

Voltage

Below 1 V

Between wiring harness between CB3 (female) (5) and


CN3 (female) (1) and grounding

Voltage

Below 1 V

Between wiring harness between CB3 (female) (15) and


CN3 (female) (2) and grounding

Voltage

Below 1 V

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

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

Resistance value

Between (14) and (24)

0.4 1.1 z

Between (6) and (16)

0.4 1.1 z

Between (5) and (15)

0.4 1.1 z

Between (5), (6), (14), (15), (16), (24)


and grounding

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

Error Code

Failure Code

E11

E98B

ADDZKB

Failure content

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

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code [E10] is displayed).

Relative
information
Cause
Fuel injector 4 defective
1 (Internal short-circuiting
or grounding fault)

Presumed cause and


standard value in normalcy

Fuel injector 5 defective


2 (Internal short-circuiting
or grounding fault)

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.
CN4 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

Between (1), (2) and grounding

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN5 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

Between (1), (2) and grounding

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN6 (male)

Resistance value

Between (1) and (2)

0.4 1.1 z

Between (1), (2) and grounding

Above 1 Mz

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)

20-416
(1)

Standard value in normalcy and references for troubleshooting

Between wiring harness between CB3 (female) (26) and


CN4 (female) (1) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (36) and


CN4 (female) (2) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (34) and


CN5 (female) (1) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (33) and


CN5 (female) (2) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (25) and


CN6 (female) (1) and grounding

Resistance
value

Above 1 Mz

Between wiring harness between CB3 (female) (35) and


CN6 (female) (2) and grounding

Resistance
value

Above 1 Mz

PC400/450(LC)-7

TROUBLESHOOTING

Cause

E98B

Standard value in normalcy and references for troubleshooting

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 CB3 (female) (26) and
CN4 (female) (1) and grounding

Voltage

Below 1 V

Between wiring harness between CB3 (female) (36) and


CN4 (female) (2) and grounding

Voltage

Below 1 V

Voltage

Below 1 V

Voltage

Below 1 V

Between wiring harness between CB3 (female) (25) and


CN6 (female) (1) and grounding

Voltage

Below 1 V

Between wiring harness between CB3 (female) (35) and


CN6 (female) (2) and grounding

Voltage

Below 1 V

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

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

Resistance value

Between (26) and (36)

0.4 1.1 z

Between (34) and (33)

0.4 1.1 z

Between (25) and (35)

0.4 1.1 z

Between (25), (26), (33), (34), (35), (36)


and grounding

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

Error Code

Failure Code

E22

E922

A000N1

Failure content

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

If the machine is used as it is, the engine may be damaged.

Relative
information

Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(Code No. 01006: Engine speed)

Presumed cause and


standard value in normalcy

Cause
Overrun of engine
1
(While system is normal)
2

Engine speed sensor


system abnormal

Engine controller defective

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

Engine

Engine speed

01006
Engine speed

High idling

1,880 1,980 rpm

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

If the machine is used as it is, the engine may be damaged.

Relative
information

Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(Code No. 01006: Engine speed)

Presumed cause and


standard value in normalcy

Cause
1

Engine mechanical system defective

Check for an external or an internal factor which lowers the engine low-idling speed,
and then check the mechanical system of the engine.

Engine speed sensor


system abnormal

If error code [E227] is displayed, carry out troubleshooting for it first.

20-418
(1)

Standard value in normalcy and references for troubleshooting

Engine controller defective

a Turn the engine starting switch ON for the preparations, and keep the engine
running during the troubleshooting.
Monitoring

Engine

Engine speed

01006
Engine speed

Low idling

975 1,025 rpm

PC400/450(LC)-7

TROUBLESHOOTING

AA10NX

Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging)


User Code

Error Code

Failure Code

AA10NX

Failure content

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

If the machine is used as it is, the engine may be damaged.

Relative
information

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

Presumed cause and


standard value in normalcy

Air cleaner clogged


(While system is normal)

Air cleaner clogging


2 switch defective
(Internal disconnection)

Disconnection of wiring
harness
3 (Disconnection or
defective contact with
connector)

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

Resistance value

Normal

Below 1 z

Clogged

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) (5) and A31
(female) (1)

Resistance
value

Below 1 z

Wiring harness between A31 (female) (2) and grounding

Resistance
value

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

20-420
(1)

Air cleaner

Voltage

Normal

Below 1 V

Clogged

20 30 V

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

Error Code

Failure Code

AB00KE

Failure content

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

If the machine is used as it is, the battery may not be charged.

Relative
information

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.

Alternator defective
(Internal defect)

Alternator

Engine

Voltage

Between terminal R
and grounding

Above low idling

Above 20 V

Presumed cause and


standard value in normalcy

If the voltage is abnormal, check the belt tension too.


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 P02 (female) (11), J02, and
alternator terminal R

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) (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

20-422
(1)

P02

Engine

Voltage

Between (11) and


grounding

Above low idling

Above 20 V

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

Error Code

Failure Code

E11

E924

B@BAZG

Failure content

Failure
phenomenon

Eng. Oil Press. Low


(Mechanical system)

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.

Relative
information

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)

Presumed cause and


standard value in normalcy

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.

Engine controller
defective

CB1

Engine

Voltage

Between (21) and grounding


(Low-pressure switch signal)

Stopped

Below 1 V

Low idling

20 30 V

Stopped

Below 1 V

Above 1,300 rpm

20 30 V

Between (15) and grounding


(High-pressure switch signal)

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

Error Code

Failure Code

B@BAZK

Failure content

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

If the machine is used as it is, the engine may be damaged.

Relative
information

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

Presumed cause and


standard value in normalcy

Engine oil level low


(While system is normal)

Engine oil level switch


2 defective
(Internal disconnection)
Disconnection of wiring
harness
3 (Disconnection or
defective contact with
connector)

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

Resistance value

Normal level

Below 1 z

Below normal level

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) (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

Voltage

Normal level

Below 1 V

Below normal level

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

Error Code

Failure Code

B@BCNS

Failure content

Failure
phenomenon

Eng. Water Overheat


(Mechanical system)

The signal circuit of the engine water high temperature sensor detected temperature above 105C.

Response from
None in particular.
controller
Phenomenon
occurring on
machine

If the machine is used as it is, the engine may be damaged.

Relative
information

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)

Presumed cause and


standard value in normalcy

Cause
1

Engine overheated
(While system is normal)

Engine water high


2 temperature sensor
system defective

Engine controller
defective

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)

Engine water temperature

Resistance value

Between (27) and (29), (39)

105C

3.28 kz

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

Error Code

Failure Code

B@BCZK

Failure content

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

If the machine is used as it is, the engine will overheat.

Relative
information

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

Presumed cause and


standard value in normalcy

Sub-tank water level low


(While system is normal)

Radiator water level


2 switch defective
(Internal disconnection)

Disconnection of wiring
harness
3 (Disconnection or
defective contact with
connector)

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

Resistance value

Within normal level

Below 1 z

Below LOW level

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) (3) and A33
(female) (1)

Resistance
value

Below 1 z

Wiring harness between A33 (female) (2), J08, J12 and


grounding

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 (3) and grounding

Sub-tank water level

Voltage

Within normal level

Below 1 V

Below LOW level

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

Error Code

Failure Code

B@HANS

Failure content

Failure
phenomenon

Hydr. Oil Overheat


(Mechanical system)

The signal of the hydraulic oil temperature sensor rises above 102C while the engine is running.

Response from
None in particular.
controller
Phenomenon
occurring on
machine

If the machine is used as it is, the hydraulic equipment may be damaged.

Relative
information

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

Presumed cause and


standard value in normalcy

Hydraulic oil overheated


(While system is normal)

Hydraulic oil temperature


2 sensor defective
(Internal short-circuiting)

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 100C

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.
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

Hydraulic oil temperature

Between (12) and (13)


Between (12) and
grounding

Resistance value
90 3.5 kz

10 100C

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-31 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

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Constant power
supply
(Fusible link: A35)

20-502
(1)

Fuse No.

Fuse capacity

10 A

20 A

10 A

10 A

5
6
7
8

10 A
10 A
10 A
10 A

10 A

10
11

10 A
20 A

12

20 A

13

20 A

14

10 A

15

10 A

16
17
18
19
20

10 A
10 A
10 A
10 A
10 A

Destination of 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)

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

Phenomena occurring on machine

Relative
information

Information on occurred failures and troubleshooting


Cause

<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

Presumed cause and


standard value in normalcy

Standard value in normalcy and references for troubleshooting

Cause for presumed


failure
(The attached No. for
3
filing and reference
purpose only. It does not
stand for any priority)

<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.

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

The engine does not start.

Relative
information

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

Electrolyte specific gravity

Min. 24 V

Min. 1.26

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.

Defective starting switch


(Internal disconnection)

H15 (male)

Starting switch

Resistance

OFF

Min. 1 Mz

START

Max. 1 z

Between (1) and (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)

Safety lock lever

Resistance

FREE

Min. 1 Mz

LOCK

Max. 1 z

Between (1) and (3)

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)

Resistance

Between (1) and (2)

100 500 z

Between (3) and (5)

Min. 1 Mz

Between (3) and (6)

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

Defective starting motor


(Internal defect)

Voltage

Between terminal B and


chassis ground

B (Power
supply)

20 30 V

Between ST (1) and chassis ground

S (Start)

20 30 V

Between ST (2) and chassis ground

R (Charge)

Max. 1 V

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.

20-504
(1)

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

Voltage

Between terminal R and chassis ground

Max. 1 V

PC400/450(LC)-7

TROUBLESHOOTING

Cause

E-1

Standard value in normalcy and references for troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.

Presumed cause and


standard value in normalcy

Disconnection in wiring
harness (Disconnection
in wiring harness or
defective contact in connector)

Wiring harness between battery relay B terminal and


A35 (male) (1)

Resistance

Max. 1 z

Wiring harness between A35 (male) (2) and H15


(female) (1)

Resistance

Max. 1 z

Wiring harness between H15 (female) (4), J01, and


R11 (female) (5)

Resistance

Max. 1 z

Wiring harness between R11 (female) (3) and ST


(female) (1)

Resistance

Max. 1 z

Wiring harness between FB1-3 and S14 (male) (1)

Resistance

Max. 1 z

Wiring harness between S14 (male) (3) and R11


(female) (1)

Resistance

Max. 1 z

Wiring harness between R11 (female) (2) and R13


(female) (6)

Resistance

Max. 1 z

Wiring harness between R13 (female) (3), J04, and


chassis ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.

Short circuit with chassis ground in wiring harness (Contact with


ground circuit)

Short circuit with power


source in wiring harness
10
(Contact with 24-V circuit)

PC400/450(LC)-7

Between wiring harness between A35 (male) (2) and


H15 (female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between H15 (female) (4), J01, and


R11 (female) (5), and other related circuits and chassis
ground

Resistance

Min. 1 Mz

Wiring harness between R11 (female) (3) and ST


(female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between FB1-3 and S14 (male) (1) and


chassis ground

Resistance

Min. 1 Mz

Wiring harness between A14 (male) (3) and R11


(female) (1) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between R11 (female) (2) and R13


(female) (6) and chassis ground

Resistance

Min. 1 Mz

Wiring harness between R13 (female) (2), J05, P02


(female) (14), and other related circuits and chassis
ground

Resistance

Min. 1 Mz

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

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

The preheater does not operate.

Relative
information

The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about
30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
Input of the preheating signal (ON or OFF) can be checked in the monitoring function.
(Code No. 04500: Monitor input 1)

Presumed cause and


standard value in normalcy

Cause

(1) When the starting switch is turned to the HEAT position, the preheating monitor does not light up.

Standard value in normalcy and references for troubleshooting

Starting switch system


1
defective

If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting (2).

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) (18) and J02
(male) (7)

Resistance
value

Below 1 z

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

Starting switch

Voltage

Between (18) and


grounding

OFF

Below 1 V

HEAT

20 30 V

Failure
information

The preheater does not operate.

Relative
information

Check that the starting motor rotates normally.


(If the starting motor does not rotate, carry out troubleshooting in Engine does not start.)
Cause

(2) When the starting switch is turned to the HEAT


position, the heater unit is not warmed.

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.

Starting switch defective


(Internal disconnection)

H15 (male)
Between (1) and (3)

Starting switch

Resistance value

OFF

Above 1 Mz

HEAT

Below 1 z

Presumed cause and


standard value in normalcy

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.
2

Heater relay defective


(Internal disconnection)

Intake air heater


3 defective
(Internal disconnection)

Disconnection of wiring
harness
4 (Disconnection or
defective contact with
connector)

20-508
(1)

Heater relay

Starting switch

Continuity and
resistance value

Between coil terminal


and grounding

OFF

Continued

Between contact terminals

HEAT

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

Continuity
Continued

Wiring harness between H15 (female) (3), J02, and


heater relay terminal

Resistance
value

Below 1 z

Wiring harness between starting motor terminal B and


heater relay

Resistance
value

Below 1 z

Wiring harness between heater relay and intake air


heater

Resistance
value

Below 1 z

Wiring harness between intake air heater and engine

Resistance
value

Below 1 z

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.

Relative
information

The auto engine warm-up device is activated, when the engine cooling water temperature is below
30C, and raise the engine rotation up to 1,200 rpm.
The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
If the engine water temperature is below 10C, the turbocharger protection function operates to keep
the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.

Presumed cause and


standard value in normalcy

Cause

a Turn the starting switch ON for the troubleshooting (monitoring).


Monitoring code
1

Engine cooling water


temperature signal fault

04107

Item

Normal display

Engine cooling water


temperature
(low temperature)

Compare the monitor


indication with the actual
engine cooling water
temperature.

If the display on the monitor panel is abnormal, carry out troubleshooting in Engine
water thermometer does not display normally.
2

20-510
(1)

Standard value in normalcy and references for troubleshooting

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.)

PC400/450(LC)-7

TROUBLESHOOTING

E-4

E-4 Auto-decelerator does not operate


Failure
information

The auto-decelerator does not operate.

Relative
information

Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above
this level.
Check the display on the monitor panel while the engine is running.
If the display on the monitor panel is abnormal, carry out troubleshooting in
is not displayed
normally in monitoring function.
Cause

Boom RAISE signal


defective

Boom LOWER signal


2
defective

3 Arm IN signal defective

Presumed cause and


standard value in normalcy

4 Arm OUT signal defective

Bucket CURL signal


defective

Bucket DUMP signal


6
defective

7 Swing signal defective

8 Travel signal defective

9 Service signal defective

10 Pump controller defective


11

Engine controller
defective

PC400/450(LC)-7

Standard value in normalcy and references for troubleshooting


Monitoring code

Item

Normal display

01900
Pressure switch 1

Boom RAISE

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01900
Pressure switch 1

Boom LOWER

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01900
Pressure switch 1

Arm IN

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01900
Pressure switch 1

Arm OUT

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01901
Pressure switch 2

Bucket CURL

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01901
Pressure switch 2

Bucket DUMP

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01900
Pressure switch 1

Swing

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01900
Pressure switch 1

Travel

Lever operated: ON
Lever in neutral: OFF

Monitoring code

Item

Normal display

01901
Pressure switch 2

Service

Lever operated: ON
Lever in neutral: OFF

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.)

20-511
(1)

TROUBLESHOOTING

E-5

E-5 All work equipment, swing and travel do not move


Failure
information

All the work equipment, swing and travel do not move.

Relative
information

Cause

1 Fuse No. 3 fault

Presumed cause and


standard value in normalcy

Safety lock switch


2 defective
(Internal disconnection)

PPC lock solenoid


defective
3 (Internal disconnection,
short-circuiting, or
grounding fault)
Assembled-type diode
4 D01 defective
(Internal short-circuiting)

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)

Safety lock lever

Between (1) and (2)

Resistance value

Free

Below 1 z

Lock

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V08 (male)

Resistance value

Between (1) and (2)

20 60 z

Between (1) and grounding

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)

Resistance value (Continuitiy)

Between (4) and (8)

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)

Grounding fault of wiring


harness
6
(Contact with grounding
circuit)

20-512
(1)

Standard value in normalcy and references for troubleshooting

Wiring harness between FB1-3 outlet and S14 (male)


(1)

Resistance
value

Below 1 z

Wiring harness from S14 (male) (2) and J02 V01


(female) (2)

Resistance
value

Below 1 z

Wiring harness between V08 (female) (1) to J13 and


grounding

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 FB1-3 outlet and S14
(male) (1) and grounding

Resistance
value

Above 1 Mz

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

Above 1 Mz

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

One-touch power max. function does not operate

Relative
information

If the one-touch power max. switch is pressed while the engine is running, the one-touch power max.
monitor is displayed on the monitor panel.
Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in
the monitoring function. (Code No. 02200: Switch input 1)
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)

M23 (male)

Presumed cause and


standard value in normalcy

Between (1) and (2)


Disconnection of wiring
harness (Disconnection
3
or defective contact with
connector)

One-touch power
max. switch

Resistance value

Released

Min. 1 Mz

Pressed

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

Resistance
value

Min. 1 Mz

Between wiring harness between M23 (female) (2) and


C01 (female) (11) 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.
5 Pump controller defective

C01
Between (11) and
grounding

One-touch power
max. switch

Voltage

Released

Max. 1 V

Pressed

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

Machine push-up function does not operate


normally.

Relative
information

When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.

Presumed cause and


standard value in normalcy

Cause
Machine push-up switch
1 defective
(Internal short-circuiting)

(1) The machine push-up function does not operate.

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

Resistance value

Low pressure position

Below 1 z

High pressure position

Above 1 Mz

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

Machine push-up function does not operate


normally.

Relative
information

When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
Cause

1 Fuse No. 2 defective

Presumed cause and


standard value in normalcy

Machine push-up switch


2 defective
(Internal disconnection)

Machine push-up
solenoid defective
3 (Internal disconnection,
short-circuiting or
grounding fault)
Assembled-type diode
4 D04 defective
(Internal short-circuiting)

(2) The machine push-up function is not turned OFF.

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)

Machine push-up switch

Resistance value

Low pressure position

Below 1 z

High pressure position

Above 1 Mz

Between (1) and (2)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V06 (male)

Resistance value

Between (1) and (2)

20 60 z

Between (2) and grounding

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during troubleshooting.
D02 (male)

Resistance value (Continuitiy)

Between (3) and (7)

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)

Resistance
value

Below 1 z

Wiring harness between M38 (male) (2), J07 and V06


(female) (2)

Resistance
value

Below 1 z

Wiring harness between V06 (female) (1) and grounding

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.
Grounding fault of wiring
harness
6
(Contact with grounding
circuit)

20-516
(1)

Between wiring harness between FB1-2 outlet and M38


(male) (1) or between FB1-2 outlet and related circuits
and grounding

Resistance
value

Above 1 Mz

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

Above 1 Mz

PC400/450(LC)-7

TROUBLESHOOTING

E-8

E-8 Attachment circuit does not change


When attachment is installed
(1) When working mode A or E is selected, attachment circuit is not
switched to crusher circuit (reciprocation circuit).
(2) When working mode B is selected, attachment circuit is not
switched to breaker circuit (one-way circuit).

Failure
information

Attachment circuit does not


change.

Relative
information

If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or disconnection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected,
however.
Cause

Presumed cause and


standard value in normalcy

Attachment return selector solenoid defective


1
(Internal disconnection
or short-circuit)

Attachment return selector relay defective


2
(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.
V12 (male)

Resistance value

Between (1) and (2)

20 60 z

Between (2) and grounding

Above 1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
R20 (male)

Resistance value

Between (3) and (5)

Below 1 z

Between (3) and (6)

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)

Short-circuit of wiring
harness
4
(Contact with 24 V
circuit)

PC400/450(LC)-7

Wiring harness between J03 (male) (8) and R20


(female) (3)

Resistance
value

Below 1 z

Wiring harness between R20 (female) (5) and V12


(female) (2)

Resistance
value

Below 1 z

Wiring harness between C03 (female) (3), (13), (23)


and V12 (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.
Between wiring harness and R20 (female) (5) and V12
(female) (2) and grounding

Voltage

Below 1 V

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

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.

Relative
information

Cause

Presumed cause and


standard value in normalcy

1 Fuse No. 12 fault

Disconnection of wiring
harness
2
(Disconnection or defect
contact with connector)
Grounding fault of wiring
harness
3 (Contact with grounding
(GND)
circuit)

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

Resistance
value

Below 1 z

Wiring harness from P01 (female) (6) (7) to J04 and


grounding

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 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

Starting switch

Voltage and resistance


value

Between (1) (2) and


grounding

ON

Voltage: 20 30 V

Between (6) (7) and


grounding

OFF

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


Part of display on monitor panel is missing

Relative
information

Presumed cause and


standard value in normalcy

Failure
information

Cause

Part of the display in the monitor panel is missing during


starting switch in ON.

Standard value in normalcy and references for troubleshooting


a Turn the starting switch ON during the troubleshooting.

1 Monitor panel LCD fault

Monitor panel
defective

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.)

E-11 Monitor panel displays contents irrelevant to the model


The monitor panels displays contents that have nothing to do with the model on which it is installed.

Relative
information

Presumed cause and


standard value in normalcy

Failure
information

Cause

a Turn the starting switch in ON during the troubleshooting (monitoring).


1

Model code signal fault


(Internal failure)

Monitoring code

Item

Normal display

00200

Controller model code

PC400-a

If the display on the monitor panel is normal, troubleshoot Error Code [E217].
2

20-520
(1)

Standard value in normalcy and references for troubleshooting

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.)

PC400/450(LC)-7

TROUBLESHOOTING

E-10, E-11

E-12 Fuel level monitor red lamp lights up while engine is running
Failure
information

The fuel level monitor red lamp lights up while the engine was running.

Relative
information

If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
(5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No.: 04200 Fuel level sensor)
Cause

Presumed cause and


standard value in normalcy

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)

Fuel level

Resistance value

Between (1) and grounding

FULL (Upper limit)

Approx. 12 z

EMPTY (Lower limit)

85 110 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) (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)

Fuel level

Resistance value

Between (2) and


grounding

FULL (Upper limit)

Approx. 12 z

EMPTY (Lower limit)

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

Presumed cause and


standard value in normalcy

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)

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)

Resistance value

Between (1) and (2)

3.5 k 90 kz

Between (1), (2) and grounding

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)

Resistance
value

Below 1 z

Wiring harness between CB2 (female) (29), (39) and


TWH (female) (2)

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 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

6 Monitor panel defective

20-522
(1)

CB2 (female)

Resistance value

Between (27), (29) and (39)

3.5 k 90 kz

Between (27), (29), (39) and grounding

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.)

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

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).

Relative
information

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)

Presumed cause and


standard value in normalcy

Between (2) and grounding


Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

Engine cooling water


temperature

Resistance value
90 3.5 kz

10 100 C

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)

Resistance
value

Below 1 z

Wiring harness between P02 (female) (13) and A61


(female) (1)

Resistance
value

Below 1 z

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.

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 P02 (female) (12) and


A61 (female) (2) and grounding

Between wiring harness between P02 (female) (12) and


A61 (female) (2) and grounding

Resistance
value

Voltage

Above
1 Mz

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

Engine cooling water


temperature

Between (12) and (13)


Between (12) and
grounding

Resistance value
90 3.5 kz

10 100 C

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

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).

Relative
information

Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No.: 04200 Fuel sensor voltage)
Cause

Presumed cause and


standard value in normalcy

Fuel level sensor 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 hold it in the OFF
position during the troubleshooting.
A60 (male)

Fuel level

Resistance value

Between (1) and


grounding

FULL (Upper limit)

Approx. 12 z

EMPTY (Lower limit)

85 110 z

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.

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.

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.

Wiring harness between P02 (female) (2) and A60


(female) (1)

Between wiring harness between P02 (female) (2) and


A60 (female) (1) and grounding

Between wiring harness between P02 (female) (2) and


A60 (female) (1) and grounding

Resistance
value

Resistance
value

Voltage

Below 1 z

Above
1 Mz

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

Fuel level

Resistance value

Between (2) and grounding

FULL (Upper limit)

Approx. 12 z

EMPTY (Lower limit)

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

(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.

Relative
information

Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
Cause

Presumed cause and


standard value in normalcy

Swing lock switch


defective
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)

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

Resistance value

OFF

Above 1 Mz

ON

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 P02 (female) (17) to J02 and X05
(male) (1)

Resistance
value

Below 1 z

Wiring harness from X05 (male) (2) to J05 and


grounding

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 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

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.

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

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

20-526
(1)

P02

Swing lock switch

Voltage

Between (17) and


grounding

OFF

20 30 V

ON

Below 1 V

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

When monitor switch is operated, nothing is dis- (1) When mode selector switch is operated, working
played.
mode monitor is not displayed.

Relative
information

Presumed
cause and
standard value
in normalcy

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

When monitor switch is operated, nothing is


displayed.

Relative
information

Presumed
cause and
standard value
in normalcy

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

When monitor switch is operated, nothing is


displayed.

Relative
information

Presumed
cause and
standard value
in normalcy

Cause
1

Monitor panel
defective

As this is an internal failure, troubleshooting cannot be conducted.

When monitor switch is operated, nothing is


displayed.

Relative
information

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

Failure
information

Presumed
cause and
standard value
in normalcy

(2) When LCD monitor adjustment switch is operated, mode selection screen is not displayed.

(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

When monitor switch is operated, nothing is


displayed.

Relative
information

When the automatic decelerator does not operate either, conduct the troubleshooting for E-4.

Presumed
cause and
standard value
in normalcy

20-528
(1)

Cause
1

Monitor panel
defective

(5) When automatic deceleration switch is operated,


automatic deceleration monitor is not displayed.

Standard value in normalcy and references for troubleshooting


As this is an internal failure, troubleshooting cannot be conducted.

PC400/450(LC)-7

TROUBLESHOOTING

E-17

Failure
information

When monitor switch is operated, nothing is


displayed.

Relative
information

When the travel speed does not change either, conduct the troubleshooting for H-22.

Presumed
cause and
standard value
in normalcy

Cause
1

Monitor panel
defective

(6) When travel speed selector switch is operated,


travel speed monitor is not displayed.

Standard value in normalcy and references for troubleshooting


As this is an internal failure, troubleshooting cannot be conducted.

Failure
information

When monitor switch is operated, nothing is


displayed.

Relative
information

When the wiper does not operate either, conduct the troubleshooting for E-18.

Presumed
cause and
standard value
in normalcy

Cause
1

PC400/450(LC)-7

Monitor panel
defective

(7) When wiper switch is operated, wiper monitor is


not displayed.

Standard value in normalcy and references for troubleshooting


As this is an internal failure, troubleshooting cannot be conducted.

20-529
(1)

TROUBLESHOOTING

E-18

E-18 Windshield wiper and window washer do not work


Failure
information

Windshield wiper and window washer do not


work.

Relative
information

Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
Cause

Window rear limit switch


fault
1
(Internal disconnection
or short-circuiting)

Presumed cause and


standard value in normalcy

Windshield wiper motor


2 fault
(Internal disconnection)

Disconnection of wiring
harness
3 (Disconnection or
defective contact with
connector)
Grounding fault of wiring
harness
4
(Contact with grounding
(GND) circuit)

Monitor panel fault


(Window rear limit switch
system)

Monitor panel fault


(Windshield wiper motor
system)

(1)

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

Resistance value

When installed at front

Above 1 Mz

When retracted at rear

Below 1 z

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
W04 (male)

Continuity and resistance value

Between (3) and (1)

Continued

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)

Resistance
value

Below 1 z

Wiring harness between P01 (female) (10) and W04


(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) (15) and
W03 (2)

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.
P02

Front window

Voltage

Between (15) and grounding

When installed at front

20 30 V

When retracted at rear

Below 1 V

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.

20-530

(1) The windshield wiper does not work.

P01

Windshield wiper switch

Resistance value

Between (9) and


grounding
Between (10) and
grounding

OFF

Below 3 V

ON

Below 3 V
20 30 V
(Constant cycle)

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

Windshield wiper and window washer do not


work.

Relative
information

Cause

1 Fuse No. 4 defective

Presumed cause and


standard value in normalcy

Washer motor defective


2 (Internal disconnection
or grounding fault)

Disconnection of wiring
harness
3 (Disconnection or
defective contact with
connector)

(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)

Resistance value

Between (1) and (2)

5 20 z

Between (1) and grounding

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 from FB1-4 to J03 to J06 and A50
(female) (1)

Resistance
value

Below 1 z

Wiring harness from A50 (female) (2) to J04 and P01


(female) (3)

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.
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

Resistance
value

Above
1 Mz

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

Above
1 Mz

a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
5

20-532
(1)

Monitor panel
defective

P01

Windshield washer switch

Voltage

Between (3) and


grounding

OFF

20 30 V

ON

Below 1 V

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

The alarm buzzer cannot be cancelled.

Relative
information

Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
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)

Presumed cause and


standard value in normalcy

Between (1) and (2)


Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

Alarm buzzer
stop switch

Resistance value

Release

Above 1 Mz

Depress

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)

Resistance
value

Below 1 z

Wiring harness from P03 (male) (2) to J05 to grounding

Resistance
value

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

Alarm buzzer stop switch

Voltage

Between (16) and


grounding

Release

20 30 V

Depress

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

Boom RAISE is not correctly displayed in monitor function


Boom RAISE is not correctly displayed in the monitor function on the monitor panel.

Relative
information

Cause

Presumed cause and


standard value in normalcy

Boom RAISE PPC


hydraulic switch fault
1
(Internal disconnection
or short-circuiting)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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

Resistance value

NEUTRAL

Above 1 Mz

Boom RAISE

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 C03 (female) (10) and S06
(female) (2)

Resistance
value

Below 1 z

Wiring harness between S06 (female) (1) and


grounding

Resistance
value

Below 1 z

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.

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 C03 (female) (10) and


S06 (female) (2) and grounding

Between wiring harness between C03 (female) (10) and


S06 (female) (2) and grounding

Resistance
value

Voltage

Above
1 Mz

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

Voltage

NEUTRAL

20 30 V

Boom RAISE

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

Boom LOWER is not correctly displayed in monitor function


Boom LOWER is not correctly displayed in the monitor function on the monitor panel.

Relative
information

Cause

Presumed cause and


standard value in normalcy

Boom LOWER PPC


hydraulic switch fault
1
(Internal disconnection
or short-circuiting)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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

Resistance value

NEUTRAL

Above 1 Mz

Boom LOWER

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 C03 (female) (20) and S02
(female) (2)

Resistance
value

Below 1 z

Wiring harness between S02 (female) (1) and grounding

Resistance
value

Below 1 z

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.

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 C03 (female) (20) and


S02 (female) (2) and grounding

Between wiring harness between C03 (female) (20) and


S02 (female) (2) and grounding

Resistance
value

Voltage

Above
1 Mz

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

Voltage

NEUTRAL

20 30 V

Boom LOWER

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

Arm IN is not displayed normally in monitoring Arm IN is not displayed normally in monitoring
function.
function (special function) of monitor panel.

Presumed cause and


standard value in normalcy

Relative
information
Cause

Standard value in normalcy and references for troubleshooting

Arm IN PPC pressure


sensor defective

The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for
error code [E247].

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

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.

Relative
information

Cause

Presumed cause and


standard value in normalcy

Arm DUMPING PPC


hydraulic switch defect
1
(Internal disconnection
and short-circuiting)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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

Resistance value

NEUTRAL

Above 1 Mz

Arm DUMPING

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 C03 (female) (40) and S08
(female) (2)

Resistance
value

Below 1 z

Wiring harness between S08 (female) (1) and


grounding

Resistance
value

Below 1 z

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.

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 C03 (female) (40) and


S08 (female) (2) and grounding

Between wiring harness between C03 (female) (40) and


S08 (female) (2) and grounding

Resistance
value

Voltage

Above
1 Mz

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

Voltage

NEUTRAL

20 30 V

Arm DUMPING

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

Bucket CURL is not displayed normally in


monitoring function.

Bucket CURL is not displayed normally in


monitoring function (special function) of monitor
panel.

Presumed cause and


standard value in normalcy

Relative
information
Cause

Standard value in normalcy and references for troubleshooting

Bucket CURL PPC pressure sensor defective

The bucket CURL PPC pressure sensor may be defective. Carry out troubleshooting for error code [E248].

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

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.

Relative
information

Cause

Presumed cause and


standard value in normalcy

Bucket DUMPING PPC


hydraulic switch fault
1
(Internal disconnection
and short-circuiting)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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

Resistance value

NEUTRAL

Above 1 Mz

Bucket DUMPING

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 C03 (female) (19) and S05
(female) (2)

Resistance
value

Below 1 z

Wiring harness between S05 (female) (1) and


grounding

Resistance
value

Below 1 z

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.

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 C03 (female) (19) and


S05 (female) (2) and grounding

Between wiring harness between C03 (female) (19) and


S05 (female) (2) and grounding

Resistance
value

Voltage

Above
1 Mz

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

Voltage

NEUTRAL

20 30 V

Bucket DUMPING

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

Swing is not displayed normally in monitoring function.

Swing is not displayed normally in monitoring


function (special function) of monitor panel.

Relative
information
Cause
Swing left PPC pressure
switch defective
1
(Internal disconnection or
short-circuit)

Presumed cause and


standard value in normalcy

Swing right PPC pressure switch defective


2
(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

Resistance value

Neutral

Min. 1 Mz

Left swing position

Max. 1 z

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

Resistance value

Neutral

Min. 1 Mz

Right swing position

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)

Grounding fault of wiring


harness
4
(Contact with grounding
circuit)

Wiring harness between C03 (female) (29) and S07


(female) (2) or S03 (female) (2)

Resistance
value

Max. 1 z

Wiring harness between S07 (female) (1) and grounding

Resistance
value

Max. 1 z

Wiring harness between S03 (female) (1) and grounding

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 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

20-542
(1)

Left work equipment


control lever

Voltage

Neutral

20 30 V

Left or right swing position

Max. 1 V

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

TRAVEL is not correctly displayed in monitor function


TRAVEL is not correctly displayed in the monitor function (special function) on the monitor panel.

Relative
information

Cause

Presumed cause and


standard value in normalcy

Travel PPC hydraulic


switch 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 keep the engine
running during the troubleshooting.
S30 (male)
Between (1) and (2)

Travel control lever

Resistance value

NEUTRAL

Above 1 Mz

Forward or reverse

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)

Resistance
value

Below 1 z

Wiring harness from S30 (female) (1) to J05 to grounding

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.
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

20-544
(1)

Pump controller
defective

C03

Travel control lever

Voltage

Between (39) and


grounding

NEUTRAL

20 30 V

Forward or backward

Below 1 V

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

Travel Differential Pressure is not correctly displayed in monitor function


Travel Differential Pressure is not correctly displayed in the monitor function (special function) on the
monitor panel.

Relative
information

When pressure difference is created between the right and left travel PPC circuits (in steering), the
travel differential mechanism is turned ON.
Cause

Presumed cause and


standard value in normalcy

Travel steering PPC


hydraulic switch fault
1
(Internal disconnection
or short-circuiting)

Disconnection of wiring
harness
2 (Disconnection or
defective contact with
connector)

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)

Travel control lever

Resistance value

NEUTRAL

Above 1 Mz

Between (1) and (2)

One side of right or left


only

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) (16) and S31
(female) (2)

Resistance
value

Below 1 z

Wiring harness from S31 (female) (1) to J05 to


grounding

Resistance
value

Below 1 z

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.

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) (16) and


S31 (female) (2) and grounding

Between wiring harness between C02 (female) (16) and


S31 (female) (2) and grounding

Resistance
value

Voltage

Above
1 Mz

Below 1 V

a Turn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
5

20-546
(1)

Pump controller
defective

C02
Between (16) and grounding

Travel control lever

Voltage

NEUTRAL

20 30 V

One side of right or left


only

Below 1 V

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

Service is not correctly displayed in monitor function


Service is not correctly displayed in the monitor function (special function) on the monitor panel.

Relative
information

Cause

Service (front) PPC


hydraulic switch fault
1
(Internal disconnection
or short-circuiting)

Presumed cause and


standard value in normalcy

Service (rear) PPC


hydraulic switch fault
2
(Internal disconnection
or short-circuiting)

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)

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

Resistance value

NEUTRAL

Above 1 Mz

Operated to front

Below 1 z

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

Resistance value

NEUTRAL

Above 1 Mz

Operated to rear

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 wiring harness between C02 (female)
(35) and S11 (female) (2)

Resistance
value

Below 1 z

Wiring harness between S10 (female) (1) and grounding

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.
Wiring harness between C02 (female) (35) and S10
(female) (2), or between wiring harness between C02
(female) (35) and S11 (female) (2) and grounding

Above
1 Mz

Resistance
value

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

20-548
(1)

C02

Service pedal

Voltage

Between (35) and grounding

NEUTRAL

20 30 V

Operated to front or rear

Below 1 V

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

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.

Relative
information

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

Presumed cause and


standard value in normalcy

2 Travel signal fault

Normal display

Travel

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)

Grounding fault of wiring


harness
4
(Contact with grounding
(GND) circuit)

5 Travel alarm fault

20-550
(1)

01900

Item

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)

Resistance
value

Below 1 z

Wiring harness between A43 (female) (2) and J01 (19)

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 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

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)

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-31 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.

20-552
(1)

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

PC400/450(LC)-7

TROUBLESHOOTING

Self-diagnosis
notice

Trouble

E-31

Disconnection in recirculated air sensor

E11
Contents of
trouble
Action of
control panel

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>

Related
information

Possible causes and


standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Defective recirculated
1 air sensor
(Internal disconnection)

Disconnection of wiring
harness (Disconnection
2
or defective contact with
connector)

Defective air conditioner


system

Self-diagnosis
notice

Trouble

a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
THI (male)

Resistance

Between (1) and (2)

300 z 430 kz

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)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and TH I


(female) (1)

Resistance

Max. 1 z

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.

Short circuit in recirculated air sensor

E12
Contents of
trouble
Action of
control panel

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>

Related
information

Possible causes and


standard value in normal state

Cause
Defective recirculated air
1 sensor (Internal short circuit)

Disconnection of wiring
harness (Disconnection
2
or defective contact with
connector)

Defective air conditioner


system

PC400/450(LC)-7

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)

Resistance

Between (1) and (2)

300 z 430 kz

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)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and TH I


(female) (1)

Resistance

Max. 1 z

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.

20-553
(1)

TROUBLESHOOTING

Self-diagnosis
notice

Trouble

E-31

Disconnection in water temperature sensor

E15
Contents of
trouble
Action of
control panel

Disconnection in the water temperature sensor system is detected.


Ignores the warm-up control and fixes the engine water temperature at 60C for control.
When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>

Related
information

Possible causes and


standard value in normal state

Cause

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

Self-diagnosis
notice

Trouble

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)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and THW


(female) (1)

Resistance

Max. 1 z

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.

Short circuit in water temperature sensor

E16
Contents of
trouble
Action of
control panel

Short circuit in the water temperature sensor system is detected.


Ignores the warm-up control and fixes the engine water temperature at 60C for control.
When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>

Related
information

Possible causes and


standard value in normal state

Cause
Defective water tempera1 ture sensor (Internal
short circuit)

Disconnection of wiring
harness (Disconnection
2
or defective contact with
connector)

20-554
(1)

Defective air conditioner


system

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)

Resistance

Between (1) and (2)

95 z 455 kz

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)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and THW


(female) (1)

Resistance

Max. 1 z

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

TROUBLESHOOTING

Self-diagnosis
notice

Trouble

E-31

Short circuit in daylight sensor

E18
Contents of
trouble
Action of
control panel<