PC400-7L A86001 and up
Short Description
pc400-7...
Description
CEBM012502
Shop Manual
PC400LC-7L HYDRAULIC EXCAVATOR SERIAL NUMBERS
PC400LC-7L
A86001
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
May 2004 Printed in USA PC400LC-7L
Copyright 2004 Komatsu DataKom Publishing Division 00-1 2
FOREWORD 12
CONTENTS
CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 2
PC400LC-7L
PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals. Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages. The Publications listed below are available for this particular machine(s). DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB040500
OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM012900
SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM012502 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM024208 SAFETY MANUAL Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE03-2
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America Corp. Extranet Literature Ordering System. If the Extranet Literature Ordering System is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax orders. PC400LC-7L R02 pubinfok.fm
5/19/04
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO
DataKom Publications and Training Division 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
COMPANY NAME PURCHASE ORDER NO.
SHIP TO ATTN.
TYPE or PRINT ONLY
STREET ADDRESS
ORDER DATE
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QTY.
PUBLICATION FORM NO.
➥
PARTS BOOK P-Paper M-Microfiche
KDC91E 071403
PUBLICATION DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
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PC400LC-7L
00-2-7 2
FOREWORD Mark
Page
00-2-8 2
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
PC400LC-7L
FOREWORD
SAFETY
12
SAFETY
00
SAFETY NOTICE
00
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
● ●
3.
If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.
When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.
5.
Keep all tools in good condition and learn the correct way to use them.
6.
Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
00
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
2.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
PC400LC-7L
00-3
FOREWORD 4.
SAFETY
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
00
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2.
The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4.
When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-4
PC400LC-7L
FOREWORD
GENERAL
12
GENERAL
00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING, ADJUSTING AND TROUBLESHOOTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
PC400LC-7L
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL VOLUMES
00
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Engine volume:
Issued for every machine model Issued for each engine series
00
REVISIONS
00
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
SYMBOLS
00
Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.
These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
Symbol
DISTRIBUTION AND UPDATING
1. 2.
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
★
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
00
See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item
3.
Remarks
00
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.
FILING METHOD
Item
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
10-4 10-4-1 10-4-2
Added pages
10-5
REVISED EDITION MARK
00
When a manual is revised, an edition mark (123…) is recorded on the bottom outside corner of the pages.
00-6
PC400LC-7L
FOREWORD
HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS
00
HOISTING
can result. Hooks have maximum strength at the middle portion.
00
WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
●
1. 2.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface with the part to be removed.
WIRE ROPES 1.
3.
WARNING! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident
00
Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire Ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
4.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°
★ The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident
PC400LC-7L
00-7
FOREWORD
COATING MATERIALS
12
COATING MATERIALS
00
★ The recommended coating materials prescribed in the shop manuals are listed below. Category
Code
Adhesives
LT-1A
Part No. 790-129-9030
Quantity
Container
150 g
Tube
LT-1B
790-129-9050
20 g (2 pes.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
2g
Polyethylene container
Aron-alpha 790-129-9130 201
50 g
Polyethylene container
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
Three bond 179-129-9140 1735
Main applications, features ●
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
●
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
●
● ●
●
Used as adhesive or sealant for metal, glass or plastic.
●
Used as sealant for machined holes.
●
Used as heat-resisting sealant for repairing engine.
●
Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
● ●
Gasket sealant
●
00-8
● ●
● ●
790-129-9070
1 kg
Quick hardening type adhesive. Quick cure type (max. strength after 30 minutes). Used mainly for adhesion of rubbers, plastics and metals. Features: Resistance to heat, chemicals Used at joint portions subject to high temperature.
●
Used as adhesive or sealant for gaskets and packing of power train case, etc.
●
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
●
LG-3
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
Can ●
PC400LC-7L
FOREWORD Category
Code
COATING MATERIALS Part No.
Quantity
Container
Main applications, features ● ●
LG-4
790-129-9020
200 g
Tube
● ●
Gasket sealant
●
LG-5
790-129-9080
1 kg
Polyethylene container
LG-6
09940-00011
250 g
Tube
●
● ● ● ●
150 g
Tube
Three bond 790-129-9090 1211
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
09920-00150
●
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
●
Used as heat-resisting sealant for repairing engines.
●
Used as lubricant for sliding parts (to prevent squeaking).
● ●
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
●
General purpose type
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYG2-160CNCA
Various
Various
●
Used for normal temperature, light load bearing at places in contact with water or steam.
400 g (10 per case)
Belows type
●
Used for places with heavy load.
Molybdenum disulphide lubricant
Grease
Molybdenum disulphide lubricant
LG-7
Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case.
PC400LC-7L
SYG2-400M
00-9
FOREWORD
STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE
00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY.
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
6
10
13.2 ± 1.4
9.2 ± 1.03
8
13
31.4 ± 2.9
23.1 ± 2.1
10
17
65.7 ± 6.8
48.4 ± 5.0
12
19
112 ± 9.8
82.6 ± 7.2
14
22
177 ± 19
130.5 ± 14.0
16
24
279 ± 29
205.7 ± 21.3
18
27
383 ± 39
282.4 ± 28.7
20
30
549 ± 58
404.9 ± 42.7
22
32
745 ± 78
549 ± 57.5
24
36
927 ± 98
683 ± 72.2
27
41
1320 ± 140
973.5 ± 103.2
30
46
1720 ± 190
1268.6 ± 140.1
33
50
2210 ± 240
1630.0 ± 177.0
36
55
2750 ± 290
2028.2 ± 213.8
39
60
3280 ± 340
2419.2 ± 250.7
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
6
10
7.85 ± 1.95
5.7 ± 1.4
8
13
18.6 ± 4.9
13.7 ± 3.6
10
14
40.2 ± 5.9
29.6 ± 4.3
12
27
82.35 ± 7.85
60.7 ± 5.7
00-10
PC400LC-7L
FOREWORD 12 TIGHTENING
STANDARD TIGHTENING TORQUE
TORQUE OF HOSE NUTS
00
Use these torques for hose nuts. Thread diameter
Width across flat
mm
mm
Nm
lbf ft
02
14
19
24.5 ± 4.9
18.0 ± 3.6
03
18
24
49 ± 19.6
36.1 ± 14.4
04
22
27
78.5 ± 19.6
57.8 ± 14.4
05
24
32
137.3 ± 29.4
101.2 ± 21.6
06
30
36
176.5 ± 29.4
130.1 ± 21.6
10
33
41
196.1 ± 49
144.6 ± 36.1
12
36
46
245.2 ± 49
180.8 ± 36.1
14
42
55
294.2 ± 49
216.9 ± 36.1
Nominal No.
Tightening torque
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
00
Use these torques for split flange bolts. Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
lbf ft
10
14
65.7 ± 6.8
48.4 ± 5.0
12
17
112 ± 9.8
82.6 ± 7.2
16
22
279 ± 29
205.7 ± 21.3
TIGHTENING TORQUE FOR FLARED NUTS
00
Use these torques for flared part of nut.
Thread diameter
Width across flat
mm
mm
Nm
lbf ft
14
19
24.5 ± 4.9
18.0 ± 3.6
18
24
49 ± 19.6
36.1 ± 14.4
22
27
78.5 ± 19.6
57.8 ± 14.4
24
32
137.3 ± 29.4
101.2 ± 21.6
30
36
176.5 ± 29.4
130.1 ± 21.6
33
41
196.1 ± 49
144.6 ± 36.1
36
46
245.2 ± 49
180.8 ± 36.1
42
55
294.2 ± 9
216.9 ± 36.1
PC400LC-7L
Tightening torque
00-11
FOREWORD
ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE
00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
00
Copper wire
Nominal number
Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Number of strands
Dia. Of strand (mm)
Cross section (mm)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE
1
Circuits Classification Primary
Priority
2
4
5
6
00-12
Auxiliary
3
00
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
Color
White & Red
—
Black & White
Green & White
Blue & White
Code
WB
—
BY
RB
YB
GR
LR
Color
White & Black
—
Black & Yellow
Red & Black
Yellow & Black
Green & Red
Blue & Red
Code
WL
—
BR
RY
YG
GY
LY
Color
White & Blue
—
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
—
—
RG
YL
GB
LB
Color
White & Green
—
—
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
—
—
—
RL
YW
GL
—
Color
—
—
—
Red & Blue
Yellow & White
Green & Blue
—
Red & White Yellow & Red
PC400LC-7L
FOREWORD
CONVERSION TABLES
12
CONVERSION TABLES
00
METHOD OF USING THE CONVERSION TABLE
00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ● Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1. B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2. C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2.
Convert 550 mm into inches. A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. B. Carry out the same procedure as above to convert 55 mm to 2.165 inches. C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
2 Millimeters to inches
1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
3 1
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
PC400LC-7L
00-13
FOREWORD
CONVERSION TABLES
12
Millimeters to Inches
1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
00-14
1 kg = 2.2046 lb 0
1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
PC400LC-7L
FOREWORD
CONVERSION TABLES
12
Liter to U.S. Gallon
1 L = 0.2642 U.S. Gal 0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon
1 L = 0.21997 U.K. Gal 0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
PC400LC-7L
00-15
FOREWORD
CONVERSION TABLES
12
kgm to ft. lb.
00-16
1 kgm = 7.233 ft. lb. 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.63
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
PC400LC-7L
FOREWORD
CONVERSION TABLES
12
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
19324
1949
1963
1977
140
1991
2005
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
PC400LC-7L
00-17
FOREWORD
CONVERSION TABLES
12 Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C -40.4 -37.2 -34.4 -31.7 -28.9
-40 .35 -30 -25 -20
°F -40.0 -31.0 -22.0 -13.0 -4.0
°C -11.7 -11.1 -10.6 -10.0 -9.4
11 12 13 14 15
°F 51.8 53.6 55.4 57.2 59.0
°C 7.8 8.3 8.9 9.4 10.0
-28.3 -27.8 -27.2 -26.7 -26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
-22.8 -22.2 -21.7 -21.1 -20.6
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
00-18
46 47 48 49 50
°F 114.8 116.6 118.4 120.2 122.0
°C 27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
°F 117.8 179.6 181.4 183.2 185.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
PC400LC-7L
01
GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
PC400LC-7L
01-1
GENERAL
SPECIFICATIONS
12
SPECIFICATIONS Item Operating weight (Variable gauge specification) Operating weight (Fixed gauge specification)
Unit
kg (lb)
Operating weight Bucket capacity Name of engine Rated horsepower of engine A Overall length B Overall height Overall width (Variable gauge specification) Overall width C (Fixed gauge specification)
C
D Track shoe width (Variable gauge) D Track shoe width (Fixed gauge) E Height of cab F Radius of upper structure G Overall length of track H Length of track on ground Min. ground clearance Traveling speed (low/middle/high) Swing speed Tg Track gage Tg (for transport)
01-2
m3 (cu.yd) kW (HP)/rpm mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) km/h (MPH) rpm F/G V/G F/G V/G
PC400LC-7L 44,600 (98,343) 43,700 (96,359) 43,700 (96,359) 1.9 (2.5) KOMATSU SAA6D125E-3 diesel engine 246(330) /1,850 12,040 (39' 6“) 3,670 (12') 3,690 (12' 1.2“) 3,640 (11' 11.3“) 800 (2' 7.5“) 900 (2' 11.4“) 3,250 (10' 8“) 3,645 (11' 12“) 5,355 (17’ 7“) 4,350 (14' 3“) 685 (2' 3“) 3.0/4.4/5.5 (1.9/2.7/3.4) 9.1 2740 2890 --2392
PC400LC-7L
GENERAL
SPECIFICATIONS
12 ● “Variable gauge specification” means the machine can extend and retract overall width (C) of the track frame. “Fixed gauge specification” means the machine cannot extend or retract overall width (C) of the track frame.
01-3
PC400LC-7L
GENERAL
SPECIFICATIONS
12 Working ranges A Max. digging reach B Max. digging depth C Max. digging height D Max. vertical wall digging depth E Max. dumping height F Min. dump height G Max. digging reached at ground level
01-4
Unit mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in)
PC400LC-7 12,030 (39' 6“) 7,830 (25' 8“) 10,930 (35' 10“) 6,870 (22' 6“) 7,625 (25') 11,820 (38' 9“)
PC400LC-7L
GENERAL
SPECIFICATIONS
12 Machine model
PC400LC-7L
Serial Number
A86001 and UP
Bucket capacity
Performance
Weight of machine Max. digging force (using power max. function) Swing speed Swing max. slope angle Travel speed Gradeability
Dimensions
Ground pressure (standard shoe width) Overall length (for transport) Overall width Overall width of track (for transport) Overall width of track when extended Overall height (for transport) Overall height to top of machine Ground clearance of upper structure Min. ground clearance Tail swing radius Min. swing radius of work equipment Height of work equipment at min. swing radius Length of track on ground Track gauge (Tg) Track gauge (for transport) Height of machine cab
kg lb kgf (lbf) kgf (lbf) rpm deg. km/h (mi/h) deg.
Performance
Engine
Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption
Fixed gauge spec.
Variable gauge spec.
43,700 96,342
44,600 98,326
26,100 (57,541) 28,000 (61,729) 9.1 20 Lo: 3.0 (0.00186), Mi: 4.4 (0.00273), Hi: 5.5 (0.00341) 35
kg/cm2 (lbf/ft2) mm (in)
0.82 (11.66) 900 (35.4)
0.67 (9.52) 800 (31.5)
mm (ft in)
12,040 (39’ 6") 3,640 (11’ 11") ----3,635 (11’ 11") 3,265 (10’ 9") 1,320 (4’ 4") 555 (1’ 10") 3,645 (12’ 0") 4,735 (15’ 6") 9,210 (30’ 3") 4,020 (13’ 2") 2,740 (9’ 0’) --3,265 (10’ 9")
12,040 (39’ 6") 3,690 (12’ 1") 3,192 (10’ 6") 3,690 (12’ 1") 3,635 (11’ 11") 3,265 (10’ 9") 1,320 (4’ 4") 685 (2’ 3") 3,645 (12’ 0") 4,735 (15’ 6") 9,210 (30’ 3") 4,020 (13’ 2") 2,890 (9’ 6") 2,392 (7’ 10") 3,265 (10’ 9")
mm (in) L (in3)
SAA6D125E-3 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler 6 - 125x150 (6 - 4.921x5.905) 11.045 (674.007)
kW/rpm (HP/rpm) kgm/rpm (lbf ft/rpm) rpm rpm g/kWh (g/HPh)
246.4/1,850 (330/1,850) 136/1,400 (983.9/rpm) 1,930 1,000 203 (151)
Model Type No. of cylinders - bore x stroke Piston displacement
1.4 1.83
m3 yd3
Starting motor Alternator Battery Radiator core type
24 V, 11 Kw 24 V, 50 A 12 V, 110 Ahx2 ALW-4
★ The "Mi" mode is on the multi-monitor specification machine only.
PC400LC-7L
01-5
GENERAL
SPECIFICATIONS
Carrier roller
2 on each side
Track roller
8 on each side
Track shoe
Assembly-type triple grouser, 49 on each side
Hydraulic pump Control valve
HPV190+190, variable displacement, piston type x2
Type x No.
Type x No.
Hydraulic motor
Hydraulic system
Undercarriage
12
Travel motor
KMV200ADT-2, Variable displacement, piston type (with brake valve, parking brake): x 2
Swing motor
KMF230ABE-5, Fixed displacement piston type (with safety valve, holding brake, reverse rotation preventive valve): x 1
Delivery Set pressure
L/min (in3)
345x2 (21053.2)
kgf/cm2 (lbf/in2)
380 (5404.87) 6-spool type + 1-spool type x 1
Control method
Hydraulic
Hydraulic cylinder
Boom Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins
Hydraulic tank Hydraulic filter Hydraulic cooler
01-6
Arm
Bucket
Double-acting piston
mm (ft in)
160 (0’ 6") 110 (0’ 4") 1,570 (5’ 2") 3,830 (12’ 7") 2,260 (7’ 5")
185 (0’ 7") 120 (0’ 5") 1,820 (6’ 0") 4,325 (14’ 2") 2,505 (8’ 3")
160 (0’ 6") 110 (0’ 4") 1,270 (4’ 2") 3,140 (10’ 4") 1,870 (6’ 2")
Closed box type Tank return side CF40-1 (Air cooled)
PC400LC-7L
GENERAL
WEIGHT TABLE
12
WEIGHT TABLE WARNING! This weight table is for use when handling components or when transporting the machine
Unit: kg (lb) Engine assembly
Engine Damper Hydraulic pump
1,500 (3,307) 1,150 (2,535) 14.7 (32) 210 (463)
Radiator, oil cooler assembly
195 (430)
Hydraulic tank, filter assembly (excluding hydraulic oil)
198 (437)
Fuel tank (excluding fuel)
251 (554)
● ● ●
Revolving frame
3,297 (7,269)
Operator’s cab
279 (616)
Operator’s seat
35 (78)
Counterweight
9,500 (20,944)
Swing machinery (including swing motor)
526 (1,160)
Control valve (with service valve0
257 (567)
Swing motor
105 (232)
Travel motor
208 (459) x 2
Center swivel joint
Track frame assembly Track frame ● ●
Center frame Crawler frame
Swing circle Idler Idler cushion Carrier roller Track roller Final drive (including travel motor)
40 (89) Fixed gauge specification
Variable gauge specification
10,965 (24,174) 6,077 (13,398) -----
11,934 (26,310) 7,096 (15,644) 3,229 (7,119) 1,921 (4,235) x 2 605 (1,334) x 2 230 (507) x 2 338 (745) x 2 32 (71) x 4 72 (159) x 16 722 (1,592) x 2
Track shoe assembly ● ● ● ●
Standard triple grouser shoe (600 mm) Standard triple grouser shoe (700 mm) Wide triple grouser shoe (800 mm) Wide triple grouser shoe (900 mm)
4,760 (10,494) 5,210 (11,486) 5,670 (12,500) 6,130 (13,515)
Boom assembly
3,290 (7,254)
Arm assembly
1,374 (3,030)
Bucket assembly
1,366 (3,012)
Boom cylinder assembly
355 (783) x 2
Arm cylinder assembly
PC400LC-7L
510 (1,125)
01-7
GENERAL
WEIGHT TABLE
Bucket cylinder assembly
280 (618)
Link assembly
258 (569)
Boom pin Arm pin
92 (203) + 20 (45) x 2 + 73 (161) + 27 (60) + 54 (120) 17 (38) + 23 (51)
Bucket pin
38 (102) x 2
Link pin
34 (75) x 2
01-8
PC400LC-7L
GENERAL
FUEL COOLANT AND LUBRICANTS
12
FUEL COOLANT AND LUBRICANTS It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your distributor. The specified fuel, coolant and lubricants recommended for this machine are as shown in the following table.
RESERVOIR
KIND OF FLUID
AMBIENT TEMPERATURE -22 -4 -30 -20
14 -10
32 0
50 10
68 20
86 104°F 30 40°C
CAPACITY - L (gal) Specified
Refill
42 (11.09)
38 (10.03)
1.07 (0.282)
---
SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 Damper case Swing machinery case Final drive case (each side)
13.4 (3.53) Engine oil
SAE 30
Idler (1 each)
12 (3.17) 0.335-0.355 (0.0884-0.0937)
Track roller (1 each)
0.28-0.31 (0.0739-0.0818)
Carrier roller (1 each)
0.12-0.18 (0.0317-0.0475) SAE 10W SAE 10W-30
Hydraulic system
SAE 15W-40 Hydraulic oil
Fuel tank
Cooling system
Diesel fuel Coolant
472 (124.6)
248 (65.5)
650 (171.7)
---
36 (9.51)
---
H046-HM (H)★★ ASTM D975 No. 2 ★ Add antifreeze
★ ASTM D975 No. 1 ★ ★ For the H-046-HM, use the oil recommended by Komatsu.
PC400LC-7L
01-9
GENERAL
FUEL COOLANT AND LUBRICANTS
12
MEMORANDUM
01-10
PC400LC-7L
10
STRUCTURE AND FUNCTION
12 RADIATOR • OIL COOLER • AFTERCOOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 IDLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 CARRIER ROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 TRIPLE GROUSER SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 HYDRAULIC PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 LS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 PC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 LS(PS)-EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41 VARIABLE VOLUME VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 SELF PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65 SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68 RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 REVERSAL PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 TRAVEL JUNCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 TRAVEL PPC SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92 WORK EQUIPMENT • SWING PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100 SERVICE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109 PPC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111 RETURN OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 BOOM HYDRAULIC DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114 ARM HYDRAULIC DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119 QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123 LIFT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125 ATTACHMENT CIRCUIT SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126 HOLDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128 HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132 BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132 ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
PC400LC-7L
10-1
STRUCTURE AND FUNCTION
TABLE OF CONTENTS
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134 DIMENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136 DIMENSION OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140 AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140 ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141 OPERATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141 STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141 ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141 STOPPING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141 COMPONENTS OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142 FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142 ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143 ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146 CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146 TOTAL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148 ENGINE AND PUMP CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150 PUMP/VALVE CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155 ONE-TOUCH POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION . . . . . . . . . . . . . . . . . . . . . . 10-158 AUTO-DECELERATION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160 AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162 SWING CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164 TRAVEL CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166 ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT) . . . . . . . . . . . . . . . . . . 10-168 SYSTEM COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169 ENGINE REVOLUTION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169 PPC OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170 PUMP PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171 PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172 MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175 MONITOR CONTROL, DISPLAY PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178 MONITOR PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178 MONITOR ITEMS AND DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183 SELECT MODE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186 MAINTENANCE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189 SERVICE METER CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192 DISPLAY LCD CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194 ENGINE OIL LEVER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194 ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194 COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195 HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195 FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195 AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
10-2
PC400LC-7L
STRUCTURE AND FUNCTION
RADIATOR • OIL COOLER • AFTERCOOLER
12
RADIATOR • OIL COOLER • AFTERCOOLER
1.
Oil cooler
7.
Radiator inlet hose
Specifications
2.
Radiator
8.
Radiator outlet hose
Radiator: ALW-4
3.
Radiator cap
9.
Aftercooler
Oil cooler: CF40-1
4.
Reservoir tank
10. Condenser
5.
Net
11. Fuel cooler
6.
Shroud
PC400LC-7L
10-3
STRUCTURE AND FUNCTION
POWER TRAIN
12
POWER TRAIN
1.
10-4
Idler
7.
Hydraulic pump (HPV190+190)
2.
Center swivel joint
8.
Travel speed solenoid valve
3.
Control valve
9.
Swing brake solenoid valve
4.
Final drive
10. Swing machinery
5.
Travel motor (KMV 200ADT-2)
11. Swing motor (KMF230ABE-5)
6.
Engine (SAA6D125-3E)
12. Swing circle
PC400LC-7L
STRUCTURE AND FUNCTION
FINAL DRIVE
12
FINAL DRIVE
PC400LC-7L
10-5
STRUCTURE AND FUNCTION
FINAL DRIVE
12 1.
Level plug
2.
Drain plug
3.
No. 1 planetary gear (No. of teeth: 43)
4.
No. 1 sun gear (No. of teeth: 10)
5.
No. 2 sun gear (No. of teeth: 18)
6.
No. 1 planetary carrier
7.
No. 2 planetary carrier
8.
Cover
9.
Ring gear (No. of teeth: 98)
10. Sprocket 11. Floating seal 12. Travel motor 13. No. 2 planetary gear (No. of teeth: 38) Specification Reduction ratio: -((10 + 98)/10)x((18+98)/18)=-68.600
Unit: mm No.
Check item
Criteria
Remedy
14
Backlash between No. 1 sun gear and No. 1 planetary gear
Standard clearance
Clearance limit
0.15 - 0.54
1.10
15
Backlash between No. 1 planetary gear and ring gear
0.18 - 0.66
1.30
16
Backlash between No. 2 planetary carrier and motor
0.06 - 0.24
---
17
Backlash between No. 2 sun gear and No. 2 planetary gear
0.15 - 0.51
1.00
18
Backlash between No. 2 planetary gear and ring gear
0.17 - 0.60
1.20
19
Backlash between No. 2 planetary carrier and No. 2 sun gear
0.15 - 0.54
---
20
Amount of wear on sprocket tooth
21
Width of sprocket tooth
22
Bolt
23
Repair limit: 6 Standard size
Repair limit
90
87
Torque Nm
Torque lbf ft
59 - 78
44 - 57
Bolt
98 - 123
73 - 90
24
Bolt
59 - 74
44 - 54
25
Bolt
640 - 785
473 - 578
26
Bolt
490 - 608
362 - 448
10-6
Replace
Rebuild or replace
PC400LC-7L
STRUCTURE AND FUNCTION
SWING MACHINERY
12
SWING MACHINERY
PC400LC-7L
10-7
STRUCTURE AND FUNCTION
SWING MACHINERY
12 1.
Swing pinion (No. of teeth: 13)
2.
Cover
3.
Case
4.
No. 2 planetary gear
5.
No. 2 sun gear
6.
Ring gear
7.
No. 1 sun gear
8.
Swing motor
9.
Oil level gauge
10. No. 1 planetary gear 11. No. 1 planetary carrier 12. No. 2 planetary carrier 13. Drain plug Specification Reduction ratio: ((19 +68)/19)x((16+68)/16)=24.039
Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.18 - 0.28
---
14
Backlash between swing motor shaft and No. 1 sun gear
15
Backlash between No. 1 sun gear and No. 1 planetary gear
0.15 - 0.51
1.00
16
Backlash between No. 1 planetary gear and ring gear
0.17 - 0.60
1.10
17
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.40 - 0.75
1.20
18
Backlash between No. 2 sun gear and No. 2 planetary gear
0.16 - 0.55
1.00
19
Backlash between No. 2 planetary gear and ring gear
0.17 - 0.60
1.10
20
Backlash between coupling and swing pinion
0.08 - 0.25
---
21
Backlash between swing pinion and swing circle
0.00 - 1.21
2.00
22
Clearance between plate and coupling
0.57 - 1.09
---
23
Wear of swing pinion surface contacting with oil seal
Standard size
Repair limit
24
Bolt
25
0 150 -0.100
---
Torque Nm
Torque lbf ft
824 - 1030
608 - 759
Bolt
343 - 427
253 - 314
26
Bolt
98 - 123
73 - 90
27
Bolt
245 - 309
181 - 228
28
Bolt
2.81 - 3.79
2.07 - 2.79
10-8
Replace
Apply hard chrome plating, recondition, or replace
PC400LC-7L
STRUCTURE AND FUNCTION
SWING CIRCLE
12
SWING CIRCLE
1.
Swing circle inner race (No. of teeth: 84)
Specification
2.
Ball
Reduction ration: - 84 = -6.462 13
3.
Swing circle outer race
Amount of grease: 33 L (8.71 gal) {G2-LI}
a.
Inner race soft zone “S” position
b.
Outer race soft zone “S” position
Unit: mm No. 4
Check item Axial clearance of bearing (when mounted on chassis)
PC400LC-7L
Criteria
Remedy
Standard clearance
Repair limit
0.5 - 1.6
3.2
Replace
10-9
STRUCTURE AND FUNCTION
TRACK FRAME AND RECOIL SPRING
12
TRACK FRAME AND RECOIL SPRING
1.
Idler
2.
Track frame
3.
Carrier roller
4.
Final drive
5.
Track roller
6.
Track shoe
7.
Center guard
8.
Recoil spring
9.
Front guard
10-10
• •
The dimensions and the number of track rollers depend on the model, but the basic structure is not different. Number of track rollers: 8
PC400LC-7L
STRUCTURE AND FUNCTION
TRACK FRAME AND RECOIL SPRING
12 Item
Fixed gage
Variable gage
Shoe width
900 mm
800 mm
Link pitch
228 mm
228 mm
49 (Pieces)
49 (Pieces)
No. on track (one side)
Unit: mm No.
10
11
Check item
Vertical width of idler guide
Horizontal width of idler guide
Criteria
Remedy
Standard size
Tolerance
Track frame
123
+2 -1
127
Idler support
120
±0.5
118
Track frame
266
+3 -1
271
Idler support
261
---
259
Standard size 12
Recoil spring
PC400LC-7L
Repair limit Rebuild or replace
Repair limit
Freelength x OD
Installation length
Installation load
Free length
Installation load
795 x 241
648
173.3 kN {17,680 kg}
---
138.56 kN {14,140 kg}
Replace
10-11
STRUCTURE AND FUNCTION
IDLER
12
IDLER
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
704
---
1
Outside diameter of protruding
2
Outside diameter of tread
660
648
3
Depth of tread
22
28
4
Total width
202
---
5
Width of tread
48.5
---
Standard size 6
Clearance between shaft and bushing 95 Standard size
7
Interference between idler and bushing 102.6
8
Bolt
10-12
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
-0.120 -0.207
+0.360 +0.220
0.340-0.507
Tolerance Shaft
Hole
Standard interference
+0.087 +0.037
-0.027 -0.079
0.064-0.149
Torque Nm
Torque lbf ft
130 - 180
96 - 132
Replace bushing
PC400LC-7L
STRUCTURE AND FUNCTION
CARRIER ROLLER
CARRIER ROLLER
Unit: mm No.
Check item
Criteria Standard size
Remedy Repair limit
1
Outside diameter of flange
175
---
2
Outside diameter of tread
148
134
3
Width of tread
50.3
---
4
Thickness of tread
32
25
5
Width of flange
19
6
7 8
Interference between shaft and bushing
Interference between roller and bushing Axial clearance of roller
PC400LC-7L
--Tolerance
Interference Replace limit
Standard size
Shaft
Hole
Standard interference
50
-0.250 -0.270
+0.099 -0.032
0.218 - 0.369
57
+0.117 +0.087
+0.040 0
0.047 0.177
---
Standard clearance
Clearance limit
0.5 - 0.7
---
10-13
STRUCTURE AND FUNCTION
TRACK ROLLER
12
TRACK ROLLER
10-14
PC400LC-7L
STRUCTURE AND FUNCTION
TRACK ROLLER
12
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
240
---
237
---
1
Outside diameter of outer flange
2
Outside diameter of inner flange (double flange)
3
Outside diameter of tread
200
188
4
Thickness of tread
56.2
50.2
5
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
---
6
Width of tread
7
Width of outer flange
8
Width of inner flange (Double flange)
9
Axial play
10
Clearance between shaft and bushing
11
Interference between roller and bushing
Tolerance
Standard size
Shaft
Hole
Standard clearance
Clearance limit
80
-0.250 -0.350
+0.174 +0.029
0.279 -0.524
1.5
87.6
+0.108 +0.008
-0.006 -0.036
Standard interference
Interference limit
0.014-0.144
---
Torque Nm
Replace bushing
Torque lbf ft
12
Bolt
10 - 20
8 - 14
13
Bolt
1st torque
200 ± 20
147 ± 14
13
Bolt
2nd torque
105 ± 5
77 ± 3
PC400LC-7L
Rebuild or replace
10-15
STRUCTURE AND FUNCTION
TRACK SHOE
12
TRACK SHOE
★ P portion shows the link of bushing press-fitting end.
10-16
PC400LC-7L
STRUCTURE AND FUNCTION
TRACK SHOE
12 Unit: mm No. 1
Check item Link pitch
2
Bushing outside diameter
3
Thickness of bushing metal
4
Link height
5
Thickness of link metal (bushing press-fitting portion)
6 7
Shoe bolt pitch
Standard size
Repair limit
228.9
231.9
Standard size
When turned
71.5
66.5
12
7
Standard size
Repair limit
129
119
34.5
24.5
Reverse or replace
Adjust or replace
Repair or replace
144
Replace
76.2
9 Link
11
Inside width
106
Overall width
51.6
Tread width
44.8
12
Protrusion of pin
4.4
13
Protrusion of regular bushing
5.25
14
Overall length of pin
252
15
Overall length of bushing
16
Thickness of spacer
17 18
Remedy
184
8 10
Criteria
Press-fitting force
❈ 19
Repair or replace
Adjust or replace
164.5 ---
Bushing
118 - 304 kN {12 - 31 ton}
Regular pin
176 - 451 kN {18 - 46 ton}
Master pin
137 - 284 kN {14 - 29 ton}
---
❈: Dry type track link
PC400LC-7L
10-17
STRUCTURE AND FUNCTION
TRACK SHOE
12
Unit: mm
No.
Check item
Criteria a. Regular link
20
Tightening torque (Nm {lbf ft}) Triple shoe
Shoe bolt b. Master link
393±39 {289±28}
---
No. of shoes (each side)
22
23
Interference between bushing and link Interference between regular pin and link Clearance between regular pin and bushing
Interference between master pin and bushing
Standard size
Clearance between master pin and bushing
---
Tolerance
Standard interference
Hole
71
+0.494 +0.454
+0.074 0
0.380 - 0.494
47
+0.235 +0.085
-0.218 -0.280
0.303 - 0.515
Standard size
Standard size
Standard size 47
10-18
---
Shaft
47
25
Retighten
49
47
24
120±10
Tightening torque Additinal tightening Lower limit torque (Nm {lbf ft}) angle (deg.) (Nm {lbf ft}) ---
21
Remedy
Additinal tightening angle (deg.)
Tolerance Shaft
Standard clearance
Hole
+0.235 +0.085
+0.915 +0.415 Tolerance
Shaft
Hole
+0.03 0
-0.218 -0.280 Tolerance
Shaft
Hole
-0.2 -0.4
+0.915 +0.415
Adjust or replace
0.180 - 0.830 Standard interference 0.218 - 0.310 Standard clearance 0.615 - 1.315
PC400LC-7L
STRUCTURE AND FUNCTION 12 TRIPLE
TRACK SHOE
GROUSER SHOE
Unit: mm No.
Check item
1
Height
2
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
7
PC400LC-7L
17.5 23.5
10-19
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
HYDRAULIC SYSTEM HYDRAULIC PIPING DRAWING
1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Swing motor 5. Control valve 6. Oil cooler 7. Hydraulic filter 8. Hydraulic pump 9. L.H. travel motor 10. Hydraulic tank 11. Multi-pattern selector valve 12. L.H. PPC valve 13. Safety lever (electric type) 14. Center swivel joint 15. R.H. PPC valve 16. Travel PPC valve 17. Attachment circuit selector valve 18. Holding valve 19. Accumulator 20. Solenoid valve assembly 20A. PPC lock solenoid 20B. Travel junction solenoid 20C. Pump merge/divider solenoid 20D. Travel speed solenoid 20E. Swing brake solenoid 20F. Machine push-up solenoid 20G. 2-stage relief solenoid
10-20
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
PC400LC-7L
10-21
STRUCTURE AND FUNCTION 12 HYDRAULIC
HYDRAULIC SYSTEM
TANK
1.
Oil filler cap
Specifications
2.
Breather
Tank capacity: 335 L (88.4 gal)
3.
Hydraulic tank
Amount of oil inside tank: 248 L (65.5 gal)
4.
Sight gauge
Pressure valve
5.
Strainer
Relief cracking Pressure: 0.17 ± 0.07 kg/cm2 (2.47 ± 0.99 psi)
6.
Filter element
Suction cracking pressure: 0 - 0.005 kg/cm2 (0 - 0.071 psi)
7.
Strainer
Bypass valve set pressure: 1.5 ± 0.3 kg/cm2 (21.3 ± 4.26 psi)
8.
Bypass valve
Breather Intake valve set pressure: 0.02 ± 0.003 kg/cm2 (0.284 ± 0.0426 psi) Exhaust valve set pressure: 1.0 ± 0.15 kg/cm2 (14.2 ± 2.13 psi)
10-22
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-23
STRUCTURE AND FUNCTION 12 HYDRAULIC
HYDRAULIC SYSTEM
PUMP
HPV160+160(190)
1. Front main pump
IM
: PC mode selector current
PENR
: Rear pump control pressure detection port
2. Rear main pump
ISIG
: LS set selector current
PLSF
: Front load pressure input
3. LS valve
PAF
: Front pump delivery
PLSFC
: Front load pressure detection port
4. PC valve
PFC
: Front pump delivery pressure detection
PLSR
: Rear load pressure input
5. LS-EPC valve
PAR
: Rear pump delivery
PLSRC
:Rear load pressure detection port
6. PC-EPC valve
PRC
: Rear pump delivery pressure detection
PS
: Pump suction
7. Variable volume valve
PBF
: Front pump pressure input
PLSCR:
: LS set selector pressure detection port
PD1F
: Case drain port
PM
: PC set selector pressure detection port
PENF
: Front pump control pressure detection PEPC
: EPC basic pressure input
PBR
: Rear pump pressure input
PDIR
: Air bleeder
PD2F
: Drain plug
PEPB
: EPC basic pressure detection port
PD2R
: Drain plug
Outline This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.
10-24
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
1.
Shaft (Front)
4.
Rocker cam
7.
Cylinder block
10. Shaft (Rear)
2.
Cradle
5.
Shoe
8.
Valve plate
11. Case (Rear)
3.
Case (Front)
6.
Piston
9.
End cap
12. Servo piston
Torque Nm
Torque lbf ft
58.8 - 78
43.3 - 57.5
14.
132 - 157
97.3 - 115.7
20.
7.8 - 9.8
5.7 - 7.2
15.
11.8 - 14.7
8.7 - 10.8
21.
637 - 764.4
470 - 563.7
13.
19.
Torque Nm
Torque lbf ft
18.6 - 23.5
13.7 - 17.3
16.
6.9 - 9.8
5.0 - 7.2
22.
246.3 - 308.7
181.7 - 227.6
17.
98.1 - 122.6
72.3 - 90.4
23.
27 - 34
119.9 - 25.0
18.
19.6 - 27.4
14.5 - 20.2
24.
343 - 427
253 - 314
PC400LC-7L
10-25
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
Function • •
The rotation and torque transmitted to the pump shaft are converted into hydraulic energy, and pressurized oil is discharged according to the load. It is possible to change the discharge amount by changing the swash plate angle.
Structure • • •
• •
Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).
10-26
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Operation 1.
Operation of pump A. Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle is called the swash plate angle.) B. Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F – E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in. C. If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)
PC400LC-7L
10-27
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. Control of discharge amount • If the swash plate angle becomes larger, the difference between volumes E and F becomes larger and discharge amount Q increases. • Swash plate angle is changed by servo piston (12). • Servo piston (12) moves in a reciprocal movement (↔) according to the signal pressure from the PC and LS valves. This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides in a rotating movement in direction of arrow.
•
•
10-28
With servo piston (12), the area receiving the pressure is different on the left and the right, so main pump discharge pressure (self pressure) PP is always brought to the chamber receiving the pressure at the small diameter piston end. Output pressure Pen of the LS valve is brought to the chamber receiving the pressure at the large diameter end. The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
PC400LC-7L
STRUCTURE AND FUNCTION 12 LS
HYDRAULIC SYSTEM
VALVE
1. Plug
PA
: Pump port
2. Locknut
PP
: Pump port
3. Sleeve
PDP
: Drain port
4. Spring
PLP
: LS control pressure output port
5. Seat
PLS
: LS pressure input port
6. Spool
PPL
: PC control pressure input port
7. Piston
PSIG
: LS mode selection pilot port
8. Sleeve
PC VALVE
1. Servo piston assembly
PA
: Pump port
2. Plug
PA2
: Pump pressure pilot port
3. Pin
PDP
: Drain port
4. Spool
PM
: PC mode selector pressure pilot port
5. Retainer
PPL
: PC control pressure output port
6. Seat 7. Cover 8. Wiring
PC400LC-7L
10-29
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Function 1.
LS valve The LS valve detects the load and controls the discharge amount. This valve controls main pump discharge amount Q according to differential pressure ∆PLS (=PP – PLS) [called the LS differential pressure] (the difference between main pump pressure PP and control valve outlet port pressure PLS). Main pump pressure PP, pressure PLS {called the LS pressure} coming from the control valve output, and pressure PSIG {called the LS selector pressure} from the proportional solenoid valve enter this valve. The relationship between discharge amount Q and differential pressure ∆PLS, (the difference between main pump pressure PP and LS pressure PLS) (= PP – PLS) changes as shown in the diagram at the right according to LS pressure selector current PSIG of the LS-EPC valve. When PSIG changes between 0 and 1A, the set pressure of the spring changes according to this, and the selector point for the pump discharge amount changes at the rated central valve between 12 27 kg/cm2 (170.6 ↔ 384.0 psi).
2.
PC valve When the pump discharge pressure PP1 (self pressure) and PP2 (other pump pressure) are high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. In other words, If the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount Q is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The controller senses the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set value, the command current to the PC-EPC valve solenoid from the controller increases according to the drop in the engine speed to reduce the pump swash plate angle.
10-30
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
OPERATION
1.
LS valve A. When control valve is at neutral position • The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the inlet port of the control valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The size of this LS pressure PLS + force Z of spring (4) and the main pump pressure (self pressure) PP determines the position of spool (6). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC valve for the LS valve entering port G also changes the position of spool (6). (The set pressure of the spring changes). • Before the engine is started, servo piston (12) is pushed to the right. (See the diagram on the right) • When the engine is started and the control lever is at the neutral position, LS pressure PLS is 0 kg/cm2 (0 psi). (It is interconnected with the drain circuit through the control valve spool.) At this point, spool (6) is pushed to the right, and port C and port D are connected. Pump pressure PP enters the large diameter end of the piston from port K and the same pump pressure PP also enters port J at the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in the area of the piston (12).
PC400LC-7L
10-31
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
B. Operation in increase direction for pump discharge amount • When the difference between the main pump pressure PP and LS pressure PLS, in other words, LS differential pressure PLS, becomes smaller (for example, when the area of opening of the control valve becomes larger and pump PP drops), spool (6) is pushed to the left by the combined force of LS pressure PLS and the force of spring (4). • When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC valve is connected to the drain port, so circuit D – K becomes drain pressure PT. (The operation of the PC valve is explained later). • For this reason, the pressure at the large diameter end of servo piston (12) becomes drain pressure PT, and pump pressure PP enters port J at the small diameter end, so servo piston (12) is pushed to the right. Therefore, the swash plate moves in the direction to make the discharge amount larger. If the output pressure of the EPC valve for the LS valve enters port G, this pressure creates a force to move piston (7) to the right. If piston (7) is pushed to the right, it acts to make the set pressure of spring (4) weaker, and the difference between PLS and PP changes when ports D and E of spool (6) are connected.
10-32
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
C. Operation in decrease direction for pump discharge amount • The following explains the situation if the servo piston (12) moves to the right (the discharge amount becomes smaller). When LS differential pressure ∆PLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (6) to the right. • When spool (6) moves, main port pressure PP flows from port C and port D and from port K, it enters the large diameter end of the piston. • Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end of servo piston (12), servo piston (12) is pushed to the right. • As a result, the swash plate moves in the direction to make angle smaller. • If LS selection pressure PSIG enters port G, it acts to make the set pressure of spring (4) weaker.
PC400LC-7L
10-33
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
D. When servo piston is balanced • Let us take the area receiving the pressure at the large diameter end of the piston as A1, the area receiving the pressure at the small diameter end as A0, and the pressure flowing into the large diameter end of the piston as Pen. If the main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS pressure PLS are balanced, and the relationship is A0 × PP = A1 × Pen, servo piston (11) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the opening of the throttle from port D to port E and from port C to port D of spool (6) is approximately the same.) • At this point, the relationship between the area receiving the pressure at both ends of piston (12) is A0: A1 = 1:2, so the pressure applied to both ends of the piston when it is balanced becomes PP: Pen = 2:1. • The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is adjusted so that it is determined when PP – PLS = 27 kg/cm2 (384 psi). However, if PSIG (the output pressure of 0 ↔ 30 kg/cm2 (426 psi) of the EPC valve of the LS valve) is applied to port G, the balance stop position will change in proportion to pressure PSIG between PP – PLS = 27 ↔ 12 kg/cm2 (384 ↔ 170 psi).
10-34
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
2.
PC Valve A. When pump controller is normal i.
When the load on the actuator is small and pump pressures PP1 and PP2 are low a. Movement of PC-EPC solenoid (1) • The command current from the pump controller flows to PC-EPC solenoid (1).This command current acts on the PC-EPC valve and outputs the signal pressure. When this signal pressure is received, the force pushing piston (2) is changed. • On the opposite side to the force pushing this piston (2) is the spring set pressure of springs (4) and (6) and pump pressure PP1 (self pressure) and PP2 (other pump pressure) pushing spool (3). Piston (2) stops at a position where the combined force pushing spool (3) is balanced, and the pressure (pressure of port C) output from the PC valve changes according to this position. • The size of command current X is determined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed. ★ Other pump pressure This is the pressure of the pump at the opposite end. For the F pump, it is the R pump pressure For the R pump, it is the F pump pressure
PC400LC-7L
10-35
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
b. Action of spring • The spring load of springs (4) and (6) in the PC valve is determined by the swash plate position. • If piston (9) moves to the right, spring (6) is compressed, and if it moves further to the right, spring (6) contacts seat (5) and is fixed in position. In other words, the spring load is changed by piston (9) extending or compressing springs (4) and (6). • If the command circuit input to PC-EPC valve solenoid (1) changes further, the force pushing piston (2) changes, and the spring load of springs (4) and (6) also changes according to the valve of the PC-EPC valve solenoid command current. • Port C of the PC valve is connected to port E of the LS valve (see (1) LS valve). Self pressure PP1 enters port B and the small diameter end of servo piston (9), and other pump pressure PP2 enters port A. • When pump pressures PP1 and PP2 are small, spool (3) is on the left. At this point, port C and D are connected, and the pressure entering the LS valve becomes drain pressure PT. If port E and port G of the LS valve are connected (see (1) LS valve), the pressure entering the large diameter end of the piston from port J becomes drain pressure PT, and servo piston (9) moves to the left. In this way, the pump discharge amount moves in the direction of increase. • As servo piston (9) moves further, springs (4) and (6) expand and the spring force becomes weaker. When the spring force becomes weaker, spool (3) moves to the right, so the connection between port C and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of piston (9) to the left is stopped. • In other words, the stop position for piston (9) (= pump discharge amount) is decided at the point where the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing force created by the pressures PP1 and PP2 acting on the spool (3) are in balance.
10-36
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
ii.
When load on actuator is large and pump discharge pressure is high • When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing spool (3) to the right becomes larger and spool (3) moves to the position in the diagram above. When this happens, as shown in the diagram above, part of the pressurized oil from port B flows out through port C where the LS valve is actuated to port D, and the pressurized oil flowing from port C to the LS valve becomes approximately half of main pump pressure PP. • When port E and port G of the LS valve are connected (see (1) LS valve), the pressure from port J enters the large diameter end of servo piston (9), and servo piston (9) stops. • If pump discharge pressure PP and PP2 increases further and spool (3) moves further to the right, main pump pressure PP1 flows to port C and acts to make the discharge amount the minimum. When piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the left, port C and port B are disconnected and port C and port D are interconnected. As a result, the pressure at port C (= J) drops, and piston (9) stops moving to the right. • The position in which piston (9) stops when this happens is further to the right than the position when pump pressures PP1 and PP2 are low.
PC400LC-7L
10-37
STRUCTURE AND FUNCTION 12
10-38
•
The relation of average pump pressure (PP1 + PP2)/2 and the position of servo piston (9) forms a bent line because of the double-spacing effect of springs (4) and (6). The relationship between average pump pressure (PP1 + PP2)/2 and pump discharge amount Q is shown in the figure at the right.
•
If command voltage X sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/2, and pump discharge amount Q is proportional to the pushing force of the PC-EPC valve solenoid and moves in parallel. In other words, the pushing force of PC-EPC solenoid (1) is added to the force pushing to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and Q moves from to in accordance with the increase in X.
HYDRAULIC SYSTEM
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
B. When pump controller is abnormal and emergency pump drive switch is ON i.
When load on main pump is light • If there is a failure in the pump controller, turn emergency pump drive switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery. But if the current is used as it is, it is too large, so use the resistor to control the current flowing to PC-EPC valve solenoid (1). • When this is done, the current becomes constant, so the force pushing piston (2) is also constant. • If the main pump pressure PP1 and PP2 are low, the combined force of the pump pressure and the force of PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left. • At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the discharge amount larger.
PC400LC-7L
10-39
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
ii.
10-40
When main pump load is heavy • In the same way as in the previous item, when the emergency pump drive switch is ON, the command current sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. • If main pump pressures PP1 and PP2 increase, spool (3) moves further to the right than when the main pump load is light, and is balanced at the position in the diagram above (See Fig. P). • In this case, the pressure from port B flows to port C, so servo piston (9) moves to the right (to make the discharge amount smaller) by the same mechanism as explained, and stops at a position to the right of the position when the load on the pump is light (See Fig. Q). In other words, even when the emergency pump drive switch is ON, the curve for the pump pressure PP and discharge amount Q is determined as shown in the diagram for the valve of the current sent to the PC-EPC valve solenoid through the resistor. The curve when the emergency pump drive switch is ON is curve c, which is to the left of curve b for when the pump controller is normal.
PC400LC-7L
STRUCTURE AND FUNCTION 12 LS(PS)-EPC
HYDRAULIC SYSTEM
VALVE
1. Body
5. Coil
PSIG
: To LS(PC) valve
2. Spool
6. Plunger
PT
: To tank
3. Spring
7. Connector
PEPC
: From self-reducing pressure valve
4. Rod
PC400LC-7L
10-41
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Function • •
The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. When it receives signal current i from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS valve.
Operation 1.
When signal current is 0 (coil de-energized) • When there is no signal current flowing from the controller to coil (5), coil (5) is de-energized. • For this reason, spool (2) is pushed to the left in the direction of the arrow by spring (3). • As a result, port PEPC closes and the pressurized oil from the main pump does not flow to the LS valve. At the same time, the pressurized oil from the LS valve passes from port PSIG(PM) through port PT and is drained to the tank.
10-42
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. When signal current is very small (coil energized) • When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated which pushes plunger (6) to the left. • Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port PEPC to port PSIG(PM). • When the pressure at port PSIG(PM) rises and the load of spring (3) + the force acting on surface a of spool (2) becomes greater than the propulsion force of plunger (6), spool (2) is pushed to the right. The circuit between port PEPC and port PSIG(PM) is shut off, and at the same time, port PSIG(PM) and port PT are connected. • As a result, spool (2) is moved up or down until the propulsion force of plunger (6) is balanced with the load of spring (3) + pressure of port PSIG(PM). • Therefore, the circuit pressure between the EPC valve and the LS valve is controlled in proportion to the size of the signal current.
3.
When signal current is maximum (coil energized) • When the signal current flows to coil (5), coil (5) is energized. • When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. • For this reason, spool (2) is pushed fully to the left by push pin (4). • As a result, the maximum flow of pressurized oil from port PEPC flows to port PSIG(PM), and the circuit pressure between the EPC valve and LS valve becomes the maximum. At the same time, port PT closes and stops the oil from flowing to the tank.
PC400LC-7L
10-43
STRUCTURE AND FUNCTION 12 VARIABLE
HYDRAULIC SYSTEM
VOLUME VALVE
1. Block
PM
: To PC valve
2. Plug
PT
: To tank
3. Spring
PEPC
: From self-reducing pressure valve
4. Piston
10-44
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Function •
This stabilizes the EPC output pressure.
Operation •
The output pressure from EPC flows to port PM, and when the propulsion force of piston (4) becomes larger than the load of spring (3), piston (4) is pushed to the left and the volume at port PM increases. When the propulsion force of piston (4) becomes less than the load on spring (3), piston (4) is pushed to the right and the volume at port PM goes down.
PC400LC-7L
10-45
STRUCTURE AND FUNCTION 12 CONTROL
HYDRAULIC SYSTEM
VALVE
1.
6-spool valve
2.
Cover 1
3.
Cover 2
4.
Pump merge-divider valve
5.
Back pressure valve
6.
Boom lock valve
7.
Boom, arm Hi valve
8.
Quick return valve
9.
Boom Hi check valve
Outline • This control valve consists of a 7-spool valve (6 spool valve + boom • arm Hi valve). A merge-divider valve, back-pressure valve, boom hydraulic drift prevention valve, quick return valve, and Hi valve check valve are installed to it. • Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the assembly, the assembly is small in size and easy to maintain. • Since one spool of this control valve is used for one work equipment unit, its structure is simple.
A1
: To bucket cylinder bottom
P11
: From arm PPC valve
A2
: o left travel motor
P12
: From arm PPC valve
A3
: To boom cylinder bottom
BP1
: Boom RAISE PPC output pressure
A4
: To swing motor
PB5
: From 2-stage safety valve solenoid valve
A5
: To right travel motor
PLS1
: To rear pump control
A6
: To arm cylinder head
PLS2
: To front pump control
A-1
: To boom cylinder bottom
PP1
: To rear pump control
A-2
: To attachment
PP2
: To front pump control
B1
: To bucket cylinder head
PPS1
: From rear main pump
B3
: To bottom cylinder head
PPS2
: From front main pump
B4
: To swing motor
PR
: To solenoid valve, PPC valve, EPC valve
B5
: To right travel motor
PS
: From pump merge-divider solenoid valve
B6
: To arm cylinder bottom
PST
: From travel junction valve
B-1
: To arm cylinder bottom
PX1
: From 2-stage solenoid valve
P1
: From bucket PPC valve
PX2
: From 2-stage solenoid valve
P2
: From bucket PPC valve
SA
: Pressure sensor fitting port
P3
: From left travel PPC valve
SB
: Pressure sensor fitting port
P4
: From left travel PPC valve
T
: To tank
P5
: From boom PPC valve
T1
: To tank
P6
: From boom PPC valve
TS
: To tank
P7
: From swing PPC valve
TSW
: To swing motor
P8
: From swing PPC valve
P9
: From right travel PPC valve
P10
: From right travel PPC valve
10-46
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 7-SPOOL VALVE (1/9)
PC400LC-7L
10-47
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (2/9)
Item
10-48
Torque Nm
Torque lbf ft
1. Bolt
33.3 - 43.1
24.5 - 31.7
2. Bolt
156.9 - 176.5
115.7 - 130.1
3. Bolt
65.7 - 85.3
48.4 - 62.9
4. Bolt
58.8 - 73.6
43.3 - 54.2
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (3/9)
1. Unload valve
9. Pressure compensation valve (Arm IN)
2. Pressure compensation valve (Arm OUT)
10. Pressure compensation valve (Bucket DUMP)
3. Pressure compensation valve (Right travel reverse
11. Pressure compensation valve (Left travel forward)
4. Pressure compensation valve (Left swing)
12. Pressure compensation valve (Boom LOWER)
5. Pressure compensation valve (Boom RAISE)
13. Pressure compensation valve (Right swing)
6. Pressure compensation valve (Left travel reverse)
14. Pressure compensation valve (Right travel forward
7. Pressure compensation valve (Bucket CURL)
15. Pressure compensation valve (Arm IN)
8. Pressure compensation valve (Boom RAISE)
16. Main relief valve
PC400LC-7L
10-49
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (4/9)
1. Spool (Arm)
6. Spool (Bucket)
2. Spool (Right travel)
7. Spool (Boom Hi)
3. Spool (Swing)
8. Spool (Arm Hi)
4. Spool (Boom)
9. Unload valve
5. Spool (Left travel)
10. Main relief valve
Unit: mm No.
11
Criteria
Check item
Spool return spring
Remedy
Standard size
Repair limit
Free length x OD
Installed length
Installed load
Free length
Installed load
54.2 x 34.8
51.2
416.5 N {42.5 kg}
---
333.2 N {34 kg}
12
Spool return spring
54.6 x 34.8
51.2
429.9 N {42.9 kg}
---
336.1 N {34.3 kg}
13
Spool return spring
54.5 x 34.8
51.2
393 N {40.1 kg}
---
314.6 N {32.1 kg}
14
Spool return spring
54.9 x 24.2
51.2
251 N {25.1 kg}
---
201.0 N {20.5 kg}
15
Spool return spring
57.2 x 32.8
51
416 N {42.5 kg}
---
333.2 N {34.0 kg}
10-50
If damaged or deformed, replace spring
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (5/9)
1. Safety-suction valve (Arm OUT)
9. Safety-suction valve (2-stage) (Boom LOWER)
2. Suction valve (Right travel reverse)
10. Suction valve (Right travel forward)
3. Suction valve (Boom RAISE)
11. Safety-suction valve (Arm IN)
4. Suction valve (Left travel reverse)
12. LS shuttle valve (Arm, right travel)
5. Safety-suction valve (Boom Hi)
13. LS select valve
6. Safety-suction valve (Arm IN)
14. LS shuttle valve (Boom, left travel, bucket)
7. Safety-suction valve (Bucket DUMP)
15. LS check valve
8. Suction valve (Left travel forward)
16. Pressure relief plug
Unit: mm No.
Check item
Criteria
Remedy
Standard size 17
Check valve spring
PC400LC-7L
Repair limit
Free length x OD
Installed length
Installed load
Free length
Installed load
11.5 x 4.6
8.5
1.5 N {0.15 kg}
---
1.2 N {0.12 kg}
If damaged or deformed, replace spring
10-51
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (6/9)
ARM CONTROL VALVE
R. H. TRAVEL CONTROL VALVE
1. Unload valve
5. Safety-suction valve
12. Suction valve
2. Main relief valve
6. Spool
13. Spool
3. Safety valve (Boom RAISE)
7. Pressure compensation valve (OUT)
14. Pressure compensation valve (Reverse)
4. Lift check valve
8. LS shuttle valve
15. LS shuttle valve
9. Pressure compensation valve (IN)
16. Pressure compensation valve (Forward)
10. Safety-suction valve
17. Suction valve
11. Check valve for regeneration circuit
10-52
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Unit: mm No.
Check item
Criteria
Remedy
Standard size Free length x OD Installed length 18
Regeneration valve spring
19 20
Repair limit Installed load
Free length Installed load
31.5 x 10.3
19.5
6.2 N {0.6 kg}
---
4.9 N {0.5 kg}
Piston return spring
36.9 x 11.1
28
29.4 N {3 kg}
---
23.5 N {2.4 kg}
Piston return spring
36.9 x 11.1
28
29.4 N {3 kg}
---
23.5 N {2.4 kg}
Item
PC400LC-7L
Torque Nm
Torque lbf ft
21. Valve
147.1 - 186.3
108.4 - 137.4
22. Valve
137.0 - 157.0
101.0 - 115.7
23. Valve
49.0 - 58.8
36.1 - 43.3
24. Valve
372.7 - 411.9
274.8 - 303.8
If damaged or deformed, replacespring
10-53
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (7/9)
SWING CONTROL VALVE
ARM CONTROL VALVE
L. H. TRAVEL CONTROL VALVE
1. Spool
5. Suction valve
13. Pump merge-divider valve (Travel junction valve)
2. Pressure compensation valve (Left)
6. Spool
14. Return spring
3. LS select valve
7. Pressure compensation valve (RAISE)
15. Suction valve
4. Pressure compensation valve (Right)
8. Hydraulic drift prevention valve
16. Spool
9. LS shuttle valve
17. Pressure compensation valve (Reverse)
10. Pressure compensation valve (Lower)
18. LS shuttle valve
11. Safety-suction valve
19. Pressure compensation valve (Forward)
12. Check valve for regeneration circuit
20. Suction valve
10-54
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Unit: mm No.
Check item
Criteria
Remedy
Standard size 21
Regeneration valve spring
Free length x OD Installed length
Repair limit Installed load
Free length Installed load
31.5 x 10.3
19.5
6.2 N {0.6 kg}
---
4.9 N {0.5 kg}
22
Piston return spring
48.1 x 10.8
28
17.5 N {1.8 kg}
---
14.0 N {1.4 kg}
23
Piston return spring
36.9 x 11.1
28
29.4 N {3 kg}
---
23.5 N {2.4 kg}
24
Spool return spring
30.7 x 20.5
23
50.0 N {5.1 kg}
---
40.0 N {4.1 kg}
Item
PC400LC-7L
Torque Nm
Torque lbf ft
25. Valve
372.7 - 411.9
274.8 - 303.8
26. Valve
107.9 - 147.1
79.5 - 108.4
27. Valve
323 - 402
238.2 - 296.5
28. Valve
196 - 240
144.5 - 177.0
29. Valve
147.1 - 186.3
108.4 - 137.4
30. Valve
137.3 - 156.9
101.2 - 115.7
If damaged or deformed, replace spring
10-55
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (8/9)
BUCKET CONTROL VALVE
BOOM, ARM HI VALVE
1. Safety-suction valve
7. Boom Hi spool
2. Spool
8. Pressure compensation valve (Boom RAISE)
3. Pressure compensation valve (CURL)
9. Boom Hi check valve
4. LS shuttle valve
10. Quick-return valve
5. Pressure compensation valve (DUMP)
11. Pressure compensation valve (Arm IN)
6. Safety-suction valve
12. Arm Hi spool 13. Safety-suction valve
10-56
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Unit: mm No.
Check item
Criteria
Remedy
Standard size 14
15
Piston return spring
Piston return spring
Free length x OD
Installed length
Installed load
48.1 x 10.8
28
17.5 N {1.8 kg}
---
14.0 N {1.4 kg}
36.9 x 11.1
28
29.4 N {3 kg}
---
23.5 N {2.4 kg}
Item
PC400LC-7L
Repair limit Free length Installed load
Torque Nm
Torque lbf ft
16. Valve
372.7 - 411.9
274.8 - 303.8
17. Valve
176.6 - 196.2
130.2 - 144.7
18. Valve
137.3 - 156.9
101.2 - 115.7
If damaged or deformed, replace spring
10-57
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 (9/9)
1. Unload valve
9. LS bypass plug
2. Main relief valve
10. Screw
3. Pump merge-divider valve (Main)
11. Poppet
4. Return spring
12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS)
13. Spring (Pressure reducing valve main)
6. Return spring
14. Valve (Pressure reducing valve)
7. Valve (Sequence valve)
15. Spring (Safety valve)
8. Spring (Sequence valve)
16. Ball
10-58
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Unit: mm No.
Check item
Criteria
Remedy
Standard size 17
Check valve spring
Repair limit
Free length x OD
Installed length
Installed load
Free length
Installed load
11.5 x 4.6
8.5
1.5 N {0.15 kg}
1.2 N {0.12 kg}
18
Spool return spring
46.6 x 21.8
3.3
156.8 N {16.0 kg}
125.5 N {12.8 kg}
19
Spool return spring
64.5 x 32.3
63
177.5 N {18.1 kg}
142.0 N {14.5 kg}
20
Sequence valve spring
70.9 x 18.0
59
199.8 N {20.4 kg}
160.0 N {16.3 kg}
Item
PC400LC-7L
Torque Nm
If damaged or deformed, replace spring
Torque lbf ft
21. Plug
67.5 - 85.3
49.7 - 62.9
22. Valve
147.1 - 186.3
108.4 - 137.4
23. Valve
49 - 58.8
36.1 - 32.5
24. Valve
34.3 - 44.1
25.2 - 32.5
25. Valve
147.1 - 186.3
108.4 - 137.4
26. Valve
66 - 82
48.6 - 60.4
27. Valve
19.6 - 27.5
14.4 - 20.2
10-59
STRUCTURE AND FUNCTION 12 MAIN
HYDRAULIC SYSTEM
RELIEF VALVE
1. Spring 2. Poppet
Function •
The relief valve set pressure is set to 2 stages. When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.
Operation • •
The relief valve set pressure is determined by the installed load of spring (1). (First stage) It is unnecessary to set the first and second stage individually. The second stage is set when the first stage is set.
1.
When pilot pressure P is OFF: Low-pressure setting. The set pressure is determined by the installed load of spring (1).
2.
When pilot pressure P is ON: High-pressure setting. In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter (d1) so the set pressure becomes higher.
10-60
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-61
STRUCTURE AND FUNCTION 12 CLSS
HYDRAULIC SYSTEM
(CLOSED CENTER LOAD SENSING SYSTEM)
Features •
CLSS stands for Closed Center Load Sensing System, and has the following features. A. Fine control not influenced by load. B. Control enabling digging even with fine control. C. Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations. D. Energy saving using variable pump control.
Structure • •
The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. The main pump body consists of the pump itself, the PC valve and LS valve.
10-62
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Basic principle 1.
Control of pump swash plate • The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure ∆PLS (the difference between pump pressure PP and control valve outlet port LS pressure ∆PLS) (load pressure of actuator) is constant. (LS pressure ∆PLS = Pump discharge pressure PP – LS pressure PLS)
•
If LS differential pressure ∆PLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.
PC400LC-7L
10-63
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. Pressure compensation • A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. • When two actuators are operated together, this valve acts to make pressure difference ∆P between the upstream (inlet port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure). In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of opening S1 and S2 of each valve.
10-64
PC400LC-7L
STRUCTURE AND FUNCTION 12 SELF
HYDRAULIC SYSTEM
PRESSURE REDUCING VALVE
Function •
This value reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves, PPC valves, etc.
Operation 1.
When engine is stopped. • Poppet (11) is pressed by spring (12) against the seat and port PR is not connected to TS. • Valve (14) is pressed by spring (13) against the left side and port P2 is connected to PR. • Valve (7) is pressed by spring (8) against the left side and port P2 is not connected to A2.
PC400LC-7L
10-65
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. When in neutral or load pressure P2 is low (When boom is lowered and arm is in IN position and they are moving down under own weight) Remark When load pressure A2 is lower than self pressure reducing valve output pressure PR. • Valve (7) receives the force of spring (8) and PR pressure (which is 0 MPa {0 kg/cm2} when the engine is stopped) in the direction to close the circuit between ports P2 and A2. If the hydraulic oil flows in port P2, the fdx P2 pressure becomes equal to the total of the force of spring (8) and the value of area of ød × PR pressure, then the area of the pass between ports P2 and A2 is so adjusted that the P2 pressure will be kept constant above the PR pressure. • If the PR pressure rises above the set level, puppet (11) opens and the hydraulic oil flows from the PR port through orifice “a” in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice “a” in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.
3.
When load pressure P2 is high • If load pressure A2 rises and the pump discharge increases because of operation of the work equipment, the fdx P2 pressure rises higher than the total of the force of spring (8) and the value of ød × PR pressure, and then valve (7) moves to the right stroke end. • As a result, the area of the pass between ports P2 and A2 increases and the pass resistance lowers and the loss of the engine power is reduced. • If the PR pressure rises above the set pressure, poppet (11) opens and the hydraulic oil flows from the PR port through orifice “a” in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice “a” in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.
10-66
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 4. When abnormal high pressure is generated • If the PR pressure on the self-pressure reducing valve rises abnormally high, ball (16) separates from the seat against the force of spring (15) and the hydraulic oil flows from output port PR to TS. Accordingly, the PR pressure lowers. By this operation, the hydraulic devices (PPC valves, solenoid valves, etc.) are protected from abnormal pressure.
PC400LC-7L
10-67
STRUCTURE AND FUNCTION 12 SWING
HYDRAULIC SYSTEM
MOTOR
KMF230ABE-5
B
: From swing lock solenoid valve
S
: From control valve
T
: To tank
MA
: From control valve
MB
: From control valve
10-68
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
Specifications Model
KMF230ABE-5
Theoretical displacement
229.4 cm3/rev 2 285+0.5 0 kg/cm
Safety valve set pressure
(396.8 +7.1 0 psi)
Rated revolving speed
1,413 rpm
Brake release pressure
19 ± 4 kg/cm2 (270.2 ±56.8 psi)
Torque Nm
Torque lbf ft
1.
Bolt
27 - 34
19.9 - 25.0
2.
Bolt
98.1 - 122.6
72.3 - 90.4
PC400LC-7L
10-69
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
1. Brake spring
8. Housing
15. Safety valve
2. Drive shaft
9. Piston
16. Check valve
3. Spacer
10. Cylinder block
17. Shuttle valve
4. Case
11. Valve plate
5. Disc
12. Reverse prevention valve
6. Plate
13. Center shaft
7. Brake piston
14. Center spring
10-70
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Unit: mm No.
Check item
Criteria
Remedy
Standard size 18
19
Check valve spring
Shuttle valve spring
Repair limit
Installed length
Installed load
Free length
Installed load
66.5 x 25.6
45
6.96 N {0.71 kg}
5.59 N {0.57 kg}
---
24.5 x 11.6
14.5
7.45 N {0.76 kg}
5.98 N {0.61 kg}
---
Free length x OD
Torque Nm
Torque lbf ft
20. Valve
294 - 392
216.8 - 289.1
21. Valve
490.5 - 608.2
361.7 - 448.5
22. Valve
176.5 - 215.8
130.1 - 159.1
PC400LC-7L
If damaged or deformed, replace spring
10-71
STRUCTURE AND FUNCTION 12 RELIEF
HYDRAULIC SYSTEM
VALVE
1.
Outline The relief portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).
2.
Function When the swing is stopped, the outlet port circuit of the motor from the control valve is closed, but the motor continues to rotate under inertia, so the pressure at the output side of the motor becomes abnormally high, and this may damage the motor. To prevent this, the abnormal high pressure oil is relieved to port S from the outlet port of the motor (high-pressure side) to prevent any damage.
3.
Operation A. When starting swing When the swing control lever is operated to swing right, the pressure oil from the pump passes through the control valve and is supplied to port MA. As a result, the pressure at port MA rises, the starting torque is generated in the motor, and the motor starts to rotate. The oil from the outlet port of the motor passes from port MA through the control valve and returns to the tank. (Fig. 1) B. When stopping swing • When the swing control lever is returned to neutral, the supply of pressure oil from the pump to port MA is stopped. With the oil from the outlet port of the motor, the return circuit to the tank is closed by the control valve, so the pressure at port MB rises. As a result, rotation resistance is generated in the motor, so the braking effect starts. • If the pressure at port MB becomes higher than the pressure at port MA, it pushes shuttle valve A (4) and chamber C becomes the same pressure as port MB. The oil pressure rises further until it reaches the set pressure of relief valve (1). As a result, a high braking torque acts on the motor and stops the motor. (Fig.2) • When relief valve (1) is being actuated, the relief oil and oil from port S passes through check valve B (3) and is supplied to port MA. This prevents cavitation at port MA.
10-72
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 C. Operation of swing lock i.
When swing lock solenoid valve is deactivated When the swing lock solenoid valve is deactivated, the pressurized oil from the main pump is shut off and port B is connected to the tank circuit. As a result, brake piston (7) is pushed down by brake spring (1), discs (5) and plates (6) are pushed together, and the brake is applied.
ii.
When swing lock solenoid valve is activated When the swing lock solenoid valve is activated, the valve is switched and the pressure oil from the main pump enters port B and flows to brake chamber a. The pressure oil entering chamber a overcomes brake spring (1) and pushes brake piston (7) up. As a result, discs (5) and plates (6) are separated and the brake is released.
PC400LC-7L
10-73
STRUCTURE AND FUNCTION 12 REVERSAL
HYDRAULIC SYSTEM
PREVENTION VALVE
Outline diagram
Explanation of effect
10-74
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Outline This valve reduces the swing back generated in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. This is effective in preventing spillage of the load and reducing the cycle time when stopping the swing (the positioning ability is good and it is possible to move swiftly to the next job.
Operation 1.
When brake pressure is being generated at port MB Pressure MB passes through the notch and goes to chamber d, spool (5) pushes spring (6) according to the difference in area D1 > D2, moves to the left, and MB is connected to e. When this happens, pressure MA is below the set pressure of spring (3), so spool (2) does not move. For this reason, the pressure oil is closed by spool (2), and the braking force is ensured.
2.
After motor stops • The motor is reversed by the closing pressure generated at port MB. (1st reversal) When this happens, reversal pressure is generated at port MA. Pressure MA goes to chamber a, so spool (2) pushes spring (3) and moves to the right, and MA is connected to B. At the same time, b is connected to f through the drill hole in spool (5), so the reversal pressure at port MA is bypassed to port T to prevent the 2nd reversal.
PC400LC-7L
10-75
STRUCTURE AND FUNCTION 12 CENTER
HYDRAULIC SYSTEM
SWIVEL JOINT
1. Cover
A1
: To LH travel motor port PB
T2
: To tank
2. Body
A2
: From control valve port A2
T1
: From LH and RH travel motors port T
3. Slipper seal
C1
: To RH travel motor port PA
D2
: From control valve port B5
4. O-ring
B2
: From control valve port B2
B1
: To LH travel motor port PA
5. Shaft
D1
: To RH travel motor port PB
C2
: From control valve port A5
E
: To LH and RH travel motors port P
Unit: mm No. 6
Check item Clearance between rotor and shaft
10-76
Criteria
Remedy
Standard Size
Standard clearance
Repair limit
80
---
---
If damaged or deformed, replace spring
PC400LC-7L
STRUCTURE AND FUNCTION 12 TRAVEL
HYDRAULIC SYSTEM
MOTOR
KMV280ADT
Port T (to tank) Port PA (from control valve) Port PB (from control valve) Port PI (from travel speed solenoid valve)
Item
Specifications Model: Theoretical delivery
KMV200ADT Min 130 cm3/rpm Max 200 cm3/rpm
Brake releasing pressure:
10 ± 4 kg/cm2 (142.2 ±56.8 psi)
Travel speed switching pressure:
8 +4 kg/cm2 (113.7 +56.8 -14.2 psi) (Differentical pressure)
Torque Nm
Torque lbf ft
1. Bolt
490 - 608
361.4 - 448.4
2. Valve
294 - 343
216.8 - 252.9
PC400LC-7L
10-77
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
1. Output shaft
8. Regulator piston
15. Safety valve
2. Motor case
9. Plate
16. Rgegulator valve
3. Piston
10. Disc
17. Spring
4. Cylinder
11. Check valve spring
18. Brake spring
5. Valve plate
12. Check valve
19. Brake piston
6. End cover
13. Counterbalance valve
20. Check valve
7. Slow return valve
14. Spool return spring
10-78
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Unit: mm No.
Check item
Criteria Standard size
21
Spool return spring
22
Check valve spring
23
Regulator piston spring
Freelength x OD
Remedy Repair limit
Installed length Installed load Free length
Installed load
62.52 x 32.0
42.0
426.6N {43.5 kg}
62.5 x 20.0
39.0
3.04 N {0.31 kg}
2.45 N {0.25 kg}
55.0x 9.0
50.0
98.1 N {10 kg}
78.5 N {8 kg}
Torque Nm
Torque lbf ft
24. Valve
24.5 - 34.3
18.0 - 25.2
25. Valve
65.7 - 82.4
49.7 - 60.7
26. Valve
19.6 - 27.5
14.4 - 20.2
27. Bolt
147.1 - 186.3
108.4 - 137.4
28. Valve
373 - 466
275.1 - 343.7
29. Valve
324 - 402
238.9 - 296.5
PC400LC-7L
341.3 N {32.2 kg}
Replace spring if dam aged or deformed
10-79
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 1. Operation of motor A. At low speed (motor swash plate angle at maximum)
• • • •
10-80
The solenoid valve is de-energized, so the pilot pressure oil from the main pump does not flow to port P. For this reason, regulator valve (16) is pushed down by spring (17). The main pressure oil from the control valve pushes check valve (20), goes to end cover (6), in regulator valve (16) and acts also on chamber b. When this happens, the propulsion force of regulator piston (8) acts in a downward direction. As a result, valve plate (5) and cylinder block (4) move in the maximum swash plate angle direction, the motor capacity becomes maximum, and the system is set to low speed.
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 B. At high speed (motor swash plate angle at minimum)
• • • •
When the solenoid valve is energized, the pilot pressure oil from the main pump flows to port P, and pushes regulator valve (16) up. As a result, the oil in chamber b is drained inside the case, and acts on chamber a via regulator valve (16). Because of this, the propulsion force of the pressure oil at chamber a of regulator piston (8) acts in a upward direction. As a result, valve plate (5) and cylinder block (4) move in the minimum swash plate angle direction, the motor capacity becomes minimum, and the system is set to high travel speed.
PC400LC-7L
10-81
STRUCTURE AND FUNCTION 12 PARKING 1.
HYDRAULIC SYSTEM
BRAKE
When starting to travel
Operation When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (13), opens the circuit to the parking brake, and flows into chamber e of brake piston (19). It overcomes the force of spring (18), and pushes piston (19) to the right. When this happens, the force pushing plate (9) and disc (10) together is lost, so plate (9) and disc (10) separate and the brake is released.
10-82
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. When stopping travel
Operation When the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber e of brake piston (19) passes through the throttle of slow return valve (7) until spool (13) of the counterbalance valve returns to neutral. When spool (13) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from the throttle f of brake piston (19) and brake piston (19) is pushed fully to the left by spring (18). As a result, plate (9) and disc (10) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (7) when the brake piston returns, and this ensures that the brake is applied after the machine stops.
PC400LC-7L
10-83
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 3. Operation of brake valve The brake valve consists of a check valve (1), counterbalance valve (2), and safety valve (3) in a circuit as shown in the diagram on the right. The function and operation of each component is as given below. A. Counterbalance valve, check valve Function When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount).
i.
10-84
Operation when pressurized oil is supplied When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open check valve (12a) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (12b) and spool (13), so the pressure at the supply side rises.
PC400LC-7L
STRUCTURE AND FUNCTION 12
HYDRAULIC SYSTEM
The pressurized oil at the supply side flows from orifice E1 in spool (13) and orifice E2 in the piston to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure, spool (13) is pushed to the right. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate.
ii.
Operation of brake when traveling downhill If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber S1 through orifices E1 and E2 will also drop. When the pressure in chamber S1 drops below the spool switching pressure, spool (13) is returned to the left by spring (14), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump.
B. Safety valve (2-direction operation, 2-stage set safety valve) Function When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve. However, the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment.
PC400LC-7L
10-85
STRUCTURE AND FUNCTION 12
HYDRAULIC SYSTEM
Operation in both directions i.
When pressure in chamber MB has become high (when rotating clockwise) When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [x/4 (D12 – D2) × pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the opposite side.
ii.
When stopping travel (low-pressure setting) When the travel lever is placed at neutral, the pressure in chamber PA drops and counterbalance valve spool (13) returns to the neutral position. While the counterbalance valve spool (13) is returning to the neutral position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left, and the set load becomes smaller. Because of this, the set pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing speed.
[Set pressure of safety valve] When starting or traveling: High-pressure setting 410 kg/cm2 (0.583 psi)
10-86
When stopping: Low-pressure setting 27.5 kg/cm2 (0.0391 psi)
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 iii. When pressure in chamber MA has become high (when rotating counterclockwise) When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia.
If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [x/4 (D32 – D12) × pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the opposite side.
Operation of mechanism for varying set pressure A. When starting travel (high-pressure setting) When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (19), and opens the pilot circuit to the safety valve. The oil passes from chamber G to passage H and flows into chamber J, pushes the piston to the right, and compresses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a large draw bar pull is made available.
PC400LC-7L
10-87
STRUCTURE AND FUNCTION 12 TRAVEL
HYDRAULIC SYSTEM
JUNCTION VALVE
Function •
This valve connects both travel circuits to each other so that the hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. • When the machine is steered, outside pilot pressure PST closes the travel junction valve to secure high steering performance. Operation When pilot pressure is turned ON •
If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (14), travel junction spool (13) moves to the left stroke end and the junction circuit between port PTL (Left travel circuit) and PTR (Right travel circuit) is closed.
10-88
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 When pilot pressure is turned OFF • •
If pilot pressure PST from the solenoid valve is 0, travel junction spool (13) is pressed by the force of spring (14) against the right side and the pass between ports PTL and PTR is open. If the oil flow rates in both travel motors become different from each other, the oil flows through the route between port PTL, travel junction spool (13), and port PTR so that the oil flow rates will be equalized again.
PC400LC-7L
10-89
STRUCTURE AND FUNCTION 12 CONTROL
HYDRAULIC SYSTEM
VALVE
Lever positions 1. Travel PPC valve
8. Solenoid valve
(1) Hold
(9) Swing RIGHT
2. Service PPC valve
9. Accumulator
(2) Boom RAISE
(10) Swing LEFT
3. Service pedal
10. Control valve
(3) Boom LOWER
(11) Neutral
4. L.H. travel lever
11. Hydraulic pump
(4) Bucket DUMP
(12) Travel REVERSE
5. R.H. travel lever
12. Junction box
(5) Bucket CURL
(13) Travel FORWARD
6. R.H. PPC valve
13. L.H. work equipment control lever
(6) Hold
7. R.H. work equipment control lever
14. L.H. PPC valve
(7) Arm IN (8) Arm OUT
10-90
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-91
STRUCTURE AND FUNCTION 12 TRAVEL
HYDRAULIC SYSTEM
PPC SHUTTLE VALVE
Function •
If boom RAISE or arm IN are operated when the machine is traveling, the stroke of the spools for the boom and arm is controlled by the travel PPC pressure and this limits the flow of oil to the boom and arm cylinders. • When the boom and arm stroke is controlled, the travel PPC pressure passes through the circuit inside the control valve to actuate the system. Operation 1.
When travel is at neutral • Stroke limit signal chambers a and b are connected to the travel PPC valve through orifices (5) and (6) in pistons (3) and (4) inside the travel spring case, and the is drained. • When arm IN is operated, spool (1) moves to the right by stroke (st0) to a point where it contacts the end face of spring case (2). • When boom RAISE is operated, spool (9) moves to the left by stroke (st3) to a point where it contacts the end face of spring case (10).
10-92
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
PC400LC-7L
10-93
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. When travel is operated • When the travel lever is operated to right REVERSE (or FORWARD), the right (REVESE (or FORWARD) PPC pressure pushes spool (7) to the left (or right). • Spool (7) pushes piston (3), orifice (5) closes, and stroke limit signal chamber a is shut off from the drain circuit of the travel PPC valve. • At the same time, the right REVERSE (or FORWARD) PPC pressure passes through orifice (6) in piston (4), acts on the right end face of piston (8), and pushes piston (8) to the left. • If arm IN is operated, spool (1) moves to the right, but the maximum stroke of the spool is limited by the amount of movement st2 of piston (8) and becomes st1. • If boom RAISE is operated, spool (9) tries to move to the left, but the travel PPC pressure enters stroke control signal chamber b, so the spool does not move.
10-94
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
WORK EQUIPMENT • SWING PPC VALVE
P
: From self pressure reducing valve
P1
:Left PPC: Arm OUT / Right PPC: Boom LOWER
T
: To tank
P2
:Left PPC: Arm IN / Right PPC: Boom RAISE
P3
:Left PPC: Swing LEFT / Right PPC: Bucket CURL
P4
:Left PPC: Swing RIGHT / Right PPC: Boom LOWER
PC400LC-7L
10-95
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
1. Spool
7. Joint
2. Metering spring
8. Plate
3. Centering spring
9. Retainer
4. Piston
10. Body
5. Disc
11. Filter
6. Nut (For connection of lever)
Unit: mm No.
Check item
Criteria
Remedy
Standard size 12
Centering spring (For P3 and P4)
Free length x OD Installed length
Repair limit Installed load
Free length
42.4 x 15.5
34
17.1 N {1.8 kg}
---
13
Centering spring (For P1 and P2)
44.4 x 15.5
34
29.4 N {3.0 kg}
---
14
Metering spring
26.5 x 8.2
24.9
16.7 N {1.7 kg}
---
10-96
Installed load 13.7 N {1.4 kg} If damaged or deformed, 23.5 N replace spring {2.4 kg} 13.7 N {1.4 kg}
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
Torque Nm
Torque lbf ft
15. Bolt
11.8 - 14.7
8.7 - 10.8
16. Nut
69 - 88
50.8 - 64.9
17. Joint
34 - 44
25.0 - 32.4
18. Nut
39 - 49
28.7 - 36.1
19. Plug
6 - 11
4.4 - 8.1
20. Plug
4-9
2.9 - 6.6
PC400LC-7L
10-97
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Operation 1.
At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1)
2.
During fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P1. When this happens, spool (1) moves up or down so that force of metering spring (2) is balanced with the pressure at port P1. The relationship in the position of spool (1) and body (10) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to position where the pressure in chamber A (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced.
10-98
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 3. During fine control (when control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil.
4.
At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D.
PC400LC-7L
10-99
STRUCTURE AND FUNCTION 12 TRAVEL
10-100
HYDRAULIC SYSTEM
PPC VALVE
P
: From self pressure reducing valve
P3 : Right reverse
T
: To tank
P4 : Right forward
P1
: Left reverse
P5 : Travel signal
P2
: Left forward
P6 : Steering signal
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
PC400LC-7L
1. Plate
6. Centering spring
2. Body
7. Valve
3. Piston
8. Damper
4. Collar
9. Steering signal
5. Metering spring
10. Steering signal valve spring
10-101
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
No.
Check item
Criteria Installed length
Installed load
26.5 x 8.15
24.7
16.7 N {1.7 kg}
13.7 N {1.4 kg} 86.3 N {8.8 kg} 7.1 N {0.72 kg}
1
Metering spring
2
Centering spring
48.1 x 15.5
32.5
108 N {11 kg}
3
Steering signal spring
12.8 x 7.3
8.5
8.8 N {0.9 kg}
10-102
Remedy
Free length x OD
Free length Installed load If damaged or deformed, replace spring
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
Torque Nm
Torque lbf ft
4.
Bolt
28 ±3
20.6 ±2.2
5.
Bolt
23.5 ±3.9
17.3 ±2.8
6.
Bolt
30.9 ±2.5
22.7 ±2.5
7.
Plug
29.4 ±4.9
21.6 ±3.6
PC400LC-7L
10-103
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Travel signal/Steering function •
Travel signal If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5. • Steering signal If the operation quantities of both levers are different from each other as in the steering operation, the higher one of the PPC output pressures on both sides is output as the steering signal. Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neutral. Accordingly, if the machine is being steered is judged by the signal of port P6. Operation 1.
While in NEUTRAL The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not output.
10-104
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. While travelling straight (The following drawing shows the circuit for traveling straight forward.) While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right spring chamber (I) of steering signal valve (J) are set high. Accordingly, the steering signal valve is kept in neutral and the steering signal (Port P6) is not output.
PC400LC-7L
10-105
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 3. When steered or pivot-turned (The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.) If the operation quantities of both levers are different from each other as in the steering operation (If the difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal. In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2. The pressure in right spring chamber (l) is P4. If (P4 – P2) × (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.
10-106
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 4. When pivot-turned (The following drawing shows the circuit for left reverse and right forward operation.) While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and outputs the steering signal (port P6).
PC400LC-7L
10-107
STRUCTURE AND FUNCTION 12 SERVICE
HYDRAULIC SYSTEM
PPC VALVE
★ Refer to the section WORK EQUIPMENT • SWING PPC VALVE for function of this valve.
Unit: mm No.
Check item
Criteria
Remedy
Standard size 9
10
Centering spring
Metering spring
11. Bolt
10-108
Free length x OD Installed length
Repair limit Installed load
Free length Installed load
33.9 x 15.3
28.4
124.5 N {12.7 kg}
---
100 N {10.2 kg}
22.7 x 8.1
22
16.7 N {1.7 kg}
---
13.7 N {1.4 kg}
Torque Nm
Torque lbf ft
13.2 ±1.4
9.7 ±1.0
If damaged or deformed, replace spring
PC400LC-7L
STRUCTURE AND FUNCTION 12 SOLENOID
HYDRAULIC SYSTEM
VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid valves.
1. PPC lock solenoid valve
T
2. Travel junction solenoid valve
A1 : To No. 1 pump (CO valve)
3. Merge-divider solenoid valve
A2 : To main valve (Travel junction valve) ACC : To accumulator
4. Travel speed solenoid valve
A3 : To main valve (Merge-divider valve)
5. Swing brake solenoid valve
A4 : To both travel motors
6. Machine push-up solenoid valve
A5 : To swing motor
8. 2-stage relief solenoid valve
A6 : To 2-stage safety valve at boom cylinder head
PC400LC-7L
: To tank
A8
: To main valve (2-stage relief valve)
P1
: From main pump
10-109
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
Operation WHEN SOLENOID IS TURNED OFF •
Since the signal current does not flow from the controller, solenoid (3) is turned off. Accordingly, spool (4) is pressed by spring (6) against the left side. By this operation, the pass from P to A is closed and the hydraulic oil from the main pump does not flow into the actuator. At this time, the oil from the actuator is drained through ports A and T into the tank.
WHEN SOLENOID IS TURNED ON •
The signal current flows from the controller to solenoid (3), and the latter is turned on. Accordingly, spool (4) is pressed against to the right side. By this operation, the hydraulic oil from the main pump flows through port P and spool (4) to port A, then flows into the actuator. At this time, port T is closed and the oil does not flow into the tank.
10-110
PC400LC-7L
STRUCTURE AND FUNCTION 12 PPC
HYDRAULIC SYSTEM
ACCUMULATOR
PC400LC-7L
10-111
STRUCTURE AND FUNCTION 12 RETURN
HYDRAULIC SYSTEM
OIL FILTER
FOR BREAKER
Specifications
10-112
1. Drain plug
Rated pressure
: 70 kg/cm2 (995.6 psi)
2. Element
Flow
: 200 L/min (52.8 gal)
3. Case
Relief valve cracking pressure:
3.5 ± 0.5 kg/cm2 (49.7 ±7.1 psi)
4. Head cover
Filter mesh size
: 6 µm
5. Relief valve
Filtering area
: 4,570 cm2 (708 in 2)
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-113
STRUCTURE AND FUNCTION 12 BOOM
HYDRAULIC SYSTEM
HYDRAULIC DRIFT PREVENTION VALVE
Function •
When the boom lever is not being operated, these valves act to prevent the oil at the boom bottom from leaking from spool (1) and prevent the boom from moving down.
Operation 1.
Boom RAISE When the boom RAISE is operated, the main pressure oil acts in the left direction on ring shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When it overcomes the force of spring (4), poppet (5) moves to the left. In addition, the main pressure oil acts in the right direction on seat diameter d3 of valve (6). When it overcomes the force of spring (4), valve (6) moves to the right. As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.
10-114
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
PC400LC-7L
10-115
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. Boom at HOLD • When the boom is raised and the control lever is returned to the HOLD position, the oil that has flowed into the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of valve (6). • Valve (6) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. As a result, the boom is held in position.
10-116
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
PC400LC-7L
10-117
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 3. Boom LOWER When boom LOWER is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the boom flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B goes to port A and flows to the control valve.
10-118
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
ARM HYDRAULIC DRIFT PREVENTION VALVE (If equipped) Function •
When the arm lever is not being operated, these valves act to prevent the oil at the arm head from leaking from spool (1) and prevent the arm from moving down.
Operation 1.
Arm DUMP When the arm DUMP is operated, the main pressure oil acts in the left direction on ring shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When it overcomes the force of spring (4), poppet (5) moves to the left. As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.
PC400LC-7L
10-119
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. Arm at HOLD • When the arm DUMP is operated and the control lever is returned to the HOLD position, the oil that has flowed into the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at the head of the arm cylinder are shut off. • At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the head of the arm cylinder are shut off. • In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of valve (6). As a result, the arm is held in position.
10-120
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 3. Arm IN • When arm IN is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber b inside the poppet is drained through orifice c. The oil at the head end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B goes to port A and flows to the control valve.
PC400LC-7L
10-121
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 4. When abnormally high pressure is generated • If abnormally high pressure is generated in the boom cylinder bottom circuit, the hydraulic oil in port B pushes check valve (6) open, then safety valve (3) operates. • If the hydraulic drift prevention valve for the arm cylinder head circuit is installed (optional), the hydraulic oil in the boom cylinder bottom circuit or that in the arm cylinder head circuit, having higher pressure, pushes check valve (6) open, then safety valve (3) operates.
10-122
PC400LC-7L
STRUCTURE AND FUNCTION 12 QUICK
HYDRAULIC SYSTEM
RETURN VALVE
Function When arm OUT is operated, this valve reduces the pressure loss of the large amount of oil returning from the cylinder bottom. Operation 1.
Arm at OUT When arm OUT is operated, the pilot pressure from the PPC valve pushes pilot spool (1), and the pressure oil from chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port A, the pressure at port A and acts on ring shaped area C (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) moves to the left and the pressure oil from port A goes to port B. From port B, the oil is drained directly to the tank.
PC400LC-7L
10-123
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 2. Arm at HOLD The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at the bottom end of the arm acts in the right direction on ring-shaped area C (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) is closed by the total of this force and the force of spring (3), so port A and port B are shut off.
10-124
PC400LC-7L
STRUCTURE AND FUNCTION 12 LIFT
HYDRAULIC SYSTEM
CHECK VALVE
Function This valve applies back pressure to the drain circuit to prevent generation of negative pressure on the hydraulic devices for the work equipment (motors, cylinders, etc.) Operation 1.
While engine is stopped Any oil is not supplied from the pump to the self pressure reducing valve and valve (1) is pressed by only the force of spring (2) toward the right and drain circuit “a” of the control valve is connected through orifice “b” of valve (1) to port T.
2.
While engine is running • Output pressure PR of the self pressure reducing valve is applied through the control valve to spring chamber “c” of the back pressure valve. • Output pressure PR applied to spring chamber “c” is applied to the left end of valve (1) (area of ød) to push valve (1) to the right. • At this time, pressure PA of drain circuit “a” of the control valve is applied to the right end of valve (1) (area of ød1) to push valve (1) to the left. • Valve (1) is balanced so that the back pressure PA will be as follows. PA = {(Area of ød) × PR + Force of spring (2)} / (Area of ød1)
PC400LC-7L
10-125
STRUCTURE AND FUNCTION 12 ATTACHMENT
HYDRAULIC SYSTEM
CIRCUIT SELECTOR VALVE
1. Spool
V
:To control valve
2. Spring
T
:To hydraulic tank
ATT
:To attachment
ACC
:To accumulator
P1
:From attachment circuit selector solenoid valve
TS
:To hydraulic tank
Unit: mm No.
Check item
Criteria Standard size
3
Spool return spring
4.
10-126
Bolt
Remedy Repair limit
Free length x OD
Installed length
Installed load
132.0 x 29
114.5
833 N {85.0 kg}
spring if any Free length Installed load Replace damages or deformations are found 666 N --{68.0 kg}
Torque Nm
Torque lbf ft
59 - 74
43.5 - 54.5
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Function When a breaker is installed, the return oil from the breaker does not pass through the main valve, but returns directly to the hydraulic tank. When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected. Operation 1.
When attachment other than breaker is installed Spool (1) is pushed fully to the left by the force of spring (2), ATT port and port V are interconnected, and ATT port and port T are shut off, so the attachment and main valve are interconnected.
2.
When breaker is installed When the pilot pressure from the attachment circuit selector solenoid valve overcomes the force of spring (2), the spool (1) moves fully to the right. ATT port and port V are shut off and ATT port and port T are interconnected, so the oil returning from the breaker does not pass through the main valve, but passes through port T and returns directly to the hydraulic tank.
PC400LC-7L
10-127
STRUCTURE AND FUNCTION 12 HOLDING
HYDRAULIC SYSTEM
VALVE
Downward movement prevention valve (For boom and arm)
1.
10-128
Bolt
V
:From control valve
T
:To hydraulic tank
CY
:To hydraulic cylinder
PI
:From PPC valve
PCY
:Fror pressure pickup and equalizer circuits
Torque Nm
Torque lbf ft
30.9 ±3.4
22.7 ±2.5
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
1. Pilot spool
4. Safety valve
2. Spring (1st stage of spool)
5. Check valve
3. Spring (2nd stage of spool)
6. Spring
Unit: mm No.
Check item
Criteria
Remedy
Standard size 7
Check valve spring
Free length x OD Installed length
Repair limit Installed load
20.8 x 12.2
13.5
12.7 N {1.3 kg}
Free length Installed load ---
9.8 N {1.0 kg}
8
Spool return spring
41.1 x 9.6
35
58.8 N {6.0 kg}
---
47.0 N {4.8 kg}
9
Spool return spring
41.9 x 25.8
41
78.4 N {8.0 kg}
---
62.7 N {6.4 kg}
10
Spool return spring
43.2 x 25.4
41
125.4 N {12.8 kg}
---
100.4 N {10.2 kg}
Torque Nm
Torque lbf ft
11. Valve
196 ±19.6
144.5 ±14.4
12. Valve
147 ±9.8
108.4 ±7.2
PC400LC-7L
If damaged of deformed, replace spring
10-129
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 Function If the piping between the main valve and a work equipment cylinder bursts, this valve prevents the oil from flowing back from the work equipment cylinder to prevent sudden fall of the work equipment. Operation 1.
When the work equipment is in neutral [When piping is normal] • Check valve (5) is closed by the work equipment cylinder holding pressure applied through port CY to chamber “b”. • When the work equipment is in neutral, no pilot pressure is applied from the PPC valve to port Pi. Accordingly, pilot spool (1) is moved to the left end by the force of springs (2) and (3), then chambers “a” and “b” are shut of from each other. • By this operation, oil does not flow between the main valve and the work equipment cylinder, thus the work equipment cylinder held. • If the pressure in the work equipment cylinder rises abnormally high, work equipment cylinder holding pressure Pb operates safety valve (4). • In the downward movement prevention valves for the boom, chambers “b” of both of them are connected through ports PCY. Accordingly, even if the leakages are different between both valves, the pressures in both chambers “b” become the same. [When piping bursts] Even if piping A between the main valve and work equipment cylinder bursts, chamber “a” is shut off from chamber “b” as in the case where the piping is normal. Accordingly, the work equipment cylinder is held.
2.
When oil is sent from main valve to cylinder [When piping is normal] • If pressure Pa of the oil sent from the main valve to chamber “a” is higher than the total of pressure Pb in chamber “b” connected to the work equipment cylinder and the force of spring (6), check valve (5) opens and chambers and the oil flows from the main valve to the work equipment cylinder.
[When piping bursts] • If piping A between the main valve and the work equipment cylinder bursts, the oil in chamber “a” flows out through the burst part and pressure Pa in chamber “a” lowers. • If Pa lowers below the total of pressure Pb in chamber “b” and the force of spring (6), check valve (5) closes and chambers “a” and “b” are shut off from each other. Accordingly, pressure Pb in the cylinder is held and the work equipment does not fall suddenly.
10-130
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12 3. When oil is returned from work equipment cylinder to main valve [When piping is normal] • The work equipment cylinder holding pressure is applied to chamber “b” and check valve (5) closes. • The pilot pressure from the PPC valve is applied to port Pi. If it is higher than the force of spring (2) (area of ød), spool (1) moves to the right standby position (1st-stage stroke). • At this time, chambers “a” and “b” are not connected to each other. • If the pilot pressure rises higher than the force of spring (3) (area of ød), spool (1) moves further to the right and chambers “a” and “b” connected to each other (2nd-stage stroke). • Accordingly, the oil is returned from the work equipment cylinder to the main valve.
[When piping bursts] • If piping A between the main valve and work equipment cylinder bursts, the oil in chamber “a” flows out through the burst part. Since the oil supplied from chamber “b” to chamber “a” flows through opening “c” of spool (1), however, the cylinder does not fall suddenly.
PC400LC-7L
10-131
STRUCTURE AND FUNCTION 12 HYDRAULIC
HYDRAULIC SYSTEM
CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-132
PC400LC-7L
STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
2
3
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing
Clearance between cylinder bottom support pin and bushing
Remedy
Shaft
Hole
Standard clearance
Clearance limit
110
-0.036 -0.090
+0.261 +0.047
0.083 0.351
0.412
120
-0.036 -0.090
+0.263 +0.048
0.084 0.353
0.412
Bucket
100
-0.036 -0.090
+0.257 +0.047
0.083 0.347
0.447
Boom
110
-0.036 -0.090
+0.169 +0.100
0.136 0.259
---
Arm
110
-0.036 -0.090
+0.169 +0.100
0.136 0.259
---
Bucket
100
-0.036 -0.090
+0.187 +0.097
0.133 0.277
---
Boom
100
-0.036 -0.090
+0.190 +0.070
0.106 0.280
---
Arm
110
-0.036 -0.090
+0.195 +0.099
0.135 0.285
---
Bucket
100
-0.036 -0.090
+0.187 +0.097
0.133 0.277
---
Cylinder
1
Criteria Tolerance
Boom Arm
Standard size
Replace bushing
Replace pin or bushing
BOOM CYLINDER Torque Nm
Torque lbf ft
4.
530 ±78.5
390.9 ±57.9
5.
294 ±29.4
216.8 ±21.6
6.
58.9 ±73.6
43.5 ±54.2
ARM CYLINDER
4.
Bolt
Torque Nm
Torque lbf ft
892 ±137
657.9 ±101.0
5.
Piston
294 ±29.4
216.8 ±21.6
6.
Set screw
58.9 ±73.6
43.5 ±54.2
Torque Nm
Torque lbf ft
530 ±78.5
390.9 ±57.9
BUCKET CYLINDER
4.
Bolt
5.
Piston
294 ±29.4
216.8 ±21.6
6.
Set screw
58.9 ±73.6
43.5 ±54.2
PC400LC-7L
10-133
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
WORK EQUIPMENT
10-134
PC400LC-7L
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12 Unit: mm No.
1
Check item
Criteria
Clearance between connecting pin Standard size and bushing of revolving frame and boom
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
120
-0.036 -0.090
+0.173 +0.101
0.137 0.263
1.0
2
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
3
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
4
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
5
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
6
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
7
Bucket clearance (a)
0.5 - 1.0
8
Bucket clearance (b)
2.0
PC400LC-7L
Replace
Adjust shims
10-135
STRUCTURE AND FUNCTION 12 DIMENSION
10-136
WORK EQUIPMENT
ARM
PC400LC-7L
STRUCTURE AND FUNCTION
WORK EQUIPMENT
12
Unit: mm 1
-0.036 φ110+0.1 +0 / 0.090
2
φ129.3+1.5 0 / 126 ±1.2
3 4
-0.036 φ120+00.1/ -0.090
5
514.8
6
195
7
1,038
8
3,375
9
2,977.5
10
502
11
720
12
719
13
537.1
14
1,850
15 16 17 Arm as individual part 18 When press fitting bushing 19
-0.3 φ355+0.5 / 351-0.8 0
-0.036 φ100+0.1 0 / -0.090
φ371+10 / 370 ± 0.5 -0.036 φ100+0.1 0 / -0.090 0 355-0.5
370
Cylinder Min. stroke
1,870
Cylinder Max. stroke
3,140
PC400LC-7L
10-137 2
STRUCTURE AND FUNCTION 12 DIMENSION
10-138
WORK EQUIPMENT
OF BUCKET
PC400LC-7L
STRUCTURE AND FUNCTION 12
9
Unit: mm 1
534.1 ± 0.5
2
56.3 ± 0.5
3
96° 1’
4
537.1
5
1,839
6
190
7
---
8
62°× 1’ A
φ140.1 ± 8.1
B
φ130+0.063 0
C
φ100+0.1 0
10 11
371 +1 0
A
57
B
72
12 13 14 15
WORK EQUIPMENT
144 562.5+0.5 -2.5
φ26
A
φ165
B
---
16
φ230
17
146.1
18
137.6
19
R115
20
R85
21
410 ± 1
22
64
PC400LC-7L
10-139
STRUCTURE AND FUNCTION
AIR CONDITIONER
12
AIR CONDITIONER AIR CONDITIONER PIPING
1. Hot water pickup piping
A. Fresh air
2. Receiver tank
B. Recirculated air
3. Hot water return piping
C. Hot air/cold air
4. Condenser 5. Air conditioner compressor 6. Refrigerant piping 7. Air conditioner unit 8. Duct
10-140
PC400LC-7L
STRUCTURE AND FUNCTION
ENGINE CONTROL
12
ENGINE CONTROL OPERATION OF SYSTEM STARTING ENGINE When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
ENGINE SPEED CONTROL The fuel control dial sends signal voltages to the engine controller according to its angle. The engine controller sends drive signals to the supply pump according to the signal voltages received from the fuel control dial and controls the fuel injection pump to control the engine speed.
STOPPING ENGINE When the engine controller detects that the starting switch is at the OFF position, it cuts the signal to the supply pump drive solenoid to stop the engine.
PC400LC-7L
10-141
STRUCTURE AND FUNCTION 12 COMPONENTS
ENGINE CONTROL
OF SYSTEM
FUEL CONTROL DIAL
Function •
•
The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine controller. The hatched area in the graph on the right is the abnormality detection area and the engine speed is set at low idling.
10-142
PC400LC-7L
STRUCTURE AND FUNCTION 12 ENGINE
ENGINE CONTROL
CONTROLLER
PC400LC-7L
10-143
STRUCTURE AND FUNCTION
ENGINE CONTROL
Input 12 and output signals CN1 [CN-E11]
CN2 [CN-E12]
Pin No.
Signal name
Input/Output
Pin No.
Signal name
Input/Output
CN1-1
POWER (+24V constant)
CN2-1
GND
CN1-2
POWER (+24V constant)
CN2-2
NC
CN1-3
Model selection 1
CN2-3
NC
Input
CN1-4
GND
CN2-4
RS232C_1RX
Input
CN1-5
NC
Input
CN2-5
NC
CN1-6
NC
Output
CN2-6
NC
CN1-7
GND
CN2-7
NC
Input
CN1-8
GND
CN2-8
NC
Input
CN1-9
NC
CN2-9
Sensor 5V power supply 2
CN1-10
GND
CN2-10
Fuel control dial
Input
Input
Output Input
CN1-11
NC
Input
CN2-11
S_NET_SHIELD GND
CN1-12
NC
Output
CN2-12
CAN_SHIELD
CN1-13
Key switch (ACC)
Input
CN2-13
NC
Output
CN1-14
NC
Input
CN2-14
RS232C_1TX
Output
CN1-15
Engine oil pressure switch (For high pressure)
Input
CN2-15
G_SHIELD (GND)
CN1-16
Memory clear
Input
CN2-16
Ne_SHIELD (GND)
CN1-17
Model selection 3
Input
CN2-17
Fuel temperature sensor
Input
CN1-18
NC
Output
CN2-18
NC
Input
CN1-19
Key switch (ACC)
Input
CN2-19
Sensor 5V power supply 1
CN1-20
Starting switch (C)
Input
CN2-20
Boost pressure sensor
CN1-21
Engine oil pressure switch (For low pressure)
Input
CN2-21
S_NET (+)
Input/Output
CN1-22
Auto deceleration signal
Input
CN2-22
CAN0_L
Input/Output
CN1-23
Model selection 2
Input
CN2-23
NC
CN1-24
NC
Output
CN2-24
FWE_switch
Input
CN2-25
G pulse (ñ)
Input
CN2-26
Ne pulse (ñ)
Input
CN2-27
Coolant temperature sensor (High)
Input
CN2-28
NC
Input
CN2-29
Analog GND
CN2-30
NC
CN2-31
S_NET (+)
Input/Output
CN2-32
CAN0_H
Input/Output
CN2-33
NC
CN2-34
GND (232C_GND)
CN2-35
G pulse (+)
Input
CN2-36
Ne pulse (+)
Input
CN2-37
Coolant temperature sensor (Low)
Input
CN2-38
NC
Input
CN2-39
Analog GND
CN2-40
Common rail pressure sensor
10-144
Output Input
Input
Input
PC400LC-7L
STRUCTURE AND FUNCTION
ENGINE CONTROL
12 CN3 [CN-E13] Pin No.
Signal name
Input/Output
CN3-1
Power supply for power
CN3-2
Power supply for power
CN3-3
NC
CN3-4
NC
CN3-5
Injector #3 (+)
Output
CN3-6
Injector #2 (+)
Output
CN3-7
NC
Input
CN3-8
Output mode selection 1 (Test mode)
Input
CN3-9
Lever neutral flag (Test mode)
Input
CN3-10
Engine rotation pulse output
Output
CN3-11
Power GND
CN3-12
Supply pump 1 (+)
Output
CN3-13
Supply pump 2 (+)
Output
CN3-14
Injector #1 (+)
Output
CN3-15
Injector #3 (ñ)
Output
CN3-16
Injector #2 (ñ)
Output
CN3-17
NC
Input
CN3-18
Output mode selection 2 (Test mode)
Input
CN3-19
NC
CN3-20
Q command output
CN3-21
Power supply for power
CN3-22
Supply pump 1 (ñ)
Output
CN3-23
Supply pump 2 (ñ)
Output
CN3-24
Injector #1 (ñ)
Output
CN3-25
Injector #6 (+)
Output
CN3-26
Injector #4 (+)
Output
CN3-27
NC
Output
CN3-28
Auto deceleration flag (Test mode)
Input
CN3-29
NC
Input
CN3-30
GND
CN3-31
Power GND
CN3-32
Power GND
CN3-33
Injector #5 (ñ)
Output
CN3-34
Injector #5 (+)
Output
CN3-35
Injector #6 (ñ)
Output
CN3-36
Injector #4 (ñ)
Output
CN3-37
NC
Output
CN3-38
Auto deceleration control (Test mode)
Input
CN3-39
NC
Input
CN3-40
GND
PC400LC-7L
Input
Input Output
10-145
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12
ELECTRONIC CONTROL SYSTEM CONTROL FUNCTIONS
★ For the self-diagnosis function, see “TROUBLE SHOOTING”
10-146
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12
MEMORANDUM
PC400LC-7L
10-147
STRUCTURE AND FUNCTION 12 TOTAL
10-148
ELECTRONIC CONTROL SYSTEM
SYSTEM DIAGRAM
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12
PC400LC-7L
10-149
STRUCTURE AND FUNCTION 12 ENGINE
10-150
ELECTRONIC CONTROL SYSTEM
AND PUMP CONTROL FUNCTION
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 Function •
The operator can set the work mode switch on the monitor panel to mode A, E, or B (or L) and select proper engine torque and pump absorption torque according to the type of work. • The engine throttle and pump controller detects the speed of the engine governor set with the fuel control dial and the actual engine speed and controls them so that the pump will absorb all the torque at each output point of the engine, according to the pump absorption torque set in each mode. ❈: The L mode is on the multi-monitor specification machine only.
PC400LC-7L
10-151
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 1. Control method in each mode Mode A, Mode E • Matching point in mode A: Rated speed
•
Mode A
246.3 kW/1,850 rpm {331 HP/1,850 rpm}
Mode E
213.3. kW/1,720 rpm {286 HP/1,720 rpm}
If the pump load increases and the pressure rises, the engine speed lowers. At this time, the controller lowers the pump discharge so that the engine speed will be near the full output point. If the pressure lowers, the controller increases the pump discharge so that the engine speed will be near the full output point. By repeating these operations, the controller constantly uses the engine near the full output point.
10-152
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 Mode B / (Mode ❈L) Mode
Mode B
Mode
Partial output point
82%
61%
Mode B
194.9 kW/1,730 rpm {261 HP / 1,730 rpm}
Mode ❈L
150.8 kW/1,250 rpm {202 HP / 1,250 rpm}
L
•
At this time, the controller keeps the pump absorption torque along the constant horsepower curve and lower the engine horsepower by the composite control of the engine and pump. By this method, the engine is used in the low fuel consumption area. ❈: The L mode is on the multi-monitor specification machine only.
PC400LC-7L
10-153
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 2. Function to control pump during travel • When the travel is operated in A operation, or E or B working mode, the working mode stays as it is, and the pump absorption torque and engine speed rise to A travel mode.
•
If the machine travels in mode L, the working mode and engine speed do not change, but the pump absorption torque is increased. ❈: The L mode is on the multi-monitor specification machine only.
3.
Function to control when emergency pump drive switch is turned ON • Even if the controller or a sensor has a trouble, the functions of the machine can be secured with pump absorption torque almost equivalent to mode E by turning on emergency pump drive switch (10). In this case, a constant current flows from the battery to the EPC valve for PC and the oil pressure is sensed by only the EPC valve for PC.
10-154
PC400LC-7L
STRUCTURE AND FUNCTION 12 PUMP/VALVE
ELECTRONIC CONTROL SYSTEM
CONTROL FUNCTION
Function The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
PC400LC-7L
10-155
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 1. LS control function • The change point (LS set differential pressure) of the pump discharge in the LS valve is changed by changing the output pressure from the LSEPC valve to the LS valve according to the operating condition of the actuator. • By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved. 2.
Cut-off function • When the cut-off function is turned on, the PCEPC current is increased to near the maximum value. • By this operation, the flow rate in the relief state is lowered to reduce fuel consumption. • Operating condition for turning on cut-off function
Condition The average value of the front and rear pressure sensors is above 285 kg/cm2 (4053 psi) and the one-touch power maximizing function is not turned on
The cut-off function does not work, however, while the machine is travelling in mode A or the arm crane operation width swing lock switch is turned on. 1.
2-stage relief function • The relief pressure in the normal work is 355 kg/cm2 (5049 psi). If the 2-stage relief function is turned on, however, the relief pressure rises to about 380 kg/cm2 (5404 psi). By this operation, the hydraulic force is increased further. • Operating condition for turning on 2-stage relief function Condition
• • • • • •
Relief pressure
Condition During travel When swing lock switch is turned on 355 kg/cm2 (5049 psi) ↓ When boom is lowered 2 When one-touch power maximizing function is 380 kg/cm (5404 psi) turned on When L mode is operated
❈: The L mode is on the multi-monitor specification machine only.
10-156
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12
MEMORANDUM
PC400LC-7L
10-157
STRUCTURE AND FUNCTION 12 ONE-TOUCH
ELECTRONIC CONTROL SYSTEM
POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION
Function • •
Power can be increased for a certain time by operating the left knob switch. When the machine push-up switch is operated, the boom pushing force is increased.
10-158
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 1. One-touch power maximizing function • When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 7% to increase the digging force. • If the left knob switch is turned on in working mode “A” or “E”, each function is set automatically as shown below.
Working mode
Engine/Pump control
2-stage relief function
Operation time
Software cut-off function
355 kg/cm (5049 psi) ⇓ 380 kg/cm2 (5404 psi)
Automatically reset at 8.5 sec
Cancel
2
A, E
2.
Matching at rated output point
Machine push-up function • Operate switch (1) to increase the boom pushing force when digging ditches or holes on hard ground.
Switch
2-stage safety valve function
OFF
Setting of safety valve at boom cylinder 150 kg/cm2 (2133 psi)
ON
Setting of safety valve at boom cylinder 290 kg/cm2 (4124 psi)
PC400LC-7L
10-159
STRUCTURE AND FUNCTION 12 AUTO-DECELERATION
ELECTRONIC CONTROL SYSTEM
FUNCTION
Function • •
If the all control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is lowered to the medium level automatically to reduce the fuel consumption and noise. If any lever is operated, the engine speed rises to the set level instantly.
10-160
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 Operation WHEN CONTROL LEVERS ARE SET IN NEUTRAL If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,300 rpm) for 4 seconds, the engine speed lowers to the second deceleration level (about 1,300 rpm) and keeps at that level until any lever is operated again. WHEN ANY CONTROL LEVER IS OPERATED If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly to the level set with the fuel control dial.
PC400LC-7L
10-161
STRUCTURE AND FUNCTION 12 AUTO-WARM-UP/OVERHEAT
ELECTRONIC CONTROL SYSTEM
PREVENTION FUNCTION
Function After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the engine. If the coolant temperature rises too high during work, the pump load is reduced to prevent overheating.
10-162
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 1. Auto-warm-up function After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the engine.
2.
Overheat prevention function If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to prevent overheating. This function is turned on when the coolant temperature rises above 95° C (203° F).
PC400LC-7L
10-163
STRUCTURE AND FUNCTION 12 SWING
ELECTRONIC CONTROL SYSTEM
CONTROL FUNCTION
Function The swing lock and swing holding brake functions are installed.
10-164
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 1. Swing lock and swing holding brake functions • The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake function (automatic) is used to prevent hydraulic drift after the machine stops swinging. • Swing lock switch and swing lock/holding brake Lock switch
Lock lamp
Function
Operation
OFF
OFF
Swing holding brake
If swing lever is set in neutral, swing brake operates in about 7 sec. If swing lever is operated, brake is released and machine can swing freely.
ON
ON
Swing lock
Swing lock operates and machine is locked from swinging. Even if swing lever is operated, swing lock is not reset and machine does not swing.
❈: Operation of swing holding brake release switch •
If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing, the swing lock can be reset with the swing holding brake release switch.
Swing holding brake release switch
ON (When control has trouble)
OFF (When controller is normal)
Swing lock switch
ON
OFF
ON
OFF
Swing brake
Swing lock is turned on
Swing lock is canceled
Swing lock is turned on
Swing holding brake is turned on
★ Even if the swing holding brake release switch is turned on, if the swing lock switch is turned on, the swing brake is not released. ★ If the swing lock is reset, swinging is stopped by only the hydraulic brake of the safety valve. Accordingly, if swinging is stopped on a slope, the upper structure may drift hydraulically. 2.
Quick hydraulic oil warm-up function when swing lock switch is turned on If swing lock switch (4) is turned on, the pump-cut function is cancelled and the relief pressure rises from 355 kg/cm2 (5049 psi) to 380 kg/cm2 (5404 psi). If the work equipment is relieved under this condition, the hydraulic oil temperature rises quickly and the warm-up time can be shortened.
PC400LC-7L
10-165
STRUCTURE AND FUNCTION 12 TRAVEL
ELECTRONIC CONTROL SYSTEM
CONTROL FUNCTION
Function The pumps are controlled and the travel speed is changed manually or automatically, to secure proper travel performance matched to the type of work and job site during travel.
10-166
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 Pump control function during travel If the machine travels in a work mode other than mode A, the work mode and the engine speed are kept as they are and the pump absorption torque is increased. ★ For details, see ENGINE/PUMP COMPOSITE CONTROL FUNCTION. 1.
Travel speed change function A. Manual change with travel speed switch If the travel speed switch is changed between Lo, (Mi), and Hi, the governor/pump controller controls the pump capacity and motor capacity at each gear speed as shown at right to change the travel speed. Travel speed switch Pump capacity (%) Motor capacity Travel speed (km/h)
Lo (Low speed)
(❈Mi) (Middle Speed)
Hi (High speed)
90
82
100
Max.
Max.
Min.
3.2
4.5
5.5
B. Automatic change according to engine speed If the fuel control dial is used to set the engine speed to less than 1,200 rpm: • When traveling in Lo, it will not switch even when set to Hi or Mi. • When traveling in Hi or Mi, it will switch automatically to Lo. C. Automatic changes according to pump discharge pressure When traveling with the travel speed switch set to Hi or Mi, it the load increases, such as when traveling uphill, and the travel pressure goes above 330 kg/cm2 (4693 psi) for more than 0.5 sec., the travel motor capacity will automatically change to low speed (equivalent to Lo). (The travel speed switch will stay at Hi or Mi.) After continuing to travel in Lo, if the load increases, such as when traveling on level ground or traveling downhill, and the travel pressure goes below 190 kg/cm2 (2702 psi) for more than 0.5 sec., the travel motor capacity will automatically change and will return to Hi or Mi. ❈: The “Mi” mode is on the multi-monitor specification machine only.
PC400LC-7L
10-167
STRUCTURE AND FUNCTION 12 ATT
ELECTRONIC CONTROL SYSTEM
FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT)
Function This function is available only with the ATT specification. The function acts as follows according to the flow command and working mode from the monitor. 1.
It throttles the ATT PPC pressure and controls the flow when the pedal is fully depressed.
2. In mode B and the other modes, it switches to ATT single acting (B) or double acting (other modes). ❈: The ATT flow control adjustment function is on the multi-monitor specification machine only.
10-168
PC400LC-7L
STRUCTURE AND FUNCTION 12 SYSTEM
ELECTRONIC CONTROL SYSTEM
COMPONENT PARTS
ENGINE REVOLUTION SENSOR
1. Sensor 2. Locknut 3. Wiring harness 4. Connector
Function • •
The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine throttle and pump controller. A magnet is used to sense the gear teeth. Each time a gear tooth passes in front of the magnet, a current is generated.
PC400LC-7L
10-169
STRUCTURE AND FUNCTION 12 PPC
ELECTRONIC CONTROL SYSTEM
OIL PRESSURE SWITCH
1. Plug 2. Switch 3. Connector Specifications Type of contacts: Normally open contacts Operating (ON) pressure:
5.0 ±1.0 kg/cm2 (71 ±14 psi)
Resetting (OFF) Pressure:
3.0 ±0.5 kg/cm2 (42 ±7 psi)
Function The junction block has 7 pressure switches, which check the operating condition of each actuator by the PPC pressure and transmit it to the engine throttle and pump controller.
10-170
PC400LC-7L
STRUCTURE AND FUNCTION 12 PUMP
ELECTRONIC CONTROL SYSTEM
PRESSURE SENSOR
1. Sensor 2. Connector
Function The pump pressure sensor is installed to the inlet circuit of the control valve. It converts the pump discharge pressure into a voltage and transmits it to the engine throttle and pump controller. Operation • • • •
The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance, then converts the change of the resistance into a voltage and transmits it to the amplifier (voltage amplifier). The amplifier, amplifies the received voltage and transmits it to the engine throttle and pump controller. Relationship between pressure P kg/cm2 (psi) and output voltage (V) is as follows. V = 0.08 [0.008] × P + 0.5
PC400LC-7L
10-171
STRUCTURE AND FUNCTION 12 PUMP
10-172
ELECTRONIC CONTROL SYSTEM
CONTROLLER
PC400LC-7L
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 Input and output signals CN-1
CN-2
Pin No.
Signal name
1
NC
2
R pump pressure sensor
3 4
Input/ Output
Pin No.
Signal name
Input/ Output
1
NC
2
Swing emergency switch
Input
NC
3
NC
Input
NC
4
232C_RxD
Input
5
NC
5
NC
6
NC
6
NC
7
NC
7
Model selection 4
8
F boom pressure sensor
8
Attachment circuit selector signal
9
NC
9
NC
10
Signal GND
10
NC
11
Knob SW
12
NC
13
Buchet CURL PPC pressure sensor
14
NC
15
NC
16
NC
17
Starting switch (Terminal C)
18
NC
19
Arm IN PPC pressure sensor
20
NC
21
NC
22
POT_PWR
23
Starting switch (terminal ACC)
24
NC
PC400LC-7L
Input
Input Input
Input
Input Output
11
NC
12
CAN shield
13
Model selection 5
14
232C_TxD
15
NC
16
Travel steering signal pressure SW
Input
17
Model selection 3
Input
18
NC
19
Auto deceleration signal
20
NC
21
S_NET
Input/output
Output
22
CAN0_L
Input/output
Input
23
NC
24
FWE_SW
25
NC
26
NC
27
Model selection 2
28
NC
29
GND (pulse GND)
30
NC
31
GND (S_NET GND)
32
CAN0_H
33
NC
34
GND (232C GND)
35
Service valve pressure switch
36
NC
37
Model selection switch 1
Input
38
Swing lock switch
Input
39
GND (pulse GND)
40
Engine speed sensor
Input Input Input Input
Input Output
Output
Input
Input
Input/ output
Input
Input
10-173
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
12 CN-3 Pin No.
Signal name
Input/Output
1
VB (controller power)
Input
2
VIS (solenoid power)
Input
3
SOL_COM (solenoid common gnd)
4
Battery relay drive
5
NC
6
LS-EPC
Output
7
Travel junction SOL
Output
8
NC
9
NC
Input
10
Boom RAISE pressure SW
Input
11
VB (controller power)
Input
12
VIS (solenoid power)
Input
13
SOL_COM (solenoid common gnd)
Input
14
KEY_SIG
Input
15
NC
16
PC-EPC
Output
17
Pump merge/divider solenoid
Output
18
Heater relay drive
Output
19
Bucket DUMP pressure switch
Input
20
Boom LOWER pressure switch
Input
21
GND (controller GND)
Input
22
NC
23
SOL_COM (solenoid common gnd)
Input
24
KEY_SIG
Input
25
NC
26
Service flow adjustment EPC (1)
Output
27
Travel Hi/Lo selector solenoid
Output
28
2-stage relief solenoid
Output
29
Swing pressure switch
Input
30
Arm IN pressure switch
31
NC
Input
32
GND (controller GND)
Input
33
GND (controller GND)
Input
34
NC
35
NC
36
NC
37
Swing parking brake solenoid
38
NC
39
Travel pressure switch
Input
40
Arm OUT pressure switch
Input
10-174
Output
Output
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12
MONITOR SYSTEM
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1.
Monitor section to output alarms when the machine has troubles
2.
Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)
The monitor panel also has various mode selector switches and functions to operate the machine control system.
PC400LC-7L
10-175
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 1. Monitor panel
Outline The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.
10-176
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
Input and output signals 12 CN-1
CN3
Pin No.
Signal name
Input/output
Pin No.
Signal name
Input/output
1
Key ON
Input
1
NC
Input
2
Key ON
Input
2
NC
Input
3
Washer motor output
Output
3
NC
Input
4
Starting signal
Input
4
NC
Input
5
Limit switch (W)
Input
5
NC
Input
6
GND
6
NC
Input
7
GND
8
VB +
9
7
RS230C CTS
Input
Input
8
RS230C RXD
Input
Wiper motor (+)
Output
9
RS230C RXD
Input/Output
10
Wiper motor (-)
Output
10
RS230C RXD
Input/Output
11
Buzzer ON signal
Input
11
BOOTSW
Input
12
Limit switch (P)
Input
12
NC
Input
13
GND
14
CAN (SHIELD)
Input
15
CAN (+)
Input
16
CAN (-)
Input
CN-2 Pin No.
Signal name
Input/output
1
Engine coolant temperature
Input
2
Fuel level
Input
3
Radiator coolant level
Input
4
(Hydraulic oil level)
Input
5
Air cleaner clogging
Input
6
NC
Input
7
Engine oil pressure
Input
8
Engine oil level
Input
9
N/W signal
Input/Output
10
N/W signal
Input/Output
11
Battery charge
Input
12
Hydraulic oil temperature (analog)
Input
13
GND (for analog signal)
14
Buzzer drive
Input
15
Limit SW (window)
Input
16
Buzzer cancel
Input
17
Swing lock
Input
18
Preheat
Input
19
Light switch
Input
20
N/W GND
PC400LC-7L
10-177
STRUCTURE AND FUNCTION 12 MONITOR
MONITOR SYSTEM
CONTROL, DISPLAY PORTION
MONITOR PORTION
10-178
1. Wiper motor
11. Fuel level monitor
2. Preheating monitor
12. Hydraulic oil temperature monitor
3. Swing lock monitor
13. Power max. monitor
4. Engine coolant temperature monitor
14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge
15. Radiator coolant level caution
6. Engine coolant temperature gauge
16. Battery charge caution
7. Working mode monitor
17. Engine oil pressure caution
8. Service monitor
18. Engine oil level caution
9. Travel speed monitor
19. Air cleaner clogging
10. Fuel gauge
20. Maintenance time warning caution
PC400LC-7L
STRUCTURE AND FUNCTION 12 MONITOR
MONITOR SYSTEM
ITEMS AND DISPLAY
Symbol
Display item
Swing lock
Preheating
Power Max
Display method Swing lock switch
Swing holding brake release switch
Swing lock monitor
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Continuous set time
Preheating monitor status
Up to 30 sec.
ON
From 30 sec. to 40 sec.
Flashes
More than 40 sec.
OFF
Power Max. switch status
Power Max. monitor status
Being pressed
Lights up but goes out after approx. 9 sec when kept pressed
Not being pressed
Flashes
Engine coolant temperature Hydraulic oiltemperature
See gauge display on the next page
Fuel level
PC400LC-7L
10-179
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12
Gauge
Engine coolant temperature (°C)
Hydraulic oil temperature (°C)
Fuel level (l)
10-180
Range
Temperature, volume
Indicator
Buzzer sound
A1
105
Red
O
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
467
Green
C2
381
Green
C3
295
Green
C4
147.5
Green
C5
114
Green
C6
80.5
Red
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 Checks before starting (caution lamps all light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed. Symbol
Display item
Check before starting item
When engine is stopped
When engine is running
Engine oil pressure
●
---
When abnormal, lights up and buzzer sounds
Battery charge
●
---
Lights up when abnormal
Radiator coolant level
●
Lights up when abnormal
When abnormal, lights up and buzzer sounds
Engine oil level
●
Lights up when abnormal
---
Air cleaner clogging
●
---
Lights up when abnormal
Maintenance
Lights up when there is a warning. Lights up for only 30 sec. after key is turned ON, then goes out.
The problems that have occurred are displayed in order from the left. When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed.
PC400LC-7L
Condition of hydraulic oil
Color of symbol
Low temperature (below B6 or equivalent)
Black on white background
Normal (B6 ñ B2)
No display
High temperature (below B2)
White on red background
10-181
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12
Display category
Symbol
Display item
Display range
Display method
Wiper
Displays set condition
Working mode
Displays set mode
Travel speed
Displays set speed
Monitor
Service meter
10-182
Auto-deceleration
ON ⇔ OFF
Displays actuation status
Service meter indicator
When service meter is working
Lights up when service meter is working
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 SWITCHES
1. Selector switch 2. Selector switch 3. Display brightness, contrast adjustment switch 4. Control switch 5. Window washer switch 6. Wiper switch 7. Maintenance switch 8. Travel speed selector switch 9. Auto-deceleration switch
PC400LC-7L
10-183
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 •
Working mode selector switch The condition of the machine changes according to the switch that is pressed (A, E, L, B). It is possible to check the condition on the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right.
Switch that is pressed
Display
Working mode status after setting
[A]
A
A mode (default)
[E]
E
E mode
[L]
L
Heavy-lift mode
[B]
B
Swing priority mode
•
Selector switch This is used when making detailed settings in each working mode. (For details, see ATTACHMENT FLOW CONTROL FUNCTION for modes A and E.)
•
Maintenance switch Check the condition of the maintenance items. (For details, see MAINTENANCE FUNCTION.)
•
Auto-deceleration switch Each time the auto-deceleration switch is pressed, the auto-deceleration function is switched ON/OFF. Use the auto-deceleration monitor display to check the present condition. When the working mode switch is operated to switch the working mode, it is automatically set to ON.
Display
Setting
Crawler symbol + Lo
Low speed (default)
Crawler symbol + Mi
Medium speed
Crawler symbol + Hi
High speed
•
Travel speed selector switch Each time the travel speed selector switch is pressed, the travel speed changes. Lo → Hi → Lo …… Use the travel speed monitor display to check the present condition. The relationship between the set speed and the monitor display in the table on the right.
•
Wiper switch Each time the wiper switch is pressed, the wiper setting changes OFF → INT → ON → OFF → …… Use the wiper monitor display to check the present condition. The relationship between the wiper setting and the monitor display is as shown in the table on the right.
10-184
Display
Setting
Wiper actuation status
None
OFF
Stowing stopped or now stowing
Wiper symbol + INT
INT
Intermittent actuation
Wiper symbol + ON
ON
Continuous actuation
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 • Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts. • Control switch This is used for control when using the maintenance function or select function. (For details, see each function.) • Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For details, see each function.)
PC400LC-7L
10-185
STRUCTURE AND FUNCTION 12 SELECT •
•
MONITOR SYSTEM
MODE FUNCTION
This is used when setting the flow in each working mode. It is possible to make the setting when genuine attachment piping is installed and the initial value setting function on the service menu has been used to set to ATTACHMENT INSTALLED. It is possible to check on the working mode monitor if this function can be set. Working mode
Monitor display
A mode
[A] + crusher symbol
E mode
[E] + crusher symbol
B mode
[B] + flow symbol
MEHOD OF USE ★ Carry out the setting on the normal screen 1.
A mode, E mode A. Press select switch (1) on the monitor to move to the adjustment screen. B. Press control switch (2) to select the flow level. Control switch
Actuation
Flow level bar graph extends to the right
Flow level bar graph retracts to the left
C. After completing the level selection, press input confirmation switch (3). The selection flow level is confirmed and the screen moves to the normal screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right.
10-186
Flow level
Flow (L/min.)
Remarks
8
530
❈ Default
7
430
6
370
5
300
4
230
3
165
2
100
1
30
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 2. B mode A. Press select switch (1) on the monitor to move to the screen for selecting the 3-stage flow level. B. Press control switch (2), or input [01] – [03] with the numeral 10-key pad to choose one on the three flow levels. No.
10-key pad operation
01
02
03
C. After completing the level selection, press input confirmation switch (3). The selected flow level is selected. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the operator screen. This function can be used to return to the previously set flow. D. After the flow level is confirmed, the screen changes to the screen shown in the diagram on the right. With this screen, it is possible to make fine adjustment to the flow.
No.
Flow level (L/min.)
Remarks
01
230
Default
02
190
03
150
E. Press control switch (2) and select the flow level. Control switch
Actuation
Flow level bar graph extends to the right
Flow level bar graph retracts to the left
PC400LC-7L
10-187
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 F.
After completing the level selection, press input confirmation switch (3). The selected flow level is confirmed and the screen moves to the operator screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, se press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right.
G. Check the set value with the working mode monitor. The relationship between the display level and the set value is as shown in the table on the right, and it is possible to check the level of the flow that can be set.
10-188
Flow level
When flow When flow is 140 L/ is 220 L/ min. min.
When flow is 300 L/ min.
7
200
280
360
6
180
260
340
5
160
240
320
4
140
220
300
3
120
200
280
2
100
180
260
1
80
160
240
Remarks
Default
Display level
Set value (L/min.)
8
220 or 360
7
200 or 340
6
180 or 320
5
160 or 300
4
140 or 280
3
120 or 260
2
100 or 240
1
80
PC400LC-7L
STRUCTURE AND FUNCTION 12 MAINTENANCE
MONITOR SYSTEM
FUNCTION
When the maintenance time for replacement, inspection, or filling has approached for the 10 maintenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the starting switch is turned ON to remind the operator to perform lubrication maintenance. ★ Maintenance items No.
Item
Replacement interval (hours)
01
Engine oil
500
02
Engine oil filter
500
03
Fuel filter
500
04
Hydraulic filter
1000
05
Hydraulic tank breather
500
06
Corrosion resistor
1000
07
Damper case oil
1000
08
Final case oil
2000
09
Machinery case oil
1000
10
Hydraulic oil
5000
★ The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the remaining time. The relationship is as shown in the table below. Display
Condition
None
Remaining time for maintenance for all items is more than 30 hours
Notice display (black symbol displayed on yellow background)
There is one or more items with less than 30 hours remaining time for maintenance
Warning display (wiper symbol displayed on red background)
There is one or more items with less than 0 hours remaining time for maintenance
PC400LC-7L
10-189
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 METHOD OF CHECKING STATUS MAINTENANCE ITEMS ★ Operate as follows when on the operator screen. 1.
Press maintenance switch (1) and switch to the maintenance list display screen. ★ The maintenance items are displayed as symbols on the screen.
2.
Press control switch (2), or use the 10-key pad to input the number (01 – 10) of the maintenance item to select the item. ★ The cursor moves and the item is highlighted. ★ The display method is the same as described on the previous page (relationship between remaining time and caution display). If the remaining time is less than 30 hours, the item is displayed in yellow, and if it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION 1.
After completing the selection, press input confirmation switch (3). The screen will change to the maintenance reset screen.
2.
Use the maintenance reset screen to check the content, and if there is any problem, press input confirmation switch (3) to move to the check screen. If the wrong item is selected, press return switch (4) to return to the maintenance list screen.
3.
Check the content on the check screen, and if there is no problem, press input confirmation switch (3) to reset the maintenance time. After the reset is completed, the screen returns to the maintenance list display screen. To check the remaining time, or if the wrong item is selected, press return switch (4) to return to the maintenance list screen. ★ The check screen shows the symbol for the maintenance item and the set time in large letters. ★ The background color of the symbol for the item where the maintenance item was reset is the same as the background of the screen, so it is possible to check that it has been reset.
10-190
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION This function is used to adjust the brightness and contrast of the display. ADJUSTMENT METHOD ★ Operate as follows when on the operator screen. 1.
Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen. ★ Relationship between menu symbol and content. No.
Symbol
Content
01
Return mark
Return
02
Contrast
03
Brightness
2.
Press control switch (2), or use the 10-key pad to input the number (00 – 02) to select either contrast or brightness. After completing the selection, press input confirmation switch (3) and return to the adjustment screen. Then press return switch (4) or use the 10-key pas to set to [00] and press input confirmation switch (3) to return to the normal screen.
3.
Press control switch (2) and adjust the brightness and contrast as desired.
Control switch
Actuation
Flow level bar graph extends to the right
Flow level bar graph retracts to the left
PC400LC-7L
10-191
STRUCTURE AND FUNCTION 12 SERVICE •
•
MONITOR SYSTEM
METER CHECK FUNCTION
When the starting switch is at the OFF position, press return switch (1) and control switch (2) on the monitor at the same time, and the service meter is shown on the display. This display is shown only while the two switches are being pressed. When the switches are released, the display goes out. Note that it takes 3 – 5 seconds after the switches are pressed for the service meter display to appear.
DISPLAY LCD CHECK FUNCTION •
•
On the password input screen or on the normal screen, if monitor return switch (1) and working mode (A) switch are kept pressed at the same time, all the LCD display will light up and the whole screen will become white, so the display can be checked. If any part of the display is black, the LCD is broken.
10-192
PC400LC-7L
STRUCTURE AND FUNCTION
MONITOR SYSTEM
12 • While the user code is being displayed, if the input confirmation switch is pressed, the service code and failure code can be displayed.
•
If there is more than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed. Even if service codes/ failure codes have occurred, if they did not cause the user code to be displayed, this function does not display them.
•
If the telephone number has been set using the telephone number input on the service menu, it is possible to switch on the service code/failure code and display the telephone symbol and telephone number. For details of inputting and setting the telephone number, see SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING AND ADJUSTING section.
PC400LC-7L
10-193
STRUCTURE AND FUNCTION
SENSOR
12
SENSOR The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the chassis ground.
Type of sensor
When normal
When abnormal
Engine oil level
Name of sensor
Contact
ON (closed)
OFF (open)
Engine oil pressure
Contact
OFF (open)
ON (closed)
Hydraulic oil temperature
Resistance
---
---
Coolant temperature
Resistance
---
---
Fuel level
Resistance
---
---
Contact type
OFF (open)
ON (closed)
Air cleaner clogging
ENGINE OIL LEVER SENSOR
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)
10-194
PC400LC-7L
STRUCTURE AND FUNCTION 12 COOLANT
SENSOR
TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
1. Thermistor
4. Tube
2. Body
5. Wire
3. Tube
6. Connector
FUEL LEVEL SENSOR
PC400LC-7L
10-195
STRUCTURE AND FUNCTION
SENSOR
AIR CLEANER CLOGGING SENSOR
10-196
PC400LC-7L
20
TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101 TROUBLESHOOTING TROUBLESHOOTING GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201 TROUBLESHOOTING ERROR CODES IN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) . . . . . . . . . . . . 20-601
Remark TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL. ★ Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1.
The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs.
2.
The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.
3.
These standard values are not the standards used in dealing with claims. WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving. WARNING! When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. WARNING! When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
PC400LC-7L
20-1 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
12
STANDARD VALUE TABLE FOR ENGINE
Item Engine speed
Engine Measurement condition High idling Low idling Rated speed
Intake air pressure
At rated output
Exhaust gas pressure
Valve clearance (normal temperature)
All speed range (intake air temp: 20°C) At sudden acceleration At high idling Intake valve Exhaust valve
Compression pressure
Oil temperature: 40-60×C (Engine speed)
Exhaust gas color
(Coolant temperature: within operating range) At rated output (Coolant temperature: within operating range) At high idling (SAE30) Oil pressure At high idling (SAE10W) At low idling (SAE30) At low idling (SAE10W) Oil temperature All speed range (inside oil pan) Fan, alternator belt Deflection when pressed with finger tension force of Approximately 58.8 N {6 kg} Air conditioner Deflection when pressed with finger compressor belt tension force of approximately 58.8 N {6 kg} Blow-by pressure
Unit rpm kPa {mmHg} °C Bosch index
Standard value 1,930 ± 50 1,000 ± 25 1,850
SAA6D125E-3 Permissible value 1,930 ± 50 1,000 ± 25 1,850
Min 107 {Min. 800}
87 {650}
mm
Max. 700 Max. 4.0 Max. 1.0 0.33 0.71
Max. 700 6.0 2.0 -----
MPa {kg/cm2} (rpm)
Min. 2.9 {Min. 30} (150-200)
2.0 {20} (150-200)
kPa {mmH2O}
Max. 1.18 {Max. 120}
1.96 {200}
MPa {kg/cm2}
0.39-0.69 {4.0- 7.0} 0.34-0.64 {3.5-6.5} Min. 0.15 {Min. 1.5} Min. 0.1 {Min. 1.0}
0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7}
°C
90-120
120
mm
Approximately 13
Approximately 13
mm
14-16
14-16
★ For further detailed information, refer to Engine Shop Manual
20-2 1
PC400LC-7L
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS Cate gory
Item
Measurement conditions
Unit
Standard value
Permissible value
1,930 ± 100
1,930 ± 100
1,830 ± 100
1,830 ± 100
1,300 ± 100
1,300 ± 100
mm
9.5 ± 0.5
9.5 ± 0.5
mm
85 ± 10 85 ± 10 85 ± 10 85 ± 10 115 ± 12 Max. 10
85 ± 10 85 ± 10 85 ± 10 85 ± 10 115 ± 12 Max. 15
Boom control lever
15.7 ± 4.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
Arm control lever
15.7 ± 4.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
24.5 ± 5.9 {2.5 ± 0.6}
Max. 39.2 {Max. 4.0}
74.5 ± 18.6 {7.6 ± 1.9}
Max. 107.6 {Max. 11}
●Engine water temperature: Within
operating range
2 pumps at relief
●Hydraulic oil temperature: Within
operating range
Engine speed
●Engine at high idling ●Arm in relief condition ●Engine water temperature: Within
operating range oil temperature: Within At 2-pump relief + one ●Hydraulic operating range touch power up ●Engine at high idling ●Arm relief + One-touch power max. switch in ON condition
Operating effort of control levers
Travel of control levers Spool stroke
Speed when auto deceleration is operated
●Engine at high idling ●Auto-deceleration switch in ON
condition
●All control levers in NEUTRAL
condition
Boom control valve Arm control valve Bucket control valve Swing control valve Travel control valve Boom control lever Arm control lever Bucket control lever Swing control lever Travel control lever Play of control levers
Bucket control lever Swing control lever Travel control: Lever Travel control: Pedal
PC400LC-7L
rpm
●Engine stopped ●At center of control lever grip ●Max. reading up to stroke end
(excepting lever play in NEUTRAL position)
●Hydraulic oil temperature: Within
operation range
●Engine at high idling ●Hydraulic oil temperature: Within
operating range ●At center of control lever grip ●Max. reading up to stroke end
N {kg}
20-3 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Category
Item
Unload pressure
Measurement conditions
Unit
●Hydraulic oil temperature: Within operation range ●Engine at high idling ●Working mode: A mode ●Hydraulic pump output pressure with all control levers in NEUTRAL position
Standard value
Permissible value
4.2 ± 1.0 {42 ± 10}
4.2 ± 1.0 {42 ± 10}
34.81+1.47
33.34-36.77
-0.98
(37.27+1.47 ) -0.98
RAISE
{340-375 (365- 400)}
At lowpressure setting
18.14 ± 0.98 {185 ± 10}
16.67-19.61 {170-200}
At highpressure setting
31.38 ± 1.47 {320 ± 15}
29.2-33.34 {300-340}
34.81+1.47
33.34-36.77
Boom
Hydraulic pressure
Arm
LOWER
-10
●Hydraulic oil temperature: Within operation range ●Engine at high idling
(35.79-39.23)
{355+15 -10 (380+15)}
●Working mode: A mode ●Hydraulic pump output pressure with all measurement circuits relieved ●Values inside parenthesis: Hydraulic oil pressure with one-touch power max. switch in ON mode (reference only)
-0.98
(37.27+1.47 ) -0.98
{355+15 -10 +15
(380 MPa {kg/cm2}
-10
)}
34.81+1.47 -0.98
{355+15
-10 (380+15)} -10
30.89+1.47 -2.45
Swing
{340-375 (365- 400)} 33.34-36.77
(37.27+1.47 ) -0.98
Bucket
(35.79-39.23)
{315+15} - -25
37.27+2.94
(35.79-39.23) {340-375 (365- 400)}
27.95-32.85 {285-335}
{380+30}
35.79-40.70 {365-415}
●Hydraulic oil temperature: Within operation range ●Engine at high idling ●Self-reducing pressure valve output pressure with all control levers in NEUTRAL position
3.24 ± 0.2 {33 ± 2}
2.84-3.43 {29-35}
●Hydraulic oil temperature: Within operation range ●Engine at high idling
When all control levers in NEUTRAL position
4.2 ± 1.0 {42 ± 10}
4.2 ± 1.0 {42 ± 10}
●Working mode: A mode When trav●Traveling speed: Hi eling at half stroke ●Hydraulic oil pump (without load) pressure-LS pressure
2.65 ± 0.1 {27 ± 1}
2.65 ± 0.1 {27 ± 1}
-0.98
Travel
-10
Control circuit source pressure
LS differential pressure
20-4 1
PC400LC-7L
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Category
Item
Swing brake angle
Measurement conditions
●Hydraulic oil temperature: Within operating
range ●Bucket: Empty ●Engine at high idling ●Working mode: A mode ●Swing circle misalignment amount when stopping after one turn
Unit
Standard value
Permissible value
deg. (mm)
Max. 130
Max. 160
3.7 ± 0.4
Max. 4.6
5.4 ± 0.5
Max. 6.4
sec.
33.0 ± 3.3
Max. 38
mm
0
0
90° Time taken to start swing
●Hydraulic oil temperature: Within
sec.
operation range
●Bucket: Empty ●Engine at high idling ●Working mode: A mode ●Time required for passing points 90
180°
Swing
and 180 degrees from starting point
Time taken to swing ●Hydraulic oil temperature: Within operating range ●Bucket: Empty ●Engine at high idling ●Working mode: A mode ●Time required for 5 more turns after making initial one turn
Hydraulic drift of swing
●Hydraulic oil temperature: Within operation
range
●Engine stopped ●Keeping upper structure transverse on slope of
15 degrees
●Notching a mating mark on inner and outer
races of swing circle
●Mating mark misalignment amount during 5
minutes
PC400LC-7L
20-5 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Category
Item
Measurement conditions
Unit
Standard value
Permissible value
L/min
Max. 5.5
Max. 11
Lo
67.3 ± 13.5
45.0-84.5
Mi
48.1 ± 7.2
34.0-58.0
Hi
36.7 ± 3.6
32.0-44.0
Lo
24.0 ± 4.8
18.9-31.0
17.1 ± 2.6
14.4-21.0
13.1 ñ 1.3
11.7-15.1
Max. 200
Max. 300
Swing
●Hydraulic oil temperature: Within
Leakage from swing motor
operation range
●Engine at high idling ●Swing lock switch: ON ●Leakage amount for one minute during
swing relief
Travel speed (Idle travel)
Travel
Travel speed (Actual travel)
Travel deviation
20-6 1
●Hydraulic oil temperature:
Within operation range ●Engine at high idling ●Working mode: A mode ●Time required for track shoes to make 5 turns after making one initial idle turn
●Hydraulic oil temperature:
Within operation range ●Engine at high idling ●Working mode: A mode ●Flat ground ●Time required for traveling 20 m after 10 m trial run
sec.
Mi
sec.
Hi
Hydraulic oil temperature: Within operation range Engine at idling Working mode: A mode Travel speed: Lo Solid and flat ground Swerving amount while traveling 20 m (X) after initial 10 m trial run.
mm
PC400LC-7L
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Category
Item
Unit
Standard value
Permissible value
mm
0
0
L/min
Max. 20
Max. 40
Whole work equipment (tooth tip fall amount)
Max. 600
Max. 900
Boom cylinder (cylinder retraction amount)
Max. 25
Max. 38
Max. 85
Max. 128
Max. 30
Max. 45
Travel
Hydraulic drift of travel
Measurement conditions
●Hydraulic oil temperature: Within
operating range ●Engine stopped ●Parking machine on slope 12 degrees with sprocket facing upslope ●Sliding distance for 5 minutes ●Hydraulic oil temperature: Within
Leakage of travel motor
operating range
●Engine at high idling ●Travel: Lock sprocket. ●Oil leakage amount for one minute with
Hydraulic drift work equipment
Work equipment
traveling in relief condition
Arm cylinder (cylinder extension amount)
●Hydraulic oil temperature: Within
operation range
●Flat and level ground ●Work equipment in measurement
posture as illustrated above ●Bucket load: 3,060 kg (6746.15 lb) Bucket cylinder (cylinder ●Engine stopped ●Work equipment control lever in retraction amount) NEUTRAL position ●Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting
PC400LC-7L
mm
20-7 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Standard value for new machine
Service limit value
4.0 ± 0.4
Max. 4.8
LOWER
2.9 ± 0.3
Max. 3.4
CURL
4.3 ± 0.4
Max. 5.0
3.6 ± 0.4
Max. 4.3
3.6 ± 0.4
Max. 4.3
2.9 ± 0.3
Max. 3.5
Measurement conditions
Unit
RAISE
Item
DUMP
Cate gory
CURL
12
Boom
●Hydraulic oil temperature: Within
operation range
●Engine at high idling ●Working mode: A mode ●Time required from raise stroke
Work equipment speed
Work equipment
end till bucket touches ground
Arm
●Hydraulic oil temperature: Within
operation range
●Engine at high idling ●Working mode: A mode ●Time required from dumping
sec.
stroke end to digging stroke end
Bucket
●Hydraulic oil temperature: Within
stroke end to digging
DUMP
operation range
●Engine at high idling ●Working mode: A mode ●Time required from dumping ●stroke end
20-8 1
PC400LC-7L
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Category
Item
Measurement Condition
Unit
Boom
Standard value
Permissible value
Max. 3.0
Max. 3.6
Max. 3.0
Max. 3.6
Max. 3.0
Max. 5.0
4.5
20
10
50
●Hydraulic oil temperature: Within operation
range
●Engine at low idling ●Working mode: A mode ●Time required from raise stroke end till bucket
Time lag
Work equipment
touches ground and pushes up machine front
Arm
●Hydraulic oil temperature: Within operation
sec.
range
●Engine at low idling ●Working mode: A mode ●Time required from dumping stroke end till
bucket stops momentarily after control lever is tilted to digging and starts to move again
Bucket
●Hydraulic oil temperature: Within operation
range
●Engine at low idling ●Working mode: A mode ●Time required from dumping stroke end till
Internal leackage
bucket stops momentarily after control lever is tilted to digging and starts to move again
Cylinders
Center swivel joint
PC400LC-7L
●Hydraulic oil temperature: Within operation
range
●Engine at high idling ●Leakage amount for one minute with cylinder
or travel to be measured in relief condition
cc/min
20-9 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12 Category
Item
Measurement Condition
Unit
Standard value
Permissible value
mm
Max. 400
Max. 440
Performance in compound operation
Swerving amount in simultaneous operation of work equipment and travel
Performance of hydraulic pump
●Hydraulic oil temperature: Within
Hydraulic pump delivery
operation range
20-10 1
●Engine at high idling ●Working mode: A mode ●Traveling speed: Lo ●Flat and level ground ●Swerving amount (X) when traveling
20 m after initial trial run of 10 m
See next page
L/min
See next page
PC400LC-7L
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12
Item
Measurement Condition
Check point
Test pump discharge Discharge pressure pressure of other pump (MPa {kg/cm2}) (MPa {kg/cm2})
Unit
Standard value
Permissible value
Performance of hydraulic pump
Category
As desired
P1
P2
Average pressure (MPa {kg/cm2})
P1+P2 2
Standard value for discharge amount Q (L/min)
See graph
Judgement standard lower limit Q (L/min)
See graph
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC400LC-7L
20-11 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
12
MEMORANDUM
20-12 1
PC400LC-7L
TESTING AND ADJUSTING
12 SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102 MEASURING ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 BLEEDING AIR FROM FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 HANDLING FUEL SYSTEM DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 RELEASING RESIDUAL FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 ADJUSTING ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 INTAKE AIR PRESSURE (BOOST PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105 FAN BELT AND ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106 AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107 SWING CIRCLE BEARING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108 TRACK SHOE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109 WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110 CONTROL CIRCUIT - BASIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115 PUMP PC CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116 PUMP LS CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120 SOLENOID VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125 PPC VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128 WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130 SWING PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130 WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131 RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-133 MEASURING OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-134 BLEEDING AIR FROM EACH PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137 DIODE TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140 MONITOR PANEL - SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-141 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . 20-167 PREPARATION WORK FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-168 PM CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170 UNDERCARRIAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
PC400LC-7L
20-101 1
TESTING AND ADJUSTING
SERVICE TOOLS
12
Measuring intake air pressure (boost pressure) Measuring exhaust temperature
A B
Part No.
1 Measuring exhaust gas color
C
Adjusting valve clearance
2
D 1
Measuring compression pressure
E 2 3
Measuring blow-by pressure
F
G
Boost gauge kit Digital thermometer Handy smoke meter
799-101-5002
Hydraulic tester
1
Dial gauge
1 with magnet
Hydraulic tester Digital hydraulic tester Nipple O-ring Hydraulic tester Digital hydraulic tester Nipple O-ring Hydraulic tester Digital hydraulic tester Nipple O-ring
1 1 2 2 1 1 2 2 1 1 4 4
790-261-1203 2
Measuring fuel pressure
1
H
2 Measuring clearance of swing circle bearing
J
Measuring and adjusting oil pressures in work K equipment, swing, and travel circuits
1 2 1
Measuring basic pressure in control circuit
L 2
Testing and adjusting oil pressure in pump PC M control circuit
20-102 1
1 2
Remarks
799-201-2202 799-101-1502 799-201-1502 Commercially available Commercially available 795-502-1590 795-471-1410 6217-71-6112 795-799-1170 799-201-1504
1 Measuring engine oil pressure
Part name
Qty
Testing/Adjusting item
Symbol
SERVICE TOOLS
799-401-2320 799-101-5002 790-261-1203 799-401-2320 Commercially available 799-101-5002 790-261-1203 799-101-5220 07002-11023 799-101-5002 790-261-1203 799-101-5220 07002-11023 799-101-5002 790-261-1203 799-101-5220 07002-11023
Smoke meter Feeler gauge Compression gauge Adapter Gasket Puller Blow-by checker
1 -101 - 200 kPa {-760 - 1,500 mmHg} 1 -99.9 - 1,299×C 1 Pollution level: 0 - 70 % (With standard color) (Pollution level x 1/10 1 Bosch index) intake side: 0.35 mm, Exhaust side: 1 Air 0.57 mm 1 0 - 6.9 MPa {0 - 70 kg/cm2} 1 For 125E-3 engine 1 1
(Pressure gauge): 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2} (Pressure gauge): 58.8 MPa {600 kg/ Digital hydraulic tester 1 cm2} (Pressure gauge): 0.98MPa {10 kg/ Hydraulic tester 1 cm2} Hydraulic tester 1 Digital hydraulic tester 1 Same as G Hydraulic tester 1
Same as G (Size): 10 x 1.25 mm Same as G1 Same as K2 Same as G
PC400LC-7L
TESTING AND ADJUSTING
SERVICE TOOLS
Part No. 1
Testing and adjusting pressure in pump LS control circuit
N
2 3 1
Measuring solenoid valve output pressure
P 2
Measuring PPC valve output pressure
Q
1 2
Measuring oil leakage
R
Testing wear of sprocket Measuring water temperature and oil temperature
-----
Measuring operating effort and pressing force
---
Measuring stroke and hydraulic drift
---
Measuring work equipment speed
---
Measuring voltage and resistance
---
799-101-5002 790-261-1203 799-101-5220 07002-11023 799-401-2701 799-101-5002 790-261-1203 799-401-3100 799-401-3200 799-101-5002 790-261-1203 970-301-1740 Commercially available 799-627-1120 799-101-1502 79A-264-0021 79A-264-0091 Commercially available Commercially available Commercially available
Part name
Qty
Testing/Adjusting item
Symbol
12
Remarks
Hydraulic tester Digital hydraulic tester Nipple O-ring Differential pressure gauge Hydraulic tester Digital hydraulic tester Adapter Adapter Hydraulic tester Digital hydraulic tester Joint
1 1 4 4 1 1 1 1 1 1 1 1
Measuring cylinder
1
Wear gauge Digital thermometer Push-pull scale Push-pull scale
1 1 Same as B 1 0 - 294 N {0 - 30 kg} 1 0 - 490 N {0 - 50 kg}
Scale
1
Stopwatch
1
Tester
1
Same as G1 Same as M2
Same as G1 (Size): 02 (Size): 03 Same as G1 (Size): PF1/4 + PT1/4
★ For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connectors and electric circuit diagram of each system.
PC400LC-7L
20-103 1
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
12
MEASURING ENGINE SPEED 1.
Turn the starting switch ON and set the monitor panel to “Monitoring”. ★ For the operating method, see “Special functions of monitor panel”. ● Monitoring code: 01002 Engine Speed 01006 Engine Speed ★ Code 01002 is information of the engine controller and code 01006 is information of the pump controller. The engine speed can be measured with either of those codes. ★ The engine speed is displayed in rpm.
2.
Run the engine and raise the engine water temperature and hydraulic oil temperature to the operating range.
3.
Measure the engine speed under each measurement condition. A. Measuring low idling speed: i.
Start the engine and set the fuel control dial in the low idling position (MIN).
ii.
Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed.
B. Measuring high idling speed: i.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
Set the working mode switch in the A-mode position.
iii. Turn the auto-decelerator switch OFF. iv. Set the work equipment control, swing control, and travel levers in neutral. C. Measuring 2-pump relief speed: i.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
Set the working mode switch in the A-mode position.
iii. Relieve the arm circuit by moving the arm in. D. Measuring 2-pump relief + one-touch power maximizing speed (near rated speed): i.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
Set the working mode switch in the A-mode position.
iii. While relieving the arm circuit by moving the arm in, keep pressing the one-touch power maximizing switch. ★ The one-touch power maximizing function is reset automatically in about 8.5 seconds even if the switch is kept held. Accordingly, measure the engine speed in that period. E. Measuring auto-deceleration speed i.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
Turn the auto-deceleration switch ON.
iii. Set the work equipment control and swing control levers in neutral. ★ The engine speed lowers to a certain level about 5 seconds after all the levers are set in neutral. This level is the auto-deceleration speed.
20-104 1
PC400LC-7L
TESTING AND ADJUSTING
ENGINE
12
ENGINE Remark To tune, test and troubleshoot the following procedures you must refer to the ENGINE SHOP MANUAL for the SAA6D125E-3 series engine, Section 12, for the tool requirements and proper procedures.
FUEL BLEEDING AIR FROM FUEL CIRCUIT FUEL PRESSURE HANDLING FUEL SYSTEM DEVICES INSPECTION OF FUEL CIRCUIT FOR LEAKAGE RELEASING RESIDUAL FUEL SYSTEM PRESSURE
ADJUSTING ENGINE SPEED SENSOR ADJUSTING VALVE CLEARANCE BLOW-BY PRESSURE COMPRESSION PRESSURE ENGINE OIL PRESSURE ENGINE SPEED SENSOR EXHAUST GAS COLOR EXHAUST TEMPERATURE INTAKE AIR PRESSURE (BOOST PRESSURE)
PC400LC-7L
20-105 1
TESTING AND ADJUSTING
FAN BELT AND ALTERNATOR BELT TENSION
12
FAN BELT AND ALTERNATOR BELT TENSION TESTING 1.
Open the engine hood and remove belt protection covers (2 pieces).
2.
Press the intermediate point between alternator pulley and fan pulley with a finger and measure deflection “a” of the belt. ★ Deflection “a” when pressing force is approximately 58.8 N {approximately 6 kg}: 13 mm
ADJUSTING ★ If the deflection is abnormal, adjust it according to the following procedure. 1.
Loosen bolts and nuts (1), (2), and (3).
2.
Turn nut (4) to move alternator (5) and adjust the belt tension. ★ If nut (4) is: ● tightened clockwise, the belt tension is decreased. ● loosened counterclockwise, the belt tension is increased. ★ Check breakage of the pulleys, wear of the V-grooves and V-belts, and contact of the belts and V-grooves. ★ If a belt is lengthened to the adjustment limit, cut, or cracked, replace it new one.
3.
Tighten nuts and bolts (3), (2), and (1). ★ If a V-belt is replaced, adjust its tension again after 1 operating hour.
20-106 1
PC400LC-7L
TESTING AND ADJUSTING
AIR CONDITIONER COMPRESSOR BELT TENSION
12
AIR CONDITIONER COMPRESSOR BELT TENSION TESTING 1.
Open the engine hood and remove belt protection covers (2 pieces).
2.
Press the intermediate point between air conditioner compressor pulley and crank pulley with a finger and measure deflection “a” of the belt. ★ Deflection “a” when pressing force is approximately 58.8 N {approximately 6 kg}: 14 mm - 16 mm
ADJUSTING ★ If the deflection is abnormal, adjust it according to the following procedure. 1.
Loosen bolts (1) and (2).
2.
Move compressor (3) to adjust the belt tension. ★ Check breakage of the pulleys, wear of the V-grooves and V-belts, and contact of the belts and V-grooves. ★ If a belt is lengthened to the adjustment limit, cut, or cracked, replace it new one.
3.
Tighten bolts (2) and (1). ★ If a V-belt is replaced, adjust its tension again after 1 operating hour.
PC400LC-7L
20-107 1
TESTING AND ADJUSTING
SWING CIRCLE BEARING CLEARANCE
12
SWING CIRCLE BEARING CLEARANCE ★ Measuring instrument for clearance of swing circle bearing. ★ When measuring the clearance of the swing circle bearing on the actual machine, observe the following procedure. WARNING! While measuring, do not put your hands or foot under the undercarriage. 1.
Fix dial gauge J to outer race (1) or inner race (2) of the swing circle and apply the probe to the end face of inner race (2) or outer race (1) on the opposite side. ★ Set dial gauge J on the front or at rear side of the machine.
2.
Set the work equipment in the maximum reach position and set the bucket tip at the height of the revolving frame bottom. ★ At this time, the front end of the upper structure lowers and the rear end rises.
3.
Set the dial gauge to 0 point.
4.
Set the arm at almost right angle to the ground and lower the boom until the track shoe at the front end of the machine rises. ★ At this time, the front end of the upper structure rises and the rear end lowers.
5.
Under this condition, read dial gauge J. ★ Dial gauge J indicates the clearance of the bearing.
6.
Return the machine to the position of step 2 and check that dial gauge J indicates 0 again. ★ If dial gauge J does not indicate 0, repeat steps 3 - 5.
20-108 1
Symbol J
Part Number Commercially available
Part Name Dial gauge
PC400LC-7L
TESTING AND ADJUSTING
TRACK SHOE TENSION
12
TRACK SHOE TENSION TESTING 1.
Run the engine at low idling and move the machine forward by the length of track on ground and stop slowly.
2.
Place square bar [1] on the track shoe between idler (1) and 1st carrier roller (2). ★ As the square bar [1], use an L-shape steel, etc. which will be deflected less.
3.
Measure maximum distance “a” between square bar [1] and track shoe. ● Standard maximum distance “a”: 10 - 30 mm
ADJUSTING ★ If the track shoe tension is abnormal, adjust it according to the following procedure. 1.
When tension is too high Loosen valve (3) to discharge the grease. WARNING! Since the valve may jump out because of the high-pressure grease, do not loosen it more than 1 turn.
2.
When tension is low Add grease through valve (3). ★ If the track shoe is not tensed well, drive the machine forward and in reverse slowly.
PC400LC-7L
20-109 1
TESTING AND ADJUSTING
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
12
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS Testing and adjusting instruments for oil pressure in work equipment, swing, and travel circuits. Symbol 1 K 2
Part Number 799-101-5002 790-261-1203 799-101-5220 07002-11023
Part Name Hydraulic tester Digital hydraulic tester Nipple (10x1.25 mm) O-ring
★ The oil pressure in work equipment, swing, and travel circuits can be checked with the monitoring function of the monitor panel (For the operating method, see “Special functions of monitor panel”). ● Monitoring code: 01100 F Pump Pressure 01101 R Pump Pressure ●
The pump oil pressure is displayed in 1 kg/cm2 (1 psi).
MEASURING 1.
Preparation work WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. A. Open the pump room cover and remove oil pressure pick-up plugs (1) and (2). ● (1): Front pump discharge pressure pickup plug. ● (2): Rear pump discharge pressure pickup plug. B. Install nipple K2 and connect it to oil pressure gauge [1] of hydraulic tester K1. ★ Use the oil pressure gauges of 600 kg/cm2, (8534 psi).
C. Run the engine and raise the hydraulic oil temperature to the operating range.
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PC400LC-7L
TESTING AND ADJUSTING
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
12 2. Combination of pump, actuator, and valve ★ When the oil from the pumps is divided, the front pump and rear pump act independently on each actuator. Note that different actuators relieve different valves. ★ When the work equipment circuit or swing circuit is relieved singly, the oils of the pumps are merged. When the travel circuit is relieved singly, the oils of the pumps are divided. ★ The actuators in the table are arranged in the order when the control valve is seen from the front of the machine (and an Pump Actuator Valve relieved attachment is installed to the service valve). 3.
Measuring unload pressure A. Start the engine. B. Run the engine at high idling and set all the control levers in neutral and measure the oil pressure. ★ The pressure measured when the unload valve is unloaded is indicated.
4.
Measuring work equipment circuit relief pressure A. Start the engine and move the cylinder to be measured to the stroke end.
(F unload valve) (F main relief valve) Service Safety valve for service Boom Hi F main relief valve Arm Hi Bucket F main relief valve Front Left travel F main relief valve RAISE: F main relief valve Boom LOWER: Safety-suction valve (Pump merge-divider valve) (Travel junction valve) (Self-pressure reducing valve) Swing Swing motor safety valve Rear Right travel R main relief valve Arm Lo R main relief valve (R unload valve) (R main relief valve) (Centralized safety valve) (Back pressure valve)
B. Run the engine at high idling and relieve the cylinder and measure the oil pressure. ★ The pressure measured when the main relief valve is relieved is indicated. ★ If the one-touch power maximizing switch is released, the valve is relieved at low pressure. If the former is pressed, the lower is relieved at high pressure. ★ If the swing lock switch is turned ON, the 2-stage relief valve is kept turned ON and the valve is relieved at high pressure. Accordingly, keep the swing lock switch turned OFF. 5.
Measuring swing circuit relief pressure A. Start the engine and turn the swing lock switch ON. B. Run the engine at high idling and relieve the swing circuit and measure the oil pressure. ★ The pressure measured when the swing motor safety valve is relieved is indicated. ★ The swing motor relief pressure is lower than the main relief valve.
6.
Measuring travel circuit relief pressure A. Start the engine and lock the travel mechanism. WARNING! Set pin [2] between the sprocket and track frame to lock the travel mechanism securely. B. Run the engine at high idling and relieve the travel circuit and measure the oil pressure. ★ The pressure measured when the main relief valve is relieved is indicated. The travel circuit is always relieved at high pressure.
PC400LC-7L
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TESTING AND ADJUSTING
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
12 ADJUSTING ★ The unload valve cannot be adjusted. 1.
Adjusting main relief pressure ★ If the relief pressure of the work equipment circuit and/or travel circuit is abnormal, adjust main relief valves (3) and (4) according to the following procedure. ● (3): Front main relief valve ● (4): Rear main relief valve ★ When adjusting the main relief valve on the front pump side, remove the control valve top cover. ★ When adjusting the main relief valve on the rear pump side, remove the control valve undercover (if the covers are installed). ★ Adjust only the low relief pressure of the main relief valve. (If the low relief pressure is adjusted, the high relief pressure is adjusted automatically.) ★ The low relief pressure is the pressure applied when the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the selector port. A. Disconnect pilot hose (5). B. Fixing holder (6), loosen locknut (7). C. Turn holder (6) to adjust the pressure. ★ If the holder is: ● turned to the right, the pressure rises. ● turned to the left, the pressure lowers. ★ Quantity of adjustment per turn of holder: Approximately 209 kg/cm2, (2972 psi) D. Fixing holder (6), tighten locknut (7). Locknut: 49.0 - 58.8 Nm (36.1 - 43.3 lbf ft) E. Connect pilot hose (5). F.
2.
After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.
Adjustment of boom LOWER relief pressure (High-pressure setting side) ★ If the high relief pressure of the boom LOWER circuit is abnormal, adjust the high pressure setting side of boom LOWER safety suction valve (8) according to the following procedure. ★ The high relief pressure is the pressure applied when the machine push-up switch is turned ON and the pilot pressure is not applied to the selector port. A. Disconnect pilot hose (9). B. Fixing holder (10), loosen locknut (11).
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PC400LC-7L
TESTING AND ADJUSTING
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
12 C. Turn holder (10) to adjust the pressure. ★ If the holder is ● turned to the right, the pressure rises. ● turned to the left, the pressure lowers. ★ Quantity of adjustment per turn of holder: Approximately 258 kg/cm2 (3669 psi). D. Fixing holder (10), tighten locknut (11). Locknut: 93 - 123 Nm (68.59 - 90.72 lbf ft) E. Connect pilot hose (9). F.
3.
After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above. ★ If the high pressure setting side is adjusted, the low pressure setting side changes. Accordingly, adjust the low pressure setting side.
Adjustment of boom LOWER relief pressure (Low-pressure setting side) ★ If the low relief pressure of the boom LOWER circuit is abnormal or the high pressure setting side was adjusted, adjust the low pressure setting side of boom LOWER safety-suction valve according to the following procedure. ★ The low relief pressure is the pressure applied when the machine push-up switch is turned OFF and the pilot pressure is applied to the selector port. A. Disconnect pilot hose (9). B. Fixing holder (12), loosen locknut (13). C. Turn holder (12) to adjust the pressure. ★ If the holder is: ● turned to the right, the pressure rises. ● turned to the left, the pressure lowers. ★ Quantity of adjustment per turn of holder: Approximately 258 kg/cm2 (3669 psi) D. Fixing holder (12), tighten locknut (13). Locknut: 78 - 93 Nm (57.5 - 68.5 lbf ft) E. Connect pilot hose (9). F.
4.
After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.
Adjusting swing relief pressure ★ If the relief pressure of the swing circuit is abnormal, adjust swing motor safety valve (14) according to the following procedure. A. Fixing adjustment screw (15), loosen locknut (16). B. Turn adjustment screw (15) to adjust the pressure. ★ If the adjustment screw is: ● turned to the right, the pressure rises. ● turned to the left, the pressure lowers. ★ Quantity of adjustment per turn of adjustment screw: 47.9 kg/cm2 (681 psi).
PC400LC-7L
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TESTING AND ADJUSTING
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
12 C. Fixing adjustment screw (15), tighten locknut (16). Locknut: 147 - 196 Nm (108.4 - 144.5 lbf ft) D. After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.
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PC400LC-7L
TESTING AND ADJUSTING
CONTROL CIRCUIT - BASIC PRESSURE
12
CONTROL CIRCUIT - BASIC PRESSURE ★ Measuring instruments for basic pressure in control circuit Symbol 1 L 2
Part No. 799-101-1502 790-261-1203 799-101-5220 07002-11023
Part Name Hydraulic tester Digital hydraulic tester Nipple (10 x 1.25 mm) O-ring
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1.
Remove the control valve top cover and remove control circuit basic pressure pick-up plug (1). ★ The figure shows the control valve seen from inside of the pump room.
2.
Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. ★ Use the oil pressure gauges of 60 kg/cm2 (853.4 psi)
3.
Run the engine and raise the hydraulic oil temperature to the operating range.
4.
Run the engine at high idling and set all the control levers in neutral and measure the oil pressure.
5.
After finishing measurement, remove the measuring instruments and return the removed parts. ★ The relief valve for the control circuit basic pressure is not adjustable.
PC400LC-7L
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TESTING AND ADJUSTING
PUMP PC CONTROL CIRCUIT
12
PUMP PC CONTROL CIRCUIT ★ Testing and adjusting instruments for oil pressure in pump PC control circuit Symbol 1 M 2
Part No. 799-101-1502 790-261-1203 799-101-5220 07002-11023
Part Name Hydraulic tester Digital hydraulic tester Nipple (10 x 1.25 mm) O-ring
MEASURING ★ Before measuring the oil pressure in the pump PC control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure in the control circuit are normal. WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1.
Measuring PC valve output pressure (servo piston inlet pressure) ★ Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and compare them. A. Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (3), and (4). ● (1): Front pump discharge pressure pickup plug. ● (2): Rear pump discharge pressure pickup plug. ● (3): Front PC valve output pressure pickup plug. ● (4): Rear PC valve output pressure pickup plug.
B. Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. ★ Use the oil pressure gauges of 600 kg/cm2 (8534 psi). ● The figure shows the pump discharge pressure side.
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TESTING AND ADJUSTING 12
●
PUMP PC CONTROL CIRCUIT
The figure shows the PC valve output pressure side.
C. Run the engine and raise the hydraulic oil temperature to the operating range.
D. Run the engine at high idling and measure the pump discharge pressure and PC valve output pressure (servo piston inlet pressure) at the same time under the following condition. ● Working mode: A ● Swing lock switch: ON (2-stage relief solenoid valve is turned ON and oil is relieved at high pressure) ● Work equipment, swing, and travel circuits: Relieve by moving arm IN. ★ Judging method: If the pump discharge pressure and PC valve output pressure (servo piston output pressure) are as follows, they are normal. Measured pressure Pump discharge pressure PC valve output pressure
Pressure ratio 1 Approximately 0.6 (3/5)
★ If the PC valve or servo piston is abnormal, the PC valve output pressure (servo piston output pressure) becomes “the same as the pump discharge pressure” or “almost 0”. E. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7L
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TESTING AND ADJUSTING
PUMP PC CONTROL CIRCUIT
12 2. Measuring PC-EPC valve output pressure A. Open the pump room cover and remove PC-EPC valve output pressure pick-up plug (5).
B. Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. ★ Use the oil pressure gauges of 60 kg/cm2 (853.4 psi).
C. Run the engine and raise the hydraulic oil temperature to the operating range.
D. Set all the control levers in neutral and measure the oil pressure while running the engine at low idling and high idling. ★ If the PC-EPC valve output pressure changes as shown below, it is normal. Engine
Control lever
Low idling Neutral High idling
Oil pressure 30 kg/cm2 (426.7 psi) 0 kg/cm2 (0 psi)
E. After finishing measurement, remove the measuring instruments and return the removed parts.
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PC400LC-7L
TESTING AND ADJUSTING
PUMP PC CONTROL CIRCUIT
12 ADJUSTING ★ If any of the following phenomena occurs and the PC valve seems to be defective, adjust PC valves (6) and (7) according to the procedure shown below. ● When the working load is increased, the engine speed lowers largely. ● The engine speed is normal but the work equipment speed is low. ● (6): Front pump PC valve. ● (7): Rear pump PC valve. ★ The width across flats of the locknut for the PC valve is 13 mm and that of the adjustment screw (inside width) is 4 mm. Do not turn any other locknut or adjustment screw since it has effects on the hydraulic pumps.
1.
Loosen locknut (8). ★ Before loosening the locknut, make match marks at the adjustment screw end so that you can see the position of the locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse).
2.
Turn adjustment screw (9) to the right or left to adjust. ★ Turn the adjustment screw in the following directions. ● If the work equipment speed is low, turn the adjustment screw to the right (to increase the pump absorption torque). ● If the engine speed lowers, turn the adjustment screw to the left (to decrease the pump absorption torque). ★ The adjustable range of the adjustment screw is as follows. ● Counterclockwise: Max. 1 turn. ● Clockwise: Max. 1 turn.
3.
Tighten locknut (8). Locknut: 27.5 - 34.3 Nm (20.2 - 25.2 lbf ft)
4.
After finishing adjustment, check that the PC valve output pressure (servo piston inlet pressure) is normal according to the procedure for measurement described above.
PC400LC-7L
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TESTING AND ADJUSTING
PUMP LS CONTROL CIRCUIT
12
PUMP LS CONTROL CIRCUIT ★ Testing and adjusting instruments for oil pressure in pump LS control circuit Symbol 1 N
2 3
Part No. 799-101-5002 790-261-1203 799-101-5220 07002-11023 799-401-2701
Part Name Hydraulic tester Digital hydraulic tester Nipple (10 Þ 1.25 mm) O-ring Differential pressure gauge
MEASURING ★ Before measuring the oil pressure in the pump LS control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure in the control circuit are normal. WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1.
Measuring LS valve output pressure (servo piston inlet pressure) ★ Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and compare them. A. Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (3), and (4). ● (1): Front pump discharge pressure pickup plug. ● (2): Rear pump discharge pressure pickup plug. ● (3): Front LS valve output pressure pickup plug. ● (4): Rear LS valve output pressure pickup plug.
B. Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1. ★ Use the oil pressure gauges of 600 kg/cm2 (8534 psi). ● The figure shows the pump discharge pressure side.
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TESTING AND ADJUSTING 12
●
PUMP LS CONTROL CIRCUIT
The figure shows the LS valve output pressure side.
C. Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. ● When measuring front circuit: Left track shoe. ● When measuring rear circuit: Right track shoe. WARNING! Since the track shoe pushed up will be driven idle for measurement, secure sufficient work area.
D. Run the engine at high idling and measure the pump discharge pressure and LS valve output pressure (servo piston inlet pressure) at the same time under the following condition. ● Working mode: A ● Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only the travel lever operated halfway (with the track shoe on one side driven idle). ★ Check the safety around the machine, drive the track shoe pushed up idle. ★ Judging method: If the pump discharge pressure and LS valve output pressure (servo piston output pressure) are as follows, they are normal. Measured pressure
All levers in neutral
Pump discharge pressure LS valve output pressure
Almost same
Pressure ratio Travel lever operated halfway 1 Approximately 0.6 (3/5)
E. After finishing measurement, remove the measuring instruments and return the removed parts. 2.
Measuring LS differential pressure ★ Measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time and calculate the difference between them. A. Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (5), and (6). ● (1): Front pump discharge pressure pickup plug. ● (2): Rear pump discharge pressure pickup plug.
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TESTING AND ADJUSTING 12
PUMP LS CONTROL CIRCUIT
(5): Front LS valve output pressure pickup plug. (6): Rear LS valve output pressure pickup plug.
● ●
B. Install nipple N2 and connect it to differential pressure gauge N3 or the oil pressure gauge of hydraulic tester N1. ★ When using differential pressure gauge: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12-V power source, connect it to a battery. ★ When using oil pressure gauge: Use the oil pressure gauge of 600 kg/cm2 (8534 psi). Since the differential pressure is about 30 kg/cm2 (427 psi) at maximum, measure it by installing the same gauge to the pick-up plugs alternately. ● The figure shows the pump discharge pressure side.
●
The figure shows the LS valve output pressure side.
C. Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. ● When measuring front circuit: Left track shoe. ● When measuring rear circuit: Right track shoe WARNING! Since the track shoe pushed up will be driven idle for measurement, secure sufficient work area. D. Run the engine at high idling and measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time under the following condition. ● Working mode: A ● Travel speed: Hi ● Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only the travel lever operated halfway (with the track shoe on one side driven idle). ★ Check the safety around the machine, drive the track shoe pushed up idle. ★ Calculation of LS differential pressure (When oil pressure gauge is used): LS differential pressure = Pump discharge pressure – LS pressure. ★ If the LS differential pressure is as follows, it is normal. Operation of lever Set all levers in neutral Operate travel lever halfway (Run track shoe idle)
LS differential pressure Unload pressure (See standard values table) Specified LS differential pressure (See standard values table)
E. After finishing measurement, remove the measuring instruments and return the removed parts.
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PC400LC-7L
TESTING AND ADJUSTING
PUMP LS CONTROL CIRCUIT
12 3. Measuring LS-EPC valve output pressure. A. Open the pump room cover and remove LSEPC valve output pressure pick-up plug (7).
B. Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1. ★ Use the oil pressure gauges of 60 kg/cm2 (853 psi).
C. Run the engine and raise the hydraulic oil temperature to the operating range. D. Operate the travel speed switch and travel lever and measure the oil pressure while running the engine at high idling. ★ If the LS-EPC valve output pressure changes as shown below, it is normal. Travel speed Lo
Travel lever Neutral
Oil pressure 30 kg/cm2 (427 psi)
Hi
Fine operation (Remark)
0 kg/cm2 (0 psi)
Remark Operate the travel lever to a degree that the PPC oil pressure switch is turned ON (Stop before the machine starts traveling). E. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7L
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TESTING AND ADJUSTING
PUMP LS CONTROL CIRCUIT
12 ADJUSTING ★ If the LS differential pressure is abnormal, adjust LS valves (8) and (9) according to the following procedure. ● (8): Front pump LS valve. ● (9): Rear pump LS valve.
1.
Fixing adjustment screw (10), loosen locknut (11).
2.
Turn adjustment screw (10) to adjust the differential pressure. ★ If the adjustment screw is: ● turned to the right, the differential pressure rises. ● turned to the left, the differential pressure lowers. ★ Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approximately 13.3 kg/cm2 (189 psi).
3.
After finishing adjustment, check that the LS pressure is normal according to the procedure for measurement described above.
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PC400LC-7L
TESTING AND ADJUSTING
SOLENOID VALVE - OUTPUT PRESSURE
12
SOLENOID VALVE - OUTPUT PRESSURE ★ Measuring instruments for solenoid valve output pressure Symbol 1 P 2
Part No. 799-101-5002 790-261-1203 799-401-3100 799-401-3200
Part Name Hydraulic tester Digital hydraulic tester Adapter (Size 02) Adapter (Size 03)
★ Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal. WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1.
Remove the control valve top cover and disconnect outlet hose (1) – (7) of the solenoid valve to be removed. ★ Since the outlet hoses of the PPC lock solenoid valves have quick couplers on the solenoid valve side, measure the pressure on the PPC valve side (on the back side of the operator’s cab)
. No. 1 2 3 4 5 6 7
Solenoid valve to be measured 2-stage relief solenoid valve Machine push-up solenoid valve Swing holding brake solenoid valve Travel speed selector solenoid valve Merge-divider solenoid valve Travel junction solenoid valve PPC lock solenoid valve
2.
Install adapter P2 and connect the disconnected hose again.
3.
Install nipple [1] of hydraulic tester P1 and connect it to hydraulic gauge [2]. ★ Use the oil pressure gauges of 60 kg/cm2 (853.4 psi). ★ The figure shows the measuring instruments connected to the outlet hose of the 2-stage relief solenoid valve.
PC400LC-7L
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TESTING AND ADJUSTING
SOLENOID VALVE - OUTPUT PRESSURE
12 4. Run the engine and raise the engine oil temperature to the operating range. 5.
Run the engine at high idling, operate the control levers and switches to turn the solenoid valve ON or OFF, and measure the oil pressure. ★ For the conditions for turning the solenoid valve ON and OFF, see the operations table of each solenoid valve. ★ The operating condition of the solenoid valve can be checked with the monitoring function of the monitor panel (For the operating method, see “Monitor Panel - Special Functions”).
★ If the output pressure is as follows, the solenoid valve is normal. Solenoid valve
Output pressure
OFF (Deenergized)
0 kg/cm (0 psi)
ON (Energized)
Almost same as control basic pressure (See standard values table)
6.
2
After finishing measurement, remove the measuring instruments and return the removed parts.
Operation table of 2nd-stage relief solenoid valve Operating condition
Operation
When overheating No. 1 setting is turned ON
OFF
When all of work equipment, swing, and travel signals are turned OFF When swing lock switch is turned ON When travel signal is turned ON When in L-mode
ON
When boom LOWER signal is turned ON When in A/E-mode
When signal other than swing single operation signal is turned When left knob switch is turned ON ON When swing single operation signal is turned ON
When not under above condition
OFF
Operation table of machine push-up solenoid valve Operating condition Machine push-up switch
OFF ON
Operation ON OFF
Operation table of swing holding brake solenoid valve Operating condition When all are turned OFF When one of them is turned ON
Work equipment, swing, travel signal
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Operation OFF ON
PC400LC-7L
TESTING AND ADJUSTING
SOLENOID VALVE - OUTPUT PRESSURE
12 Operation table of travel speed shifting solenoid valve Operating condition
Operation
When overheating No. 2 setting is turned ON When fuel control dial is below 1,200 rpm When travel speed switch is set to Lo
OFF
When travel signal is turned OFF When travel speed switch is set to Mi or Hi
When travel signal is turned ON
When F or R pump pressure is above 330 kg/ cm2 (4693 psi) When F or R pump pressure is below 190 kg/cm2 (2702 psi)
ON
When not under above condition
Operation table of merge-divider solenoid valve When in B-mode
When travel signal is turned ON
When travel signal is turned OFF
Operating condition When service signal is turned ON When travel operation is performed singly
When work equipment, switch, and service signals are turned ON
When swing signal is turned OFF
Operation
When F or R pump pressure is above 200 kg/cm2 (2844 psi) When not in L-mode When F or R pump pressure is below 150 kg/cm2 (2133 psi) When F or R pump pressure is above 170 kg/cm2 (2418 psi) When in L-mode When F or R pump pressure is below 120 kg/cm2 (1707 psi) When arm IN and bucket When 2F or R pump pressure is above 250 CURL PPC pressures are kg/cm (3556 psi) above 19.5 kg/cm2 (277 When F or R pump pressure is below 200 psi) kg/cm2 (2844 psi)
ON
OFF ON OFF ON OFF
When not under above condition
Operation table of travel junction solenoid valve Operating condition
Operation
When F or R pump pressure is above 350 When travel system is kg/cm2 (4978 psi) When travel steering signal is turned OFF operated singly When not under above condition
ON
When travel steering signal is turned ON
OFF
Operation table of PPC lock solenoid valve Operating condition Lock Safety lock lever Free
PC400LC-7L
OFF ON
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TESTING AND ADJUSTING
PPC VALVE - OUTPUT PRESSURE
12
PPC VALVE - OUTPUT PRESSURE ★ Measuring instruments for PPC valve output pressure Symbol Q
1 2
Part No. 799-101-5002 790-261-1203 790-301-1740
Part Name Hydraulic tester Digital hydraulic tester Joint (PF 1/4 + PT 1/8)
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1.
Remove the control valve top cover and operator’s cab undercover.
2.
Disconnect PPC oil pressure switch or PPC pressure sensor (1) - (10) of the solenoid valve to be removed. ★ If the starting switch is turned ON while the arm IN or bucket CURL PPC pressure sensor is disconnected, an electrical equipment system error is detected. Accordingly, if the pressure sensor is removed, connect it to the connector again and clamp it to the nearest bracket, etc. No. 1 2 3 4 5 6
3.
Circuit to be measured Boom RAISE (S06) Boom LOWER (S02) Arm IN (S04) Arm OUT (S08) Bucket CURL (S01) Bucket DUMP (S05)
No. 7 8 9 10
Circuit to be measured Swing LEFT (S07) Swing RIGHT (S03) Travel (S30) Steering (S31)
Install joint Q2 and nipple [1] of hydraulic tester Q1 and connect them to oil pressure gauge [2]. ★ Use joint Q2 only when measuring the pressure at the pressure sensor mounting part. ★ Use the oil pressure gauges of 60 kg/cm2 (853 psi) ★ The figure shows the measuring instruments installed to the mounting part of the arm IN PPC pressure sensor.
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PC400LC-7L
TESTING AND ADJUSTING
PPC VALVE - OUTPUT PRESSURE
12 4. Run the engine and raise the engine oil temperature to the operating range.
5.
Run the engine at high idling and measure the oil pressure while the control lever of the measured circuit is in neutral and while it is operated to the stroke end. ★ If the PPC valve output pressure is as follows, the solenoid valve is normal. Operation of lever In neutral Operated to stroke end
6.
Output pressure 0 kg/cm2 (0 psi) Almost same as control basic pressure (See standard values table)
After finishing measurement, remove the measuring instruments and return the removed parts.
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TESTING AND ADJUSTING
WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT
12
WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT SWING PPC VALVE - PLAY ADJUSTMENT ★ If the work equipment and swing levers have large play, adjust them according to the following procedure. 1.
Remove the work equipment and swing PPC valve assembly.
2.
Remove bellows (1).
3.
Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4). ★ Do not move the piston at this time.
4.
Fix disc (3) and tighten locknut (2) to the specified torque. Locknut: 98 - 127 Nm (73 - 93 lbf ft)
5.
Install bellows (1).
6.
Install the work equipment and swing PPC valve assembly.
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PC400LC-7L
TESTING AND ADJUSTING
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE
12
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE ★ If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylinder packing side or control valve side according to the following procedure.
1.
Testing boom cylinder and bucket cylinder. A. Set the machine in the position of measuring hydraulic drift and stop the engine. ★ Fill the bucket with a rated load or with dirt and sand. B. When testing the boom cylinder, set the boom control lever in the RAISE position. When testing the bucket cylinder, set the bucket control lever in the CURL position. ● If the lowering speed is increased at this time, the cylinder packing is defective. ● If the lowering speed does not change at this time, the control valve is defective. ★ Operate the control lever while the starting switch is in the ON position. ★ If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator.
2.
Testing arm cylinder. A. Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine.
B. Operate the arm control lever in the IN position. ● If the lowering speed is increased at this time, the cylinder packing is defective. ● If the lowering speed does not change at this time, the control valve is defective. ★ Operate the control lever while the starting switch is in the ON position. ★ If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. Remark Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: A. If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. B. As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then the lowering speed is lowered. C. If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.
PC400LC-7L
20-131 1
TESTING AND ADJUSTING
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE
12 3. Testing PPC valve. While the pressure in the accumulator is high, set the safety lock lever in the LOCK/FREE position and measure the lowering distance. ★ Operate the control lever while the starting switch is in the ON position. ★ If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. ★ If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).
20-132 1
PC400LC-7L
TESTING AND ADJUSTING
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT
12
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT 1.
Releasing residual pressure in hydraulic tank. WARNING! Since the hydraulic tank is enclosed and pressurized, release the residual pressure in it when removing a hose or a plug connected to it. A. Lower the work equipment to the ground in a stable position and stop the engine. B. Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank.
2.
Releasing residual pressure in hydraulic cylinder circuit. WARNING! When disconnecting a pipe between a hydraulic cylinder and the control valve, release the residual pressure in the piping according to the following procedure. A. Release the residual pressure in the hydraulic tank. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK. ★ Keep the oil filler cap of the hydraulic tank removed. B. Turn the starting switch ON and set the safety lock lever in the FREE position, and then operate the work equipment control levers on both sides forward, backward, to the right, and to the left. ★ The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up, however, after the control valve is operated 2 - 3 times. C. Run the engine at low idling for 5 seconds to heighten the pressure in the accumulator. ★ When starting engine, set the safety lock lever in the LOCK position. D. Repeat steps B and C above 2 - 3 times, and the residual pressure in the piping is released.
3.
Releasing residual pressure in swing motor circuit. ★ The residual pressure in the swing motor circuit can be released by performing the operation for RELEASING RESIDUAL PRESSURE IN HYDRAULIC CYLINDER CIRCUIT (Operate the lever in the swing direction only, however).
4.
Releasing residual pressure in travel motor circuit. ★ Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by performing RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK.
PC400LC-7L
20-133 1
TESTING AND ADJUSTING
MEASURING OIL LEAKAGE
12
MEASURING OIL LEAKAGE ★ Measuring device for oil leakage Symbol R
1.
Part No. Commercially available
Part Name Measuring cylinder
Measuring oil leakage from boom cylinder. A. Run the engine and raise the engine oil temperature to the operating range. B. Move the boom cylinder to the RAISE stroke end and stop the engine. WARNING! Release the residual pressure in the piping on the boom cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the boom RAISE direction only, however). C. Disconnect hose (1) on the cylinder head side and block the hose side with a plate. WARNING! Take care not to disconnect the hose on the cylinder bottom side. ★ Use the following part to block the hose side. 07379-01044 (Flange #10) D. Run the engine at high idling and relieve the boom circuit by raising the boom. WARNING! Take care not to “lower the boom”. E. Measure the oil leakage for 1 minute after 30 seconds since relieving is started. F.
2.
After finishing measurement, return the removed parts.
Measuring oil leakage from arm cylinder. A. Run the engine and raise the engine oil temperature to the operating range. B. Move the arm cylinder to the IN stroke end and stop the engine. WARNING! Release the residual pressure in the piping on the arm cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the arm IN direction only, however). C. Disconnect hose (2) on the cylinder head side and block the hose side with a plate. WARNING! Take care not to disconnect the hose on the cylinder bottom side. ★ Use the following part to block the hose side. 07379-01044 (Flange #10) D. Run the engine at high idling and relieve the arm circuit by moving the arm IN. WARNING! Take care not to “move the arm OUT”. E. Measure the oil leakage for 1 minute after 30 seconds since relieving is started. F.
After finishing measurement, return the removed parts.
20-134 1
PC400LC-7L
TESTING AND ADJUSTING
MEASURING OIL LEAKAGE
12 3. Measuring oil leakage from bucket cylinder. A. Run the engine and raise the engine oil temperature to the operating range. B. Move the bucket cylinder to the CURL stroke end and stop the engine. WARNING! Release the residual pressure in the piping on the bucket cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the arm CURL direction only, however). C. Disconnect hose (3) on the cylinder head side and block the hose side with a plate. WARNING! Take care not to disconnect the hose on the cylinder bottom side. ★ Use the following part to block the hose side. 07379-01044 (Flange #10) D. Run the engine at high idling and relieve the bucket circuit by curling the bucket. WARNING! Take care not to “dump the bucket”. E. Measure the oil leakage for 1 minute after 30 seconds since relieving is started. F. 4.
After finishing measurement, return the removed parts.
Measuring oil leakage from swing motor. A. Run the engine and raise the engine oil temperature to the operating range. B. Disconnect drain hose (4) and block the hose side with a plug. ★ Use the following part to block the hose side. 07376-70522 (Plug #05) C. Turn the swing lock switch ON. D. Run the engine at high idling and relieve the swing circuit by swinging. ★ Measure the oil leakage for 1 minute after 30 seconds since relieving is started. ★ After measuring 1 time, swing 180°, and then measure again. E. After finishing measurement, return the removed parts.
PC400LC-7L
20-135 1
TESTING AND ADJUSTING
MEASURING OIL LEAKAGE
12 5. Measuring oil leakage from travel motor. A. Remove the travel motor cover. B. Run the engine and raise the engine oil temperature to the operating range, and then lock the travel system and stop the engine. WARNING! Put pin [1] between the sprocket and track frame to lock the travel system securely.
C. Disconnect drain hose (5) of the travel motor and block the hose side with a plug. ★ Use the following part to block the hose side. 07376-70522 (Plug #05) D. Run the engine at high idling and relieve the travel circuit. WARNING! Wrong operation of the lever can cause an accident. Accordingly, make signs and checks securely. ★ Measure the oil leakage for 1 minute after 30 seconds since relieving is started. ★ Measure several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time. E. After finishing measurement, return the removed parts.
20-136 1
PC400LC-7L
TESTING AND ADJUSTING
BLEEDING AIR FROM EACH PART
12
BLEEDING AIR FROM EACH PART
Work Replacing hydraulic oil
1 Air bleeding item Bleeding air from hydraulic pump
Replacing return filter element Replacing and repairing hydraulic pump Removing suction piping Replacing and repairing control valve Removing control valve piping Replacing and repairing cylinder Removing cylinder piping Replacing and repairing swing motor Removing swing motor piping Replacing and repairing travel motor Removing travel motor piping Replacing and repairing swivel joint Removing swivel joint piping
2 Starting engine
•
•
3
Air bleeding procedure 4
air Bleeding air Bleeding swing from cylinder from motor
5
6
Bleeding air from travel motor
Check oil level and starting work
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Remark Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1.
Bleeding air from hydraulic pump. A. Loosen bleeder (1) and check that oil flows out. B. If the oil does not flow out, disconnect drain hose (2) and fill the pump case with oil through the drain port. ★ Fix the drain hose adapter to a place higher than the oil level in the hydraulic tank. ★ Fill the pump case with oil until oil containing no bubbles flows out of the bleeder. C. After oil containing no bubbles flows out of bleeder (1), tighten air bleeder (1). Air bleeder: 7.8 - 9.8 Nm (5.75 - 7.22 lbf ft) ★ If the drain hose has been disconnected, connect it after tightening the air bleeder.
2.
Starting engine. When running the engine after performing step 1, keep its speed at low idling for 10 minutes. ★ If the engine water temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).
PC400LC-7L
20-137 1
TESTING AND ADJUSTING
BLEEDING AIR FROM EACH PART
12 3. Bleeding air from cylinder. ★ If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. A. Run the engine at low idling for about 5 minutes. B. Running the engine at low idling, raise and lower the boom 4 - 5 times. ★ Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil. C. Running the engine at high idling, perform step B. D. Running the engine at low idling, move the piston rod to the stroke end and relieve the oil. E. Bleed air from the arm cylinder and bucket cylinder according to steps B - D. 4.
Bleeding air from swing motor. A. Run the engine at low idling. B. Loosen hose (3) of port S slowly and check that oil flows out. WARNING! At this time, do not perform the swinging operation. C. If the oil does not flow out, stop the engine and disconnect the hose of port S and fill the pump case with oil. ★ After filling the pump case with oil, connect the hose of port S, and then repeat steps A and B. D. After oil containing no bubbles flows out, tighten the hose of port S. E. Swing slowly 2 turns or more in each direction.
5.
Bleeding air from travel motor. A. Remove the travel motor cover. B. Run the engine at low idling. C. Loosen bleeder (4) and check that oil flows out. D. After oil containing no bubbles flows out, tighten bleeder (4). Bleeder: 9.8 - 12.74 Nm (7.22 - 9.39 lbf ft) E. Using the work equipment, raise the track shoe on either side. F.
Drive the raised track shoe idle slowly for about 2 minutes. ★ Drive the track shoe on the opposite side idle similarly.
20-138 1
PC400LC-7L
TESTING AND ADJUSTING
BLEEDING AIR FROM EACH PART
12 6. Check oil level and starting work. A. Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.
B. Check the oil level by sight gauge (5) of the hydraulic tank. ★ If the oil level is between lines H and L, it is normal. ★ If the oil level is below line L, add new oil.
PC400LC-7L
20-139 1
TESTING AND ADJUSTING
DIODE TESTING PROCEDURE
12
DIODE TESTING PROCEDURE ★ Test an assembled-type diode or a diode unit according to the following procedure. ★ The conductive direction of an assembled-type diode is marked as shown in the figure. ★ The conductive direction of each diode is marked on its surface. 1.
When using a digital tester. A. Set the tester in the diode range and check the indicated value. ★ If an ordinary tester is used, the voltage of the battery in itself is indicated. B. Apply the red (+) test pin to the anode (P) side of the diode and the black (–) test pin to the cathode (N) side and read the indicated value.
C. Judge the condition of the diode from the indicated value. ● The indicated value does not change: There is not continuity (Defective). ● The indicated value changes: There is continuity (Normal) (Remark). Remark In the case of a silicon diode, the tester indicates a value of 460 – 600. 2.
When using an analog tester. A. Set the tester in the resistance range. B. Apply the test pins as shown below and check movement of the pointer. i.
Apply the red (+) test pin to the anode (P) side of the diode and the black (–) test pin to the cathode (N) side.
ii.
Apply the red (+) test pin to the cathode (N) side of the diode and the black (–) test pin to the anode (P) side.
C. Judge the condition of the diode from movement of the pointer. ● The pointer does not move in i above but moves in ii: Normal (Moving angle (Resistance) depends on the type and measurement range of the tester, however) ● The pointer moves in both i and ii: Defective (Internal short circuit) ● The pointer does not move in either of i and ii: Defective (Internal disconnection)
20-140 1
PC400LC-7L
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12
MONITOR PANEL - SPECIAL FUNCTIONS
[1] Numeral input switch 1 [2] Numeral input switch 2 [3] Numeral input switch 3 [4] Numeral input switch 4 [5] Numeral input switch 5
PC400LC-7L
[6] Numeral input switch 6 [7] Numeral input switch 7 [8] Numeral input switch 8 [9] Numeral input switch 9 [0] Numeral input switch 0
[/ [∆ [∇ [✓
] Return switch ] Move-up switch ] Move-down switch ] Input check switch
20-141 1
TESTING AND ADJUSTING 12 ORDINARY
MONITOR PANEL - SPECIAL FUNCTIONS
FUNCTIONS AND SPECIAL FUNCTIONS OF MONITOR PANEL
The monitor panel has the ordinary functions and special functions and displays various pieces of information on the multi-display unit. Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by operating switches. 1.
Ordinary functions: Operator menu The items in this menu are displayed normally. The operator can display and set them by operating switches.
2.
Special functions: Service menu The items in this menu are not displayed normally. Each serviceman can display them by operating special switches.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Operator’s Menu Screen to display KOMATSU logo Function of check before starting Function of displaying maintenance items Function of displaying caution items Function of checking working mode and travel speed Function of displaying ordinary screen Function of adjusting brightness and contrast of display Function of adjusting flow rate for breaker and attachments Function of checking maintenance information Function of displaying service meter Function of checking display LCD Function of displaying cautions Function of displaying user code Function of displaying error code and failure code
20-142 1
Service Menu 15 Function of monitoring [01] Function of Electrical system 16 abnormality Mechanical system record [02] 17 Function of maintenance record [03] 18 Function of maintenance mode change [04] 19 Function of phone No. entry [05] Mode in which key is ON Function of initial Language 20 setting and default Unit [06] With/Without service circuit Pump absorption torque Function of Adjustment of flow for 21 adjustment [07] attachment during compound operation Function of cylinder cut out mode operation 22 [09]
PC400LC-7L
TESTING AND ADJUSTING 12 OPERATION
MONITOR PANEL - SPECIAL FUNCTIONS
AND DISPLAY OF OPERATOR’S MENU
(OUTLINE) ★ Only outline of the operating method is described in this section. For details of contents and operation of each menu, see OPERATION MANUAL or the volume of STRUCTURE AND FUNCTION. 1.
Screen to display KOMATSU logo. When a password is input (if it is set) or when the starting switch is turned ON, the KOMATSU logo is displayed for 2 seconds.
2.
Function of check before starting. After the KOMATSU logo is displayed, the screen for check before starting is displayed for 2 seconds.
3.
Function of displaying maintenance items. After the screen for check before starting is displayed, if any oil or filter is near or has passed the set maintenance time, the maintenance mark is displayed for 30 seconds. ★ This screen is displayed only when the maintenance function is set.
4.
Function of displaying caution items. After the screen for check before starting is displayed, if any check item is abnormal, the corresponding symbol mark is displayed.
PC400LC-7L
20-143 1
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 5. Function of checking working mode and travel speed. After the screen for check before starting is displayed, the symbol marks of the working mode and travel speed are displayed in large size for 2 seconds to urge the operator to check the setting.
6.
Function of displaying ordinary screen. After the screen for checking the working mode and travel speed is displayed, the ordinary screen is displayed. ★ When the ordinary screen is displayed, if the working mode or travel speed is changed or if the auto deceleration or windshield wiper is set effective, the corresponding symbol mark is displayed in large size for 2 seconds. ★ The preheating monitor is displayed only when the pre-heater is turned ON.
7.
Function of adjusting brightness and contrast of display. The operator can adjust the brightness and contrast of the display with the screen adjustment switches.
8.
Function of adjusting flow rate for breaker and attachments (for machine with breaker or attachment). The operator can adjust the pump flow rate for the breaker or an attachment wit h the selector switch. ★ The symbol marks and description of the breaker and attachment shown on the screen are partly different.
20-144 1
PC400LC-7L
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 9. Function of checking maintenance information. The operator can check the detailed information about the maintenance items (set time and elapsed time) and reset them after checking with the maintenance switches. ★ The maintenance function is set and reset and the maintenance time is set with the service menu.
10. Function of displaying service meter. When the starting switch is turned OFF, the operator can display only the service meter by operating the following switches. ● Operation of switches: [/] + [∆] (Operate these switches simultaneously)
11. Function of checking display LCD. On the password inputting screen or ordinary screen, the operator can check the display LCD. ● Operation of switches: [/] + [A] (Operate these switches simultaneously) ★ The whole LCD unit is turned ON and all the surface becomes white. If there is not any black part, the LCD unit is normal. ★ If any switch is operated while the LCD unit is being checked, the screen before the check is displayed again.
12. Function of displaying cautions. If there is any abnormal one in the calculation items, the corresponding symbol mark is displayed in large size for 2 seconds, and then it is displayed in small size until the abnormal item is repaired.
PC400LC-7L
20-145 1
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 13. Function of displaying user code. If the machine has any failure, the corresponding user code is displayed to urge the operator to take a proper remedy, depending on the degree of the failure. ★ If any switch is operated while the user code is displayed, the service code and failure code screen appears (See 14).
★ User codes and instructions given to operator User code
Failure mode
E02
Error in pump control system
E03
Error in swing brake system
E10 E11 E14 E15 E0E
20-146 1
Error in engine controller power supply or abnormality in engine controller drive system circuit (Engine stops) Error in engine controller system (Engine protection output is down) Error in throttle system Error in engine sensor (water temperature, fuel temperature, or oil pressure) Error in network
Instructions given to operator If the emergency pump drive switch is set in the upper (emergency) position, the machine can operate normally. Have the machine inspected immediately, however. Set the swing holding brake release switch in the upper (release) position to release the brake. Apply the swing brake manually with the swing lock switch, if necessary. The brake may not be released, depending on the cause of the failure. In any case, have the machine inspected immediately. Have the machine inspected immediately. Set the machine in a safe position and have the machine inspected immediately. Set the machine in a safe position and have the machine inspected immediately. Although the machine can operate normally, have the machine inspected immediately. Set the machine in a safe position and have the machine inspected immediately.
PC400LC-7L
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 14. Function of displaying error code and failure code. While a user code is displayed, if the following switches are operated, the phone mark (if registered), phone No. (if registered), error code, and failure code are displayed in order. ● Operation of switch: [✓] ★ The following are displayed in order repeatedly as the switch is operated. (1) Phone mark
⇓ (2) Phone No.
⇓ (3) Error code and failure code
★ The phone mark and phone No. are displayed only when the phone No. is registered in the monitor panel. The phone No. is registered, changed, or deleted with the service menu. ★ For details of the displayed error code and failure code, see the error codes and failure codes table.
PC400LC-7L
20-147 1
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 Table for Error and Failure Code Nos.
-----------
E112 E113 E114 E115 E116
Wiper Drive (For) S/C Wiper Drive (Rev) S/C Washer Drive S/C Wiper Working Abnormality Wiper Parking Abnormality
DY2DKB DYDEKB DY2CKB DY20KA DY20MA
Wiper motor (Forward) Wiper Motor (Reverse) Windshield Washer Motor Wiper Motor Wiper Motor
---
E117 Eng. Controller S-NET Comm Err.
DAC0KR
Engine Controller
---
E118 Pump Controller S-NET Comm Err. DAB0KR
Pump Controller
E128 Monitor Comm. Abnormality
DAFRMC
E201 Travel Junction Sol. S/C
DW91KB
E03
E203 Swing Brake Sol. S/C
DW45KB
---
E204 Merge-divider Sol. S/C
DWJ0KB
---
E205 2-stage Relief Sol. S/C
DWK0KB
---
E206 Travel Speed Sol. S/C
DW43KB
---
E211 Travel Junction Sol. Disc.
DW91KA
E03
E213 Swing Brake Sol. Disc.
DW45KA
---
E214 Merge-divider Sol. Disc.
DWJ0KA
---
E215 2-stage Relief Sol. Disc.
DWK0KA
---
E216 Travel Speed Sol. Disc.
DW43KA
---
E217 Model Selection Abnormality
DA2SKQ
E218 S-Net Comm. Disc.
DA2SKA
---------
E222 E223 E224 E225
DXE0KB DXE0KA DHPAMA DHPBMA
---
E226 Press. Sensor Power Abnormality
DA25KP
----E02
E227 Engine Speed Sensor Abnormality E228 Service Return Relay S/C E232 PC-EPC Sol. S/C
DLE2MA D196KB DXA0KB
Monitor CAN Communication Travel Neutral Solenoid Valve Swing Holding Brake Solenoid Valve Pump Merge-divider Solenoid Valve 2-stage Relief Solenoid Valve Travel Speed Hi/Lo Selector Solenoid Valve Travel Neutral Solenoid Valve Swing Holding Brake Solenoid Valve Pump Merge-divider Solenoid Valve 2-stage Relief Solenoid Valve Travel Speed Hi/Lo Selector Solenoid Valve Pump Controller Model Selection Wiring Harness Pump Controller S-NET Communication LS-EPC Solenoid Valve LS-EPC Solenoid Valve F Pump Pressure Sensor R Pump Pressure Sensor Pump Controller Power Supply Output Engine Speed Sensor ATT Selector Relay TVC Solenoid Valve
E0E ---
E0E
20-148 1
Contents
LS-EPC Sol. S/C LS-EPC Sol. Disc. F Pump P. Sensor Abnormality R Pump P. Sensor Abnormality
Code
Component
Trouble Short Circuit Short Circuit Short Circuit Disconnection Malfunction Defective communication (Abnormality in related component) Defective communication (Abnormality in related component) Defective Operation Short Circuit Short Circuit Short Circuit Short Circuit
Electrical system
Code
History division
Failure code
User code
Error code
Short Circuit Disconnection Disconnection Disconnection Disconnection Disconnection Disagreement of Model Selection Signals Disconnection Short Circuit Disconnection Malfunction Malfunction Lowering of Output Voltage Malfunction Short Circuit Short Circuit
PC400LC-7L
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12
E02 ---------
E233 E238 E245 E246 E247
Contents PC-EPC Sol. Disc. Service Return Relay Disc. Service Current EPC S/C Service Current EPC Disc. Arm Curl PPC Sen. Abnormality
Code DXA0KA D196KA DXE4KB DXE4KA DHS3MA
Component TVC Solenoid Valve ATT Selector Relay ATT Flow Throttle EPC Valve ATT Flow Throttle EPC Valve Arm IN PPC Pressure Sensor Bucket CURL PPC Pressure Sensor
---
E248 Bucket Curl PPC Sen. Abnormality
DHS4MA
---
E251 Overload Sensor Abnormality
DHX1MA
E257 Pump Comm. Abnormality
DA2RMC
---
E315 Battery Relay Drive S/C
D110KB
Pump Controller CAN Communication Battery Relay
E11
E91B Engine Ne Sensor Problem
DLE3LC
NE Speed Sensor
E11
E91C Engine G Sensor Problem
DLH1LC
G Speed Sensor
E11
E920 Engine Type Selection Error
DB29KQ
Engine Controller Model Selection Wiring Harness
E11
E921 Engine Type Mismatch
DB20KQ
Engine Controller
E14
E931 Fuel Dial sys. error
DK10KX
E15
E934 Engine Coolant Sensor Hi Error
DGE2KX
Throttle Angle Sensor Engine Coolant Temperature Sensor
E15
E936 Engine Oil Press. Sw. Error
DDE2L6
Engine Oil Pressure Switch
E11 E15
E93C Engine Boost Sensor Error E93D Engine Fuel Temp. Sensor Error
DH30KX DGE4KX
E0E
E953 Engine Comm. Abnormality
DB2RMC
E954 Short Engine Starter SW.
DD11KB
E0E
E955 Engine S-NET error
DB2SMC
E10
E956 Engine Power Failure (1)
DB22KK
E15
E957 Engine Power Failure (2)
D1D0KB
---
E95A Engine Q-adj. Sw. Signal Error
DB2AMA
E15
E96A Engine Coolant Sensor Lo Error
DGE3L6
E11 E11 E11 E11 E11
E970 E971 E974 E975 E977
AD11KB AD51KB AD11KA AD51KA DH40KX
Boost Pressure Sensor Fuel Temperature Sensor Engine Controller CAN Communication Starter SW. Engine Controller S-NET Communication Engine Controller Load Power Supply Line Engine Controller Load Power Supply Relay Rotary Switch in Engine Controller Engine Coolant Temperature Sensor Supply Pump (1) Solenoid Valve Supply Pump (2) Solenoid Valve Supply Pump (1) Solenoid Valve Supply Pump (2) Solenoid Valve Common Rail Pressure Sensor
E0E
---
PCV1 Over Current PCV2 Over Current PCV1 Line Cut PCV2 Line Cut Rail Press. Sensor Error
PC400LC-7L
History division
Code
Failure code Trouble Disconnection Disconnection Short Circuit Disconnection Malfunction Malfunction Malfunction Defective Operation Short Circuit Disagreement of Speed Signal Disagreement of Speed Signal Disagreement of Model Selection Signals Disagreement of Model Selection Signals Out of input signal range Out of input signal range Disagreement of signal with operation of engine Out of input signal range Out of input signal range
Electrical system
User code
Error code
Defective Operation Short circuit Defective Operation Lowering of source voltage (Input) Short Circuit Malfunction Disagreement of signal with operation of engine Short Circuit Short Circuit Disconnection Disconnection Out of input signal range
20-149 1
Code
Contents
E11
E979 Rail Press. High 1
E11 E15 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E22 -----------------
E97A E97B E97C E97D E980 E981 E982 E983 E984 E985 E986 E98A E98B E922
Rail Press. High 2 Rail press. low Rail press. too low Rail Press. Out of Control Eng. Controller Abnormality Fuel Injector 1 Disc. Fuel Injector 2 Disc. Fuel Injector 3 Disc. Fuel Injector 4 Disc. Fuel Injector 5 Disc. Fuel Injector 6 Disc. Fuel Injector 1 - 3 S/C Fuel Injector 4 - 6 S/C Eng. Hi Out of Std Eng. Lo Out of Std Aircleaner Clogging Charge Voltage Low Eng. Oil Press. Low Eng. Oil LvI. Low Eng. Water Overheat Eng. Water Lvl Low Hydr. Oil Overheat
Failure code Code AD00L2 AD00MA AD10L3 AD10MB AD10MA DB20KT ADA1KA ADB1KA ADC1KA ADD1KA ADE1KA ADF1KA ADAZKB ADDZKB A000N1 A000N2 AA10NX AB00KE B@BAZG B@BAZK B@BCNS B@BCZK B@HANS
Component
History division
Error code
Trouble
Abnormally High Fuel Pressure Common Rail Malfunction Supply Pump Out of control Supply Pump Lowering of Function Supply Pump Malfunction Engine Controller Abnormality in Controller Injector 1 Solenoid Valve Disconnection Injector 2 Solenoid Valve Disconnection Injector 3 Solenoid Valve Disconnection Injector 4 Solenoid Valve Disconnection Injector 5 Solenoid Valve Disconnection Injector 6 Solenoid Valve Disconnection Injector 1, 2, 3 Solenoid Valve Short Circuit Injector 4, 5, 6 Solenoid Valve Short Circuit Engine Overrun Engine Out of input signal range Air Cleaner Element Clogging Alternator Defective Charge Engine Oil Lowering of Oil Pressure Engine Oil Lowering of level Coolant Overheating Coolant Lowering of level Hydraulic Oil Overheating Common Rail
Electrical system
User code
12
MONITOR PANEL - SPECIAL FUNCTIONS
Mechanical system
TESTING AND ADJUSTING
★ The items in this table are arranged in the order of the error codes. ★ The error codes having no numbers in the user code column and the failure codes having no numbers in the user code column and error code column are not displayed on the normal screen, even if abnormality related to them occurs. They are simply recorded in the failure history of the service menu (Electrical equipment system or mechanical equipment system). ★ The history division column shows in which division each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the failure history. ★ Letter “E” at the head of each error code indicates the following condition. ● With E: The failure has not been repaired yet. ● Without E: The failure has been repaired.
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TESTING AND ADJUSTING 12 OPERATION
MONITOR PANEL - SPECIAL FUNCTIONS
AND DISPLAY OF SERVICE MENU
How to select service menu ★ When using the service menu, perform the following special operation to change the screen. A. Checking display. Check that the ordinary screen is displayed. ★ The service menu can be selected only while the ordinary screen is displayed.
B. Operating switches. Operate the following switches. ● Operation of switches: [∆] → [1] → [2] → [3] (While pressing [∆], press the numeral keys) C. Displaying menu screen. The initial screen of the service menu is displayed. Select a menu which you will use.
No. 00 01 02 03 04 05 06 07 09
Service menu Return (Finish service menu) Monitoring Abnormality record Maintenance record Maintenance mode change Phone number entry Initial setting/Default Adjust Cylinder cut out mode operation
D. Finishing menu and function. To finish the service menu screen or each menu screen, perform one of the following operations. (1) Press the [/] switch (This operation is effective on all screens). (2) When the “Return” switch is displayed, press it. (3) When the “Return” menu is displayed, select it and press the [✓] switch.
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MONITOR PANEL - SPECIAL FUNCTIONS
12 15. Function of monitoring [01]. The monitor panel monitors the signals from various switches, sensors, and actuators installed to various parts of the machine. The operator can display and check the monitoring information in real time by the following operation. A. Selecting menu. On the initial screen of the service menu, select “01 Monitoring” and press the [✓] switch.
B. Setting monitoring items. Select and register monitoring items with the following switches. ● [∆] switch: Select ● [∇] switch: Select ● [✓] switch: Register ★ You can set up to 4 monitoring items (You cannot set up to 4 monitoring items, however, depending on the selected items). ★ When monitoring up to 3 items, go to the monitoring information screen by either of the following operations after registering those items. ● Hold the [✓] switch (for about 3 seconds). ● Select menu “99999” and press the [✓] switch. ★ If all of the settleable items are registered, the monitoring information screen appears automatically after registering those items. ★ For the detail, display units, etc. of the monitoring items, see the monitoring items table. C. Operating for monitoring. After the monitoring information screen appears, operate the machine to check the monitoring information.
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MONITOR PANEL - SPECIAL FUNCTIONS
12 D. Function of holding monitoring information. If the [∆] switch is pressed during the monitoring operation, all the monitoring information is held. If the [∇] switch is pressed while the monitoring information is held, the monitoring information is released.
E. Function of selecting machine setting mode. To change settings of the working mode, travel speed, or auto deceleration during the monitoring operation, press the switches for those items, and the mode checking screen appears. ★ After checking the settings, press the [✓] switch, and the monitoring screen appears again. ★ If the settings are changed during the monitoring operation, the new settings are held even after monitoring is finished and the service menu disappears and the operator menu appears again.
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MONITOR PANEL - SPECIAL FUNCTIONS
12 Monitoring items list
00000 99999 00200 00201 01002 01601 01100 01101
Return To Display Screen Controller Model Select Controller Model Select Engine Speed 2nd Eng. Speed Command F Pump Pressure R Pump Pressure
Unit (Default: ISO) SI meter (Not displayed) (Not displayed) Numerals Numerals r/min rpm r/min rpm MPa kg/cm2 MPa kg/cm2
07200 07300 04102 14200 04401 01300 01500 01700 03200 03500 04300 01006 04107 36400
Arm Curl PPC Pressure Bucket Curl PPC Pressure Engine Water Temp. Hi Fuel Temperature Hydr. Oil Temperature PC-EPC Sol. Curr. LS-EPC Sol. Curr. Service Sol. Curr. Battery Voltage Battery Relay O/P Vol. Battery Charge Vol. Engine Speed Engine Water Temp. Low Rail Pressure
MPa MPa ×C ×C ×C mA mA mA V V V r/min ×C MPa
36500 36700 03000 04200 04106 04105 14201 36501 36401 17200 17300 31701 36100 36200 36300
Boost Pressure Torque Ratio Fuel Dial Vol. Fuel Level Sensor Vol. Eng. Water Temp. Vol. Hi Eng. Water Temp. Vol. Lo Fuel Temp. Sensor Vol. Boost Press. Sensor Vol. Rail Press. Sensor Vol. PCV Close Angle Eng. Control Mode Throttle Level Fuel Delivery Command Rail Pressure Command Injection Timing Angle
kPa % V V V V V V V CA
Code No.
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Monitoring item
% mm /st MPa CA 3
kg/cm2 kg/cm ×C ×C ×C mA mA mA V V V rpm ×C
2
kg/cm2 kg/cm2 % V V V V V V V CA Numeral % mm /st 3
kg/cm CA
2
inch
Remarks Finish Menu Display and Execution Menu
rpm rpm psi psi psi psi ×F ×F ×F mA mA mA V V V rpm ×F psi psi % V V V V V V V CA % mm3/st psi CA
PC400LC-7L
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 Code No.
Monitoring item
01900
Pressure Switch 1
01901
Pressure Switch 2
02300
Solenoid 1
02301
Solenoid 2
02200
Switch Input 1
02201
Switch Input 2
02202 03700
Switch Input 3 Controller Output 1
04500
Monitor Input 1
04501
Monitor Input 2
04502
Monitor Input 3
PC400LC-7L
Swing Travel Boom Lower Boom Raise Arm Curl Arm Dump Bucket Curl Bucket Dump Service Travel Steering Travel Junction Swing Brake Merge-divider 2-stage Relief Travel Speed Service Return Lever Sw. Swing Release Sw. Swing Brake Sw. Model Select 1 Model Select 2 Model Select 3 Model Select 4 Model Select 5 Key Switch (ACC) Batt. Relay Dr. Key Switch Start Preheat Light Rad. Level Aircleaner Eng. Oil Level Battery Charge Swing Brake Sw. Bzzr Cancel Sw. Window Limit Sw. W Limit Sw. P Limit Sw.
Unit (Default: ISO) SI meter inch ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF
Remarks
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MONITOR PANEL - SPECIAL FUNCTIONS
12 Codem No.
Monitoring item
17400
Eng. Controller Input
36800 36801
Q Adjust Switch R (ROT-SW1) Q Adjust Switch L (ROT-SW2)
05100
S-NET Connection
20200 20212 20209
Monitor Prog. Version Pump Con. Prog. Version Eng. Con. Prog. Version
SI Key SW (C) Eng. Oil Press. Lo Eng. Oil Press. Hi Machine Sel. 1 Machine Sel. 2 Machine Sel. 3
Pump Controller Eng. Controller
Unit (Default: ISO) meter ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF Alphanumerals Alphanumerals ON/OFF ON/OFF Numerals Numerals Numerals
inch
Remarks
★ As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be selected. The unit of display can be changed with “Selecting unit” in the “Setting initial values” function of the service menu. ★ “CA” of the unit of display denotes the crankshaft angle.
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MONITOR PANEL - SPECIAL FUNCTIONS
12 16. Function of abnormality record [02]. The monitor panel classifies and records the past failures into the electrical system group and mechanical system group. The operator can display and check those failures by the following operation. A. Selecting menu. On the initial screen of the service menu, select “02 Abnormality Record” and press the [✓] switch.
B. Selecting sub-menu. On the abnormality record menu screen, select a sub-menu and press the [✓] switch. No. 00 01 02
Sub-menu of abnormality record Return (Finish sub-menu) Electrical systems Mechanical systems
C. Contents of electrical system abnormality record screen [1]: Reverse sequential order/Total number of records [2]: Error code [3]: Failure code (Component: 4 characters, Trouble: 2 characters) [4]: Advance of service meter after 1st occurrence [5]: Contents of failure ★ See “Error codes and failure codes table” in the operator menu.
D. Contents of mechanical system abnormality record screen [1]: Record No. [2]: Contents of failure [3]: Failure code (Component: 4 characters, Trouble: 2 characters) [4]: Total number of occurrences [5]: Service meter reading at 1st occurrence ★ See “Error codes and failure codes table” in the operator menu.
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MONITOR PANEL - SPECIAL FUNCTIONS
12 E. Resetting electrical system abnormality record. ★ Only the abnormality record of the electrical system can be reset (deleted). The abnormality record of the mechanical system cannot be reset. ★ If necessary, reset each item or all items of the abnormality record of the electrical system according to the following procedure. i.
While the electrical system abnormality record screen is displayed, operate the following switches to display the reset screen. ● Operation of switches: [∆] + [1] [2] [3] ★ This operation is the same as that for selecting the service menu.
ii.
Operate the switches according to the direction shown on the reset screen. ★ When resetting only 1 item, be sure display it with the [∆] switch or [∇] switch, and then perform the reset procedure. ★ When resetting all the items, you can perform the reset procedure, regardless of the item displayed on the screen.
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TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 17. Function of maintenance record [03]. The monitor panel records the maintenance information about the filters and oils. The operator can display and check that information by the following operation. A. Selecting menu. On the initial screen of the service menu, select “03 Maintenance Record” and press the [✓] switch.
B. Displayed information. (1) Names of oils and filters. (2) Number of replacement times up to now. (3) Service meter reading at previous replacement.
18. Function of maintenance mode change [04]. The condition for setting the operation of the maintenance display function can be changed according to the following procedure. ● Set the function effective or ineffective. ● Change the set replacement interval. A. Selecting menu. On the initial screen of the service menu, select “04 Maintenance Mode Change” and press the [✓] switch.
B. Selecting item to be changed. On the screen of maintenance mode changing menu, select an item to be changed. No. 00 01 02 03 04 05 06 07 08 09 10 11 12
Item of maintenance mode change Return Use/Disuse maintenance mode Replacement interval of engine oil Replacement interval of engine oil filter Replacement interval of fuel filter Replacement interval of hydraulic oil filter Replacement interval of hydraulic tank breather Replacement interval of corrosion resistor (if equipped) Check and refill interval of damper case oil Replacement interval of final drive case oil Replacement interval of machinery case oil Replacement interval of hydraulic oil Return all items to initial values
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MONITOR PANEL - SPECIAL FUNCTIONS
★ Menus “01” and “12” are used to set the whole maintenance mode and menus “02” - “11” are used to set the items one by one. C. Contents of setting of “maintenance mode On/Off”. ● On: The function of displaying all the oil and filter items becomes effective (This setting is applied, even if On/Off is set for each item). ● Off: The function of displaying all the oil and filter items becomes ineffective (This setting is applied, even if On/ Off is set for each item).
D. Contents of setting of each item. i.
Default: Maintenance time set in monitor. (Value recommended by manufacturer. Constant value.)
ii.
Set value: Maintenance time which operation can set freely. Monitor panel operates according to this value in maintenance mode. (This value can be changed by 50 hours with [∆] and [∇] switches.)
iii. Off: Function of displaying this maintenance item becomes ineffective. iv. On: Function of displaying this maintenance item becomes effective. ★ The lower limit of the set time is 50 h. E. Contents of setting “Return all items to initial values”. If this menu is selected and the [✓] switch is pressed, all the information items are changed to the initial values.
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MONITOR PANEL - SPECIAL FUNCTIONS
12 19. Function of phone number entry [05]. The operator can input a phone No. and change it according to the following procedure. Once the phone No. is input, it and service code are displayed alternately when the user code is displayed. ★ If a phone No. is not input, the phone No. screen is not displayed. A. Selecting menu. On the initial screen of the service menu, select “05 Phone Number Entry” and press the [✓] switch.
B. Selecting input screen. Select “Entry” to display the phone No. input screen. ★ Even if a phone No. has been registered, if the phone No. input screen is displayed, the registered phone No. is cleared.
C. Inputting and setting phone No. On the phone No. input screen, input a phone No. according to the following procedure (The phone No. is input from the cursor at the left end automatically). i.
Input a No. with the numeral keys from the cursor at the left end.
ii. After finishing inputting the No., press the [✓] switch. ★ Up to 12 digits can be input. You do not need to input a digit to an unnecessary place, however. ★ If you input a wrong No., press the [B] switch, and the cursor returns 1 place by 1. ★ If the phone No. is input, the “Entry” screen above is displayed again. If the phone No. is displayed on this screen, it is input normally.
PC400LC-7L
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MONITOR PANEL - SPECIAL FUNCTIONS
12 20. Function of initial setting and default [06]. The operator can change the following items related to the monitor panel and machine, if necessary. ● Working mode when starting switch is turned ON. ● Language displayed on service menu. ● Unit displayed in monitoring function mode. ● With/Without attachment. A. Selecting menu. On the initial screen of the service menu, select “06 Function of initial setting and default” and press the [✓] switch.
B. Selecting sub-menu. Select a sub-menu to change its setting and press the [✓] switch. No. 00 01 02 03 04
Sub-menu of initial value/default Return (Finish initial value/default) Key-on mode Language Unit With/Without service circuit
C. Function of selecting mode when key is ON. When the starting switch is turned ON, a working mode is displayed on the monitor panel. The operator can change this working mode. ● A-mode, E-mode, L-mode, B-mode: If any of these mode is set, the machine is started in the selected mode when the starting switch is turned ON. ● Mode when key was turned off last: If this mode is set, the machine is started in the mode used last when the starting switch is turned ON. ● Initial value: If this mode is set, the machine is started in the default mode set in the factory when the starting switch is turned ON. ★ If the machine having an attachment is stopped in the B-mode, it is started in the B-mode when the starting switch is turned ON next time, regardless of this setting.
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MONITOR PANEL - SPECIAL FUNCTIONS
12 D. Function of setting language. The operator can select Japanese or English as the language displayed on the service menu. ★ The default language of the monitor panel is English. ★ When using a spare monitor panel in the Japanese language area, select Japanese with this function.
E. Function of selecting unit. The operator can select 1 of the 3 unit systems as the unit system used for the data displayed by the monitoring function of the service menu. ★ The default unit system of the monitor panel is the SI unit system.
F.
Function of selecting “with/without service circuit”. The operator can set “with/without service circuit”. ● With service circuit: When attachment is installed. ● Without service circuit: When attachment is not installed. ★ When an service circuit is installed, if “With service circuit” is not set on this screen, the operator cannot use the select function (adjustment of oil flow for the attachment) in the operator mode.
PC400LC-7L
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MONITOR PANEL - SPECIAL FUNCTIONS
12 21. Function of adjustment [07]. The operator can adjust various items of the machine on the monitor panel. A. Selecting menu. On the initial screen of the service menu, select “07 Adjustment” and press the [✓] switch. B. Selecting sub-menu. Select a sub-menu to change its setting and press the [✓] switch. No. 00 01 02
Sub-menu of adjustment Return (Finish adjustment) Pump absorption torque Adjustment of oil flow for attachment in compound operation
C. Function of pump absorption torque. The operator can adjust the pump absorption torque within the ranges shown in the following table. Adjustment value 220 221 222 223 224
Adjustment Adjustment torque value +8.0 kgm 225 +6.0 kgm 226 +4.0 kgm 227 +2.0 kgm 228 0.0 kgm
Adjustment torque -2.0 kgm -4.0 kgm -6.0 kgm -8.0 kgm
D. Function of adjustment of oil flow for attachment in compound operation. The operator can adjust the oil flow for the attachment in compound operation within the ranges shown in the following table. Adjustment value 370 371 372 373
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Oil flow for attachment 0.5 times 0.7 times 1.0 times 0.4 times
PC400LC-7L
TESTING AND ADJUSTING
MONITOR PANEL - SPECIAL FUNCTIONS
12 22. Function of cylinder cut out mode operation [09]. The operator can operate the machine in the cylinder cut out mode with the monitor panel. Cylinder cut out mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). A. Selecting menu. On the initial screen of the service menu, select “09 Cylinder cut out mode operation” and press the [✓] switch.
B. Setting cylinders to be disabled. Press switches [1] - [6] on the monitor panel corresponding to the cylinder Nos. to be disabled. ★ After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed white in a white frame, the cylinder is disabled (If setting is wrong, press the same switch again). ★ Only one or more cylinders can be disabled for the reduced cylinder mode operation.
C. Cancellation of disabled cylinders. Press switches [1] - [6] on the monitor panel corresponding to the disabled cylinder Nos. to cancel disabling of those cylinders. ★ After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed black in a black frame, disabling of the cylinder is cancelled.
PC400LC-7L
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MONITOR PANEL - SPECIAL FUNCTIONS
12 D. Function of holding engine speed. If the [∆] switch is pressed while the reduced cylinder mode operation screen is used, the engine speed is held and displayed on the lower line. If the [∇] switch is pressed while the engine speed is held, holding of the engine speed is cancelled and the engine speed displayed on the lower line goes off. ★ If the holding function is used, the held engine speed is displayed in ( ) on the lower line and the current engine speed is displayed on the upper line. ★ The holding function can be used both in and out of the cylinder cut out mode.
[Reference]: How to use holding function effectively The engine speed displayed by the holding function is held on the screen until the holding function is cancelled, regardless of setting and cancellation of the cylinder cut out mode. Accordingly, a defective cylinder can be found out effectively according to the following procedure. 1.
Run the engine normally (without disabling any cylinder) and hold the engine speed.
2.
Disable a cylinder to be checked.
3.
Run the engine under the same condition as the normal operation in step (1) and compare the engine speed at this time with the held engine speed.
4.
Cancel the cylinder cut out mode, regardless of the change of the engine speed.
5. Repeat steps (2) - (4) to check the other cylinders. ★ If the engine speed does not lower at all or lowers less when a cylinder is selected for the cylinder cut out mode operation, combustion in that cylinder must be abnormal.
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TESTING AND ADJUSTING
HANDLING OF ENGINE CONTROLLER
12
HANDLING OF ENGINE CONTROLLER WARNING! The engine controller has a high-voltage circuit (110 - 130 V) to drive the fuel injector. This circuit is connected to the wiring harness and connectors between the engine controller and fuel injector. ★ Normally, the engine controller outputs the high voltage to the fuel injector only while the engine is running and stops outputting if the engine stops. WARNING! If you touch the high-voltage circuit directly, you may get an electric shock. To avoid this, observe the following precautions. 1.
The following connectors are used in the high voltage circuit. ● Engine controller connector: CB3. ● Junction connector: ER03. ● Injector connectors: CN1, CN2, CN3, CN4, CN5, CN6. ● Injector head terminal (in head cover).
2.
When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF.
3.
If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start the engine. ★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
PC400LC-7L
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TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING
12
PREPARATION WORK FOR TROUBLESHOOTING ★ When carrying out troubleshooting for an electric circuit related to the monitor panel, engine controller, or pump controller, expose the related connectors according to the following procedure. 1.
Monitor panel. A. Remove cover (1). ★ The cover is fixed with the upper and lower 2 clips. You can remove the cover by pulling it up. ★ If the sunlight sensor for the air conditioner is installed, disconnect connector P15 on the back side of the cover.
B. Remove the 3 mounting screws and disconnect monitor panel (2) from the mount. ★ Take care not to drop the mounting screws in the console. C. Insert or connect T-adapters in or to connectors P01, P02, P70 of the monitor panel.
2.
Engine controller. A. Open the right side cover and remove radiator sub tank (3) and bracket together.
B. Remove the 4 mounting bolts and pull out engine controller (4). C. Insert or connect T-adapters in or to connectors CB1, CB2, and CB3 of the engine controller. ★ Since the connectors are secured with screws, loosen those screws before disconnecting. ★ When connecting the connectors again, tighten their screws to the specified torque. Screw: 2.82 Nm (2.07 lbf ft)
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TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING
12 3. Pump controller. ★ The pump controller is installed inside the cover at the rear of the operator’s seat. A. Remove the 3 mounting bolts and cover (5).
B. Insert or connect T-adapters in or to connectors C01, C02, and C03 of the pump controller. ★ Since the connectors are secured with screws, loosen those screws before disconnecting. ★ When connecting the connectors again, tighten their screws to the specified torque. Screw: 2.82 Nm (2.07 lbf ft)
PC400LC-7L
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TESTING AND ADJUSTING
PM CLINIC SERVICE
12
PM CLINIC SERVICE
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PC400LC-7L
TESTING AND ADJUSTING
PM CLINIC SERVICE
12 Positions to install measuring devices (Related to engine)
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PM CLINIC SERVICE
12 Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
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PC400LC-7L
TESTING AND ADJUSTING
PM CLINIC SERVICE
12
PC400LC-7L
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TESTING AND ADJUSTING
PM CLINIC SERVICE
12
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PC400LC-7L
TESTING AND ADJUSTING
PM CLINIC SERVICE
12
Pm-CLINIC SERVICE PC400 (LC) Visual check of welded structures ★ If any crack is found, draw its shape below.
Arm
Boom
Revolving frame
1. Arm cylinder bracket ❑ Left ❑ Right 2. Arm foot
4. Boom top bracket ❑ Left ❑ Right 5. Boom cylinder bracket
9. Boom bracket ❑ Left ❑ Right
❑ Left 3. Arm top boss ❑ Left
PC400LC-7L
❑ Right ❑ Right
❑ End plate
❑ Left
❑ Right
6. Arm cylinder bracket ❑ Left ❑ Right 7. Boom lower plate ❑ Left ❑ Right 8. Boom foot ❑ Left ❑ Right
Track frame 10. Circle bracket ❑ Front ❑ Left
❑ Rear ❑ Right
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TESTING AND ADJUSTING
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PM CLINIC SERVICE
PC400LC-7L
TROUBLESHOOTING GENERAL
12 POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203 SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-205 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 20-206 HANDLING WIRING HARNESSES AND CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206 REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES . . . . 20-208 HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS . . . . . . . . . . . . . . . 20-212 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-212 CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215 CLASSIFICATION OF TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215 STEPS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NOS. . . . . . . . . . . . . 20-216 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219 MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230 ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231 PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-233 T-BRANCH BOX AND T-BRANCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-254 CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258
PC400LC-7L
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TROUBLESHOOTING 12
MEMORANDUM
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PC400LC-7L
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. WARNING! If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: ● Parts that have no connection with the failure or other unnecessary parts will be disassembled. ● It will become impossible to find the cause of the failure. It will also cause a waste of man hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2.
Points to ask user or operator A. Have any other problems occurred apart from the problem that has been reported? B. Was there anything strange about the machine before the failure occurred? C. Did the failure occur suddenly, or were there problems with the machine condition before this? D. Under what conditions did the failure occur? E. Had any repairs been carried out before the failure? When were these repairs carried out? F.
3.
Has the same kind of failure occurred before?
Check before troubleshooting A. Check the oil level B. Check for any external leakage of oil from the piping or hydraulic equipment.
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TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
C. Check the travel of the control levers. D. Check the stroke of the control valve spool. E. Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4.
5.
Confirming failure ● Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. ★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure, then use the troubleshooting flow chart to locate the position of the failure exactly. The basic procedure for troubleshooting is as follows.
●
A. Start from the simple points. B. Start from the most likely points. C. Investigate other related parts or information. 6.
Measures to remove root cause of failure ● Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
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PC400LC-7L
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC400LC-7L
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TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
12
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and Handling hydraulic equipment, particularly gear oil and hydraulic oil.
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT HANDLING WIRING HARNESSES AND CONNECTORS Wiring harnesses consist of wiring connecting one component to another one, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. MAIN FAILURES OCCURRING IN WIRING HARNESS 1.
Faulty Contact of Connectors, Faulty Contact Between Male and Female Problems with faulty contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidation of the contact surfaces.
2.
Faulty Crimping or Soldering of Connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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PC400LC-7L
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
12 3. Disconnections in Wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4.
High Pressure Water Entering Connector The connector is designed to make it difficult for water to enter, drip proof structure, but if high pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in immediately dry the connector or take other appropriate action before passing electricity through it.
5.
Oil or Dirt Stuck to Connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be faulty contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. ★ When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. ★ If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
PC400LC-7L
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TROUBLESHOOTING 12 REMOVING,
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES
DISCONNECTING CONNECTORS 1.
Hold the Connectors When Disconnecting When disconnecting the connectors hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Never pull with one hand.
2.
When Removing from Clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. ★ If the connector is twisted up and down or to the left or right, the housing may break.
3.
Action to Take after Removing Connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. ★ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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PC400LC-7L
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
12 CONNECTING CONNECTORS 1.
Check the Connector Visually A. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). B. Check that there is no deformation, faulty contact, corrosion, or damage to the connector pins. C. Check that there is no damage or breakage to the outside of the connector. ★ If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. ★ If there is any damage or breakage, replace the connector.
2.
Fix the Connector Securely Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position.
3.
Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. ★ If the connector cannot be corrected easily, remove the clamp and adjust the position.
4.
If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
5.
Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. A. Male connector, 2. Female connector ● Normal locking state (Horizontal): a, b, d ● Incomplete locking state (Diagonal): c
PC400LC-7L
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TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
12 DRYING WIRING HARNESS If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1.
Disconnect the connector and wipe off water with a dry cloth. ★ If the connector is blown dry with compressed air, there is the risk that oil in the air may cause faulty contact, so remove all oil and water before blowing with air.
2.
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. ★ Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3.
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble.
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PC400LC-7L
TROUBLESHOOTING 12 HANDLING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CONTROL BOX
1.
The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box.
2.
Do not open the cover of the control box unless necessary.
3.
Do not place objects on top of the control box.
4.
Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.
5.
During rainy weather, do not leave the control box in a place where it is exposed to rain.
6.
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time, place it on a suitable dry stand.
7.
Precautions when carrying out arc welding. When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
PC400LC-7L
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TROUBLESHOOTING 12 POINTS
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS
1.
Always turn the power OFF before disconnecting or connect connectors.
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Disconnect and connect the related connectors several times to check.
3.
Always connect any disconnected connectors before going on to the next step. ★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4.
When carrying out troubleshooting of circuits; measuring the voltage, resistance, continuity, or current, move the related wiring and connectors several times and check that there is no change in the reading of the tester. ★ If there is any change, there is probably faulty contact in that circuit.
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
BE CAREFUL OF THE OPERATING ENVIRONMENT Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
DISASSEMBLY AND MAINTENANCE WORK IN THE FIELD If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust proof workshop, and the performance should be confirmed with special test equipment.
SEALING OPENINGS After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
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PC400LC-7L
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
12 DO NOT LET ANY DIRT OR DUST GET IN DURING REFILLING OPERATIONS. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
CHANGE HYDRAULIC OIL WHEN THE TEMPERATURE IS HIGH. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit. If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
FLUSHING OPERATIONS After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
CLEANING OPERATIONS After repairing the hydraulic equipment; pump, control valve, etc. or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine [about 3] particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
PC400LC-7L
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TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
12
CHECKS BEFORE TROUBLESHOOTING Item
Lubricating oil, coolant
Electrical equipment Hydraulic mechanical equipment
Electronics, electrical equipment
1. Check fuel level, type of fuel 2. Check for impurities 3. Check hydraulic oil level 4. Check hydraulic strainer 5. Check swing machinery oil level 6. Check engine oil level, type of oil 7. Check coolant level 8. Check dust indicator for clogging 9. Check hydraulic filter 10. Check final drive oil level 1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starter motor terminal, wiring 1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding 1. Check battery voltage, engine stopped 2. Check battery electrolyte level 3. Check for discolored, burnt, exposed wires 4. Check for missing wiring clamps, hanging wiring 5. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) 6. Check for blown, corroded fuses 7. Check alternator voltage, ½ throttle or above 8. Check operating sound of battery, when switch is turned On/Off
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Judgement value --------------------------------20 to 30 V -------
Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Replace Add oil Tighten or replace Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair
---
Disconnect and dry
Action
--Replace After running for several Replace minutes: 27.5 to 29.5 V --Replace
PC400LC-7L
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
12
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING CLASSIFICATION OF TROUBLESHOOTING Mode Code display E mode H mode S mode
Content Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are displayed. Troubleshooting of electrical system Troubleshooting of hydraulic and mechanical systems Troubleshooting of engine
Remark TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL
STEPS FOR TROUBLESHOOTING If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. 1.
Troubleshooting steps when calling User Code display in the monitor panel In the User Code display, select and depress [✓] switch to display Error Code. Following displayed Error Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2.
Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is recorded in the failure history: If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system Failure Code, using the failure history function of the monitor panel. ★ If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to check if the same abnormality still persists. ★ Failure Code in the mechanical system cannot be deleted.
3.
Troubleshooting steps without User Code display and no failure history is available If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from among “Failure like Phenomena and Troubleshooting No.” and carry out E mode or H mode troubleshooting related to the phenomenon in question.
PC400LC-7L
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TROUBLESHOOTING 12 PHENOMENA
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CONSIDERED TO BE FAILURES AND TROUBLESHOOTING
NOS. Remark TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL. No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Phenomena considered to be failures
Display of code Possible faults related to user code, error code, or failure code According to User code is displayed on monitor panel displayed code When failure history is checked, error code is displayed in electrical system When failure history is checked, error code is displayed in mechanical system Possible faults related to engine Engine does not start easily (It always takes time to start) Engine does not start - Engine does not crank Engine does not start - Engine cranks but exhaust smoke does not come out Engine does not start - Exhaust smoke comes out but engine does not start Engine speed does not rise sharply (Follow-up performance is low) Engine stops during operation Engine rotation is abnormal (Engine hunts) Output is insufficient (Power is low) Exhaust gas color is bad (Incomplete combustion) Oil is consumed much or exhaust gas color is bad Oil becomes dirty quickly Fuel is consumed much Coolant contains oil (or it blows back or reduces) Engine oil pressure caution lamp lights up (Oil pressure lowers) Oil level rises (Water or fuel is mixed in oil) Water temperature rises too high (Overheating) Abnormal sound comes out Vibration is excessive Engine is not preheated normally Automatic warm-up function does not work Automatic decelerator does not work Possible faults related to work equipment, swing, and travel Speed or power of whole work equipment, travel, and swing is low Engine speed lowers extremely or engine stalls Work equipment, travel, and swing systems do not work Abnormal sound comes out from around hydraulic pump Fine control performance or response is low
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Troubleshooting E-mode H-mode
S-1 S-2 a) S-2 b) S-2 c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16
E-1
E-2 E-3 E-4
E-5
S-mode
H-5 H-1 H-2 H-3 H-4 H-6
S-6 S-4
PC400LC-7L
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
12 Troubleshooting No.
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 47 48 50 51 52 53 54 55 56 57
Phenomena considered to be failures
Display of code Possible faults related to work equipment
E-mode
Speed or power of boom is low Speed or power of arm is low Speed or power of bucket is low Work equipment does not move singly Hydraulic drift of work equipment is large Time lag of work equipment is large When a work equipment device is relieved singly, other work equipment device moves One-touch power maximizing function does not work E-6 Machine push-up function does not work normally E-7 Attachment circuit is not selected (when attachment is installed) E-8 Oil flow in attachment circuit cannot be adjusted (when attachment is installed) Possible faults related to compound operation In compound operation of work equipment, speed of part loaded more is low When machine swings and raises boom simultaneously, boom rising speed is low When machine swings and travels simultaneously, travel speed lowers largely Possible faults related to travel Machine deviates during travel Travel speed is low Machine is not steered well or steering power is low Travel speed does not change or it is lower or higher than set speed Travel motor does not work (only 1 side) Travel alarm does not sound or does not stop sounding E-31 Possible faults related to swing Machine does not swing Swing acceleration or swing speed is low Upper structure overruns remarkably when it stops swinging Large shock is made when upper structure stops swinging Large sound is made when upper structure stops swinging Hydraulic drift of swing is large Possible faults related to monitor panel (Operator menu: Ordinary screen) No items are displayed on monitor panel E-9 Some items are not displayed on monitor panel E-10 Items displayed on monitor panel are not matched to machine model E-11 Fuel level monitor lights red while engine is running E-12
PC400LC-7L
H-mode
S-mode
H-7 H-8 H-9 H-10 H-11 H-12 H-13 H-14 H-15 H-30 H-31 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23
H-24 H-25 H-26 H-27 H-28 H-29
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TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
12 Troubleshooting No. 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
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Phenomena considered to be failures
Display of code
E-mode
H-mode
S-mode
Engine coolant temperature gauge does not indicate normally E-13 Hydraulic oil temperature gauge does not indicate normally E-14 Fuel level gauge does not indicate normally E-15 Swing lock monitor does not indicate normally E-16 When monitor switches are operated, no items are displayed E-17 Windshield wiper or windshield washer does not operate E-18 Alarm buzzer cannot be cancelled E-19 Possible faults related to monitor panel (Service menu: Special function screen) Monitoring function does not indicate “Boom RAISE“ normally. E-20 Monitoring function does not indicate “Boom LOWER“ normally. E-21 Monitoring function does not indicate “Arm IN“ normally. E-22 Monitoring function does not indicate “Arm OUT“ normally. E-23 Monitoring function does not indicate “Bucket CURL“ normally. E-24 Monitoring function does not indicate “Bucket DUMP“ normally. E-25 Monitoring function does not indicate “Swing” normally. E-26 Monitoring function does not indicate “Travel” normally. E-27 Monitoring function does not indicate “Travel differential pressure“ E-28 normally. Monitoring function does not indicate "Service" normally. E-29 Other failure Air conditioner does not operate (Troubleshooting for air conditioner E-31 system)
PC400LC-7L
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12
CONNECTOR ARRANGEMENT DRAWING CONNECTORS LIST ★ The address of each connector roughly shows the place of the connector in the connectors stereogram and the circuit diagram of each system. Connector No.
Type
No. of pins
A01 A02 A03 A04 A05 A06 A07 A09 A10 A11 A12 A13 A14 A15 A16 A20 A21 A22 A23 A31 A33 A34 A35 A40 A41 A42 A43 A44 A50 A51 A52 A60 A61 A73 A80 AL/B AL/E AL/R C01 C02 C03 C09 CB1 CB2 CB3
X X DT SWP SWP SWP SWP SWP Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal D X L M Terminal Terminal M D M KES0 D D X D D DT Terminal Terminal Terminal DRC DRC DRC S DRC DRC DRC
4 4 12 6 14 14 16 8 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 2 1 2 3 3 1 2 2 8 1 1 1 24 40 40 8 24 40 40
PC400LC-7L
Name of device Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Battery relay (Terminal E) Battery relay (Terminal BR) Battery relay (Terminal N) Battery relay (Terminal B) Air cleaner clogging sensor Radiator water level sensor Fusible link (65 A) Fusible link (30 A) Horn (Low tone) Horn (High tone) Intermediate connector Travel alarm Right headlamp Windshield washer motor (Tank) F pump oil pressure sensor R pump oil pressure sensor Fuel level sensor Hydraulic oil temperature sensor Fuel priming pump Intermediate connector Alternator B terminal Alternator E terminal Alternator R terminal Pump controller Pump controller Pump controller Model selection connector (Pump controller) Pump controller Pump controller Pump controller
Stereogram T-1 T-1 N-2 O-1 T-1 O-1 S-1 N-2 H-2 I-2 I-2 I-2 F-1 J-3 J-3 D-1 D-2 F-2 F-2 H-9 H-9 D-2 G-9 G-9 G-9 H-9 J-3 D-5 L-5 L-8 L-7 G-9 L-5 G-9 S-1 AE-6 AE-6 AE-6 U-9 U-9 W-9 W-9 I-9 I-9 J-9
Address M E circuit circuit H-6 D-7 H-6 H-6 D-7 H-5 H-5 A-4 I-1 I-1 I-1 I-1 I-1 I-1 L-5 J-6 J-5 J-6 K-4 K-5 K-6 K-6
D-7 F-1 F-1
D-8
D-9
P circuit G-7 G-7 G-7 G-6 G-6 G-5 G-5 G-5 J-8
J-8 J-8 J-8 K-8 K-9 K-9 K-9 K-9
K-9 K-9
J-7 K-5 K-7 K-5 L-5 L-5 K-4 K-5 H-3
D-6
G-4
A-3 A-3 A-2
A-8 A-8
K-1 K-1
A-6 A-5 A-3
A-8 A-7 A-6 B-1 L-8 L-8
20-219 b
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12 Connector No.
Type
No. of pins
CB5 CN1 CN2 CN3 CN4 CN5 CN6 D01 D02 E06 ENE ER02 ER03 F02 FB1 G GND GND2 GND3 H08 H09 H10 H11 H12 H15 HT/B HT/S J01 J02 J03 J04 J05 J06 J07 J08 K19 K30 K31 M07 M09 M13 M19 M21 M22 M23 M26 M27 M29 M30 M31 M32
DT DT DT DT DT DT DT SWP SWP M DT HD30 HD30 M ó YAZAKI DT Terminal Terminal M S S S S S090 Terminal Terminal J J J J J J J J M DT DT M M M YAZAKI PA Y090 Y090 S YAZAKI 040 040 M M
8 2 2 2 2 2 2 8 8 3 2 31 31 2 ó 2 2 1 1 8 8 16 16 12 20 1 1 20 20 20 20 20 20 20 20 2 3 3 3 1 2 2 9 2 2 12 18 20 16 2 2
20-220 b
Name of device Model selection connector (Engine controller) No. 1 fuel injector No. 2 fuel injector No. 3 fuel injector No. 4 fuel injector No. 5 fuel injector No. 6 fuel injector Concentrated diode Concentrated diode Fuel control dial Engine speed sensor Intermediate connector Intermediate connector Rotary lamp Fuse box Engine G sensor Joint connector (with diode) Engine grounding Engine grounding Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Heater relay B terminal Heater relay S terminal Junction connector (Black) Junction connector (Black) Junction connector (Green) Junction connector (Green) Junction connector (Pink) Junction connector (Orange) Junction connector (Orange) Junction connector (Pink) Pump resistor (For driving pump in emergency) CAN terminal resistance CAN terminal resistance Light switch Working lamp (Right front) Speaker (Right) Cigarette lighter Radio Horn switch One-touch power maximizing switch Intermediate connector Air conditioner unit Air conditioner control panel Air conditioner control panel Optional power supply (2) Optional power supply (1)
Address M Stereogram circuit J-9 AI-2 AI-3 AJ-3 AJ-5 AJ-6 AJ-6 W-7 A-9 W-5 A-8 P-7 AJ-5 AF-8 J-3 AF-8 AA-9 V-2 I-9 AH-2 AJ-6 AJ-5 AE-7 W-6 J-8 W-6 J-8 T-9 D-6 S-9 D-6 S-9 D-5 O-7 C-2 AH-9 AJ-7 T-9 C-9 T-9 D-9 U-9 D-9 V-3 E-9 V-3 E-9 W-3 F-9 W-5 F-9 W-5 W-5 K-9 A-2 N-4 A-4 P-8 C-1 E-9 K-7 AC-9 N-3 U-2 O-7 T-1 W-4 W-4 U-2 U-2 W-7 W-6
E circuit A-7 K-3 K-2 K-2 K-2 K-3 K-2
P circuit
A-4 A-4 K-7 I-5 I-3
K-6
E-7 K-3
G-8
I-7
E-2 E-2 E-2 A-2
I-6 I-7
H-9 H-9 H-9 I-9 I-9 I-9 A-9 K-6
B-9 C-1 C-9 C-9 D-9 D-9 D-9 E-9 B-1 I-3 E-1
F-9
PC400LC-7L
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12 Connector No.
Type
No. of pins
M33 M33 M34 M37 M38 M38 M40 M41 M42 M43 M45 M46 M71 M72 M73 M79 NE OL P01 P02 P03 P05 P15 P70 PCV1 PCV2 PSH PSL PFUEL PIM R10 R11 R13 R20 R22 R30 R31 S01 S02 S03 S04 S05 S06 S07 S08 S09 S10 S11 S14 S21 S22
M SUMITOMO X Terminal Terminal M M M M M D X M M M M YAZAKI DT 070 040 M M Y050 040 SUMITOMO SUMITOMO Terminal Terminal AMP SUMITOMO R R R R R R R D X X D X X X X X X X M Terminal Terminal
2 4 1 1 1 2 2 2 1 1 12 4 2 4 2 2 2 2 12 20 2 2 2 16 2 2 1 1 3 3 5 5 5 5 5 5 5 4 2 2 3 2 2 2 2 2 2 2 3 6 6
PC400LC-7L
Name of device Optional power supply (3) Air conditioner unit Air conditioner compressor electromagnetic clutch Horn switch (High tone) Horn switch (Low tone) Machine push-up switch Working lamp Working lamp (Additional) Intermediate connector Working lamp (Rear) Intermediate connector RS232C junction connector Room lamp DC/DC converter Speaker (Left) 12-V accessory outlet Engine Ne sensor Engine oil level sensor Monitor panel Monitor panel Buzzer cancel switch Rotary lamp switch Air conditioner daylight sensor Monitor panel Fuel supply pump PCV1 Fuel supply pump PCV2 Engine oil pressure switch (High pressure) Engine oil pressure switch (Low pressure) Common rail pressure sensor Boost pressure sensor Light relay Starting motor cutout relay (PPC lock) Starting motor cutout relay (Personal code) ATT circuit selector relay Power supply relay for engine controller Air conditioner blower relay Air conditioner compressor relay Bucket CURL pressure sensor Boom LOWER oil pressure switch Swing RIGHT oil pressure switch Arm IN pressure switch Bucket DUMP oil pressure switch Boom RAISE oil pressure switch Swing LEFT oil pressure switch Arm DUMP oil pressure switch Service oil pressure switch (Intermediate connector) Service front oil pressure switch Service rear oil pressure switch Safety lock lever switch Emergency pump drive switch Swing holding brake release switch
Stereogram V-9 W-4 I-9 H-1 G-1 Q-8 Z-8 Y-7 H-9 J-9 W-7 V-9 AA-8 U-2 AD-8 V-9 AJ-5 AJ-3 N-6 N-5 Q-8 U-2 N-5 N-5 AH-2 AI-2 AH-2 AG-1 AJ-4 AJ-8 P-7 P-8 Q-8 W-7 W-6 W-4 W-3 K-3 L-2 L-2 K-3 L-2 L-2 L-2 L-1 L-1 K-1 L-1 S-1 R-9 R-8
Address M E circuit circuit
P circuit
A-1 K-8 K-8 J-7, K-7 K-7 A-4
K-4 K-2 A-7 A-6 D-1
A-5
K-7 K-6
E-1 E-1
K-6 K-1 K-1 L-5 L-5 K-5 K-5
E-1
E-1 E-1 F-1 E-9 G-9
K-9
K-3 K-2 K-2 K-3 K-2 K-2 K-2 K-2 K-1 K-1 K-1 E-9 C-1 D-1
20-221 b
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12 Connector No.
Type
No. of pins
S25 S30 S31 ST ST/B T05 T06 T06A T11 THL TWH TWL V01 V02 V03 V04 V05 V06 V08 V12 V21 V22 V30 W03 W04 X05
S090 X X DT Terminal Terminal Terminal M Terminal DT DT DT DT DT D D D D D D D D X M M M
16 2 2 2 1 1 1 1 1 3 2 3 2 2 2 2 2 2 2 2 2 2 2 2 6 4
20-222 b
Name of device Intermediate connector Travel oil pressure switch Travel steering oil pressure switch Starting motor Starting motor B terminal Floor frame grounding Radio body grounding Intermediate connector Cab grounding Spill fuel temperature sensor Engine water temperature sensor (High temperature) Engine water temperature sensor (Low temperature) PPC oil pressure lock solenoid valve Travel junction solenoid valve Merge-divider solenoid valve Travel speed solenoid valve Swing holding brake solenoid valve Machine push-up solenoid valve 2nd-stage relief solenoid valve ATT return selector solenoid valve PC-EPC solenoid valve LS-EPC solenoid valve ATT flow adjustment EPC solenoid valve Rear limit switch (Window) Wiper motor Swing lock switch
Stereogram R-9 P-1 P-1 AF-7 AF-7 V-3 S-9 T-2
Address M E circuit circuit
K-3
P circuit C-2 A-9 A-9 K-6
J-8
K-8 AJ-4 AE-7 AG-8 J-3 J-2 J-2 J-2 J-2 J-2 J-1 J-1 L-6 L-6 P-1 AB-9 Y-5 Q-8
K-3 K-5 K-5 K-5 K-5 K-4 K-4 K-4 K-4 K-4 K-4 L-7 L-7 F-1 K-8 B-9 D-2
A-1
PC400LC-7L
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12 Connector type D or DT L J M R S X PA SWP DRC 040 070 Y050 S090 Y090 YAZAKI SUMITOMO KES0 Terminal Terminal
PC400LC-7L
Detailed information Japanese and German makes DT type connector (08192-XXXXX) Product of Yazaki Corporation L type connector (08056-2XXXX) Product of Sumitomo Wiring Systems 090 type splice Product of Yazaki M type connector (08056-0XXXX) Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector Product of Yazaki S type connector (08056-1XXXX) Product of Yazaki X type connector (08055-0XXXX) Product of Yazaki PA type connector Product of Yazaki SWP type connector (08055-1XXXX) Japanese and German makes DRC type connector Product of Japan AMP 040 type connector Product of Japan AMP 070 type connector Product of Yazaki 050 type connector Product of Sumitomo 090 type connector Product of Yazaki 090 type connector Yazaki-made connector Product of Sumitomo Wiring Systems 6098 type connector KESO type connector (08027-0XXXX) Round pin type single terminal connector Round terminal
20-223 b
TROUBLESHOOTING 12 CONNECTOR
20-224 b
CONNECTOR ARRANGEMENT DRAWING
LOCATION DIAGRAM
PC400LC-7L
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12
PC400LC-7L
20-225 b
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12
20-226 b
PC400LC-7L
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12
PC400LC-7L
20-227 b
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12
20-228 b
PC400LC-7L
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
12
PC400LC-7L
20-229 b
TROUBLESHOOTING 12 MONITOR
CONNECTOR ARRANGEMENT DRAWING
PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT)
Remark This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging system, light system, and communication network system from the general electric circuit diagram. See FOLDOUT 17 & 18 on pages 90-35 and 90-37.
20-230 b
PC400LC-7L
TROUBLESHOOTING 12 ENGINE
CONNECTOR ARRANGEMENT DRAWING
CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT)
Remark This circuit diagram is made by extracting the engine controller system from the general electric circuit diagram. See FOLDOUT 19 & 20 on pages 90-39 and 90-41.
PC400LC-7L
20-231 b
TROUBLESHOOTING 12 PUMP
CONNECTOR ARRANGEMENT DRAWING
CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT)
Remark This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram. See FOLDOUT 21, 22, 23 & 24 on pages 90-43 thru 90-49.
20-232 b
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.
No.of pins
Male (female housing) Part No.: 08055-00181
1
X type connector Female (male housing) Part No.: 08055-00191
2
799-601-7020
Part No.: 08055-00282
Part No.: 08055-00292
3
799-601-7030
Part No.: 08055-00381
Part No.: 08055-00391
4
---
---
T-adapter Part No. 799-601-7010
799-601-7040
Part No.: 08055-00481 Terminal part No.: 79A-222-3370 Electric wire size: 0.85 Grommet: Black Q’ty: 20 Terminal part No.: 79A-222-3380 Electric wire size: 2.0 Grommet: Red Q’ty: 20
PC400LC-7L
Part No.: 08055-00491 Terminal part No.: 79A-222-3390 Electric wire size: 0.85 Grommet: Black Q’ty : 20 Terminal part No.: 79A-222-3410 Electric wire size: 2.0 Grommet: Red Q’ty: 20
---
---
20-233 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
No.of pins
SWP type connector Male (female housing)
Female (male housing)
6
799-601-7050
Part No.: 08055-10681
Part No.: 08055-10691
8
799-601-7060
Part No.: 08055-10881
Part No.: 08055-10891
12
799-601-7310
Part No.: 08055-11281
Part No.: 08055-11291
14
799-601-7070
Part No.: 08055-11481
20-234 b
T-adapter Part No.
Part No.: 08055-11491
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
SWP type connector No.of pins
Male (female housing)
Female (male housing)
16
---
---
T-adapter Part No.
799-601-7320
Part No.: 08055-11681 Terminal part No.: Electric wire size: 0.85 Grommet: Black Q’ty: 20 Terminal part No.: Electric wire size: 1.25 Grommet: Red Q’ty: 20
PC400LC-7L
Part No.: 08055-11691 Terminal part No.: Electric wire size: 0.85 Grommet: Black Q’ty: 20 Terminal part No.: Electric wire size: 1.25 Grommet: Red Q’ty: 20
---
---
20-235 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins 1
Male (female housing) Part No.: 08056-00171
M type connector Female (male housing) Part No.: 08056-00181
2
799-601-7090
Part No.: 08056-00271
Part No.: 08056-00281
3
799-601-7110
Part No.: 08056-00371
Part No.: 08056-00381
4
799-601-7120
Part No.: 08056-00471
Part No.: 08056-00481
6
799-601-7130
Part No.: 08056-00671
Part No.: 08056-00681
8
799-601-7340
Part No.: 08056-00871
20-236 b
T-adapter Part No. 799-601-7080
Part No.: 08056-00881
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Male (female housing)
S type connector Female (male housing)
8
799-601-7140
Part No.: 08056-10871
Part No.: 08056-10881
10 (White)
799-601-7150
Part No.: 08056-11071
Part No.: 08056-11081
12 (White)
799-601-7350
Part No.: 08056-11271
Part No.: 08056-11281
16 (White)
799-601-7330
Part No.: 08056-11671
PC400LC-7L
T-adapter Part No.
Part No.: 08056-11681
20-237 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Male (female housing)
S type connector Female (male housing)
10 (Blue)
---
---
---
12 (Blue)
799-601-7160
Part No.: 08056-11272
Part No.: 08056-11282
16 (Blue)
799-601-7170
Part No.: 08056-11672
20-238 b
T-adapter Part No.
Part No.: 08056-11682
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins 7 11
Male (female housing) Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2680 (Q’ty: 5)
MIC type connector Female (male housing) Body part No.: 79A-222-2630 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5)
5
T-adapter Part No. -----
799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5)
Body part No.: 79A-222-2610 (Q’ty: 5)
9
799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5)
Body part No.: 79A-222-2650 (Q’ty: 5)
13
799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2)
PC400LC-7L
Body part No.: 79A-222-2690 (Q’ty: 2)
20-239 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
No.of pins
Male (female housing)
MIC type connector Female (male housing)
17
T-adapter Part No.
799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2)
Body part No.: 79A-222-2720 (Q’ty: 2)
21
799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Terminal part No.: 79A-222-2770 (Q’ty: 50)
20-240 b
Body part No.: 79A-222-2740 (Q’ty: 2) Terminal part No.: 79A-222-2760 (Q’ty: 50)
---
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Male (female housing)
AMP040 type connector Female (male housing)
8
T-adapter Part No.
799-601-7180
---
Housing part No.: 79A-222-3430 (Q’ty: 5)
12
799-601-7190
---
Housing part No.: 79A-222-3440 (Q’ty: 5)
16
799-601-7210
---
Housing part No.: 79A-222-3450 (Q’ty: 5)
20
799-601-7220
---
Housing part No.: 79A-222-3460 (Q’ty: 5)
★ Terminal part No.: 79A-222-3470 (No relation with number of pins)
PC400LC-7L
20-241 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Male (female housing)
AMP070 type connector Female (male housing)
10
799-601-7510
---
Part No.: 08195-10210
12
799-601-7520
---
Part No.: 08195-12210
14
799-601-7530
---
Part No.: 08195-14210
18
799-601-7540
---
Part No.: 08195-18210
20
799-601-7550
---
20-242 b
T-adapter Part No.
Part No.: 08195-20210
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Male (female housing)
L type connector Female (male housing)
2
---
---
No.of pins
Male (female housing)
---
Connector for PA Female (male housing)
9
---
Bendix MS connector Male (female housing)
Female (male housing)
10
T-adapter Part No.
799-601-3460
---
PC400LC-7L
T-adapter Part No.
---
---
No.of pins
T-adapter Part No.
---
20-243 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Male (female housing)
KES 1 (Automobile) connector Female (male housing)
2
---
Part No.: 08027-10210 (Natural color) 08027-10220 (Black)
Part No.: 08027-10260 (Natural color) 08027-10270 (Black)
3
---
Part No.:08027-10310
Part No.:08027-10360
4
---
Part No.: 08027-10410 (Natural color) 08027-10420 (Black)
Part No.: 08027-10460 (Natural color) 08027-10470 (Black)
6
---
Part No.: 08027-10610 (Natural color) 08027-10620 (Black)
20-244 b
T-adapter Part No.
Part No.: 08027-10660 (Natural color) 08027-10670 (Black)
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 No.of pins
Male (female housing)
KES 1 (Automobile) connector Female (male housing)
8
T-adapter Part No.
---
Part No.: 08027-10810 (Natural color) 08027-10820 (Black)
No.of pins
Male (female housing)
Part No.: 08027-10860 (Natural color) 08027-10870 (Black)
Connector for relay (Socket type) Female (male housing)
5
799-601-7360
---
---
6
799-601-7370
---
No.of pins
Male (female housing)
---
F type connector Female (male housing)
4
T-adapter Part No.
---
---
PC400LC-7L
T-adapter Part No.
---
20-245 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). Type (shell size code)
HD30 Series connector Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part No.
799-601-9210
18-8 (1)
Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)
Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male terminal)
799-601-9210
Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)
Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female terminal)
799-601-9220
18-14 (2)
Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206 Pin (female terminal)
Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106 Pin (male terminal)
799-601-9220
Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206
20-246 b
Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). Type (shell size code)
HD30 Series connector Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part No.
799-601-9230
Part No.:08191-31201, 08191-31202 Pin (female terminal)
Part No.:08191-34101, 08191-34102 Pin (male terminal)
18-20 (3)
799-601-9230
Part No.:08191-32201, 08191-32202 Pin (male terminal)
Part No.:08191-33101, 08191-33102 Pin (female terminal)
799-601-9240
Part No.:08191-41201, 08191-42202 Pin (female terminal)
Part No.:08191-44101, 08191-44102 Pin (male terminal)
18-21 (4)
799-601-9240
Part No.:08191-42201, 08191-42202
PC400LC-7L
Part No.:08191-43101, 08191-43102
20-247 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). Type (shell size code)
HD30 Series connector Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part No.
799-601-9250
24-9 (5)
Part No.:08191-51201, 08191-51202 Pin (female terminal)
Part No.:08191-54101, 08191-54102 Pin (male terminal)
799-601-9250
Part No.:08191-52201, 08191-52202 Pin (male terminal)
Part No.:08191-53101, 08191-53102 Pin (female terminal)
799-601-9260
24-16 (6)
Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206 Pin (female terminal)
Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106 Pin (male terminal)
799-601-9260
Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206
20-248 b
Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). Type (shell size code)
HD30 Series connector Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part No.
799-601-9270
24-21 (7)
Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206 Pin (female terminal)
Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 Pin (male terminal)
799-601-9270
Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)
Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female terminal)
799-601-9280
24-22 (8)
Part No.: 08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 Pin (female terminal)
Part No.: 08191-84101, 08191-84102 08191-84103, 08191-84104 08191-84105, 08191-84106 Pin (male terminal)
799-601-9280
Part No.: 08191-82201, 08191-82202 08191-82203, 08191-82204 08191-82205, 08191-82206
PC400LC-7L
Part No.: 08191-83101, 08191-83102 08191-83103, 08191-83104 08191-83105, 08191-83106
20-249 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). Type (shell size code)
HD30 Series connector Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter Part No.
799-601-9290
24-31 (9)
Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206 Pin (female terminal)
Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 Pin (male terminal)
799-601-9290
Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206
20-250 b
Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). DT Series connector
No.of pins
Body (plug)
Body (receptacle)
2
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)
3
799-601-9030
Part No.: 08192-13200 (normal type) 08192-23200 (fine wire type)
Part No.: 08192-13100 (normal type) 08192-23100 (fine wire type)
4
799-601-9040
Part No.: 08192-14200 (normal type) 08192-24200 (fine wire type)
Part No.: 08192-14100 (normal type) 08192-24100 (fine wire type)
6
799-601-9050
Part No.: 08192-16200 (normal type) 08192-26200 (fine wire type)
PC400LC-7L
Part No.: 08192-16100 (normal type) 08192-26100 (fine wire type)
20-251 b
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). No.of pins
Body (plug)
DT Series connector Body (receptacle)
8GR: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8BR: 799-601-9090
8
Part No.: 08192-1820 (normal type) 08192-2820 (fine wire type)
Part No.: 08192-1810 (normal type) 08192-2810 (fine wire type)
12GR: 799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12BR: 799-601-9140
12
Part No.: 08192-1920 (normal type) 08192-2920 (fine wire type)
20-252 b
T-adapter Part No.
Part No.: 08192-1910 (normal type) 08192-2910 (fine wire type)
PC400LC-7L
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12 Remark The pin No. is also marked on the connector (electric wire insertion end). DTM Series connector
No.of pins
Body (plug)
Body (receptacle)
2
T-adapter Part No.
799-601-9010
Part No.: 08192-02200
No.of pins
Body (plug)
Part No.: 08192-02100
DTHD Series connector Body (receptacle)
2
T-adapter Part No.
---
Part No.: 08192-31200 (Contact size#12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)
PC400LC-7L
Part No.: 08192-31100 (Contact size#12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)
20-253 b
TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH TABLE
12
T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 ---
★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker Assembly. Part No.
Connector type or part name
No. of pins
799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060
Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP
Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P
O
5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P
O O O O
O O O O OOO OOO
O O O O O O O O O O
O O O O O O O O O
20-254 b
1P 2P 3P 4P 6P 8P
OO
OO
O
O O OO OO OOO
O O O
O O O
O O O O
O O O O O O O O O O O
O O O O O
O
O
O O O O O
O O O O O
O O O O O O
O O O O
PC400LC-7L
T-BRANCH BOX AND T-BRANCH TABLE
Part No.
Connector type or part name
No. of pins
799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340
SWP SWP SWP M M M M M M
12P 14P 16P 1P 2P 3P 4P 6P 8P
PC400LC-7L
799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 ---
TROUBLESHOOTING
O O
O O
O O O O
O O O O
O O O O O
O O O O O O
20-255 b
TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH TABLE
Connector type or part name
No. of pins
799-601-7140
S
8P
799-601-7150
S
799-601-7160
S
799-601-7170 799-601-7330
O O O
O
10P-White
O O O
O
12P-Blue
O O O
S
16P-Blue
O O O
S
16P-White
799-601-7350
S
12P-White
799-601-7180
AMP040
8P
O
799-601-7190
AMP040
12P
O
O
799-601-7210
AMP040
16P
O O O
O
799-601-7220
AMP040
20P
O O O
O
799-601-7230
Short connector
X-2
O O O
O
799-601-7240
Case
799-601-7270
Case
799-601-7510
070
10P
O
799-601-7520
070
12P
O
799-601-7530
070
14P
O
799-601-7540
070
18P
O
799-601-7550
070
20P
O
799-601-7360
Relay connector
5P
O
799-601-7370
Relay connector
6P
O
799-601-7380
JFC connector
2P
O
799-601-9010
DTM
2P
O
O
799-601-9020
DT
2P
O
O
799-601-9030
DT
3P
O
O
799-601-9040
DT
4P
O
O
799-601-9050
DT
6P
O
O
799-601-9060
DT
8P-Gray
O
O
799-601-9070
DT
8P-Black
O
O
799-601-9080
DT
8P-Green
O
O
799-601-9090
DT
8P-Brown
O
O
799-601-9110
DT
12P-Gray
O
O
799-601-9120
DT
12P-Black
O
O
799-601-9130
DT
12P-Green
O
O
799-601-9140
DT
12P-Brown
O
O
799-601-9210
HD30
18-8
20-256 b
O
---
Part No.
799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300
12
O O O
O O O
O O
PC400LC-7L
Part No.
Connector type or part name
No. of pins
799-601-9220
HD30
18-14
O O
799-601-9230
HD30
18-20
O O
799-601-9240
HD30
18-21
O O
799-601-9250
HD24
24-9
O O
799-601-9260
HD30
24-16
O O
799-601-9270
HD30
24-21
O O
799-601-9280
HD30
24-23
O O
799-601-9290
HD30
24-31
O O
---
T-BRANCH BOX AND T-BRANCH TABLE 799-601-2500 799-601-2700 799-601-2800 799-601-2900 799-601-3000 799-601-5500 799-601-6000 799-601-6500 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300
TROUBLESHOOTING
799-601-9310
Plate
For HD30
O O
O
799-601-9320
Measurement box
For DT, HD
O O
O
799-601-9330
Case
799-601-9340
Case
799-601-9350
DEUTSCH
40P
O
799-601-9360
DEUTSCH
24P
O
799-601-9410
For NE, G sensor
2P
O
799-601-9420
For fuel, boost press.
3P
O
799-601-9430
PVC socket
2P
O
PC400LC-7L
O O
20-257 b
TROUBLESHOOTING
CONNECTION TABLE OF FUSE BOX
12
CONNECTION TABLE OF FUSE BOX ★ This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). ★ When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if the power is supplied normally. Type of power supply
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Constant power supply (Fusible link: A35)
20-258 b
Fuse No.
Fuse capacity
1
10 A
2
20 A
3
10 A
4
10 A
5 6 7 8
10 A 10 A 10 A 10 A
9
10 A
10 11
10 A 20 A
12
20 A
13
20 A
14
10 A
15
10 A
16 17 18 19 20
10 A 10 A 10 A 10 A 10 A
Destination of powerDestination of power Pump controller (Controller power supply) Swing holding brake solenoid (When emergency brake is released) PC-EPC solenoid (When emergency pump is driven) Pump controller (Solenoid power supply) Machine push-up solenoid ATT return selector relay & solenoid Starting motor cutout relay (For PPC lock) PPC lock solenoid Cigarette lighter Windshield washer motor Horn (Spare) Rotary lamp Right front working lamp & boom working lamp One-touch power maximizing switch (Input to pump controller input) Radio (Spare) Air conditioner unit Monitor panel Starting motor cutout relay (For personal code) Light relay (For right front working lamp & boom working lamp) Headlamp & additional headlamp Service power supply 1 (M32 connector) Travel alarm Service power supply 2 (DC/DC converter) Radio (For backing up) Monitor panel (For backing up) Starting switch Room lamp (Spare)
PC400LC-7L
TROUBLESHOOTING ERROR CODES IN MONITOR SYSTEM POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF . . . . . . . . . . . . 20-307 USER CODE MEMORY RETENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307 INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-308 E101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310 ERROR IN DATA HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310 E112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312 SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312 E113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-314 SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE . . . . . . . . . . . . . . . . . . . . . 20-314 E114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316 SHORT OR OPEN IN WINDOW WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316 E115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318 ABNORMAL WIPER MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318 E116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320 ABNORMALITY IN PARKING WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320 E117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322 ENGINE CONTROLLER S-NET COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322 E118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324 PUMP CONTROLLER S-NET COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324 E128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326 MONITOR COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326 E201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328 SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328 E203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-330 SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . 20-330 E204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332 SHORT IN MERGE/DIVIDE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332 E205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334 SHORT IN 2-STAGE RELIEF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334 E206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336 SHORT IN TRAVEL SPEED SHIFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336 E211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338 OPEN IN TRAVEL INTERLOCKING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338 E213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340 OPEN IN SWING HOLDING BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340 E214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342 OPEN IN MERGE/DIVIDE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342 E215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344 OPEN IN 2-STAGE RELIEF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344 E216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346 OPEN IN TRAVEL SPEED SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346 E217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348 ABNORMAL INPUT MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348 E218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350 OPEN IN S-NET COMMUNICATION SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350 E222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352
PC400LC-7L
20-301 1
TROUBLESHOOTING
TABLE OF CONTENTS
SHORT IN LS-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352 E223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354 OPEN IN LS-EPC SOLENOID SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354 E224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356 ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356 E225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358 ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358 E226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360 ABNORMAL PRESSURE SENSOR POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360 E227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362 ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362 E228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364 SHORT IN ATTACHMENT RETURN SWITCHING RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364 E232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366 SHORT IN PC-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366 E233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368 OPEN IN PC-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368 E238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370 OPEN IN ATTACHMENT RETURN SWITCHING RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370 E245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372 SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM . . . . . . . . . . . . . . . . . . . . 20-372 E246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-374 OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20-374 E247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376 ABNORMALITY IN ARM IN PPC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376 E248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378A BNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378 E257 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380 ABNORMALITY IN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380 E315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382 SHORT IN BATTERY RELAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382 E91B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384 ENGNE NE SENSOR PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384 E91C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386 ENGINE G SENSOR PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386 E920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388 ENGINE TYPE SELECTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388 E921 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390 ENGINE TYPE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390 E931 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392 FUEL DIAL SYSTEM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392 E934 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394 ENGINE COOLANT SENSOR HI ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394 E96A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396 ENGINE COOLANT SENSOR LO ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396 E936 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398 ENGINE OIL PRESSURE SWITCH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398 E93C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400 ENGINE BOOST SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400 E93D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402 ENGINE FUEL TEMPERATURE SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402 E953 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404 ENGINE COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404 E954 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406 SHORT IN ENGINE IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406 E955 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408 ENGINE S-NET ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
20-302 1
PC400LC-7L
TROUBLESHOOTING
TABLE OF CONTENTS
E956 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410 ENGINE POWER FAILURE (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410 E957 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412 ENGINE POWER FAILURE (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412 E95A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414 ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414 E970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416 PCV1 OVER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416 E971 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418 PCV2 OVER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418 E974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420 PCV1 LINE CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420 E975 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422 PCV2 LINE CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422 E977 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424 RAIL PRESSURE SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424 E979 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426 RAIL PRESSURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426 E97A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427 RAIL PRESSURE ABNORMAL HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427 E97B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428 RAIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428 E97C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430 RAIL PRESSURE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430 E97D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431 RAIL PRESSURE OUT OF CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431 E980 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432 ENGINE CONTROLLER ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432 E981 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434 FUEL INJECTOR 1 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434 E982 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435 FUEL INJECTOR 2 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435 E983 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436 FUEL INJECTOR 3 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436 E984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-437 FUEL INJECTOR 4 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-437 E985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438 FUEL INJECTOR 5 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438 E986 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439 FUEL INJECTOR 6 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439 E98A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440 FUEL INJECTOR 1 - 3 S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440 E98B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442 FUEL INJECTOR 4 - 6 S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442 A000N1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444 ENGINE HIGH IDLING SPEED OUT OF STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444 A000N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445 ENGINE LOW IDLING SPEED OUT OF STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445 AA10NX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446 AIR CLEANER CLOGGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446 AB00KE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448 CHARGE VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448 B@BAZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450 ENGINE OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450 B@BAZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452 ENGINE OIL LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452 B@BCNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
PC400LC-7L
20-303 1
TROUBLESHOOTING
TABLE OF CONTENTS
ENGINE WATER OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454 B@BCZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456 ENGINE WATER LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456 B@HANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458 HYDRAULIC OIL OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
20-304 1
PC400LC-7L
TROUBLESHOOTING 12
MEMORANDUM
PC400LC-7L
20-305 1
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 1.
Always turn power OFF before disconnecting or connecting connectors.
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Disconnect and connect the related connectors several times to check. ★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3.
Always connect any disconnected connectors before going on to the next step. ★ If power is turned ON with the connectors still disconnected, unnecessary displays will be generated.
4.
When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related wiring and connectors several times and check that there is no charge in the reading of the tester. ★ If there is any charge, there is probably defective contact in that circuit.
5.
When checking a single diode circuit: ★ Isolate the diode from the circuit. ★ using a digital volt ohm meter, in the Ohms mode, check the polarity of the diode as shown in the illustration. Reversing the meter leads, you should have a reading in one direction only. ★ Electrical flow should be negative (-) to positive (+) only, red lead positive and black lead negative.
6.
When checking a dual diode circuit: ★ Isolated the diode from the circuit. ★ using a digital volt ohm meter, in the Ohms mode, check the polarity of the diode as shown in the illustration. Reversing the meter leads, you should have a reading in one direction only. ★ Electrical flow should be negative (-) to positive (+) only, red lead positive and black lead negative.
7.
Always be aware of what you are measuring. Voltage, Ohms or Amps. Always use caution when measuring a circuit. ★ When measuring voltage, be sure the meter is set in the voltage range, AC or DC and above the voltage value you are measuring. ★ When measuring ohms, be sure the circuit is dead and has no voltage in it before you take any readings. Be sure the meter is set in the proper ohms range. ★ When measuring Amps, be sure your meter is rated for the amount of amps you will be measuring. Failure to follow these procedures may damage you equipment or possibly cause injury. Always study the operators manuel for the meter you will be using.
20-306 1
PC400LC-7L
TROUBLESHOOTING 12 POINTS
ITSELF
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY
There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully. 1.
If any abnormality returns to normal by itself.
2.
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting on the failure, and the service code is no longer displayed, or if the monitor display returns to normal.
3.
After completing troubleshooting, always erase the user code from memory.
USER CODE MEMORY RETENTION FUNCTION When displaying the codes in the memory and carrying out troubleshooting, record the content of the display first, then erase the display. After re-enacting the problem, carry out troubleshooting according to the failure codes that are now displayed. There are cases where mistaken operation or abnormalities occur when a connector is disconnected. Erasing the data in this way saves any wasted work.
PC400LC-7L
20-307 1
TROUBLESHOOTING
INFORMATION CONTAINED IN TESTING PROCEDURES
12
INFORMATION CONTAINED IN TESTING PROCEDURES ★ The testing table and the related circuit diagrams contain the following information. Read all information and each step carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to isolate each part of the circuit. • • •
Tools and Procedures
Contents Of Trouble
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Service Code
What you testing
are
4.
No.
Readings
Resistance Ω or Voltage
Test procedure for component only.
readings
1
Your information
Test procedure for component only.
readings
2
Your information
Diode test • With ignition switch in the OFF position. (The importance of these tests are to isolate each component for testing separately) • When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm electrical flow. Electrical flow should be one way only. A.Diode test
3.
Specifications
Sensor or actuator • With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸) • Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately) • Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual) A.
2.
Failure. Failure code displayed. Additional information.
Resistance Ω
At a diode, between point (x) and (x) reverse meter lead polarity each time to check diode.
Continuity one way only?
3
Yes or No
Wiring harness assembly test • With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸) • Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately) • Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual) A.Open or high resistance
Resistance Ω or Voltage
Test procedure for harness. (connector) to (connector)
readings
4
Your information
Test procedure for harness. (connector) to (connector)
readings
5
Your information
B.Short to chassis ground or within harness
Resistance Ω or Voltage
Test procedure for harness. (connector) to (connector)
readings
6
Your information
Test procedure for harness. (connector) to (connector)
readings
7
Your information
Additional components to be tested • With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸) • Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately) • Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual) A.What you are testing
20-308 1
Resistance Ω or Voltage
Test procedure for any additional components.
readings
8
Your information
PC400LC-7L
TROUBLESHOOTING
INFORMATION CONTAINED IN TESTING PROCEDURES
12 Circuit Diagram This is part of the electrical circuit diagram which shows the portion where the failure occurred. • •
Connector No.: Indicates (Type - numbers of a pin) (color) Arrow: Roughly indicates the location in the machine where it is installed.
PC400LC-7L
20-309 1
TROUBLESHOOTING
E101
12
E101 ERROR IN DATA HISTORY
Tools and Procedures
Contents Of Trouble
• • • •
• • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E101] Batteries
Fuse link and fuses 1.
Data chain error Failure code DAF0KT displayed. Can not access failure codes on monitor.
Specifications
No.
Readings
—
Check condition of batteries and connections before proceeding with these tests.
Good Condition?
1
Yes or No
—
Check condition of fuse links A34(L-2) and A35(M-2) Check condition of fuses in fuse box FB1 12 (20A) and 17 (10A).
Good Condition?
2
Yes or No
At fuse link A34, between (1) and (2)
0.0 to 1.0Ω
3
At fuse link A35, between (1) and (2)
0.0 to 1.0Ω
4
Good?
5
* At connector H10, between (1) and chassis ground
30 to 20V
6
* At connector H10, between (5) and chassis ground
30 to 20V
7
At connector H10, between (4) and chassis ground
0.0 to 1.0Ω
8
At connector H10, between (1) and chassis ground
(OL) open
9
At connector H10, between (5) and chassis ground
(OL) open
10
At connector H10, between (4) and (5)
(OL) open
11
At connector H10, between (1) and (5)
(OL) open
12
Fuse link and fuses (FB1) • With ignition switch in the OFF position. • Disconnect A34 and A35 fuse link connectors. • Zero meter leads for proper Ω readings. A.
Fuse tests
Resistance Ω
Check condition of fuses at (FB1) 2.
A.
B.
3.
Yes or No
Wiring harness assembly test • With ignition switch in the OFF position. • Disconnect H10 connector from monitor panel. • * Turn ignition switch to the ON position for these tests only. Open or high resistance Short to chassis ground or within harness
Voltage Resistance Ω
Resistance Ω
Monitor panel test • With ignition in the OFF position. • Disconnect P01 connector from monitor panel and install T-adapter between P01 wiring harness connector and monitor panel. • Turn ignition switch to the ON position. A.
Monitor panel
Voltage Resistance Ω
20-310 1
Between P01, (1) (2) and chassis ground
30 to 20V
Between P01, (8) and chassis ground
30 to 20V
13 14
Between P01, (6) (7) and chassis ground
0.0 to 1.0Ω
15
PC400LC-7L
TROUBLESHOOTING
E101
12 Electrical circuit diagram for E101 error in data history
PC400LC-7L
20-311 1
TROUBLESHOOTING
E112
12
E112 SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM
Tools and Procedures
Contents Of Trouble
• • • •
Possible short or open in wiper motor drive system. Failure code DY2DBK. No wiper operation.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
• • •
Circuit Diagnostic Procedures For Code [E112]
A.
Wiper motor
Voltage Resistance Ω
2.
No.
Readings
* At connector W04, between (1) and (3), wiper switch 20 to 30V cycling set ON.
1
At connector W04, (1) and chassis ground.
2
(OL) open
Wiring harness assembly test • With ignition switch in the OFF position. • Disconnect W04 connector from wiper motor. • Disconnect P01 connector from controller and install T-adapter between P01 connector and monitor panel. • Disconnect P02 connector from controller and install T-adapter between P02 connector and monitor panel.
A.
B.
3.
Specifications
Wiper motor • With ignition switch in the OFF position. • Disconnect W04 connector from motor and install T-adapter between motor and connector W04. • * Turn ignition switch to the ON position for this test.
Open or high resistance
Short to chassis ground or within harness
Resistance Ω
Resistance Ω
Between connectors W04, (1) and P01, (10)
0.0 to 1.0Ω
3
Between connectors W04, (3) and P01, (9)
0.0 to 1.0Ω
4
Between connectors W04, (4) and P01, (12)
0.0 to 1.0Ω
5
Between connectors W04, (5) and chassis ground
0.0 to 1.0Ω
6
Between connectors W04, (6) and P01, (5)
0.0 to 1.0Ω
7
Between connectors W04, (5) and P02, (15)
0.0 to 1.0Ω
8
At connector W04, (1) and chassis ground
(OL) open
9
At connector W04, (3) and chassis ground
(OL) open
10
At connector W04, (4) and chassis ground
(OL) open
11
At connector W04, (5) and chassis ground
(OL) open
12
At connector W04, (6) and chassis ground
(OL) open
13
At connector W04, (1) and (3) (4) (5) (6)
(OL) open
14
At connector W04, (4) and (5) (6)
(OL) open
15
At connector W04, (5) and (6)
(OL) open
16
At connector P02 (15) and W03 (2)
(OL) open
17
At connector W04 (5) and W03 (1)
(OL) open
18
Monitor panel test • With ignition switch in the OFF position. • Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel. • Turn ignition switch to the ON position. A.
Monitor panel
20-312 1
Voltage
Between P01, (9) and chassis ground, wiper ON
20 to 30V cycling
19
Between P01, (9) and chassis ground, wiper OFF
0V
20
PC400LC-7L
TROUBLESHOOTING
E112
12 Electrical circuit diagram for the windshield wiper motor
PC400LC-7L
20-313 1
TROUBLESHOOTING
E113
12
E113 SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE
Tools and Procedures
Contents Of Trouble
• • • •
Possible short or open in wiper motor drive system. Failure code DY2EKB. No wiper operation.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
• • •
Circuit Diagnostic Procedures For Code [E113]
A.
Wiper motor
Voltage Resistance Ω
2.
No.
Readings
* At connector W04, between (1) and (3), wiper switch 20 to 30V cycling set ON.
1
At connector W04, (1) and chassis ground.
2
(OL) open
Wiring harness assembly test • With ignition switch in the OFF position. • Disconnect W04 connector from wiper motor. • Disconnect P01 connector from controller and install T-adapter between P01 connector and monitor panel. • Disconnect P02 connector from controller and install T-adapter between P02 connector and monitor panel.
A.
B.
3.
Specifications
Wiper motor • With ignition switch in the OFF position. • Disconnect W04 connector from motor and install T-adapter between motor and connector W04. • * Turn ignition switch to the ON position for this test.
Open or high resistance
Short to chassis ground or within harness
Resistance Ω
Resistance Ω
Between connectors W04, (1) and P01, (10)
0.0 to 1.0Ω
3
Between connectors W04, (3) and P01, (9)
0.0 to 1.0Ω
4
Between connectors W04, (4) and P01, (12)
0.0 to 1.0Ω
5
Between connectors W04, (5) and chassis ground
0.0 to 1.0Ω
6
Between connectors W04, (6) and P01, (5)
0.0 to 1.0Ω
7
Between connectors W04, (5) and P02, (15)
0.0 to 1.0Ω
8
At connector W04, (1) and chassis ground
(OL) open
9
At connector W04, (3) and chassis ground
(OL) open
10
At connector W04, (4) and chassis ground
(OL) open
11
At connector W04, (5) and chassis ground
(OL) open
12
At connector W04, (6) and chassis ground
(OL) open
13
At connector W04, (1) and (3) (4) (5) (6)
(OL) open
14
At connector W04, (4) and (5) (6)
(OL) open
15
At connector W04, (5) and (6)
(OL) open
16
At connector P02 (15) and W03 (2)
(OL) open
17
At connector W04 (5) and W03 (1)
(OL) open
18
Monitor panel test • With ignition switch in the OFF position. • Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel. • Turn ignition switch to the ON position. A.
Monitor panel
20-314 1
Voltage
Between P01, (9) and chassis ground, wiper ON
20 to 30V cycling
19
Between P01, (9) and chassis ground, wiper OFF
0V
20
PC400LC-7L
TROUBLESHOOTING
E113
12 Circuit diagram for monitor panel wiper motor.
PC400LC-7L
20-315 1
TROUBLESHOOTING
E114
12
E114 SHORT OR OPEN IN WINDOW WASHER SYSTEM
Tools and Procedures
Contents Of Trouble
• • • •
Circuit Diagnostic Procedures For Code [E114]
B.
Readings
Washer motor
Voltage
* At connector A05, between (13) and (14), washer switch set ON.
20 to 30V
1
At connector A05, between (13) and (14), washer switch set OFF.
0V
2
Open or high resistance Short to chassis ground or within harness
Voltage Resistance Ω Resistance Ω
* Between connector A05, (13) and chassis ground
20 to 30V
3
Between connectors A05, (14) and P01, (3)
0.0 to 1.0Ω
4
At connector A05, (13) and chassis ground
(OL) open
5
At connector A05, (14) and chassis ground
(OL) open
6
Continuity one way only?
7
Diode test • With ignition switch in the OFF position. • Disconnect D04 diode connector and isolate diode A.
4.
No.
Wiring harness assembly test • With ignition switch in the OFF position. • Disconnect A05 connector from washer motor. • Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only. • * Turn ignition switch to the ON position for this test. A.
3.
Specifications
Washer motor • With ignition switch in the OFF position. • Disconnect A05 connector from motor and install T-adapter between motor and connector A05. • * Turn ignition switch to the ON position for this test. A.
2.
Possible short or open in wiper motor drive system. Failure code DY2CKB. No wiper operation.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
• • •
Diode test
Resistance Ω
At diode D04, between (4) and (8) reversing meter lead polarity each time to check.
Yes or No
Monitor panel test • With ignition switch in the OFF position. • Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel. • Turn ignition switch to the ON position. A.
Monitor panel
20-316 1
Voltage
Between P01, (3) and chassis ground, washer OFF
20 to 30V
8
Between P01, (3) and chassis ground, washer ON
0V
9
PC400LC-7L
TROUBLESHOOTING
E114
12 Monitor panel window washer motor circuit diagram
PC400LC-7L
20-317 1
TROUBLESHOOTING
E115
12
E115 ABNORMAL WIPER MOTOR OPERATION
Tools and Procedures
Contents Of Trouble
• • • •
Circuit Diagnostic Procedures For Code [E115]
No.
Readings
Wiper motor
Resistance Ω
At connector W04, between (6) and (5), wiper at far end of operation.
0.0 to 1.0Ω
1
At connector W04, between (6) and (5), wiper at mid point on windshield.
(OL) open
2
Between W04, (1) and P01, (10)
0.0 to 1.0Ω
3
Between W04, (3) and P01, (9)
0.0 to 1.0Ω
4
Between W04, (4) and P01, (12)
0.0 to 1.0Ω
5
Between W04, (5) and chassis ground
0.0 to 1.0Ω
6
Between W04, (6) and P01, (5)
0.0 to 1.0Ω
7
Between P02, (15) and chassis ground
0.0 to 1.0Ω
8
At connector W04, (1) and chassis ground
(OL) open
9
At connector W04, (3) and chassis ground
(OL) open
10
At connector W04, (4) and chassis ground
(OL) open
11
At connector W04, (6) and chassis ground
(OL) open
12
At connector W04, (1) and (3) (4) (5) (6)
(OL) open
13
At connector W04, (3) and (4) (5) (6)
(OL) open
14
At connector W04, (4) and (5) (6)
(OL) open
15
At connector W04, (5) and (6)
(OL) open
16
Wiring harness assembly test • With ignition switch in the OFF position. • Disconnect W04 connector from wiper motor. • Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.
A.
B.
3.
Specifications
Wiper motor park system • With ignition switch in the OFF position. • Disconnect W04 connector from motor and install T-adapter between motor and connector W04. A.
2.
Abnormal wiper motor operation. Failure code DY20KA. No wiper operation.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
• • •
Open or high resistance
Short to chassis ground or within harness
Resistance Ω
Resistance Ω
Monitor panel test • With ignition switch in the OFF position. • Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel. • Turn ignition switch to the ON position. A.
Monitor panel
20-318 1
Voltage
Between P01, (5) and chassis ground, wiper end Between P01, (5) and chassis ground, wiper at mid point
0V
17
20 to 30V
18
PC400LC-7L
TROUBLESHOOTING
E115
12 Monitor panel windshield wiper motor circuit diagram
PC400LC-7L
20-319 1
TROUBLESHOOTING
E116
12
E116 ABNORMALITY IN PARKING WIPER ARM
Tools and Procedures
Contents Of Trouble
• • • •
Circuit Diagnostic Procedures For Code [E116]
No.
Readings
Wiper motor
Resistance Ω
At connector W04, between (6) and (5), wiper at far end of operation.
0.0 to 1.0Ω
1
At connector W04, between (6) and (5), wiper at mid point on windshield.
(OL) open
2
Between W04, (1) and P01, (10)
0.0 to 1.0Ω
3
Between W04, (3) and P01, (9)
0.0 to 1.0Ω
4
Between W04, (4) and P01, (12)
0.0 to 1.0Ω
5
Between W04, (5) and chassis ground
0.0 to 1.0Ω
6
Between W04, (6) and P01, (5)
0.0 to 1.0Ω
7
Between P02, (15) and chassis ground
0.0 to 1.0Ω
8
At connector W04, (1) and chassis ground
(OL) open
9
At connector W04, (3) and chassis ground
(OL) open
10
At connector W04, (4) and chassis ground
(OL) open
11
At connector W04, (6) and chassis ground
(OL) open
12
At connector W04, (1) and (3) (4) (5) (6)
(OL) open
13
At connector W04, (3) and (4) (5) (6)
(OL) open
14
At connector W04, (4) and (5) (6)
(OL) open
15
At connector W04, (5) and (6)
(OL) open
16
Wiring harness assembly test • With ignition switch in the OFF position. • Disconnect W04 connector from wiper motor. • Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.
A.
B.
3.
Specifications
Wiper motor park system • With ignition switch in the OFF position. • Disconnect W04 connector from motor and install T-adapter between motor and connector W04. A.
2.
Abnormal in parking wiper motor arm. Failure code DY20MA. Wiper will not park.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
• • •
Open or high resistance
Short to chassis ground or within harness
Resistance Ω
Resistance Ω
Monitor panel test • With ignition switch in the OFF position. • Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel. • Turn ignition switch to the ON position. A.
Monitor panel
20-320 1
Voltage
Between P01, (12) and chassis ground, wiper parked Between P01, (12) and chassis ground, wiper at mid point
0V
17
20 to 30V
18
PC400LC-7L
TROUBLESHOOTING
E116
12 Monitor panel wiper motor circuit diagram
PC400LC-7L
20-321 1
TROUBLESHOOTING
E117
12
E117 ENGINE CONTROLLER S-NET COMMUNICATION ERROR Contents Of Trouble
• •
The monitor panel detected communication failure in the S-NET communication circuit to the engine controller. Failure code DAC0KR.
Response from monitor panel
• •
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%. When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall.
•
Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E117]
A.
B.
2.
Readings
Open or high resistance
Resistance Ω
Grounding fault wiring harness (Contact with grounding circuit)
of Resistance Ω
Between pump controller C02 (21) and monitor panel P02 (9) or (10)
0.0 to 1.0Ω
1
Between pump controller C02 (21) and engine controller CB2 (21) and (31)
0.0 to 1.0Ω
2
Between monitor panel P02 (20) and chassis ground
0.0 to 1.0Ω
3
Between monitor panel P02 (9), (10) and engine controller CB2 (21), (31) and related circuits and grounding
Above 1 MΩ
4
Between monitor panel P02 (9), (10) and pump controller C02 (21) and related circuits and grounding
Above 1 MΩ
5
Between monitor panel P02 (9), (10) and engine controller CB2 (21), (31) and related circuits and grounding
Short-circuit (Contact with 24V circuit)
Voltage
0V
6
Between monitor panel P02 (9), (10) and pump controller C02 (21) and related circuits and grounding
0V
7
CB2 (21) [S-NET (+)] and (11) [GND]
6 - 9V
8
CB2 (21) [S-NET (+)] and (11) [GND]
6 - 9V
9
Between P02 (9) [N/W signal] and (20) [N/W GND]
6 - 9V
10
Between P02 (10) [N/W signal] and (20) [N/W GND]
6 - 9V
11
Engine controller • Turn the engine ignition switch OFF for the preparations. • Disconnect CB2 connector and install T-adapter. • Hold ignition switch in the ON position during the troubleshooting. A.
4.
No.
Wiring harness assembly test • With ignition switch in OFF position, make the test preparations. • During test hold ignition switch in the ON position. A.
3.
Specifications
Wiring harness assembly test • With ignition switch in OFF position.
Defective test
controller
Voltage
Monitor panel test • With ignition switch in the OFF position. • Disconnect P02 connector from monitor and install T-adapter. • Turn ignition switch to the ON position during the troubleshooting. A.
Monitor panel test
20-322 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E117
12 Engine controller S-net communication circuit diagram
PC400LC-7L
20-323 1
TROUBLESHOOTING
E118
12
E118 PUMP CONTROLLER S-NET COMMUNICATION ERROR Contents Of Trouble
• •
The monitor panel detected communication failure in the S-NET communication circuit to the pump controller. Failure code DAB0KR.
Response from monitor panel
• •
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%. When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall.
•
Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E118]
A.
B.
2.
Readings
Open or high resistance
Resistance Ω
Grounding fault wiring harness (Contact with grounding circuit)
of Resistance Ω
Between P02 (9), (10) monitor panel and CB2 (21), (31) engine controller
0.0 to 1.0Ω
1
Between P02 (9), (10) monitor panel and C02 (21) pump controller
0.0 to 1.0Ω
2
Between P02 (20) monitor panel and chassis ground
0.0 to 1.0Ω
3
Between monitor panel P02 (9), (10) and engine controller CB2 (21), (31) and related circuits and grounding
Above 1 MΩ
4
Between monitor panel P02 (9), (10) and pump controller C02 (21) and related circuits and grounding
Above 1 MΩ
5
Between monitor panel P02 (9), (10) and engine controller CB2 (21), (31) and related circuits and grounding
Short-circuit (Contact with 24V circuit)
Voltage
0V
6
Between monitor panel P02 (9), (10) and pump controller C02 (21) and related circuits and grounding
0V
7
6 - 9V
8
Between P02 (9) [N/W signal] and (20) [N/W GND]
6 - 9V
10
Between P02 (10) [N/W signal] and (20) [N/W GND]
6 - 9V
11
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C02 connector and install T-adapter. • Hold ignition switch in the ON position during the troubleshooting. A.
4.
No.
Wiring harness assembly test • With ignition switch in OFF position, make the test preparations. • During test hold ignition switch in the ON position. A.
3.
Specifications
Wiring harness assembly test • With ignition switch in OFF position.
Defective test
controller
Voltage
C02 (21) S-NET and (31) S-NET GND
Monitor panel test • With ignition switch in the OFF position. • Disconnect P02 connector from monitor and install T-adapter. • Turn ignition switch to the ON position during the troubleshooting. A.
Monitor panel test
20-324 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E118
12 Pump controller S-net communication circuit diagram
PC400LC-7L
20-325 1
TROUBLESHOOTING
E128
12
E128 MONITOR COMMUNICATION ABNORMALITY •
The monitor panel detected communication failure in the CAN communication circuit to the engine controller or pump controller. Failure code DAF0MC.
Contents Of Trouble • • Response from monitor panel •
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%. When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall.
Relative information
---
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E128]
A.
No.
Open or high resistance
Resistance Ω
Between P70 (16) monitor panel and CB2 (22) engine controller
0.0 to 1.0Ω
1
Between P70 (16) monitor panel and C02 (22) pump controller
0.0 to 1.0Ω
2
Between P70 (15) monitor panel and CB2 (32) engine controller
0.0 to 1.0Ω
3
Between P70 (15) monitor panel and C02 (32) pump controller
0.0 to 1.0Ω
4
0.0 to 1.0Ω
5
Between monitor panel P70 (16) and engine controller CB2 (22)
Above 1 MΩ
6
Between monitor panel P70 (16) and engine controller C02 (22)
Above 1 MΩ
7
Between monitor panel P70 (16) and related circuits and grounding
Above 1 MΩ
8
Between monitor panel P70 (15) and engine controller CB2 (32)
Above 1 MΩ
9
Between monitor panel P70 (15) and engine controller C02 (32)
Above 1 MΩ
10
Between monitor panel P70 (15) and related circuits and grounding
Above 1 MΩ
11
Between monitor panel P70 (16) and engine controller CB2 (22)
0V
6
Between monitor panel P70 (16) and pump controller C02 (22)
0V
7
Between monitor panel P70 (16) and related circuits and grounding
0V
8
Between monitor panel P70 (15) and engine controller CB2 (32)
0V
9
Between monitor panel P70 (15) and pump controller C02 (32)
0V
10
Between monitor panel P70 (15) and related circuits and grounding
0V
11
Between P70 (14) monitor panel and chassis ground
B.
2.
Specifications
Readings
Wiring harness assembly test • With ignition switch in OFF position.
Grounding fault wiring harness (Contact with grounding circuit)
of Resistance Ω
Wiring harness assembly test • With ignition switch in OFF position, make the test preparations. • During test hold ignition switch in the ON position.
A.
Short-circuit (Contact with 24V circuit)
20-326 1
Voltage
PC400LC-7L
TROUBLESHOOTING Steps 3.
Circuit Diagnostic Procedures For Code [E128]
Specifications
No.
Readings
CAN terminal resistors • Turn the engine ignition switch OFF. • Hold the ignition switch in the OFF position for this test A.
4.
E128
Defective CAN resistor tests
Resistance Ω
K30 between (A) and (B)
40 - 80Ω
12
K31 between (A) and (B)
40 - 80Ω
13
Monitor panel, engine controller or pump controller • If causes 1 - 3 are not detected, monitor panel, engine controller or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
Monitor Communication related to CAN communication
PC400LC-7L
20-327 1
TROUBLESHOOTING
E201
12
E201 SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID Contents Of Trouble Response from controller Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
• •
When power was turned on, there was abnormal current supplied to the travel interlocking circuit. Failure code DW91KB.
• •
Power supply to the travel interlocking circuit is switched OFF. Even if the failure cause disappears of itself, the solenoid circuit does not return to normal, unless the engine starting switch is turned OFF.
•
It is difficult to steer the machine at turns. (LH and RH travel circuits cannot be disconnected).
•
Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E201]
A. 2.
No.
Readings
Resistance Ω
Solenoid test
At solenoid V02, between (1) and (2)
20 to 60Ω
1
At solenoid V02, between (1) and chassis ground
(OL) open
2
Above 1MΩ
3
C03 (7) and ground - Levers - Neutral position
0V
4
C03 (7) and ground - Levers - Steering actuated
20 - 30V
5
Wiring harness assembly test • With ignition switch in OFF position, make the test preparations. • Hold ignition switch in OFF position during troubleshooting. A.
3.
Specifications
Solenoid test • With ignition switch in the OFF position. • Disconnect V02 connector from solenoid. • Zero meter leads for proper Ω readings.
Ground fault test (Contact with grounding circuit)
Resistance Ω
Between pump controller C03 (7) to travel junction solenoid V02 (2) connection and ground
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C02 connector and install T-adapter. • Ignition switch in the ON position, engine running during the troubleshooting. • Move RH & LH travel control levers A.
Defective test
controller
Voltage
Travel interlocking solenoid circuit diagram
20-328 1
PC400LC-7L
TROUBLESHOOTING
E201
12
MEMORANDUM
PC400LC-7L
20-329 1
TROUBLESHOOTING
E203
12
E203 SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM Contents Of Trouble Response from controller Phenomenon occurring on machine
Relative information
Tools and Procedures
• • • • •
• •
When power was turned on, there was abnormal current supplied to the swing holding brake solenoid circuit. Failure code DW45KB.
• •
Power supply to the swing holding brake solenoid circuit is switched OFF. Even if the failure cause disappears of itself, the swing and steering brake does not return to normal, unless the engine starting switch is turned OFF.
•
The upper structure cannot swing. (The swing holding brake cannot be released.
•
Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing holding brake release switch to the RELEASE position. (In this case, however, the holding brake does not work, when stopping the machine.)
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E203]
A.
2.
Readings
Swing holding brake solenoid test (Internal short or ground fault)
At solenoid V05, between (1) and (2) Resistance Ω
At solenoid V05, between (2) and ground
20 to 60Ω
1
Above 1MΩ
2
Resistance Ω
Diode test
At diode D01, between (3) and (7) reversing meter lead polarity each time to check.
Continuity one way only?
3
Wiring harness assembly test • With ignition switch in OFF position. • Disconnect V05 connector from solenoid. • Disconnect S25 and X05 connectors from swing lock and park brake switches. • Disconnect C03 and C02 connectors from controller and install T-adapter on C03 and C02 wire harness connectors only. • Hold ignition switch in OFF position during troubleshooting.
A.
B.
4.
No.
Diode test • With ignition switch in the OFF position. • Disconnect D01 diode connector and isolate. A.
3.
Specifications
Solenoid test • With ignition switch in the OFF position. • Disconnect V05 connector from solenoid. • Zero meter leads for proper Ω readings.
Open or high resistance
Resistance Ω
Short to chassis ground or within harness
Resistance Ω
Between connectors C03 (37) and S25 (8)
Above 1MΩ
4
Between connectors C03 (37) and X05 (3)
Above 1MΩ
5
Between connectors C02 (2) and S25 (9)
Above 1MΩ
6
Between connectors V05 (2) and X05 (4)
Above 1MΩ
7
Between connectors V05 (1) and S25 (8)
Above 1MΩ
8
Between connectors V05 (1) and chassis ground
Above 1MΩ
9
At connectors V05 (2) and chassis ground
(OL) open
10
At connector V05 between (1) and (2)
(OL) open
11
C03 (37) and ground - Levers - Neutral position
0V
12
C03 (37) and ground - Levers - Steering actuated
20 - 30V
13
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Ignition switch in the ON position, engine running during the troubleshooting. • Move RH & LH travel control levers A.
Defective test
20-330 1
controller
Voltage
PC400LC-7L
TROUBLESHOOTING
E203
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400LC-7L
20-331 1
TROUBLESHOOTING
E204
12
E204 SHORT IN MERGE/DIVIDE SOLENOID Contents Of Trouble Response from controller Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
• •
Short in merge/divide solenoid circuit (Pump controller system). Failure code DWJ0KB.
• •
Power supply to the merge/divide solenoid circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
•
In L mode, the work equipment moves slowly or the swing speed is slow in single operation. (F•R pumps cannot be disconnected).
•
Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E204]
A.
2.
3.
Specifications
No.
Readings
Solenoid test • With ignition switch in the OFF position. • Disconnect V05 connector from solenoid. • Zero meter leads for proper Ω readings. Swing holding brake solenoid test (Internal short or ground fault)
At solenoid V03, between (1) and (2) Resistance Ω
At solenoid V03, between (1) and ground
20 to 60Ω
1
Above 1MΩ
2
Wiring harness assembly test • With ignition switch in OFF position. • Disconnect V03 connector from solenoid. • Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only. • Hold ignition switch in OFF position during troubleshooting. A.
Open or high resistance
Resistance Ω
B.
Short to chassis ground or within harness
Resistance Ω
Between connectors C03 (17) and V01 (2)
Above 1MΩ
3
At connector V02, between (1) and chassis ground
(OL) open
4
At connector V02, between (1) and (2)
(OL) open
5
0V
6
20 - 30V
7
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Ignition switch in the ON position, engine running during the troubleshooting. • Move RH & LH travel control levers A.
Defective test
20-332 1
controller
Voltage
C03 (17) and ground - Levers - Neutral position C03 (17) and ground - Levers - operating one side only
PC400LC-7L
TROUBLESHOOTING
E204
Electrical Circuit Diagram for Merge/Divide Solenoid
PC400LC-7L
20-333 1
TROUBLESHOOTING
E205
12
E205 SHORT IN 2-STAGE RELIEF SOLENOID Contents Of Trouble Response from controller Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
• •
Short in 2-stage relief solenoid circuit (Pump controller system). Failure code DWK0KB.
• •
Power supply to the 2-stage relief solenoid circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
•
The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.)
•
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E205]
A.
2.
3.
Specifications
No.
Readings
Solenoid test • With ignition switch in the OFF position. • Disconnect V08 connector from solenoid. • Zero meter leads for proper Ω readings. Swing holding brake solenoid test (Internal short or ground fault)
At solenoid V08, between (1) and (2) Resistance Ω
At solenoid V08, between (1) and ground
20 to 60Ω
1
Above 1MΩ
2
Wiring harness assembly test • With ignition switch in OFF position. • Disconnect V03 connector from solenoid. • Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only. • Hold ignition switch in OFF position during troubleshooting. A.
Open or high resistance
Resistance Ω
B.
Short to chassis ground or within harness
Resistance Ω
Between connectors C03 (28) and V08 (2)
Above 1MΩ
3
At connector V08, between (1) and chassis ground
(OL) open
4
At connector V02, between (1) and (2)
(OL) open
5
0V
6
20 - 30V
7
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Turn ignition switch ON. A.
Defective test
20-334 1
controller
Voltage
C03 (28) and ground - Other than L mode C03 (28) and ground - L mode
PC400LC-7L
TROUBLESHOOTING
E205
Electric Circuit Diagram for 2-stage Relief Solenoid
PC400LC-7L
20-335 1
TROUBLESHOOTING
E206
12
E206 SHORT IN TRAVEL SPEED SHIFT SOLENOID Contents Of Trouble Response from controller Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
• •
Short in travel speed shifting solenoid circuit (Pump controller system). Failure code DW43KB.
• •
Power supply to the travel speed shifting solenoid circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
•
The travel speed does not turn to HI. (The travel motor swash plate angle does not turn to minimum.)
•
Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E206]
A.
2.
3.
Specifications
No.
Readings
Solenoid test • With ignition switch in the OFF position. • Disconnect V04 connector from solenoid. • Zero meter leads for proper Ω readings. Travel speed shifting solenoid test (Internal short or ground fault)
20 to 60Ω
1
Above 1MΩ
2
Above 1MΩ
3
At connector V04, between (1) and chassis ground
(OL) open
4
At connector V02, between (1) and (2)
(OL) open
5
C03 (27) and ground - travel speed Lo + travel lever Neutral
0V
6
C03 (27) and ground - travel speed Hi + travel lever in operation
20 - 30V
7
At solenoid V04, between (1) and (2) Resistance Ω
At solenoid V04, between (1) and ground
Wiring harness assembly test • With ignition switch in OFF position. • Disconnect V04 connector from solenoid. • Disconnect C03 connector from governor pump controller an install T-adapter. • Hold ignition switch in OFF position during troubleshooting. A.
Open or high resistance
Resistance Ω
B.
Short to chassis ground or within harness
Resistance Ω
Between connectors C03 (27) and V04 (2)
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Turn ignition switch ON. A.
Defective test
20-336 1
controller
Voltage
PC400LC-7L
TROUBLESHOOTING
E206
12 Electrical Circuit Diagram for Travel Speed Shifting Solenoid
PC400LC-7L
20-337 1
TROUBLESHOOTING
E211
12
E211 OPEN IN TRAVEL INTERLOCKING SOLENOID Contents Of Trouble
• •
No current flows to the travel interlocking solenoid circuit, when power is supplied (Pump controller system). Failure code DW91KA.
Response from controller
• •
None in particular (The solenoid does not function because there is no current). When the failure cause disappears of itself, the machine operation returns to normal.
•
It is difficult to steer the machine while traveling. (LH and RH travel circuits cannot be disconnected.)
•
Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code E201).
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E211]
A.
2.
3.
Specifications
No.
Readings
Solenoid test • With ignition switch in the OFF position. • Disconnect V02 connector from solenoid. • Zero meter leads for proper Ω readings. Travel speed shifting solenoid test (Internal short or ground fault)
At solenoid V02, between (1) and (2) Resistance Ω
At solenoid V02, between (1) and ground
20 to 60Ω
1
Above 1MΩ
2
Wiring harness assembly test • With ignition switch in OFF position. • Disconnect V04 connector from solenoid. • Disconnect C03 connector from governor pump controller an install T-adapter. • Hold ignition switch in OFF position during troubleshooting. A.
Open or high resistance
Resistance Ω
Between connectors C03 (7) and V02 (2)
Below 1Ω
3
B.
Short to chassis ground or within harness
Resistance Ω
Between C03 (3), (13), (23) and V02 (1)
Below 1Ω
4
20 - 60Ω
5
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Hold ignition in the OFF position. A.
Defective test
20-338 1
controller
Voltage
Between C03 (7) and (3), (13), (23)
PC400LC-7L
TROUBLESHOOTING
E211
12 Electrical Circuit Diagram for Travel Interlocking Solenoid
PC400LC-7L
20-339 1
TROUBLESHOOTING
E213
12
E213 OPEN IN SWING HOLDING BRAKE SOLENOID Contents Of Trouble
• •
No current flows to the swing holding brake solenoid circuit, when power is supplied (Pump controller system). Failure code DW45KA.
Response from controller
• •
None in particular (The solenoid does not function because there is no current). When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on machine
•
The upper structure cannot swing. (The swing holding brake cannot be released.
•
Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing holding brake release switch to the RELEASE position. (In this case, however, the holding brake does not work, when stopping the machine.) While in troubleshooting, hold both the swing lock switch and the swing holding brake release switch in the OFF position. The controller detects disconnection, when solenoid power is ON. Therefore be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code E203.)
• Relative information • •
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E203]
A.
2.
Specifications
No.
Readings
Solenoid test • With ignition switch in the OFF position. • Disconnect V05 connector from solenoid. • Zero meter leads for proper Ω readings. Swing holding brake solenoid test (Internal short or ground fault)
At solenoid V05, between (1) and (2) Resistance Ω
At solenoid V05, between (2) and ground
20 to 60Ω
1
Above 1MΩ
2
Swing lock switch test • With ignition switch in OFF position. • Disconnect X05 connector and install T-adapter. • Hold ignition switch in OFF position during troubleshooting. Swing lock switch A.
3.
Resistance Ω
Between X05 (3) and (4)
OFF
Below 1Ω
3
ON
Above 1MΩ
4
Continuity one way only?
5
Diode test • With ignition switch in the OFF position. • Disconnect D01 diode connector and isolate. A.
4.
Swing lock switch test
Diode test
Resistance Ω
At diode D01, between (3) and (7) reversing meter lead polarity each time to check.
Wiring harness assembly test • Disconnection or defective contact with connector. • With ignition switch in OFF position. • Disconnect V05 connector from solenoid. • Disconnect S25 and X05 connectors from swing lock and park brake switches. • Disconnect C03 and C02 connectors from controller and install T-adapter on C03 and C02 connectors. • Hold ignition switch in OFF position during troubleshooting. A.
B.
Open or high resistance
Resistance Ω
Between connectors C03 (37) and D01 (7)
Below 1Ω
6
Between connectors D01 (3) to J02 to X05 (3)
Below 1Ω
7
Between connectors X05 (4) to V05 (2)
Below 1Ω
8
Between connectors C03 (3), (13), (23) and V05(1)
Below 1Ω
9
Short between wires or ground • With ignition switch in OFF position for preparation. • Hold ignition switch in ON position during trouble shooting.
20-340 1
PC400LC-7L
TROUBLESHOOTING Steps
Circuit Diagnostic Procedures For Code [E203]
--5.
E213
---
Voltage
At connectors C03 (37) and D01 (7) and ground
Specifications
No.
Below 1V
10
20 - 60Ω
11
Readings
Pump controller • With ignition switch in OFF position. • Disconnect C03 connector from controller and install T-adapter on C03connector. • Disconnect D01 and connect pins (3) and (7) of female side for test. • Hold ignition switch in OFF position during troubleshooting. A.
Defective pump controller test
Resistance Ω
At C03 (17) and between pins (3), (13), (23)
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400LC-7L
20-341 1
TROUBLESHOOTING
E214
12
E214 OPEN IN MERGE/DIVIDE SOLENOID Contents Of Trouble
• •
No current flows to the merge/divide solenoid circuit, when power is supplied (Pump controller system). Failure code DWJ0KA.
Response from controller
• •
None in particular (The solenoid does not function because there is no current). When the failure cause disappears of itself, the machine operation returns to normal.
•
In L mode, speeds of the work equipment and swing in its single operation are too fast. (F• R pumps cannot be disconnected.)
•
Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code E204).
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E214]
A.
2.
3.
No.
Readings
Merge/divide solenoid test (Internal short or ground fault)
At solenoid V02, between (1) and (2) Resistance Ω
At solenoid V02, between (1) and ground
20 to 60Ω
1
Above 1MΩ
2
Wiring harness assembly test • Checking for disconnection or defective contact with connector. • With ignition switch in OFF position. • Disconnect V02 connector from solenoid. • Disconnect C03 connector from governor pump controller an install T-adapter. • Hold ignition switch in OFF position during troubleshooting. A.
Open or high resistance
Resistance Ω
Between connectors C03 (17) and V03 (2)
Below 1Ω
3
B.
Short to chassis ground or within harness
Resistance Ω
Between C03 (3), (13), (23) and V03 (1)
Below 1Ω
4
Below 1V
5
20 - 60Ω
6
Short in wiring harness (Contact with 24V circuit). • With ignition switch in OFF position. • Hold ignition switch in ON position during troubleshooting. A.
4.
Specifications
Solenoid test • With ignition switch in the OFF position. • Disconnect V03 connector from solenoid. • Zero meter leads for proper Ω readings.
Short & contact with 24V circuit
Voltage
Check wiring harness from C03 (17) to V03 (2) and grounding
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Hold ignition in the OFF position. A.
Defective test
20-342 1
controller
Resistance Ω
Between C03 (17) and (3), (13), (23)
PC400LC-7L
TROUBLESHOOTING
E214
12 Electrical Circuit Diagram for Merge/Divide Solenoid
PC400LC-7L
20-343 1
TROUBLESHOOTING
E215
12
E215 OPEN IN 2-STAGE RELIEF SOLENOID Contents Of Trouble
• •
No current flows to the 2-stage relief solenoid circuit, when power is supplied (Pump controller system). Failure code DWK0KA.
Response from controller
• •
None in particular (The solenoid does not function because there is no current). When the failure cause disappears of itself, the machine operation returns to normal.
•
The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.)
•
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code E205).
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E215]
A.
2.
3.
No.
Readings
2-stage relief solenoid test (Internal short or ground fault)
At solenoid V08, between (1) and (2) Resistance Ω
At solenoid V08, between (1) and ground
20 to 60Ω
1
Above 1MΩ
2
Wiring harness assembly test • Checking for disconnection or defective contact with connector. • With ignition switch in OFF position. • Disconnect V08 connector from solenoid. • Disconnect C03 connector from governor pump controller an install T-adapter. • Hold ignition switch in OFF position during troubleshooting. A.
Open or high resistance
Resistance Ω
Between connectors C03 (28) and V08 (2)
Below 1Ω
3
B.
Short to chassis ground or within harness
Resistance Ω
Between C03 (3), (13), (23) and V08 (1)
Below 1Ω
4
Below 1V
5
20 - 60Ω
6
Short in wiring harness (Contact with 24V circuit). • With ignition switch in OFF position. • Hold ignition switch in ON position during troubleshooting. A.
4.
Specifications
Solenoid test • With ignition switch in the OFF position. • Disconnect V08 connector from solenoid. • Zero meter leads for proper Ω readings.
Short & contact with 24V circuit
Voltage
Check wiring harness from C03 (28) to V08 (2) and grounding
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Hold ignition in the OFF position. A.
Defective test
20-344 1
controller
Resistance Ω
Between C03 (28) and (3), (13), (23)
PC400LC-7L
TROUBLESHOOTING
E215
12 Electrical Circuit Diagram for 2-stage Relief Solenoid
PC400LC-7L
20-345 1
TROUBLESHOOTING
E216
12
E216 OPEN IN TRAVEL SPEED SOLENOID Contents Of Trouble
• •
No current flows to the travel speed solenoid circuit, when power is supplied (Pump controller system). Failure code DW43KA.
Response from controller
• •
None in particular (The solenoid does not function because there is no current). When the failure cause disappears of itself, the machine operation returns to normal.
•
The travel speed does not shift to Hi. (The travel motor swash plate angle does not turn to minimum.)
•
Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code E206).
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E216]
A.
2.
3.
No.
Readings
Travel speed solenoid test (Internal short or ground fault)
At solenoid V04, between (1) and (2) Resistance Ω
At solenoid V04, between (1) and ground
20 to 60Ω
1
Above 1MΩ
2
Wiring harness assembly test • Checking for disconnection or defective contact with connector. • With ignition switch in OFF position. • Disconnect V04 connector from solenoid. • Disconnect C03 connector from governor pump controller an install T-adapter. • Hold ignition switch in OFF position during troubleshooting. A.
Open or high resistance
Resistance Ω
Between connectors C03 (27) and V04 (2)
Below 1Ω
3
B.
Short to chassis ground or within harness
Resistance Ω
Between C03 (3), (13), (23) and V04 (1)
Below 1Ω
4
Below 1V
5
20 - 60Ω
6
Short in wiring harness (Contact with 24V circuit). • With ignition switch in OFF position. • Hold ignition switch in ON position during troubleshooting. A.
4.
Specifications
Solenoid test • With ignition switch in the OFF position. • Disconnect V04 connector from solenoid. • Zero meter leads for proper Ω readings.
Short & contact with 24V circuit
Voltage
Check wiring harness from C03 (27) to V04 (2) and grounding
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C03 connector and install T-adapter. • Hold ignition in the OFF position. A.
Defective test
20-346 1
controller
Resistance Ω
Between C03 (27) and (3), (13), (23)
PC400LC-7L
TROUBLESHOOTING
E216
12 Electrical Circuit Diagram for Travel Speed Shifting Solenoid
PC400LC-7L
20-347 1
TROUBLESHOOTING
E217
12
E217 ABNORMAL INPUT MODEL CODE Contents Of Trouble Response from controller Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
• •
A model code signal for a model which is not registered in the controller is inputted. (Pump controller system). Failure code DA2SKQ.
• •
The controller controls the machine as a default model (PC750). Even after the failure cause disappears of itself, the machine operation does not return to normal, unless the engine starting switch is turned OFF.
•
Since the controller controls the machine as PC750/800, the working speed changes and operation becomes difficult.
•
The model name (number) recognized by the controller can be checked in the monitoring function. (Code No. 00200: Controller model code.) Input of the model selection signal (ON or OFF) can be checked in the monitoring function. (Code No. 02201: Switch input 2.)
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E217]
A.
2.
Specifications
No.
Readings
Model selection connector • With ignition switch in the OFF position. • Disconnect C09 connector and use T-adapter. • Hold ignition switch in OFF position for troubleshooting. Model selection connector test (Internal short or ground fault)
At C09, between (4), (5), (6), (8) Resistance Ω
At C09, between (1), (2), (3), (7), (8)
Μin. 1MΩ
1
Μax. 1Ω
2
Wiring harness assembly test • Checking for disconnection or defective contact with connector. • With ignition switch in OFF position. • Disconnect C02 connector from governor pump controller an install T-adapter. • Hold ignition switch in OFF position during troubleshooting.
A.
Open or high resistance
Resistance Ω
C02 (37) and C09 (1)
Μax. 1Ω
3
C02 (27) and C09 (2)
Μax. 1Ω
4
C02 (17) and C09 (3)
Μax. 1Ω
5
C02 (13) and C09 (7)
Μax. 1Ω
6
C09 (8), J05, and ground (A13)
Μax. 1Ω
7
Μin. 1MΩ
8
3.
Short in wiring harness. • With ignition switch in OFF position. • Hold ignition switch in OFF position during troubleshooting.
4.
Pump controller • Turn the engine ignition switch OFF for the preparations. • Disconnect C02 connector and install T-adapter. • Hold ignition in the ON position during troubleshooting.
A.
A.
Short & contact
Defective test
20-348 1
controller
Resistance Ω
Voltage
Check wiring harness from C02 (7) to C09 (4) and ground
Between C02 (7) and ground
5 - 30V
9
Between C02 (37), (27), (17), (13) and ground
Max. 1V
10
PC400LC-7L
TROUBLESHOOTING
E217
12 Electrical circuit diagram related to model selection connector (for pump controller)
PC400LC-7L
20-349 1
TROUBLESHOOTING
E218
12
E218 OPEN IN S-NET COMMUNICATION SIGNAL • •
The pump controller detected communication failure in the S-NET communication circuit to the monitor panel or engine controller. Failure code DA2SKA.
Response from controller
• •
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%. When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall.
•
Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET)
Contents Of Trouble
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E218]
A.
B.
2.
Specifications
No.
Readings
Wiring harness assembly test • With ignition switch in OFF position. • Hold in the OFF position during troubleshooting.
Open or high resistance
Resistance Ω
Grounding fault wiring harness (Contact with grounding circuit)
of
Resistance Ω
Between P02 (9), (10) monitor panel and CB2 (21), (31) engine controller
Max. 1Ω
1
Between P02 (9), (10) monitor panel and C02 (21) pump controller
Max. 1Ω
2
Between P02 (20) monitor panel and chassis ground
Max. 1Ω
3
Between monitor panel P02 (9), (10) and engine controller CB2 (21), (31)
Min. 1MΩ
4
Between monitor panel P02 (9), (10) and pump controller C02 (21) and related circuits and grounding
Min. 1MΩ
5
Between monitor panel P02 (9), (10) related circuits and grounding
Min. 1MΩ
6
Between monitor panel P02 (9), (10) and engine controller CB2 (21), (31) and related circuits and grounding
Max. 1V
7
Between monitor panel P02 (9), (10) and pump controller C02 (21) and related circuits and grounding
Max. 1V
8
Between monitor panel P02 (9), (10) related circuits and grounding
Max. 1V
9
6 - 9V
10
6 - 9V
11
Wiring harness assembly test • With ignition switch in OFF position, make the test preparations. • During test hold ignition switch in the ON position.
A.
Short-circuit (Contact with 24V circuit)
Voltage
3.
Monitor panel test • With ignition switch in the OFF position. • Disconnect P02 connector from monitor and install T-adapter. • Turn ignition switch to the ON position during the troubleshooting.
4.
Engine controller test • Turn the engine ignition switch OFF for the preparations. • Disconnect CB2 connector and install T-adapter. • Hold ignition switch in the ON position during the troubleshooting.
A.
A.
Monitor panel test
Defective test
20-350 1
controller
Voltage
Voltage
Between P02 (9), (10) [N/W signal] and (20) [N/W GND]
CB2 (21), (31) and (11)
PC400LC-7L
TROUBLESHOOTING Steps 5.
E218
Circuit Diagnostic Procedures For Code [E218]
Specifications
No.
Readings
Pump controller test • With ignition switch in the OFF position. • Disconnect C02 connector from monitor and install T-adapter. • Turn ignition switch to the ON position during the troubleshooting. A.
Monitor panel test
Voltage
C02, between (21) and (31)
6 - 9V
12
Electrical Circuit Diagram for S-NET Communication
PC400LC-7L
20-351 1
TROUBLESHOOTING
E222
12
E222 SHORT IN LS-EPC SOLENOID Contents Of Trouble Response from controller Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
• •
Short in LS-EPC solenoid circuit. Failure code DXE0KB.
• •
The controller reduces the output to the LS-EPC solenoid circuit to 0. Even if the failure cause disappears, the current does not return to normal, unless the engine ignition switch is turned OFF.
•
The travel speed is slow at Mi and Lo or in L mode, speeds of the work equipment and swing are too fast (The LS valve set pressure cannot be controlled.)
•
Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01500 LS-EPC solenoid current.)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E222]
A.
2.
3.
Specifications
No.
Readings
LS-EPC solenoid • Turn the engine ignition switch OFF for preparations • Disconnect V22 connection. • Hold ignition switch OFF during troubleshooting. LS-EPC solenoid test (internal short or ground fault)
At connection V22, between (1) and (2) Resistance Ω
7 - 14Ω
1
Above 1 MΩ
2
Between C03 (6) and V22 (1) and ground
Above 1 MΩ
3
At connector V22, between (1) and ground
(OL) open
4
At connector V22, between (2) and ground
(OL) open
5
At connector V22, between (1) and (2)
(OL) open
6
7 - 14Ω
7
Above 1 MΩ
8
At connection V22, Between (1) and ground
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting. A.
Open or high resistance
B.
Grounding fault wiring harness (Contact with grounding circuit)
Resistance Ω of Resistance Ω
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting. A.
Pump controller
20-352 1
Resistance Ω
Between C03 (6) and (3), (13), (23) Between C03 (6) and ground
PC400LC-7L
TROUBLESHOOTING
E222
Electrical Circuit Diagram for LS-EPC Solenoid
PC400LC-7L
20-353 1
TROUBLESHOOTING
E223
12
E223 OPEN IN LS-EPC SOLENOID SYSTEM Contents Of Trouble
• •
Open (no current flow) in LS-EPC solenoid circuit. Failure code DXE0KA.
Response from controller
• •
None in particular (The solenoid does not function as there is no current flow to it). When the failure cause disappears by itself, the machine operation returns to normal.
•
The travel speed is slow at Mi and Lo or in L mode, speeds of the work equipment and swing are too fast (The LS valve set pressure cannot be controlled.)
•
Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01500 LS-EPC solenoid current.)
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E223]
A.
2.
Specifications
No.
Readings
LS-EPC solenoid • Turn the engine ignition switch OFF for preparations • Disconnect V22 connection. • Hold ignition switch OFF during troubleshooting. LS-EPC solenoid test (internal short or ground fault)
At connection V22, between (1) and (2) Resistance Ω
At connection V22, Between (1) and ground
7 - 14Ω
1
Above 1 MΩ
2
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch ON during this test. A. B.
3.
Open or high resistance Grounding fault wiring harness (Contact with 24V grounding circuit)
Resistance Ω
Between C03 (6) and V22 (1) and ground
Below 1Ω
3
Between C03 (3), (13), (23) and V22 (2)
Below 1Ω
4
★ Between C03 (6) and V22 (1) and ground
Below 1V
of Voltage
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting. A.
Pump controller
20-354 1
Resistance Ω
Between C03 (6) and (3), (13), (23)
7 - 14Ω
PC400LC-7L
TROUBLESHOOTING
E223
Electrical Circuit Diagram for LS-EPC Solenoid
PC400LC-7L
20-355 1
TROUBLESHOOTING
E224
12
E224 ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL Contents Of Trouble
• •
Signal voltage from the front pump pressure sensor is below 0.3V or above 4.42V. (Pump controller system.) Failure code DHPAMA.
Response from controller
• •
The controller sets the F pump to 0 kg/cm2 (0 psi) for control. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
•
The travel speed does not shift automatically (The travel load pressure cannot be detected).
★ If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be Relative information
Tools and Procedures
• • • • •
•
broken. Accordingly, take extreme care when checking. Input from the front pump pressure sensor (pressure) can be checked in the monitoring function. (Code No.: 01100: Front pump pressure.)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E224]
1.
Sensor power supply system defective
2.
Front pump pressure sensor defective (Internal defect) • Turn the engine ignition switch OFF for preparations
★ Ignition switch ON or keep the engine running during troubleshooting. ★ At connection A51, between (B) and (A) - power A.
Front pump pressure sensor test
supply Voltage
Specifications
If error code 226 is displayed, carry out troubleshooting for it first.
★ At connection A51, Between (C) and (A) - signal
No.
Readings
1
4.5 - 5.5V
2
0.5 - 4.5v
3
The pressure voltage is measured with the wiring harness connected. According, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, then judge. 3.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect A51 connector from sensor. • Disconnect pump controller C01 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should be in the ON position during troubleshooting. A.
B.
C.
4.
Disconnection or defective contact with connector (Wiring harness)
Resistance Ω
Ground fault of wiring harness (Contact with ground circuit)
Resistance Ω
Short in wiring harness (Contact with 24V circuit)
Voltage
Between C01 (22) and A51 (B)
Max. 1Ω
4
Between C01 (10) and A51 (A)
Max. 1Ω
5
Between C01 (8) and A51 (C)
Max. 1Ω
6
Min. 1 MQ
7
★ Between C01 (22) and A51 (B) and ground
Max. 1V
8
★ Between C01 (8) and A51 (C) and ground
Max. 1V
9
4.5 - 5.5V
10
0.5 - 4.5V
11
Between C01 (8) and A51 (C) and ground
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C01 and install T-adapter.
★ Ignition switch should be in the ON position or keep the engine running during troubleshooting. ★ Between C01 (22) and (10) A. Pump controller test Voltage ★ Between C01 (8) and (10)
20-356 1
PC400LC-7L
TROUBLESHOOTING
E224
12 Electrical circuit diagram related to front pump pressure sensor
PC400LC-7L
20-357 1
TROUBLESHOOTING
E225
12
E225 ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL Contents Of Trouble
• •
Signal voltage from the rear pump pressure sensor is below 0.3V or above 4.42V. (Pump controller system.) Failure code DHPBMA.
Response from controller
• •
The controller sets the R pump to 0 kg/cm2 (0 psi) for control. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
•
The travel speed does not shift automatically (The travel load pressure cannot be detected).
★ If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be Relative information
Tools and Procedures
• • • • •
•
broken. Accordingly, take extreme care when checking. Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function. (Code No.: 01101: Rear pump pressure.)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E225]
1.
Sensor power supply system defective
2.
Front pump pressure sensor defective (Internal defect) • Turn the engine ignition switch OFF for preparations
★ Ignition switch ON or keep the engine running during troubleshooting. ★ At connection A52, between (B) and (A) - power A.
Front pump pressure sensor test
supply Voltage
Specifications
If error code 226 is displayed, carry out troubleshooting for it first.
★ At connection A52, Between (C) and (A) - signal
No.
Readings
1
4.5 - 5.5V
2
0.5 - 4.5v
3
The pressure voltage is measured with the wiring harness connected. According, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, then judge. 3.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect A52 connector from sensor. • Disconnect pump controller C01 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should be in the ON position during troubleshooting. A.
B.
C.
4.
Disconnection or defective contact with connector (Wiring harness)
Resistance Ω
Ground fault of wiring harness (Contact with ground circuit)
Resistance Ω
Short in wiring harness (Contact with 24V circuit)
Voltage
Between C01 (22) and A52 (B)
Max. 1Ω
4
Between C01 (10) and A52 (A)
Max. 1Ω
5
Between C01 (2) and A52 (C)
Max. 1Ω
6
Min. 1 MQ
7
★ Between C01 (22) and A52 (B) and ground
Max. 1V
8
★ Between C01 (2) and A52 (C) and ground
Max. 1V
9
4.5 - 5.5V
10
0.5 - 4.5V
11
Between C01 (2) and A52 (C) and ground
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C01 and install T-adapter.
★ Ignition switch should be in the ON position or keep the engine running during troubleshooting. ★ Between C01 (22) and (10) A. Pump controller test Voltage ★ Between C01 (2) and (10)
20-358 1
PC400LC-7L
TROUBLESHOOTING
E225
12 Electrical circuit diagram related to rear pump pressure sensor
PC400LC-7L
20-359 1
TROUBLESHOOTING
E226
12
E226 ABNORMAL PRESSURE SENSOR POWER SUPPLY • •
Abnormal pressure sensor power supply (5V). Failure code DH25KP.
Response from controller
• •
Power to the power supply (5V) circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• •
The pressure sensor signal is not input normally. The error code of abnormality in the pressure sensor is displayed.
Relative information
---
Contents Of Trouble
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E226]
A.
2.
No.
Readings
If the error code goes off when one Pressure sensor test of the listed items (in order listed) Disconnect the parts is disconnected, that part is shown at right in order. defective.
Front pump pressure sensor - connector A51
1
Rear pump pressure sensor - connector A52
2
Arm IN PPC pressure sensor - connector S04
3
Bucket CURL PPC pressure sensor - connector S01
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C01 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting.
A.
3.
Specifications
Pressure sensor defective (Internal short) • Turn the engine ignition switch OFF for preparations • Ignition switch ON during troubleshooting.
Ground fault of wiring harness (Contact with ground circuit)
Resistance Ω
Between C01 (22) and A51 (B) and ground (F pump)
Min. 1 MQ
5
Between C01 22) and A52 (B) and ground (R pump)
Min. 1 MQ
6
Between C01 (22) and S04 (A) and ground (Bucket CURL PPC)
Min. 1 MQ
7
Between C01 (22) and S01 (A) and ground (Arm IN PPC)
Min. 1 MQ
8
4.5 - 5.5V
9
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C01 and install T-adapter. • Ignition switch should be in the ON position for troubleshooting. A.
Pump controller test
20-360 1
Voltage
Between C01 (22) and (10)
PC400LC-7L
TROUBLESHOOTING
E226
12 Electrical circuit diagram related to pressure sensor power supply
PC400LC-7L
20-361 1
TROUBLESHOOTING
E227
12
E227 ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR Contents Of Trouble
• •
A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor. Failure code DLE2MA.
Response from controller
• •
The controller exercises a control equivalent to E mode. If the failure cause disappears by itself, the signal input returns to normal.
Phenomenon occurring on machine
• •
The machine lacks power a bit. (The engine rotation sensing does not work.) The engine speed (in the pump controller system) is not monitored on the monitor panel.
•
Input from the engine rotation sensor (RPM) can be confirmed in the monitor function. (Code No.: 01006 Engine RPM)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E227]
Specifications
No.
Readings
Engine rotation sensor (Internal short) • Turn the engine ignition switch OFF for preparations • Ignition switch OFF during troubleshooting. A.
Engine rotation sensor test - internal short or disconnected sensor
Resistance Ω adjustment
Between ENE (1) and (2)
500 - 1,000Ω
1
Between ene (1) and ground
Above 1MΩ
2
2.
Engine rotation improper
3.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C02 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting.
Refer to the section “Adjusting Engine Rotation Sensor” in this manual for inspection and adjustment.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
4.
Wiring harness Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with 24V circuit)
Voltage
Between C02 (40) and ENE (1)
Below 1Ω
3
Between C02 (29), (39) and ENE (2)
Below 1Ω
4
★ Between C02 (40) and ENE (1) and ground
Below 1V
5
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C02 and install T-adapter. • Ignition switch should be in the ON position for troubleshooting. A.
Pump controller test
20-362 1
Resistance Ω
Between C02 (40) and (29), (39)
500 - 1,000Ω
6
Between C02 (40) and ground
Above 1MΩ
7
PC400LC-7L
TROUBLESHOOTING
E227
12 Electrical Circuit Diagram for Engine Rotation Sensor
PC400LC-7L
20-363 1
TROUBLESHOOTING
E228
12
E228 SHORT IN ATTACHMENT RETURN SWITCHING RELAY Contents Of Trouble
• •
Short in attachment return switching relay. (Pump controller system) Failure code D196KB.
Response from controller
• •
The controller turned OFF power to the attachment return switching relay circuit. Even when the failure cause disappears by itself, the current does not return to normal.
•
The hydraulic circuit for attachments is not switched to the single operation circuit. (The switching valve is not switched to the tank circuit.)
•
It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No.: 02301 Solenoid 2) This error code detects abnormal on the primary side (coil side) of the attachment return selector relay and cannot detect abnormality on the secondary side (contact side).
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E228]
A.
2.
No.
Readings
Attachment return switching relay test internal short or disconnected
Resistance Ω
Between R20, between (1) and (2)
100 - 500Ω
1
Below 1V
2
Working mode - Other than B mode
20 − 30V
3
Working mode - B mode
Below 1V
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C02 and install T-adapter. • Ignition switch should remain in the ON position during troubleshooting. A.
3.
Specifications
Attachment return switching relay (Internal short) • Turn the engine ignition switch OFF for preparations • Ignition switch OFF during troubleshooting.
Wiring harness Short (Contact with 24V circuit)
Voltage
Between C02 (8) and R20 (2) and ground
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C02 and install T-adapter. • Ignition switch should be in the ON position for troubleshooting. A.
Pump controller test
20-364 1
Voltage
C02 (8) and ground
PC400LC-7L
TROUBLESHOOTING
E228
12 Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400LC-7L
20-365 1
TROUBLESHOOTING
E232
12
E232 SHORT IN PC-EPC SOLENOID Contents Of Trouble Response from controller Phenomenon occurring on machine
Relative information
• •
Short in PC-EPC solenoid. (Pump controller system) Failure code DXA0KB.
• •
The controller reduces the output to the PC-EPC solenoid circuit to OFF. Even when the failure cause disappears by itself, the current does not return to normal, unless the engine ignition switch is turned OFF.
•
As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled.)
•
Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01300 PC-EPC solenoid current) If there is no abnormality with the solenoid or any of the wiring harness, the machine can be operated in a working mode equivalent to E mode by turning the emergency pump drive switch to the emergency position. (At that time the monitor panel continues to display Error Code No. E233, but this is not abnormal.) Have the emergency driving switch in normal during the troubleshooting.
•
• Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E232]
A.
2.
Readings
PC-EPC solenoid test internal short or disconnected
At V21, between (1) and (2) Resistance Ω
7 - 14Ω
1
Above 1 MΩ
2
Above 1 MΩ
3
Above 1 MΩ
4
Between C03 (16) and S25 (3) and ground
Above 1 MΩ
5
Between S25 (2) and V21 (1) and ground
Above 1 MΩ
6
At V21, between (1) and ground
Emergency pump drive switch test internal short or disconnected
Resistance Ω
Emergency At S25, between (3) and (4) pump drive switch - Normal At S25, between (3) and ground
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should remain in the OFF position during troubleshooting. A.
4.
No.
Emergency pump driving switch • Turn the engine ignition switch OFF for preparations • Disconnect pump controller S25 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
3.
Specifications
PC-EPC solenoid (Internal short) • Turn the engine ignition switch OFF for preparations • Ignition switch OFF during troubleshooting.
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should be in the OFF position for troubleshooting. A.
Pump controller test
20-366 1
Resistance Ω
At C03, between (16) and (3), (13), (23) At C03, between (16) and ground
7 - 14Ω
7
Above 1 MΩ
8
PC400LC-7L
TROUBLESHOOTING
E232
12 Electrical Circuit Diagram for PC-EPC Solenoid
PC400LC-7L
20-367 1
TROUBLESHOOTING
E233
12
E233 OPEN IN PC-EPC SOLENOID Contents Of Trouble
• •
No current flow to PC-EPC solenoid circuit. (Pump controller system) Failure code DXA0KA.
Response from controller
• •
None in particular (the solenoid does not function because there is no current flow to it.) When the failure cause disappears by itself, the current returns to normal.
•
As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled.)
•
Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01300 PC-EPC solenoid current) If there is no abnormality with the solenoid or any of the wiring harness, the machine can be operated in a working mode equivalent to E mode by turning the emergency pump drive switch to the emergency position.
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E233]
A.
2.
Specifications
No.
Readings
PC-EPC solenoid (Internal short) • Turn the engine ignition switch OFF for preparations • Ignition switch OFF during troubleshooting. PC-EPC solenoid test internal short or disconnected
At V21, between (1) and (2) Resistance Ω
At V21, between (1) and ground
7 - 14Ω
1
Above 1 MΩ
2
Emergency pump driving switch • Turn the engine ignition switch OFF for preparations • Disconnect pump controller S25 and install T-adapter. • Ignition switch OFF during troubleshooting. Emergency pump drive switch A.
3.
Emergency pump drive switch test internal short or disconnected
- Normal Resistance Ω
- Emergency
At S25, between (2) and (3)
Below 1Ω
3
Above 1 MΩ
4
Below 1Ω
5
Above 1 MΩ
6
Between C03 (16) and S25 (3)
Below 1Ω
7
Between S25 (2) and V21 (1)
Below 1Ω
8
At C03, between (3), (13), (23) and S25 (6)
Below 1Ω
9
Between S25 (5) and V21 (2)
Below 1Ω
10
★ Between C03 (16) and S25 (3) and ground
Below 1V
11
★ Between S25 (2) and V21 (1) and ground
Below 1V
12
7 - 14Ω
13
- Normal - Emergency
At S25, between (5) and (6)
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C03 and S25 RH console emergency switch and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
4.
Wiring harness Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with 24V circuit)
Voltage
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should be in the OFF position for troubleshooting. A.
Pump controller test
20-368 1
Resistance Ω
At C03, between (16) and (3), (13), (23)
PC400LC-7L
TROUBLESHOOTING
E233
12 Electrical Circuit Diagram for PC-EPC Solenoid
PC400LC-7L
20-369 1
TROUBLESHOOTING
E238
12
E238 OPEN IN ATTACHMENT RETURN SWITCHING RELAY • •
When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24V voltage is not generated. (Pump controller system) Failure code D196KA.
• •
None in particular. When the failure cause disappears by itself, the current returns to normal.
•
The hydraulic circuit for attachments cannot be switched to the single operation. (The switching valve cannot be switched to the tank circuit.)
•
It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No.: 02301 Solenoid 2) This code detects abnormality on the primary side (coil side) of the attachment return selector relay and cannot detect abnormality on the secondary side (contact side).
Contents Of Trouble Response from controller Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E238]
1.
Fuse No. 2 fault
2.
Attachment return switching relay (Internal short) • Turn the engine ignition switch OFF for preparations • Disconnect R20 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
3.
No.
Readings
Resistance Ω
At R20, between (1) and (2)
100 - 500Ω
1
Between C02 (8) and R20 (2)
Below 1Ω
2
At R20 (1) to J03 to FB1-2 outlet
Below 1Ω
3
Between C02 (8) and R20 (2) and ground
Above 1ΜΩ
4
Between R20 (1) to J03 to FB1-2 and ground
Above 1ΜΩ
5
20 - 30V
6
Below 1V
7
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C02 and R20 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
4.
Attachment return switching relay test internal short or disconnected
Specifications
If fuse No. 2 has been blown, there is a big possibility that a grounding fault occurred in the relay circuit. (See Step 3B)
Wiring harness Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C02 and install T-adapter. • Ignition switch should be in the ON position for troubleshooting. Working mode A.
Pump controller test
Voltage
Other than B mode B mode
20-370 1
At C02, between (8) and ground
PC400LC-7L
TROUBLESHOOTING
E238
12 Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400LC-7L
20-371 1
TROUBLESHOOTING
E245
12
E245 SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM Contents Of Trouble Response from controller Phenomenon occurring on machine
• •
Short in attachment oil flow rate adjusting EPC solenoid circuit. (Pump controller system) Failure code DXE4KB.
• •
The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF. Even when the failure cause disappears, the EPC solenoid circuit does not return to normal, unless the engine ignition switch is turned OFF.
•
The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
•
It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E245]
A.
2.
No.
Readings
Attachment oil flow rate EPC valve test internal short or disconnected
At V30, between (1) and (2) Resistance Ω
At V30, between (1) and grounding
7 - 14Ω
1
Above 1ΜΩ
2
Above 1ΜΩ
3
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Attachment oil flow rate EPC valve (Internal short) • Turn the engine ignition switch OFF for preparations • Disconnect V30 and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Between C03 (26) and V30 (1) and ground
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should be in the OFF position for troubleshooting. A.
Pump controller test
20-372 1
Resistance Ω
At C03, between (26) and (3), (13), (23) At C03, between (26) and grounding
7 - 14Ω
4
Above 1ΜΩ
5
PC400LC-7L
TROUBLESHOOTING
E245
12 Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400LC-7L
20-373 1
TROUBLESHOOTING
E246
12
E246 OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM Contents Of Trouble
• •
No current flow to the attachment oil flow rate adjusting EPC solenoid circuit. (Pump controller system) Failure code DXE4KA.
Response from controller
• •
None in particular (The solenoid does not work, as there is no current flowing to it.) If the failure cause disappears, the EPC solenoid circuit returns to normal by itself.
Phenomenon occurring on machine
•
The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
•
It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E246]
A.
2.
Specifications
No.
Readings
Attachment oil flow rate EPC valve (Internal short) • Turn the engine ignition switch OFF for preparations • Disconnect V30 and install T-adapter. • Ignition switch OFF during troubleshooting. Attachment oil flow rate EPC valve test internal short or disconnected
At V30, between (1) and (2) Resistance Ω
7 - 14Ω
1
Above 1ΜΩ
2
Between C03 (26) and V30 (1) and grounding
Below 1Ω
3
Between C03 (3), (13), (23) and V30 (2) and grounding
Below 1Ω
4
★ Between C03 (26) and V30 (1) and ground
Below 1V
5
7 - 14Ω
6
At V30, between (1) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
3.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with 24V circuit)
Voltage
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C03 and install T-adapter. • Ignition switch should be in the OFF position for troubleshooting. A.
Pump controller test
20-374 1
Resistance Ω
At C03, between (26) and (3), (13), (23)
PC400LC-7L
TROUBLESHOOTING
E246
12 Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400LC-7L
20-375 1
TROUBLESHOOTING
E247
12
E247 ABNORMALITY IN ARM IN PPC PRESSURE SENSOR Contents Of Trouble
• •
Signal voltage from the arm IN PPC pressure sensor is below 0.3V or above 4.42V. Failure code DHS3MA.
Response from controller
• •
The controller sets the arm IN PPC pressure to 0 kg/cm2 (0 psi) for control. If the failure cause disappears by itself, the machine operation returns to normal.
•
If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The arm IN PPC circuit pressure cannot be detected).
Phenomenon occurring on machine
★ If the 5V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be Relative information
Tools and Procedures
• • • • •
•
broken. Accordingly, take extreme care when checking. Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function. (Code No.: 07200 Arm IN PPC pressure)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E247]
1.
Sensor power supply system
2.
Arm IN PPC pressure sensor (Internal short) • Turn the engine ignition switch OFF for preparations • Disconnect S04 and install T-adapter. • Ignition switch ON or keep engine running during troubleshooting. A.
3.
Arm IN PPC pressure sensor test - internal short or disconnected
Specifications
No.
Readings
If error code 226 is displayed, carry out troubleshooting for it first.
Voltage
S04 Power supply, between (A) and (C)
4.5 − 5.5V
1
S04 Signal, between (B) and (C)
0.5 − 4.5V
2
Between C01 (22) and S04 (A)
Max. 1Ω
3
Between C01 (10) and S04 (C)
Max. 1Ω
4
Between C01 (19) and S04 (B)
Max. 1Ω
5
Between C01 (19) and S04 (B) and ground
Min. 1MΩ
6
★ At C01 (22) and S04 (A) and ground
Max. 1V
7
★ At C01 (19) and S04 (B) and ground
Max. 1V
8
4.5 − 5.5V
9
0.5 − 4.5V
10
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C01 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
C.
4.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test ground fault (Contact with grounding circuit)
Resistance Ω
Wiring harness test Short (Contact with 24V circuit)
Voltage
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C01 and install T-adapter.
★ Ignition switch should remain in the ON position or keep the engine running during troubleshooting. ★ At C01, between (22) and (10) A. Pump controller test Voltage ★ At C01, between (19) and (10)
20-376 1
PC400LC-7L
TROUBLESHOOTING
E247
12 Circuit diagram related to arm IN PPC pressure sensor
PC400LC-7L
20-377 1
TROUBLESHOOTING
E248
12
E248 ABNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR Contents Of Trouble
• •
Signal voltage from the bucket CURL PPC pressure sensor is below 0.3V or above 4.42V. Failure code DHS4MA.
Response from controller
• •
The controller sets the bucket CURL PPC pressure to 0 kg/cm2 (0 psi) for control. If the failure cause disappears by itself, the machine operation returns to normal.
•
If auto deceleration is operated, auto deceleration cannot be released when moving the bucket CURL (The bucket CURL PPC circuit pressure cannot be detected).
Phenomenon occurring on machine
★ If the 5V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be Relative information
Tools and Procedures
• • • • •
•
broken. Accordingly, take extreme care when checking. Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function. (Code No.: 07300 Bucket CURL PPC pressure)
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E248]
1.
Sensor power supply system
2.
Bucket CURL (Dig) PPC pressure sensor (Internal defect) • Turn the engine ignition switch OFF for preparations • Disconnect S01 and install T-adapter. • Ignition switch ON or keep engine running during troubleshooting. A.
Bucket CURL (Dig) PPC pressure sensor test - internal short or disconnected
Specifications
No.
Readings
If error code 226 is displayed, carry out troubleshooting for it first.
Voltage
S01 Power supply, between (1) and (3)
4.5 − 5.5V
1
S01 Signal, between (2) and (3)
0.5 − 4.5V
2
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller for another cause of the trouble and then judge. 3.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect pump controller C01, S01 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
C.
4.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test ground fault (Contact with grounding circuit)
Resistance Ω
Wiring harness test Short (Contact with 24V circuit)
Voltage
Between C01 (22) and S01 (1)
Max. 1Ω
3
Between C01 (10) and S01 (3)
Max. 1Ω
4
Between C01 (19) and S01 (2)
Max. 1Ω
5
Between C01 (19) and S01 (2) and ground
Min. 1MΩ
6
★ At C01 (22) and S01 (1) and ground
Max. 1V
7
★ At C01 (19) and S01 (2) and ground
Max. 1V
8
Pump controller • With ignition switch in OFF position. • Disconnect pump controller C01 and install T-adapter.
★ Ignition switch should remain in the ON position or keep the engine running during troubleshooting. ★ At C01, between (22) and (10) A. Pump controller test Voltage ★ At C01, between (19) and (10)
20-378 1
4.5 − 5.5V
9
0.5 − 4.5V
10
PC400LC-7L
TROUBLESHOOTING
E248
12 Circuit diagram related to bucket CURL PPC pressure sensor
PC400LC-7L
20-379 1
TROUBLESHOOTING
E257
12
E257 ABNORMALITY IN PUMP • •
The pump controller detected communication failure in the CAN communication circuit to the monitor panel or engine controller. Failure code DA2RMC.
Response from controller
• •
The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. If the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall.
Relative information
---
Contents Of Trouble
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E257]
Specifications
No.
Readings
Wiring harness assembly • With ignition switch in OFF position. • Disconnect P70, C02, CB2 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test ground fault (Contact with grounding circuit) Resistance Ω
C.
Wiring harness test Short (Contact with 24V circuit) Voltage
2.
Below 1Ω
1
Below 1Ω
2
Between P70 (15) and CB2 (32)
Below 1Ω
3
Between P70 (15) and C02 (32)
Below 1Ω
4
Between P70 (16) and CB2 (22)
Above 1MΩ
5
Between P70 (16) and C02 (22)
Above 1MΩ
6
Between P70 (16) and related circuits and grounding
Above 1MΩ
7
Between P70 (15) and CB2 (32)
Above 1MΩ
8
Between P70 (15) and C02 (32)
Above 1MΩ
9
Between P70 (15) and related circuits and grounding
Above 1MΩ
10
Between P70 (16) and CB2 (22)
Below 1V
11
Between P70 (16) and C02 (22)
Below 1V
12
Between P70 (16) and related circuits and grounding
Below 1V
13
Between P70 (15) and CB2 (32)
Below 1V
14
Between P70 (15) and C02 (32)
Below 1V
15
Between P70 (15) and related circuits and grounding
Below 1V
16
At K30, between (1) and (2)
40 - 80Ω
17
At K31, between (1) and (2)
40 - 80Ω
18
CAN terminal resistor • Turn the ignition switch OFF for the preparations. • Disconnect K30 and K31 CAN connectors and install T-adapter. • Hold ignition switch in the OFF position during the troubleshooting. A.
3.
Between P70 (16) and CB2 (22) Between P70 (16) and C02 (22)
CAN terminal resistor test
Resistance Ω
Monitor panel, engine controller or pump controller • If 1 - 2 are not detected, monitor panel, engine controller or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
20-380 1
PC400LC-7L
TROUBLESHOOTING
E257
12 Electrical circuit diagram related to CAN communication
PC400LC-7L
20-381 1
TROUBLESHOOTING
E315
12
E315 SHORT IN BATTERY RELAY SYSTEM Contents Of Trouble
• •
Short in battery relay system Failure code D110KB.
Response from controller
• •
The controller turns OFF the output to the battery relay drive circuit. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
•
There may be a trouble in writing data into ROM (non-volatile memory) of each controller.
•
Operation of the battery relay (ON or OFF) can be checked in the monitoring function. (Code No.: 03700 Controller output 1)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E315]
A. 2.
Readings
Battery relay test
Resistance Ω
Approximately 100Ω
1
Min. 1MΩ
2
At diode D1, between (1) and (5) reversing meter lead polarity each time to check.
Continuity one way only?
3
Yes or No
At diode D1, between (2) and (6) reversing meter lead polarity each time to check.
Continuity one way only?
4
Yes or No
Between C03 (4), D01, J01, battery relay terminal BR and grounding
Min. 1MΩ
5
Between C03 (4) and ignition switch terminal BR and grounding
Min. 1MΩ
6
Between C03 (4) and D01 (2) and grounding
Min. 1MΩ
7
20 - 30V (for 0.5 sec.)
8
At battery relay unit
Between BR and E Between BR and grounding
Diode test
Resistance Ω
Wiring harness assembly • With ignition switch in OFF position. • Disconnect C03 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
4.
No.
Diode • With ignition switch in OFF position. • Disconnect D01 diode connector and isolate diode. A.
3.
Specifications
Battery relay • Turn the ignition switch OFF for the preparations. • Disconnect A20 and A21 wires from battery relay. • Hold the ignition switch in the OFF position during the troubleshooting. • Zero meter leads for proper Ω readings.
Wiring harness test ground fault (Contact with grounding circuit)
Resistance Ω
Pump controller • With ignition switch in OFF position. • Ignition switch should remain in the ON position during troubleshooting. A.
Pump controller
20-382 1
Voltage
Ignition switch ON → OFF
At C03, between (4) and grounding
PC400LC-7L
TROUBLESHOOTING
E315
12 Electrical circuit diagram related to battery relay drive
PC400LC-7L
20-383 1
TROUBLESHOOTING
E91B
12
E91B ENGNE NE SENSOR PROBLEM Contents Of Trouble
• •
Cranking angle cannot be judged from engine Ne speed sensor signal. (Engine controller system) Failure code DLE3LC.
Response from controller
• •
The machine is driven with limited output. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above lower idling.
•
Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function. (Code No.: 01002 Engine speed)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E91B]
A.
2.
No.
Readings
Engine Ne speed sensor test - internal short or disconnected
At NE, between (1) and (2) Resistance Ω
85 - 210Ω
1
Above 1ΜΩ
2
Between CB2 (36) and NE (2)
Below 1Ω
3
Between CB2 (26) and NE (1)
Below 1Ω
4
Between CB2 (36) aand NE (2) and ground
Above 1ΜΩ
5
Between CB2 (26) aand NE (1) and ground
Above 1ΜΩ
6
At NE, between (1), (2) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Engine Ne speed sensor • Turn the engine ignition switch OFF for preparations • Disconnect NE and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch should be in the OFF position for troubleshooting. A.
Engine controller test
20-384 1
Resistance Ω
At CB2, between (36) and (26) At CB2, between (36), (26) and grounding
85 - 210Ω
7
Above 1ΜΩ
8
PC400LC-7L
TROUBLESHOOTING
E91B
12 Electrical circuit diagram related to engine Ne speed sensor
PC400LC-7L
20-385 1
TROUBLESHOOTING
E91C
12
E91C ENGINE G SENSOR PROBLEM Contents Of Trouble
• •
Cylinder cannot be judged from the engine G speed sensor signal. (Engine controller system) Failure code DLH1LC.
Response from controller
• •
The machine is driven with limited output. Control is carried out with the Ne sped sensor signal.
Phenomenon occurring on machine
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above lower idling.
Relative information
•
Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E91C]
A.
2.
No.
Readings
Engine G speed sensor test - internal short or disconnected
Resistance Ω
At G, between (1) and (2)
1.4 - 3.5kΩ
1
At G, between (1), (2) and grounding
Above 1ΜΩ
2
Between CB2 (35) and G (2)
Below 1Ω
3
Between CB2 (25) and G (1)
Below 1Ω
4
Between CB2 (35) aand G (2) and ground
Above 1ΜΩ
5
Between CB2 (25) aand G (1) and ground
Above 1ΜΩ
6
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Engine G speed sensor • Turn the engine ignition switch OFF for preparations • Disconnect G connector and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch should be in the OFF position for troubleshooting. A.
Engine controller test
20-386 1
Resistance Ω
At CB2, between (35) and (25)
1.4 - 3.5kΩ
7
At CB2, between (35) and grounding
Above 1ΜΩ
8
At CB2, between (25) and grounding
Above 1ΜΩ
9
PC400LC-7L
TROUBLESHOOTING
E91C
12 Electrical circuit diagram related to engine G speed sensor
PC400LC-7L
20-387 1
TROUBLESHOOTING
E920
12
E920 ENGINE TYPE SELECTION ERROR • Contents Of Trouble • Response from controller Phenomenon occurring on machine
Relative information
Tools and Procedures
• • • • •
• •
Control is carried out with the default model (PC400). Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine starting switch is once turned OFF.
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above lower idling.
•
The model name (figure) recognized by the controller can be checked in the monitoring function. (Code No.: 00201 Controller model code) Input of the model selection signal (ON or OFF) can be checked in the monitoring function. (Coed No.: 17400 Engine controller input state)
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E920]
No.
Readings
Model selection connector test internal short or disconnected
Resistance Ω
At CB5, between (2) and (8)
Above 1ΜΩ
1
At CB5, between (3) and (8)
Above 1ΜΩ
2
At CB5, between (4) and (8)
Above 1ΜΩ
3
At CB5, between (5) and (8)
Above 1ΜΩ
4
At CB5, between (6) and (8)
Above 1ΜΩ
5
At CB5, between (7) and (8)
Above 1ΜΩ
6
At CB5, between (1) and (8)
Below 1Ω
7
Between CB1 (3) and CB5 (1)
Below 1Ω
8
Between CB2 (1) and CB5 (8)
Below 1Ω
9
Between CB1 (23) aand CB5 (2) and ground
Above 1ΜΩ
10
Between CB1 (17) aand CB5 (3) and ground
Above 1ΜΩ
11
Between CB1 (23) and CB2 (1)
20 − 30V
12
Between CB1 (17) and CB2 (1)
20 − 30V
13
Between CB! (3) and CB2 (1)
Below 1V
14
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB1 and CB2 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Model selection connector • Turn the engine ignition switch OFF for preparations • Disconnect CB5 connector and install T-adapter. • Ignition switch OFF during troubleshooting.
A.
2.
The model selection signal directly taken by the engine controller does not conform to the model in the controller or is not confirmed. (Engine controller system) Failure code DB29KQ.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch should be held in the ON position for troubleshooting. CB1, CB2 A.
Engine controller test
20-388 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E920
12 Electrical circuit diagram related to model selection connector (for engine controller)
PC400LC-7L
20-389 1
TROUBLESHOOTING
E921
12
E921 ENGINE TYPE MISMATCH • Contents Of Trouble • Response from controller Phenomenon occurring on machine
Relative information
The model information taken by the engine controller through the model selection connector does not conform to the model information taken from the pump controller by communication. (Engine controller system) Failure code DB20KQ.
• •
The normal operation is continued. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above lower idling.
•
The model name (figure) recognized by the controller can be checked in the monitoring function. (Code No.: 00201 Controller model code) The model name (figure) recognized by the pump controller can be checked in the monitoring function. (Code No.: 00200 Controller model code)
•
Steps
Circuit Diagnostic Procedures For Code [E921]
Specifications
No.
Readings
1.
Model selection connector system defective
If error code E920 is displayed, carry out troubleshooting for it.
2.
Engine controller defective
Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)
3.
Pump controller defective
Pump controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)
20-390 1
PC400LC-7L
TROUBLESHOOTING
E921
12
MEMORANDUM
PC400LC-7L
20-391 1
TROUBLESHOOTING
E931
12
E931 FUEL DIAL SYSTEM ERROR Contents Of Trouble
Response from controller
Phenomenon occurring on machine Relative information
Tools and Procedures
• • • • •
• •
The signal voltage from the fuel control dial is below 0.3V or above 4.5V. (Engine controller system) Failure code DK10KX.
•
•
If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or 100% after the engine is started. If the abnormality is detected while the engine is running, the fuel control dial signal just before the abnormality is detected is kept. When the failure cause disappears by itself, the machine operation returns to normal.
•
The engine speed cannot be controlled.
•
Input from the fuel control dial (voltage) can be checked in the monitoring function. (Code No.: 03000 Fuel control dial voltage)
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E931]
A.
2.
Specifications
No.
Readings
Fuel control dial defective • Turn the engine ignition switch OFF for preparations • Disconnect E06 connector and install T-adapter. • Ignition switch ON or keep the engine running during troubleshooting. Fuel control dial test internal short or disconnected
Resistance Ω
At E06, between (1) and (3)
4.0 − 6.0kΩ
1
At E06, between (1) and (2)
0.25 − 7.0kΩ
2
At E06, between (3) and (2)
0.25 − 7.0kΩ
3
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and E06 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
C.
3.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Wiring harness Contact with 24V circuit
Voltage
Between CB2 (19) and E06 (1)
Below 1Ω
4
Between CB2 (10) and E06 (2)
Below 1Ω
5
Between CB2 (29) and E06 (3)
Below 1Ω
6
Between CB2 (39) and E06 (3)
Below 1Ω
7
Between CB2 (19) and E06 (1) and ground
Above 1ΜΩ
8
Between CB2 (10) and E06 (2) and ground
Above 1ΜΩ
9
★ Between CB2 (19) and E06 (1) and ground
Below 1V
10
★ Between CB2 (10) and E06 (2) and ground
Below 1V
11
At CB2, Between (19) and (29)
4.6 - 5.4V
12
At CB2, Between (19) and (39)
4.6 - 5.4V
13
At CB2, Between (10) and (29)
0.3 - 4.5V
14
At CB2, Between (10) and (39)
0.3 - 4.5V
15
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch ON or keep the engine running during troubleshooting.
A.
Engine controller test
20-392 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E931
Electrical circuit diagram related to fuel control dial
PC400LC-7L
20-393 1
TROUBLESHOOTING
E934
12
E934 ENGINE COOLANT SENSOR HI ERROR • •
The signal voltage from the engine water high temperature sensor is below 0.5V or above 4.5V. (Engine controller system) Failure code DGE2KX.
Response from controller
• •
The signal of the engine water high temperature sensor is kept at 90°C. When the failure cause disappears, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The engine does not start easily when the temperature is low. The overheat protection function does not operate. If the controller is also defective, the engine does not stop.
•
Input from the engine high temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No.: 04106 Engine water temperature sensor Hi, Code No.: 04102 Engine water temperature (High temperature))
Contents Of Trouble
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E934]
A.
2.
No.
Readings
Engine water high temperature sensor test - internal short or disconnected
Resistance Ω
At TWH, between (1) and (2)
3.5 − 90kΩ
1
At TWH, between (1) and grounding
Above 1ΜΩ
2
At TWH, between (2) and grounding
Above 1ΜΩ
3
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and TWH and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Engine water high temperature sensor defective • Turn the engine ignition switch OFF for preparations • Disconnect TWH connector and install T-adapter. • Ignition switch ON or keep the engine running during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Between CB2 (27) and TWH (1)
Below 1Ω
4
Between CB2 (29) and TWH (2)
Below 1Ω
5
Between CB2 (39) and TWH (2)
Below 1Ω
6
Above 1ΜΩ
7
Between E12 (27) and TWH (1) and ground
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch OFF during troubleshooting.
A.
Engine controller test
20-394 1
Resistance Ω
At CB2, Between (27) and (39)
3.5k - 90kΩ
8
At CB2, Between (29) and (39)
3.5k - 90kΩ
9
At CB2, Between (27) and grounding
Above 1ΜΩ
10
At CB2, Between (29) and grounding
Above 1ΜΩ
11
At CB2, Between (39)and grounding
Above 1ΜΩ
12
PC400LC-7L
TROUBLESHOOTING
E934
12 Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC400LC-7L
20-395 1
TROUBLESHOOTING
E96A
12
E96A ENGINE COOLANT SENSOR LO ERROR Contents Of Trouble
• •
The signal voltage from the engine water low temperature sensor is above 4.5V. (Engine controller system) Failure code DGE3L6.
• •
The signal of the engine water low temperature sensor is kept at 20°C. (If the signal of the high temperature sensor is effective, it is used as a substitute.) When the failure cause disappears, the machine operation returns to normal.
• • •
The engine does not start easily when the temperature is low. The overheat protection function does not operate. If the controller is also defective, the engine does not stop.
•
Input from the engine low temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No.: 04105 Engine water temperature sensor Lo, Code No.: 04107 Engine water temperature (Low temperature))
Response from controller Phenomenon occurring on machine
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E96A]
A.
2.
No.
Readings
Engine water low temperature sensor test - internal short or disconnected
0.3 − 9kΩ
1
At TWL, between (1) and grounding
Above 1ΜΩ
2
At TWL, between (2) and grounding
Above 1ΜΩ
3
At TWL, between (1) and (2) Resistance Ω
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and TWL and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Engine water high temperature sensor defective • Turn the engine ignition switch OFF for preparations • Disconnect TWL connector and install T-adapter. • Ignition switch ON or keep the engine running during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Between CB2 (37) and TWL (1)
Below 1Ω
4
Between CB2 (29) and TWL (2)
Below 1Ω
5
Between CB2 (39) and TWL (2)
Below 1Ω
6
Above 1ΜΩ
7
At CB2, Between (37) and (39)
0.3 − 9kΩ
8
At CB2, Between (29) and (39)
0.3 − 9kΩ
9
At CB2, Between (29) and grounding
Above 1ΜΩ
10
At CB2, Between (37) and grounding
Above 1ΜΩ
11
At CB2, Between (39)and grounding
Above 1ΜΩ
12
Between E12 (37) and TWL (1) and ground
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch OFF during troubleshooting.
A.
Engine controller test
20-396 1
Resistance Ω
PC400LC-7L
TROUBLESHOOTING
E96A
12 Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC400LC-7L
20-397 1
TROUBLESHOOTING
E936
12
E936 ENGINE OIL PRESSURE SWITCH ERROR •
•
The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the high-pressure switch is opened (disconnected from grounding) while the engine is running. The signal circuit of the low-pressure switch is opened (disconnected from ground) while the engine is stopped (the starting signal is OFF). The signal circuit of the high-pressure switch is opened (disconnected from ground) while the engine is stopped (the starting signal is OFF). Failure code DDE2L6.
Response from controller
• •
None in particular. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The engine does not start easily when the temperature is low. The overheat protection function does not operate. If the controller is also defective, the engine does not stop.
•
Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring function. (Code No.: 17400 Engine controller input)
• Contents Of Trouble •
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E936]
A.
B.
2.
No.
Readings
Engine water low oil pressure switch test internal short or disconnected Engine water high oil pressure switch test internal short or disconnected
Engine Resistance Ω
PSL Below 1Ω
1
Above 1ΜΩ
2
Below 1Ω
3
Above 1ΜΩ
4
Between CB1 (21) and PSL
Below 1Ω
5
Between CB1 (15) and PSH
Below 1Ω
6
Between CB1 (21) and PSL and ground
Above 1ΜΩ
7
Between CB1 (15) and PSH and ground
Above 1ΜΩ
8
Stopped Low idling
Between terminal and grounding
Engine Resistance Ω
PSH
Stopped Running at 1,300 Between terminal and grounding rpm or higher
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB1 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Engine low oil pressure switch defective • Turn the engine ignition switch OFF for preparations • Ignition switch OFF or keep the engine running during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB1 and install T-adapter. • Ignition switch ON and start the engine during troubleshooting. Engine Stopped A.
Engine controller test
---
20-398 1
Voltage
−−−
CB1 Between (21) and ground (Low pressure switch signal)
Below 1V
9
20 - 30V
10
Stopped Between (21) and ground (Low Running at 1,300 pressure switch signal) rpm or higher
Below 1V
11
20 - 30V
12
Low idling
Carry out troubleshooting while the engine is running 15 seconds after the engine is started.
PC400LC-7L
TROUBLESHOOTING
E936
12 Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)
PC400LC-7L
20-399 1
TROUBLESHOOTING
E93C
12
E93C ENGINE BOOST SENSOR ERROR Contents Of Trouble
• •
The signal voltage from the boost pressure sensor is below 0.3V or above 4.7V. Failure code DH30KX.
Response from controller
• •
None in particular. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above idling.
•
Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No.: 36501 Boost pressure sensor voltage, (Code No.: 36500 Boost pressure) Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor.
Relative information • Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E93C]
A.
2.
Specifications
No.
Readings
Boost pressure sensor defective • Turn the engine ignition switch OFF for preparations. • Disconnect PIM boost pressure sensor. • Ignition switch ON or keep the engine running during troubleshooting. Engine boost pressure sensor test internal short or disconnected
PIM Voltage
Power supply
Between (3) and (1)
4.6 − 5.4V
1
Signal
Between (2) and (1)
0.5 - 4.5V
2
Between CB2 (9) and PIM (3)
Below 1Ω
3
Between CB2 (29) and PIM (1)
Below 1Ω
4
Between CB2 (39) and PIM (1)
Below 1Ω
5
Between CB2 (20) and PIM (2)
Below 1Ω
6
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
C.
3.
Wiring harness test Disconnection or defective contact with connector Wiring harness Short (Contact with grounding circuit) Wiring harness Contact with 24V circuit
Resistance Ω
Resistance Ω
Voltage
Between CB2 (9) and PIM (3) and ground
Above 1ΜΩ
7
Between CB2 (9) and related circuits and ground
Above 1ΜΩ
8
Between CB2 (20) and PIM (2) and ground
Above 1ΜΩ
9
Below 1V
10
★ Between CB2 (9) and PIM (3) ★ Between CB2 (9) and related circuits and ground ★ Between CB2 (20) and PIM (2) and ground
Below 1V
11
Below 1V
12
At CB2, between (9) and (29)
4.6 - 5.4V
13
At CB2, between (9) and (39)
4.6 - 5.4V
14
At CB2, between (20) and (29)
0.3 - 4.7V
15
At CB2, between (20) and (39)
0.3 - 4.7V
16
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch ON and start the engine during troubleshooting.
A.
Engine controller test
20-400 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E93C
12 Electrical circuit diagram related to boost pressure sensor
PC400LC-7L
20-401 1
TROUBLESHOOTING
E93D
12
E93D ENGINE FUEL TEMPERATURE SENSOR ERROR Contents Of Trouble
• •
The signal voltage from the fuel temperature sensor is above 4.5V. Failure code DGE4KX.
Response from controller
• •
None in particular. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The engine does not start easily when temperature is low. The overheat protection function does not operate. If the controller is also defective, the engine does not stop.
•
Input from the fuel temperature sensor (voltage) can be checked in the monitoring function. (Code No.: 14201 Fuel temperature sensor voltage)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E93D]
A.
2.
No.
Readings
Fuel temperature sensor test - internal short or disconnected
At THL, between (1) and (2) Resistance Ω
0.3k - 9kΩ
1
At THL, between (1) and grounding
Above 1ΜΩ
2
At THL, between (2) and grounding
Above 1ΜΩ
3
Between CB2 (17) and THL (13)
Below 1Ω
4
Between CB2 (29) and THL (2)
Below 1Ω
5
Between CB2 (39) and THL (2)
Below 1Ω
6
Above 1ΜΩ
7
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Fuel temperature sensor defective • Turn the engine ignition switch OFF for preparations. • Disconnect THL connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness Short (Contact with grounding circuit)
Resistance Ω
Between CB2 (17) and THL (1) and ground
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch OFF during troubleshooting.
A.
Engine controller test
20-402 1
Resistance Ω
At CB2, between (17) and (39)
0.3k - 9kΩ
8
At CB2, between (29) and (39)
0.3k - 9kΩ
9
At CB2, between (17) and (39) and grounding
Above 1ΜΩ
10
At CB2, between (29) and (39) and grounding
Above 1ΜΩ
11
PC400LC-7L
TROUBLESHOOTING
E93D
12 Electrical circuit diagram related to fuel temperature sensor
PC400LC-7L
20-403 1
TROUBLESHOOTING
E953
12
E953 ENGINE COMMUNICATION ABNORMALITY • •
The engine controller detected communication failure in the CAN communication circuit to the monitor panel or pump controller. Failure code DB2RMC.
Response from controller
• •
The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall.
Relative information
---
Contents Of Trouble
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E953]
Specifications
No.
Readings
Wiring harness assembly • With ignition switch in OFF position. • Disconnect P70, C02, CB2 connectors and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
C.
2.
Wiring harness Short (Contact with grounding circuit)
Wiring harness Contact with 24V circuit
Resistance Ω
Resistance Ω
Voltage
Between P70 (16) and CB2 (22)
Below 1Ω
1
Between P70 (16) and C02 (22)
Below 1Ω
2
Between P70 (15) and CB2 (32)
Below 1Ω
3
Between P70 (15) and C02 (32)
Below 1Ω
4
Between P70 (16) and CB2 (22) and ground
Above 1ΜΩ
5
Between P70 (16) and C02 (22) and ground
Above 1ΜΩ
6
Between P70 (16) and related circuits and ground
Above 1ΜΩ
7
Between P70 (15) and CB2 (32) and ground
Above 1ΜΩ
8
Between P70 (15) and C02 (32) and ground
Above 1ΜΩ
9
Between P70 (15) and related circuits and ground
Above 1ΜΩ
10
★ ★ ★ ★ ★ ★
Between P70 (16) and CB2 (22)
Below 1V
11
Between P70 (16) and C02 (22)
Below 1V
12
Between P70 (16) and related circuits and ground
Below 1V
13
Between P70 (15) and CB2 (32) and ground
Below 1V
14
Between P70 (15) and C02 (32) and ground
Below 1V
15
Between P70 (15) and related circuits and ground
Below 1V
16
CAN terminal resister • With ignition switch in OFF position. • Disconnect K30 and K31 connectors and install T-adapter. • Ignition switch OFF during troubleshooting. A.
3.
Wiring harness test Disconnection or defective contact with connector
CAN terminal resister test
Resistance Ω
Monitor panel, engine controller or pump controller defective
20-404 1
At K30, between (1) and (2)
40 - 80Ω
17
At K31, between (1) and (29)
40 - 80Ω
18
If causes 1A, 1B, 1C are not detected, monitor panel, engine controller or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E953
12 Electrical circuit diagram related to CAN communication
PC400LC-7L
20-405 1
TROUBLESHOOTING
E954
12
E954 SHORT IN ENGINE IGNITION SWITCH Contents Of Trouble
• •
Ignition switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher). Failure code DD11KB.
Response from controller
• •
Ignition switch signal is recognized to be OFF. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
•
The machine operates normally.
•
Input from ignition switch signal C (ON or OFF) can be checked in the monitoring function. (Code No.: 17400 Engine controller input)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E954]
A.
2.
No.
Readings
Ignition switch test internal short or disconnected
−−−
Ignition switch Resistance Ω
Above 1ΜΩ
1
Below 1Ω
2
Between ignition switch terminal C, J01 and CB1
Below 1V
3
Between ignition switch terminal C and C01 (17)
Below 1V
4
Between ignition switch terminal C and P01 (4)
Below 1V
5
Between ignition switch terminal C and R11 (5)
Below 1V
6
Between ignition switch terminal C and related circuits
Below 1V
7
Between ignition switch terminal C and grounding
Below 1V
8
Between terminal B and terminal C
OFF START
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
A.
3.
Specifications
Ignition switch defective • Turn the engine ignition switch OFF for preparations. • Disconnect THL connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Short (Contact with 24V ground circuit)
Voltage
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB1 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
20-406 1
Voltage
CB1
Ignition switch
Between (20) and grounding ON (Engine is running)
--Below 1V
9
PC400LC-7L
TROUBLESHOOTING
E954
12 Electrical circuit diagram related to engine preheating, starting, charging
PC400LC-7L
20-407 1
TROUBLESHOOTING
E955
12
E955 ENGINE S-NET ERROR • •
The engine controller detected communication failure in the S-NET communication circuit to the monitor panel or pump controller (Engine controller system). Failure code DB2SMC.
Response from controller
• •
The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The output lowers (The pump absorption torque is reduced). If the working load increases, the engine may stall.
•
Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No.: 05100 Connection of S-NET)
Contents Of Trouble
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E955]
Specifications
No.
Readings
Wiring harness assembly • With ignition switch in OFF position. • Disconnect P02, C02, CB2 connectors and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
C.
2.
Wiring harness Short (Contact with grounding circuit)
Wiring harness Contact with 24V circuit
Resistance Ω
Between P02 (9) and CB2 (21)
Below 1Ω
1
Between P02 (9) and C02 (21)
Below 1Ω
2
Below 1Ω
3
Between P02 (10) and C02 (21)
Resistance Ω
Voltage
Between P02 (9) and CB2 (21) and ground
Above 1ΜΩ
4
Between P02 (10) and CB2 (31) and ground
Above 1ΜΩ
5
Between P02 (9) and C02 (21) and ground
Above 1ΜΩ
6
Between P02 (10) and C02 (21) and ground
Above 1ΜΩ
7
Between P02 (9) and related circuits and ground
Above 1ΜΩ
8
Between P02 (10) and related circuits and ground
Above 1ΜΩ
9
Between P02 (9) and CB2 (21) and ground
Below 1V
10
Between P02 (10) and CB2 (31) and ground
Below 1V
11
Between P02 (9) and C02 (21) and ground
Below 1V
12
Between P02 (10) and C02 (21) and ground
Below 1V
13
Between P02 (9) and related circuits and ground
Below 1V
14
Between P02 (10) and related circuits and ground
Below 1V
15
At P02, between (9) and (20)
6 - 9V
16
At P02, between (10) and (20)
6 - 9V
17
At CB2, between (21) and (11)
6 - 9V
18
At CB2, between (31) and (11)
6 - 9V
19
★ ★ ★ ★ ★ ★
Monitor panel • With ignition switch in OFF position. • Disconnect P02 connector and install T-adapter. • Ignition switch ON during troubleshooting. A.
3.
Wiring harness test Disconnection or defective contact with connector
Monitor panel test
Voltage
Engine controller • With ignition switch in OFF position. • Disconnect CB2 connector and install T-adapters. • Ignition switch ON during troubleshooting. A.
Engine controller test
20-408 1
Voltage
PC400LC-7L
TROUBLESHOOTING Steps 4.
E955
Circuit Diagnostic Procedures For Code [E955]
Specifications
No.
Readings
Pump controller • With ignition switch in OFF position. • Disconnect C02 connector and install T-adapters. • Ignition switch ON during troubleshooting. A.
Pump controller test
Voltage
At C02, between (21) and (31)
6 - 9V
20
Electrical circuit diagram related to S-NET communication
PC400LC-7L
20-409 1
TROUBLESHOOTING
E956
12
E956 ENGINE POWER FAILURE (1) Contents Of Trouble
• •
When the ignition switch is turned ON, the source voltage of the controller is below 10V. (Engine controller system) Failure code DB22KK.
Response from controller
• •
None in particular. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• •
The engine stalls. The engine cannot be started.
Relative information
---
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E956]
Specifications
1.
Circuit breaker 7 defective If circuit breaker is turned OFF, the circuit probably has grounding fault, etc. (See cause 3B.)
2.
Engine controller power supply relay defective • Turn the engine ignition switch OFF for preparations. • Ignition switch ON during troubleshooting. A.
3.
---
Readings
Replace the power supply relay, R22, with another one. If the condition becomes normal, the relay is defective.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and R22 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
A.
B.
4.
Engine controller power supply relay test - internal short or disconnected
No.
Wiring harness test Disconnection or defective contact with connector
Wiring harness test Short (Contact with ground circuit)
Resistance Ω
Resistance Ω
Between CB3 (1) and R22 (5)
Below 1Ω
1
Between CB3 (2) and R22 (5)
Below 1Ω
2
Between CB3 (21) and R22 (5)
Below 1Ω
3
Between R22 (3) and CB3 (1), (2), (21)
Below 1Ω
4
Between R22 (1) and H15 (5) and CB1 (13), (19)
Below 1Ω
5
Between R22 (2) and CB1 (7), (8) and CB2 (11) and A10 ground
Below 1Ω
6
Between CB3 (1), (2), (21) and R22 (3)
Above 1MΩ
7
Between R22 (5) and battery relay B and ground
Above 1MΩ
8
Between R22 (1) and H15 (5)
Above 1MΩ
9
Between R22 (1) and BCB1 (13), (19)
Above 1MΩ
10
Between R22 (1) and related circuits and grounding
Above 1MΩ
11
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. CB3 A.
Engine controller test
20-410 1
Voltage
Between (1), (2), (21) and (11), (31), (32)
Ignition switch
---
OFF
Below 1V
12
ON
20 - 30V
13
PC400LC-7L
TROUBLESHOOTING
E956
12 Electrical circuit diagram related to engine controller power supply
PC400LC-7L
20-411 1
TROUBLESHOOTING
E957
12
E957 ENGINE POWER FAILURE (2) Contents Of Trouble
• •
When the ignition switch is turned OFF, the source voltage of the controller is above 10V. (Engine controller system) Failure code D1D0KB.
Response from controller
• •
None in particular. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The engine does not start easily when temperature is low. The over heat protection function does not operate. If the controller is also defective, the engine does not stop.
Relative information
---
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E957]
A.
2.
No.
Readings
Engine controller power supply relay test - internal short or disconnected
---
Replace the power supply relay, R22, with another one. If the condition becomes normal, the relay is defective.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and R22 and install T-adapters. • Ignition switch should remain in the ON position during troubleshooting. A.
3.
Specifications
Engine controller power supply relay defective • Turn the engine ignition switch OFF for preparations. • Ignition switch ON during troubleshooting.
Wiring harness test Short (Contact with 24V ground circuit)
Voltage
Between CB3 (1), (2), (21) and R22 (3) and ground
Below 1V
1
Between R22 (1) and J03 or related circuits and ground
Below 1V
2
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. CB3 A.
Engine controller test
20-412 1
Voltage
Between (1), (2), (21) and (11), (31), (32)
Ignition switch
---
OFF
Below 1V
3
ON
20 - 30V
4
PC400LC-7L
TROUBLESHOOTING
E957
12 Electrical circuit diagram related to engine controller power supply
PC400LC-7L
20-413 1
TROUBLESHOOTING
E95A
12
E95A ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR Contents Of Trouble
• •
The fuel injection adjustment switch of the controller is not set to the correct position. (Engine controller system) Failure code DB2AMA.
Response from controller
• •
None in particular. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
•
Setting of the fuel injection amount adjustment switch cannot be changed.
•
Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring function. (Code No.: 36800 Right fuel injection amount adjustment switch Code No.: Left fuel injection amount adjustment switch)
Tools and Procedures
Relative information
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [E95A]
Specifications
No.
Readings
1.
Setting of fuel injection amount adjustment If fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting is wrong. switch of engine controller defective
2.
Engine controller defective
20-414 1
If the cause is not detected, engine controller may be defective.
PC400LC-7L
TROUBLESHOOTING
E95A
12
MEMORANDUM
PC400LC-7L
20-415 1
TROUBLESHOOTING
E970
12
E970 PCV1 OVER CURRENT • •
Abnormal current flowed in the fuel supply pump PCV1 circuit. (Engine controller system) Failure code AD11KB.
• •
Power to the fuel supply pump PCV1 circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is first turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
•
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E970]
A.
2.
Specifications
No.
Readings
Fuel supply pump PCV1 defective • Turn the engine ignition switch OFF for preparations. • Disconnect PCV1 connection and install T-adapter. • Ignition switch OFF during troubleshooting. Fuel supply pump PCV1 test - internal short or disconnected
At PCV1, between (1) and (2) Resistance Ω
2.3 - 5.3Ω
1
Above 1ΜΩ
2
Above 1ΜΩ
3
★ Between CB3 (2) and PCV1 (1)
Below 1V
4
★ Between CB3 (22) and PCV1 (2)
Below 1V
5
At PCV1, between (1) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and PCV1 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
3.
Wiring harness test Contact with grounding circuit Wiring harness Short (Contact with 24V grounding circuit)
Resistance Ω
Voltage
Between CB3 (12) and PCV1 (1)
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
20-416 1
Resistance Ω
At CB3, between (12) and (22) At CB3, between (12) and (22) and grounding
2.3 - 5.3Ω
6
Above 1ΜΩ
7
PC400LC-7L
TROUBLESHOOTING
E970
Electrical circuit diagram related to fuel supply pump PCV1
PC400LC-7L
20-417 1
TROUBLESHOOTING
E971
12
E971 PCV2 OVER CURRENT • •
Abnormal current flowed in the fuel supply pump PCV2 circuit. (Engine controller system) Failure code AD51KB.
• •
Power to the fuel supply pump PCV2 circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is first turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
•
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E91]
A.
2.
Specifications
No.
Readings
Fuel supply pump PCV2 defective • Turn the engine ignition switch OFF for preparations. • Disconnect PCV1 connection and install T-adapter. • Ignition switch OFF during troubleshooting. Fuel supply pump PCV2 test - internal short or disconnected
At PCV2, between (1) and (2) Resistance Ω
2.3 - 5.3Ω
1
Above 1ΜΩ
2
Above 1ΜΩ
3
★ Between CB3 (13) and PCV2 (1)
Below 1V
4
★ Between CB3 (23) and PC2 (2)
Below 1V
5
At PC2, between (1) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and PCV1 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
★ Ignition switch should remain in the ON position during troubleshooting. A.
B.
3.
Wiring harness test Contact with grounding circuit Wiring harness Short (Contact with 24V grounding circuit)
Resistance Ω
Voltage
Between CB3 (13) and PCV2 (1)
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
20-418 1
Resistance Ω
At CB3, between (13) and 3) At CB3, between (13) and (23) and grounding
2.3 - 5.3Ω
6
Above 1ΜΩ
7
PC400LC-7L
TROUBLESHOOTING
E971
12 Electrical circuit diagram related to fuel supply pump PCV2
PC400LC-7L
20-419 1
TROUBLESHOOTING
E974
12
E974 PCV1 LINE CUT • •
Fuel supply pump PCV1 circuit is disconnected. (Engine controller system) Failure code AD11KA.
• •
Power to the fuel supply pump PCV1 circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is first turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
•
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E974]
A.
2.
No.
Readings
Fuel supply pump PCV1 test - internal short or disconnected
At PCV1, between (1) and (2) Resistance Ω
2.3 - 5.3Ω
1
Above 1ΜΩ
2
Below 1Ω
3
Between CB3 (22) and PCV1 (2)
Below 1Ω
4
Between CB3 (22) and PCV1 (2)
Above 1ΜΩ
5
At PCV1, between (1) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and PCV1 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Fuel supply pump PCV1 defective • Turn the engine ignition switch OFF for preparations. • Disconnect PCV1 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Between CB3 (12) and PCV1 (1)
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
20-420 1
Resistance Ω
At CB3, between (12) and (22) At CB3, between (12) and (22) and grounding
2.3 - 5.3Ω
6
Above 1ΜΩ
7
PC400LC-7L
TROUBLESHOOTING
E974
12 Electrical circuit diagram related to fuel supply pump PCV1
PC400LC-7L
20-421 1
TROUBLESHOOTING
E975
12
E975 PCV2 LINE CUT • •
Fuel supply pump PCV2 circuit is disconnected. (Engine controller system) Failure code AD51KA.
• •
Power to the fuel supply pump PCV2 circuit is switched OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is first turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
•
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E975]
A.
2.
No.
Readings
Fuel supply pump PCV2 test - internal short or disconnected
At PCV2, between (1) and (2) Resistance Ω
2.3 - 5.3Ω
1
Above 1ΜΩ
2
Below 1Ω
3
Between CB3 (23) and PCV2 (2)
Below 1Ω
4
Between CB3 (23) and PCV2 (2)
Above 1ΜΩ
5
At PCV2, between (1) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and PCV21 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
3.
Specifications
Fuel supply pump PCV2 defective • Turn the engine ignition switch OFF for preparations. • Disconnect PCV2 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Between CB3 (13) and PCV2 (1)
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
20-422 1
Resistance Ω
At CB3, between (13) and (23) At CB3, between (13) and (23) and grounding
2.3 - 5.3Ω
6
Above 1ΜΩ
7
PC400LC-7L
TROUBLESHOOTING
E975
12 Electrical circuit diagram related to fuel supply pump PCV2
PC400LC-7L
20-423 1
TROUBLESHOOTING
E977
12
E977 RAIL PRESSURE SENSOR ERROR Contents Of Trouble
• •
The signal voltage from the common rail fuel pressure sensor is below 0.7V or above 4.5V. (Engine controller system) Failure code DH40KX.
Response from controller
• •
The machine is driven with limited output. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling.
•
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No.: 36401 Common rail pressure sensor voltage Code No.: 36400 Common rail fuel pressure) Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.
Relative information • Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E977]
A.
2.
No.
Readings
Common rail fuel pressure sensor test internal short or disconnected
Voltage
At PFUEL, between (3) and (1), power supply
4.6 - 5.4V
1
At PFUEL, (2) and (1), signal
0.7 - 4.5V
2
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller for another cause of the trouble and then judge.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB2 and PFUEL and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
B.
C.
3.
Specifications
Common rail fuel pressure sensor defective • Turn the engine ignition switch OFF for preparations. • Disconnect PFUEL connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
Wiring harness test Contact with 24V circuit
Voltage
Between CB2 (9) and PFUEL (3)
Below 1Ω
3
Between CB2 (39) and PFUEL (1)
Below 1Ω
4
Between CB2 (40) and PFUEL 2)
Below 1Ω
5
Between CB2 (9) and PFUEL (3)
Above 1ΜΩ
6
Between CB2 (9) and related circuits and grounding
Above 1ΜΩ
7
Between CB2 (40) and PFUEL (2) and grounding
Above 1ΜΩ
8
Between CB2 (9) and PFUEL (3)
Below 1V
9
Between CB2 (9) and related circuits and grounding
Below 1V
10
Between Cb2 (40) and PFUEL (2) and grounding
Below 1V
11
At CB2, between (9) and (39)
4.6 - 5.4V
12
At CB2, between (40) and (39)
0.7 - 4.5V
13
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
20-424 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E977
12 Electrical circuit diagram related to common rail fuel pressure sensor
PC400LC-7L
20-425 1
TROUBLESHOOTING
E979
12
E979 RAIL PRESSURE HIGH • •
The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1). (Engine controller system) Failure code AD00L2.
Response from controller
• •
The machine is driven with limited output. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling.
•
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No.: 36401 Common rail pressure sensor voltage Code No.: 36400 Common rail fuel pressure)
Contents Of Trouble
Relative information
Steps
Cause
Standard value in normal and references for troubleshooting
1.
Related systems defective
If any other error code or failure code is displayed, carry out troubleshooting for it first.
2.
Fuel used improper
Fuel used may be improper. Check it directly.
3.
Electric system or common rail fuel pressure sensor defective
Carry out troubleshooting for error code E977.
4.
Mechanical system of common rail fuel The common rail fuel pressure sensor may have a mechanical defect. Check it directly. pressure sensor defective
5.
Overflow valve defective
The overflow valve may have trouble of breakage of spring, wear of seat or fixing of ball. Check it directly.
6.
Overflow piping clogged
The overflow piping may be clogged. Check it directly.
7.
Pressure limiter defective
The pressure limiter may have a mechanical defect. Check it directly.
20-426 1
PC400LC-7L
TROUBLESHOOTING
E97A
12
E97A RAIL PRESSURE ABNORMAL HIGH Contents Of Trouble
• •
The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2). (Engine controller system) Failure code AD00MA.
Response from controller
• •
The machine is driven with limited output. When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on machine
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling.
•
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No.: 36401 Common rail pressure sensor voltage Code No.: 36400 Common rail fuel pressure)
Relative information
Steps 1.
Cause Common rail related device defective
PC400LC-7L
Standard value in normal and references for troubleshooting Carry out troubleshooting for error code E979.
20-427 1
TROUBLESHOOTING
E97B
12
E97B RAIL PRESSURE LOW Contents Of Trouble Response from controller Phenomenon occurring on machine
• •
No pressure feed by fuel supply pump (level 1) occurred. (Engine controller system) Failure code AD10L3.
• •
The machine is driven with limited output. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
• • •
The engine does not start easily when temperature is low. The overheat protection function does not operate. If the controller is also defective, the engine does not stop.
•
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No.: 36401 Common rail pressure sensor voltage Code No.: 36400 Common rail fuel pressure)
Relative information
Steps
Cause
Standard value in normal and references for troubleshooting
1.
Related systems defective
If any other error code or failure code is displayed, carry out troubleshooting for it first.
2.
Fuel used improper
Fuel used may be improper. Check it directly.
3.
Fuel low pressure circuit device defective
A low pressure circuit device may be defective. Referring to Note 1, carry out troubleshooting.
4.
Fuel filter/strainer clogged
The fuel filter /strainer may be clogged. Referring to Note 2, carry out troubleshooting.
5.
Electrical system of fuel supply pump PCV1 Carry out troubleshooting for error codes E970, E971,E974 and E975. defective
6.
Fuel supply pump defective
7.
Common rail fuel pressure sensor defective The common rail fuel pressure sensor may be defective. Check it directly.
The fuel supply pump may be defective. Check it directly.
8.
Pressure limiter defective
The pressure limiter may have a mechanical defect. Check it directly.
9.
Fuel injector defective
The fuel injector may be defective. Referring to Note 3. Check it directly.
Note 1: Check the low-pressure circuit devices for the following points. 1.
Insufficiency of fuel.
2.
Fixing and wear of feed pump and clogging of filter.
3.
Leakage from and clogging of low-pressure fuel piping.
4.
Malfunction of bypass valve and installation of wrong part (See Fig. 1).
5.
Clogging of fuel filter.
6.
Entry of fuel in oil pan (Fuel leakage in head cover). • Fuel low-pressure circuit pressure: 0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}(21.3 - 42.6 psi).
20-428 1
PC400LC-7L
TROUBLESHOOTING
E97B
12 Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) • Overflow valve (1): Spring is seen through both holes. • Bypass valve (2): Spring is seen through hole on nut side. • Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1. 2. 3.
Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it. Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too. Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
Note 3: Judge the condition of the fuel injector by measuring the fuel spill rate. WARNING! When performing the follow work, take care not to scald yourself with the fuel which becomes hot (up to 90°C). 1. 2.
Disconnect the hose connected to the centralized return spill tube adapters (at the rear of the engine). Connect another hose to the spill tube end so that spill fuel can be received in a container.
3.
Run the engine and stall at each speed (relieve the arm circuit by moving the arm in). Measure the quantity of the fuel spilling in 1 minute under this condition. ★ Limit of spill of fuel (Total of spill from 6 cylinders. Stall speed (rpm)
Limit of spill (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
PC400LC-7L
20-429 1
TROUBLESHOOTING
E97C
12
E97C RAIL PRESSURE TOO LOW Contents Of Trouble Response from controller Phenomenon occurring on machine
• •
No pressure feed by fuel supply pump (level 2) occurred. (Engine controller system) Failure code AD10MB.
• •
The machine is driven with limited output. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling.
•
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No.: 36401 Common rail pressure sensor voltage Code No.: 36400 Common rail fuel pressure)
Relative information
Steps 1.
Cause Common rail related device defective
20-430 1
Standard value in normal and references for troubleshooting Carry out troubleshooting for error code E97B.
PC400LC-7L
TROUBLESHOOTING
E97D
12
E97D RAIL PRESSURE OUT OF CONTROL Contents Of Trouble Response from controller Phenomenon occurring on machine
• •
Abnormal fuel pressure was generated in the common rail. (Engine controller system) Failure code AD10MA.
• •
The machine is driven under the normal control. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling.
•
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No.: 36401 Common rail pressure sensor voltage Code No.: 36400 Common rail fuel pressure)
Relative information
Steps 1.
Cause Common rail related device defective
PC400LC-7L
Standard value in normal and references for troubleshooting Carry out troubleshooting for error code E97B.
20-431 1
TROUBLESHOOTING
E980
12
E980 ENGINE CONTROLLER ABNORMALITY • •
The controller has an abnormality in it. (Engine controller system) Failure code DB20KT.
• •
The machine is driven with limited output or all output is turned OFF. Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling.
Relative information
---
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E977]
A.
2.
Specifications
No.
Readings
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. Wiring harness test Disconnection or defective contact with connector
Engine controller defective
20-432 1
Resistance Ω
Between CB3 (11) and grounding
Below 1Ω
1
Between CB3 (31) and grounding
Below 1Ω
2
Between CB3 (32) and grounding
Below 1Ω
3
If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E980
12 Electrical circuit diagram related to engine controller power supply
PC400LC-7L
20-433 1
TROUBLESHOOTING
E981
12
E981 FUEL INJECTOR 1 DISCONNECTION • •
Fuel injector 1 circuit is disconnected. (Engine controller system) Failure code ADA1KA.
• •
Power to the fuel injector 1 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E981]
A.
2.
No.
Readings
Fuel injector 1 test internal short or disconnected
Resistance Ω
At CN1, between (1) and (2)
0.4 - 1.1Ω
1
Between CB3 (14) and CN1 (1)
Below 1Ω
2
Between CB3 (24) and CN1 (2)
Below 1Ω
3
0.4 - 1.1Ω
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Fuel injector 1 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN1 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
Resistance Ω
At CB3, between (14) and (24)
Electrical circuit diagram related to fuel injector 1
20-434 1
PC400LC-7L
TROUBLESHOOTING
E982
12
E982 FUEL INJECTOR 2 DISCONNECTION • •
Fuel injector 2 circuit is disconnected. (Engine controller system) Failure code ADB1KA.
• •
Power to the fuel injector 2 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E982]
A.
2.
No.
Readings
Fuel injector 2 test internal short or disconnected
Resistance Ω
At CN2, between (1) and (2)
0.4 - 1.1Ω
1
Between CB3 (6) and CN2 (1)
Below 1Ω
2
Between CB3 (16) and CN2 (2)
Below 1Ω
3
0.4 - 1.1Ω
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Fuel injector 2 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN2 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
Resistance Ω
At CB3, between (6) and (16)
Electrical circuit diagram related to fuel injector 1
PC400LC-7L
20-435 1
TROUBLESHOOTING
E983
12
E983 FUEL INJECTOR 3 DISCONNECTION • •
Fuel injector 3 circuit is disconnected. (Engine controller system) Failure code ADC1KA.
• •
Power to the fuel injector 3 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E983]
A.
2.
No.
Readings
Fuel injector 3 test internal short or disconnected
Resistance Ω
At CN3, between (1) and (2)
0.4 - 1.1Ω
1
Between CB3 (5) and CN3 (1)
Below 1Ω
2
Between CB3 (15) and CN3 (2)
Below 1Ω
3
0.4 - 1.1Ω
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Fuel injector 3 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN3 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
Resistance Ω
At CB3, between (5) and (15)
Electrical circuit diagram related to fuel injector 1
20-436 1
PC400LC-7L
TROUBLESHOOTING
E984
12
E984 FUEL INJECTOR 4 DISCONNECTION • •
Fuel injector 4 circuit is disconnected. (Engine controller system) Failure code ADD1KA.
• •
Power to the fuel injector 4 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E984]
A.
2.
No.
Readings
Fuel injector 4 test internal short or disconnected
Resistance Ω
At CN4, between (1) and (2)
0.4 - 1.1Ω
1
Between CB3 (26) and CN4 (1)
Below 1Ω
2
Between CB3 (36) and CN4 (2)
Below 1Ω
3
0.4 - 1.1Ω
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Fuel injector 4 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN4 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
Resistance Ω
At CB3, between (26) and (36)
Electrical circuit diagram related to fuel injector 1
PC400LC-7L
20-437 1
TROUBLESHOOTING
E985
12
E985 FUEL INJECTOR 5 DISCONNECTION • •
Fuel injector 5 circuit is disconnected. (Engine controller system) Failure code ADE1KA.
• •
Power to the fuel injector 5 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E985]
A.
2.
No.
Readings
Fuel injector 5 test internal short or disconnected
Resistance Ω
At CN5, between (1) and (2)
0.4 - 1.1Ω
1
Between CB3 (33) and CN5 (1)
Below 1Ω
2
Between CB3 (34) and CN5 (2)
Below 1Ω
3
0.4 - 1.1Ω
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Fuel injector 5 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN5 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
Resistance Ω
At CB3, between (34) and (3)
Electrical circuit diagram related to fuel injector 1
20-438 1
PC400LC-7L
TROUBLESHOOTING
E986
12
E986 FUEL INJECTOR 6 DISCONNECTION • •
Fuel injector 6 circuit is disconnected. (Engine controller system) Failure code ADF1KA.
• •
Power to the fuel injector 6 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E986]
A.
2.
No.
Readings
Fuel injector 6 test internal short or disconnected
Resistance Ω
At CN6, between (1) and (2)
0.4 - 1.1Ω
1
Between CB3 (25) and CN6 (1)
Below 1Ω
2
Between CB3 (35) and CN6 (2)
Below 1Ω
3
0.4 - 1.1Ω
4
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Fuel injector 6 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN6 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting. A.
Engine controller test
Resistance Ω
At CB3, between (25) and (35)
Electrical circuit diagram related to fuel injector 1
PC400LC-7L
20-439 1
TROUBLESHOOTING
E98A
12
E98A FUEL INJECTOR 1 - 3 S/C • Contents Of Trouble •
Abnormal current in the fuel injector 1 circuit, fuel injector 2 circuit and fuel injector 3 circuit. (Engine controller system) Failure code ADAZKB.
• •
Power to the fuel injector 1 circuit, fuel injector 2 circuit and fuel injector 3 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E98A]
A.
2.
Readings
Fuel injector 1 test internal short or disconnected
At CN1, between (1) and (2) Resistance Ω
At CN1, between (1) and (2) and grounding
0.4 - 1.1Ω
1
Above 1MΩ
2
Fuel injector 2 test internal short or disconnected
At CN2, between (1) and (2) Resistance Ω
0.4 - 1.1Ω
3
At CN2, between (1) and (2) and grounding
Above 1MΩ
4
0.4 - 1.1Ω
5
Above 1MΩ
6
Fuel injector 3 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN3 connection and install T-adapter. • Ignition switch OFF during troubleshooting. A.
4.
No.
Fuel injector 2 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN2 connection and install T-adapter. • Ignition switch OFF during troubleshooting. A.
3.
Specifications
Fuel injector 1 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN1 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Fuel injector 3 test internal short or disconnected
At CN3, between (1) and (2) Resistance Ω
At CN3, between (1) and (2) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
A.
Wiring harness test Contact with grounding circuit
20-440 1
Resistance Ω
Between CB3 (14) and CN1 (1) and grounding
Above 1MΩ
7
Between CB3 (24) and CN1 (2) and grounding
Above 1MΩ
8
Between CB3 (6) and CN2 (1) and grounding
Above 1MΩ
9
Between CB3 (16) and CN2 (2) and grounding
Above 1MΩ
10
Between CB3 (5) and CN3 (1) and grounding
Above 1MΩ
11
Between CB3 (15) and CN3 (2) and grounding
Above 1MΩ
12
PC400LC-7L
TROUBLESHOOTING Steps 5.
Circuit Diagnostic Procedures For Code [E98A]
Specifications
No.
Between CB3 (14) and CN1 (1) and grounding
Below 1V
13
Between CB3 (24) and CN1 (2) and grounding
Below 1V
14
Between CB3 (6) and CN2 (1) and grounding
Below 1V
15
Between CB3 (16) and CN2 (2) and grounding
Below 1V
16
Between CB3 (5) and CN3 (1) and grounding
Below 1V
17
Between CB3 (15) and CN3 (2) and grounding
Below 1V
18
At CB3, between (14) and (24)
0.4 - 1.1Ω
19
At CB3, between (6) and (16)
0.4 - 1.1Ω
20
At CB3, between (5) and (15)
0.4 - 1.1Ω
21
At CB3, between (5) and grounding
Above 1MΩ
22
At CB3, between (6) and grounding
Above 1MΩ
23
At CB3, between (14) and grounding
Above 1MΩ
24
At CB3, between (15) and grounding
Above 1MΩ
25
At CB3, between (16) and grounding
Above 1MΩ
26
At CB3, between (24) and grounding
Above 1MΩ
27
Readings
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the ON position during troubleshooting.
A.
6.
E98A
Wiring harness test Contact with 24V circuit
Voltage
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting.
A.
Engine controller test
Resistance Ω
Electrical circuit diagram related to fuel injectors 1, 2, and 3
PC400LC-7L
20-441 1
TROUBLESHOOTING
E98B
12
E98B FUEL INJECTOR 4 - 6 S/C • Contents Of Trouble •
Abnormal current in the fuel injector 4 circuit, fuel injector 5 circuit and fuel injector 6 circuit. (Engine controller system) Failure code ADDZKB.
• •
Power to the fuel injector 4 circuit, fuel injector 5 circuit and fuel injector 6 circuit is switched OFF Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.
Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Response from controller
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [E98B]
A.
2.
Readings
Fuel injector 4 test internal short or disconnected
At CN4, between (1) and (2) Resistance Ω
At CN4, between (1) and (2) and grounding
0.4 - 1.1Ω
1
Above 1MΩ
2
Fuel injector 5 test internal short or disconnected
At CN5, between (1) and (2) Resistance Ω
0.4 - 1.1Ω
3
At CN5, between (1) and (2) and grounding
Above 1MΩ
4
0.4 - 1.1Ω
5
Above 1MΩ
6
Fuel injector 6 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN6 connection and install T-adapter. • Ignition switch OFF during troubleshooting. A.
4.
No.
Fuel injector 5 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN5 connection and install T-adapter. • Ignition switch OFF during troubleshooting. A.
3.
Specifications
Fuel injector 4 defective • Turn the engine ignition switch OFF for preparations. • Disconnect CN4 connection and install T-adapter. • Ignition switch OFF during troubleshooting.
Fuel injector 6 test internal short or disconnected
At CN6, between (1) and (2) Resistance Ω
At CN6, between (1) and (2) and grounding
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting.
A.
Wiring harness test Contact with grounding circuit
20-442 1
Resistance Ω
Between CB3 (26) and CN4 (1) and grounding
Above 1MΩ
7
Between CB3 (36) and CN4 (2) and grounding
Above 1MΩ
8
Between CB3 (34) and CN5 (1) and grounding
Above 1MΩ
9
Between CB3 (33) and CN5 (2) and grounding
Above 1MΩ
10
Between CB3 (25) and CN6 (1) and grounding
Above 1MΩ
11
Between CB3 (35) and CN6 (2) and grounding
Above 1MΩ
12
PC400LC-7L
TROUBLESHOOTING Steps 5.
Circuit Diagnostic Procedures For Code [E98B]
Specifications
No.
Between CB3 (26) and CN4 (1) and grounding
Below 1V
13
Between CB3 (36) and CN4 (2) and grounding
Below 1V
14
Between CB3 (34) and CN5 (1) and grounding
Below 1V
15
Between CB3 (33) and CN5 (2) and grounding
Below 1V
16
Between CB3 (25) and CN6 (1) and grounding
Below 1V
17
Between CB3 (35) and CN6 (2) and grounding
Below 1V
18
At CB3, between (26) and (36)
0.4 - 1.1Ω
19
At CB3, between (34) and (33)
0.4 - 1.1Ω
20
At CB3, between (25) and (35)
0.4 - 1.1Ω
21
At CB3, between (25) and grounding
Above 1MΩ
22
At CB3, between (26) and grounding
Above 1MΩ
23
At CB3, between (33) and grounding
Above 1MΩ
24
At CB3, between (34) and grounding
Above 1MΩ
25
At CB3, between (35) and grounding
Above 1MΩ
26
At CB3, between (364) and grounding
Above 1MΩ
27
Readings
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapters. • Ignition switch should remain in the ON position during troubleshooting.
A.
6.
E98B
Wiring harness test Contact with 24V circuit
Voltage
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB3 and install T-adapter. • Ignition switch OFF during troubleshooting.
A.
Engine controller test
Resistance Ω
Electrical circuit diagram related to fuel injectors 4, 5, and 6
PC400LC-7L
20-443 1
TROUBLESHOOTING
A000N1
12
A000N1 ENGINE HIGH IDLING SPEED OUT OF STANDARD User Code
Error Code
Failure Code
E22
E922
A000N1
Failure phenomenon
Failure content
•
While the engine is running, its speed above 2,350 rpm is detected.
Response from controller
•
None in particular.
Phenomenon occurring • on machine Relative information Step 1.
•
Engine high-idling speed out of standard (Mechanical system)
If the machine is used as it is, the engine may be damaged. Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01006: Engine speed)
Standard value in normal and references for troubleshooting
Cause
Check for an external or an internal factor which heightens the engine high idling speed and then Overrun of engine (While system is normal) check the mechanical system of the engine.
2.
Engine speed sensor system abnormal
3.
Engine controller defective • Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting. A.
Engine controller test
20-444 1
Engine speed
If error code E227 is displayed, carry out troubleshooting it first.
Engine High idling
Monitoring 01006 Engine speed
1,880 − 1,980 rpm
1
PC400LC-7L
TROUBLESHOOTING
A000N2
12
A000N2 ENGINE LOW IDLING SPEED OUT OF STANDARD User Code
Error Code
Failure Code
---
---
A000N2
Failure phenomenon
Engine low-idling speed out of standard (Mechanical system)
Failure content
•
While the engine is running, its speed below 500 rpm is detected.
Response from controller
• •
None in particular. When the failure cause disappears by itself, the machine returns to normal.
Phenomenon occurring • on machine Relative information Step
•
If the machine is used as it is, the engine may be damaged. Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01006: Engine speed)
Standard value in normal and references for troubleshooting
Cause
Engine mechanical system defective
Check for an external or an internal factor which heightens the engine low idling speed and then check the mechanical system of the engine.
2.
Engine speed sensor system abnormal
If error code E227 is displayed, carry out troubleshooting it first.
3.
Engine controller defective • Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting.
1.
A.
Engine controller test
PC400LC-7L
Engine speed
Engine Low idling
Monitoring 01006 Engine speed
975 − 1,025 rpm
1
20-445 1
TROUBLESHOOTING
AA10NX
12
AA10NX AIR CLEANER CLOGGED • •
The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine is running. (Mechanical system) Failure code AA10NX.
Response from controller
•
None in particular.
Phenomenon occurring on machine
•
If the machine is used as it is, the engine may be damaged.
•
If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function. (Code No.: 04501 Monitor input 1)
Contents Of Trouble
Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [AA10NX]
1.
Air cleaner clogged (While Check the air cleaner. If it is clogged, clean or replace it. system is normal)
2.
Air cleaner clogging switch defective • Turn the engine ignition switch OFF for preparations. • Disconnect A31 connection and install T-adapter. • Ignition switch OFF during troubleshooting. A.
3.
Resistance Ω
No.
At A31, between (1) and (2) - Normal
Below 1Ω
1
At A31, between (1) and (2) - Clogged
Above 1MΩ
2
Between P02 (5) and A31 (1)
Below 1Ω
3
Between A31 (2) and grounding
Below 1Ω
4
Between P02 (5) and grounding - Normal
Below 1V
5
Between P02 (5) and grounding - Clogged
20 - 30V
6
Readings
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller P02 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
4.
Air cleaner clogging switch test - internal short or disconnected
Specifications
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Monitor panel defective • Turn the ignition switch OFF for preparations. • Disconnect P02 and install T-adapter. • Hold the ignition switch in the ON position or keep the engine running during the troubleshooting. A.
Monitor panel test
20-446 1
Voltage
PC400LC-7L
TROUBLESHOOTING
AA10NX
12 Electrical circuit diagram related to air cleaner clogging switch
PC400LC-7L
20-447 1
TROUBLESHOOTING
AB00KE
12
AB00KE CHARGE VOLTAGE LOW Contents Of Trouble
• •
Signal voltage from alternator is below 20V while the engine is running. (Mechanical system) Failure code AB00KE.
Response from controller
•
None in particular.
Phenomenon occurring on machine
•
If the machine is used as it is, the engine may be damaged.
•
If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function. (Code No.: 04300 Charge voltage Code No.: 04501 Monitor input 2)
Relative information
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [AB00KE]
Readings
Alternator test - internal short or disconnected
At Alternator, between (terminal R) and grounding Voltage
Above 20V
1
Below 1Ω
2
If the voltage is abnormal, also check the belt tension.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Between P02 (11), J02 and Alternator terminal R
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller P02 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
4.
No.
Wiring harness assembly • With ignition switch in OFF position. • Disconnect engine controller P02 and install T-adapters. • Ignition switch should remain in the OFF position during troubleshooting. A.
3.
Specifications
Alternator defective • Turn the engine ignition switch OFF for preparations. • Disconnect terminal R connection and install T-adapter. • Keep the engine running during troubleshooting. A.
2.
•
Wiring harness test Contact with grounding circuit
Resistance Ω
Between P02 (11), J02 and Alternator terminal R
Above 1MΩ
3
Between P02 (11), D01, J01 and ignition switch terminal BR
Above 1MΩ
4
Between P02 (11), battery relay terminal BR and grounding
Above 1MΩ
5
Above 20V
6
Monitor panel defective • Turn the ignition switch OFF for preparations. • Disconnect P02 and install T-adapter. • Hold the ignition switch in the ON position or keep the engine running during the troubleshooting. A.
Monitor panel test
20-448 1
Voltage
Between P02 (11) and grounding
PC400LC-7L
TROUBLESHOOTING
AB00KE
12 Electrical circuit diagram related to engine preheating, starting, charging
PC400LC-7L
20-449 1
TROUBLESHOOTING
B@BAZG
12
B@BAZG ENGINE OIL PRESSURE LOW •
•
The signal circuit of the low pressure switch is closed (connected to ground) and the signal circuit of the high pressure switch is closed (connected to ground) while the engine speed is above 600 rpm. The signal circuit of the low pressure switch is opened (disconnected from ground) and the signal circuit of the high pressure switch is closed (connected to ground) while the engine speed is above 1,300 rpm. (Mechanical system) Failure code B@BAZG.
Response from controller
•
None in particular.
Phenomenon occurring on machine
•
If the machine is used as it is, the engine may be damaged.
•
When this failure occurs, the error code is displayed only when the user code is turned ON and the failure code is recorded in only the mechanical system of the failure history. If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function. (Code No.: 17400 Engine controller input)
Contents Of Trouble
Relative information
•
• •
Tools and Procedures
• • • • •
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [B@BAZG]
Specifications
No.
Readings
1.
Engine oil pressure lowered (While system is Check the engine oil pressure. If it is abnormal, find out the cause and check the engine for damage, if normal) need be, repair it.
2.
Engine oil pressure switch system defective
3.
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB1 and install T-adapters. • Hold ignition switch in the ON position or start engine during the troubleshooting.
Carry out troubleshooting for error code E936.
Engine Stopped A.
Engine controller test
Voltage
Low idling Stopped Above 1,300 rpm
20-450 1
−−−
CB1 Between (21) and grounding (Low pressure switch signal) Between (15) and grounding (High pressure switch signal)
Below 1V
1
20 - 30V
2
Below 1V
3
20 - 30V
4
PC400LC-7L
TESTING AND ADJUSTING
B@BAZG
12 Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
PC400LC-7L
20-451
TESTING AND ADJUSTING
B@BAZK
12
B@BAZK ENGINE OIL LEVEL LOW • •
The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the engine is stopped. (Mechanical system) Failure code B@BAZK.
Response from controller
•
None in particular.
Phenomenon occurring on machine
•
If the machine is used as it is, the engine may be damaged.
•
If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function. (Code No.: 04501 Monitor input 2)
Contents Of Trouble
Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [B@BAZK]
1.
Engine oil level low (While system is normal)
2.
Engine oil level switch • Turn the engine ignition switch OFF for the preparations. • Hold ignition switch in the OFF position during troubleshooting. A.
3.
Engine oil level Resistance Ω
No.
Readings
Normal level Below normal level
OL
--Below 1Ω
1
Above 1MΩ
2
Below 1Ω
3
Engine oil level - Normal
Below 1V
4
Engine oil level - Below normal
20 - 30V
5
Between (1) and ground
Wiring harness • Turn the engine ignition switch OFF for the preparations. • Disconnect P02 connector and install T-adapter. • Hold ignition switch in the OFF position during troubleshooting. A.
4.
Engine oil level switch defective Internal disconnection
Specifications
Check the engine oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently find out the cause.)
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Between P02 (8) and OL (1)
Monitor panel • With ignition switch in OFF position. • Disconnect engine controller P02 and install T-adapters. • Hold ignition switch in the ON position or start engine during the troubleshooting. A.
20-452
Monitor panel test
Voltage
Between P02 (8) and grounding
PC400LC-7L
TESTING AND ADJUSTING
B@BAZK
12 Electrical circuit diagram related to engine oil level switch
PC400LC-7L
20-453
TESTING AND ADJUSTING
B@BCNS
12
B@BCNS ENGINE WATER OVERHEAT Contents Of Trouble
• •
The signal circuit of the engine water temperature sensor detected temperature above 105°C. (Mechanical system) Failure code B@BCNS.
Response from controller
•
None in particular.
Phenomenon occurring on machine
•
If the machine is used as it is, the engine may be damaged.
•
If the engine water temperature monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. Input from the engine water high temperature sensor (water temperature and voltage) can be checked in the monitoring function. (Code No.: 04102 Engine water temperature (High), Code No.: Engine water temperature sensor voltage Hi)
Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [B@BCNS]
Specifications
No.
Readings
1.
Engine overheated (While system is normal)
Check the engine for overheating. If it has been overheated, find out the cause and check the engine for damage, then repair.
2.
Engine water high temperature sensor system defective
Carry out troubleshooting for “Display of engine water temperature gauge on monitor panel is abnormal” in E mode.
3.
Engine controller • With ignition switch in OFF position. • Disconnect engine controller CB2 and install T-adapters. • Hold ignition switch in the ON position or start engine during the troubleshooting. A.
20-454
Engine controller test
Resistance Ω
At CB2, between (27) and (29) At CB2, between (27) and (39)
Engine water temperature 105°C
3.28kΩ
1
3.28kΩ
2
PC400LC-7L
TESTING AND ADJUSTING
B@BCNS
12 Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC400LC-7L
20-455
TESTING AND ADJUSTING
B@BCZK
12
B@BCZK ENGINE WATER LEVEL LOW • •
The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the engine is running. (Mechanical system) Failure code B@BCZK.
Response from controller
•
None in particular.
Phenomenon occurring on machine
•
If the machine is used as it is, the engine may be damaged.
•
If the radiator water level monitor on the monitor panel lights up red while the engine is stopped (the ignition switch is at the ON position), this failure code is recorded. Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function. (Code No.: 04500 Monitor input 1)
Contents Of Trouble
Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [B@BCZK]
1.
Sub-tank water level low (While system is normal)
2.
Radiator water level switch • Turn the engine ignition switch OFF for the preparations. • Hold ignition switch in the OFF position during troubleshooting. A.
3.
Sub-tank water level Resistance Ω
No.
Readings
Within normal level
A33
--Below 1Ω
1
Above 1MΩ
2
Between P02 (3) and A33 (1)
Below 1Ω
3
Between A33 (2), J08, J12 and grounding
Below 1Ω
4
Sub-tank water level - Within normal
Below 1V
4
Sub-tank water level - Below LOW level
20 - 30V
5
Below normal level
Between (1) and (2)
Wiring harness • Turn the engine ignition switch OFF for the preparations. • Disconnect P02 connector and install T-adapter. • Hold ignition switch in the OFF position during troubleshooting. A.
4.
Radiator water level switch defective Internal disconnection
Specifications
Check the radiator sub-tank water level. If it is low, add water. (If it is reduced frequently, find out the cause.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Monitor panel • With ignition switch in OFF position. • Disconnect engine controller P02 and install T-adapters. • Hold ignition switch in the ON position or start engine during the troubleshooting. A.
20-456
Monitor panel test
Voltage
Between P02 (3) and grounding
PC400LC-7L
TESTING AND ADJUSTING
B@BCZK
Electrical circuit diagram related to radiator water level switch
PC400LC-7L
20-457
TESTING AND ADJUSTING
B@HANS
12
B@HANS HYDRAULIC OIL OVERHEAT Contents Of Trouble
• •
The signal of the hydraulic oil temperature sensor rises above 102°C, while the engine is running. (Mechanical system) Failure code B@HANS.
Response from controller
•
None in particular.
Phenomenon occurring on machine
•
If the machine is used as it is, the engine may be damaged.
•
If the hydraulic oil temperature monitor on the monitor panel lights up red while the engine is running, this failure code is recorded. Input from the hydraulic oil temperature sensor can be checked in the monitoring function. (Code No.: 04401 Hydraulic oil temperature)
Relative information
Tools and Procedures
• • • • •
•
Digital Volt Ohm Meter. T-adapter kit if appropriate. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [B@HANS]
1.
Hydraulic oil overheated (While system is normal)
2.
Hydraulic oil temperature sensor • Turn the engine ignition switch OFF for the preparations. • Hold ignition switch in the OFF position during troubleshooting. A.
3.
A61 Resistance Ω
No.
Readings
Hydraulic oil temperature
Between (1) and (2) Between (2) and grounding
10 - 100°C
--90 - 3.5kΩ
1
Above 1MΩ
2
Above 1MΩ
3
90 - 3.5kΩ
4
Above 1MΩ
5
Wiring harness • Turn the engine ignition switch OFF for the preparations. • Disconnect P02 connector and install T-adapter. • Hold ignition switch in the OFF position during troubleshooting. A.
4.
Hydraulic oil temperature sensor test Internal disconnection
Specifications
Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the hydraulic equipment for damage, then repair.
Wiring harness test Contact with grounding circuit
Resistance Ω
Between P02 (12) and A61 (2)
Monitor panel • With ignition switch in OFF position. • Disconnect engine controller P02 and install T-adapters. • Hold ignition switch in the ON position or start engine during the troubleshooting. A.
20-458
Monitor panel test
Resistance Ω
Between P02 (12) and (13) Hydraulic oil temperature Between P02 (12) and 10 - 100°C grounding
PC400LC-7L
TESTING AND ADJUSTING
B@HANS
Electrical circuit diagram related to hydraulic oil temperature sensor
PC400LC-7L
20-459
TESTING AND ADJUSTING
B@HANS
12
MEMORANDUM
20-460
PC400LC-7L
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 12 BEFORE CARRYING OUT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502 CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-503 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF . . . . . . . . . . . . 20-504 USER CODE MEMORY RETENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504 INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-505 E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507 THE ENGINE DOES NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507 E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510 PREHEATER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510 PREHEATING MONITOR DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510 HEATER UNIT DOES NOT WARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-511 E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514 E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515 AUTO-DECELERATOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515 E-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . 20-516 E-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518 ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518 E-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . 20-520 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520 MACHINE PUSH-UP FUNCTION IS NOT TURNED OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521 E-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523 ATTACHMENT CIRCUIT DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523 E-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525 NO DISPLAY IN MONITOR PANEL AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525 E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527 PART OF DISPLAY ON MONITOR PANEL IS MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527 E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL . . . . . . . . . . . . . . . . . . 20-527 E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-528 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING . . . . . . . . . . . . . . 20-528 E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-529 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . 20-529 E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-531 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . 20-531 E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533 FUEL GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533 E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535 E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-537 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . 20-537 E-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539 WINDSHIELD WIPER DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539
PC400LC-7L
20-501 1
TROUBLESHOOTING
TABLE OF CONTENTS
WINDSHIELD WASHER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-541 E-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543 ALARM BUZZER CANNOT BE CANCELLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543 E-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-545 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . 20-545 E-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-547 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . 20-547 E-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-549 “ARM IN” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . . . . . . . . 20-549 E-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-550 “ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . 20-550 E-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552 “BUCKET CURL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . 20-552 E-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-553 “BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . 20-553 E-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-555 “SWING” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . . . . . . . . 20-555 E-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-557 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . . . . . . 20-557 E-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559 “TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559 E-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-561 “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . . . . . 20-561 E-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-563 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING . . . . . . . . . . . . . . . . . . . . 20-563 E-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565 TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . 20-565 TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565 E-32-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 20-566 E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-566 E-32-E15 DISCONNECTION IN WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . 20-567 E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . 20-567 E-32-E18 SHORT IN DAYLIGHT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568 E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568 E-32-E44 ABNORMALITY IN AIR MIX DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-569 E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER . . . . . . . . . . . . . . 20-569 E-32 - TROUBLESHOOTING BY FAILURE PHENOMENON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-571
20-502 1
PC400LC-7L
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING
12
BEFORE CARRYING OUT TROUBLESHOOTING CONNECTION TABLE OF FUSE BOX
★ This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). ★ When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if the power is supplied normally.
Type of power supply
Fuse No.
Fuse capacity
Destination of power Pump controller (Controller power supply)
1
10 A
Swing holding brake solenoid (When emergency brake is released) PC-EPC solenoid (When emergency pump is driven) Pump controller (Solenoid power supply)
2
20 A
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Constant power supply (Fusible link: A35)
PC400LC-7L
Machine push-up solenoid ATT return selector relay & solenoid Starting motor cutout relay (For PPC lock)
3
10 A
4
10 A
5
10 A
Horn
6
10 A
(Spare)
7
10 A
Rotary lamp
8
10 A
Right front working lamp & boom working lamp
9
10 A
10
10 A
(Spare)
11
20 A
Air conditioner unit
12
20 A
13
20 A
14
10 A
15
10 A
16
10 A
Radio (For backing up)
17
10 A
Monitor panel (For backing up)
18
10 A
Starting switch
19
10 A
Room lamp
20
10 A
(Spare)
PPC lock solenoid Cigarette lighter Windshield washer motor
One-touch power maximizing switch (Input to pump controller input) Radio
Monitor panel Starting motor cutout relay (For personal code) Light relay (For right front working lamp & boom working lamp) Headlamp & additional headlamp Service power supply 1 (M32 connector) Travel alarm Service power supply 2 (DC/DC converter)
20-503 1
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 1.
Always turn power OFF before disconnecting or connecting connectors.
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Disconnect and connect the related connectors several times to check. ★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3.
Always connect any disconnected connectors before going on to the next step. ★ If power is turned ON with the connectors still disconnected, unnecessary displays will be generated.
4.
When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related wiring and connectors several times and check that there is no charge in the reading of the tester. ★ If there is any charge, there is probably defective contact in that circuit.
5.
When checking a single diode circuit: ★ Isolate the diode from the circuit. ★ using a digital volt ohm meter, in the Ohms mode, check the polarity of the diode as shown in the illustration. Reversing the meter leads, you should have a reading in one direction only. ★ Electrical flow should be negative (-) to positive (+) only, red lead positive and black lead negative.
6.
When checking a dual diode circuit: ★ Isolated the diode from the circuit. ★ using a digital volt ohm meter, in the Ohms mode, check the polarity of the diode as shown in the illustration. Reversing the meter leads, you should have a reading in one direction only. ★ Electrical flow should be negative (-) to positive (+) only, red lead positive and black lead negative.
7.
Always be aware of what you are measuring. Voltage, Ohms or Amps. Always use caution when measuring a circuit. ★ When measuring voltage, be sure the meter is set in the voltage range, AC or DC and above the voltage value you are measuring. ★ When measuring ohms, be sure the circuit is dead and has no voltage in it before you take any readings. Be sure the meter is set in the proper ohms range. ★ When measuring Amps, be sure your meter is rated for the amount of amps you will be measuring. Failure to follow these procedures may damage you equipment or possibly cause injury. Always study the operators manuel for the meter you will be using.
20-504 1
PC400LC-7L
TROUBLESHOOTING 12 POINTS
ITSELF
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY
There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully. 1.
If any abnormality returns to normal by itself.
2.
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting on the failure, and the service code is no longer displayed, or if the monitor display returns to normal.
3.
After completing troubleshooting, always erase the user code from memory.
USER CODE MEMORY RETENTION FUNCTION When displaying the codes in the memory and carrying out troubleshooting, record the content of the display first, then erase the display. After re-enacting the problem, carry out troubleshooting according to the failure codes that are now displayed. There are cases where mistaken operation or abnormalities occur when a connector is disconnected. Erasing the data in this way saves any wasted work.
PC400LC-7L
20-505 1
TROUBLESHOOTING
INFORMATION CONTAINED IN TESTING PROCEDURES
12
INFORMATION CONTAINED IN TESTING PROCEDURES ★ The testing table and the related circuit diagrams contain the following information. Read all information and each step carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to isolate each part of the circuit. • • •
Tools and Procedures
Contents Of Trouble
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Service Code
What you testing
are
4.
No.
Readings
Resistance Ω or Voltage
Test procedure for component only.
readings
1
Your information
Test procedure for component only.
readings
2
Your information
Diode test • With ignition switch in the OFF position. (The importance of these tests are to isolate each component for testing separately) • When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm electrical flow. Electrical flow should be one way only. A.Diode test
3.
Specifications
Sensor or actuator • With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸) • Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately) • Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual) A.
2.
Failure. Failure code displayed. Additional information.
Resistance Ω
At a diode, between point (x) and (x) reverse meter lead polarity each time to check diode.
Continuity one way only?
3
Yes or No
Wiring harness assembly test • With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸) • Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately) • Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual) A.Open or high resistance
Resistance Ω or Voltage
Test procedure for harness. (connector) to (connector)
readings
4
Your information
Test procedure for harness. (connector) to (connector)
readings
5
Your information
B.Short to chassis ground or within harness
Resistance Ω or Voltage
Test procedure for harness. (connector) to (connector)
readings
6
Your information
Test procedure for harness. (connector) to (connector)
readings
7
Your information
Additional components to be tested • With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸) • Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately) • Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual) A.What you are testing
20-506 1
Resistance Ω or Voltage
Test procedure for any additional components.
readings
8
Your information
PC400LC-7L
TROUBLESHOOTING
INFORMATION CONTAINED IN TESTING PROCEDURES
12 Circuit Diagram This is part of the electrical circuit diagram which shows the portion where the failure occurred. • •
Connector No.: Indicates (Type - numbers of a pin) (color) Arrow: Roughly indicates the location in the machine where it is installed.
PC400LC-7L
20-507 1
TROUBLESHOOTING
E-1
12
E-1 THE ENGINE DOES NOT CRANK • •
The engine will not crank. Failure code none displayed.
Relative information
•
The engine starting circuit has the start lock mechanism of the safety lock lever type
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
A.
Battery test Insufficient capacity
Voltage ---
Battery voltage
Min. 24V
1
Min. 1.26
2
Fusible link A35
3.
Fuse No. 3 or 17
4.
Ignition switch • Prepare with ignition switch in the OFF position. • Disconnect H15 connector and install T-adapter. A.
Ignition switch test Internal disconnection
If circuit breaker is turned OFF or the fuse is broken, the circuit probably has a ground fault (See cause 9).
Resistance Ω
At H15, between (1) and (4) key OFF position At H15, between (1) and (4) key START position
Min. 1MΩ
2
Max. 1Ω
3
Safety lock switch test Internal short circuit
Resistance Ω
At S14, between (1) and (3), locked At S14, between (1) and (3), unlocked
Min. 1MΩ
4
Max. 1Ω
5
Starting motor cut-out relays • Prepare with ignition switch in the OFF position. • Disconnect R11 and R13 connector and install T-adapter.
A.
7.
Readings
Safety lock switch • Prepare with ignition switch in the OFF position. • Disconnect S14 connector and install T-adapter. A.
6.
No.
Electrolyte specific gravity
2.
5.
Specifications
Battery • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test.
Starting motor cut-out relays Internal defect
Resistance Ω
At R11, between (1) and (2)
100 - 500Ω
6
At R11, between (3) and (5)
Min. 1MΩ
7
At R11, between (3) and (6)
Max. 1Ω
8
At R13, between (1) and (2)
100 - 500Ω
9
At R13, between (3) and (5)
Min. 1MΩ
10
At R13, between (3) and (6)
Max. 1Ω
11
Starting motor • Prepare with ignition switch in the OFF position. • Turn ignition switch to START and carry out troubleshooting.
A.
Starting motor test Internal defect
B - power supply
Starting motor, between terminal B and chassis ground
20 - 30V
12
S - start
Starting motor, between ST (1) and chassis ground
20 - 30V
13
R - charge
Starting motor, between ST (2) and chassis ground
Max. 1V
14
Voltage
If the above voltage is normal and the starting motor does not crank, starting motor has a defect in it or engine is defective. 8.
Alternator • Prepare with ignition switch OFF (with only wiring harness R disconnected). • Turn ignition switch ON and carry out troubleshooting. A.
Alternator test Internal short circuit
20-508 1
Voltage
Alternator, between terminal R and chassis ground
Max. 1V
15
PC400LC-7L
TROUBLESHOOTING Steps 9.
E-1
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Wiring harness assembly test • With ignition switch in the OFF position. • Disconnect A35, H15, R1, R13, S14 connectors from and install T-adapter. • Carry out troubleshooting with ignition switch OFF.
★ Turn ignition switch ON during troubleshooting
A.
Wiring harness Disconnection in harness or defective contact in connector
Resistance Ω
Resistance Ω B.
C.
Wiring harness Short to chassis ground or within harness Contact with ground circuit
Wiring harness Contact with 24V circuit
PC400LC-7L
Voltage
Between battery relay terminal B and A35 (1)
Max. 1Ω
16
Between A35 (2) and H15 (1)
Max. 1Ω
17
Between H15 (4), J01 and R11 (5)
Max. 1Ω
18
Between R11 (3) and ST (1)
Max. 1Ω
19
Between FB1 (3) and S14 (1)
Max. 1Ω
20
Between S14 (3) and R11 (1)
Max. 1Ω
21
Between R11 (2) and R13 (6)
Max. 1Ω
22
Between R13 (3), J04 and chassis ground
Max. 1Ω
23
Between A35 (2) and H15 (1) and chassis ground
Min. 1MΩ
24
Between H15 (4), J01 and R11 (5) and other related circuits and chassis ground
Min. 1MΩ
25
Between R11 (3) and ST (1) and chassis ground
Min. 1MΩ
26
Between FB1 (3) and S14 (1) and chassis ground
Min. 1MΩ
27
Between A14 (3) and R11 (1) and chassis ground
Min. 1MΩ
28
Between R11 (2) and R13 (6) and chassis ground
Min. 1MΩ
29
Between R13 (2), J05, P02 (14 and other related circuits and chassis ground
Min. 1MΩ
30
Max. 1V
31
★ Between ST(2), alternator terminal R, J02, D01 (6) and P02 (11) and chassis ground
20-509 1
TROUBLESHOOTING
E-1
Electrical circuit diagram for engine preheating, starting, charging
20-510 1
PC400LC-7L
TROUBLESHOOTING
E-2
12
E-2 PREHEATER DOES NOT OPERATE PREHEATING MONITOR DOES NOT LIGHT Failure information
Tools and Procedures
Relative information
• • • •
The preheater does not operate.
•
The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds). Input of the preheating signal (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1)
•
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Ignition switch defective
2.
Wiring harness • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
3.
1. When the starting switch is turned to the HEAT position, the preheating monitor does not light up.
•
system
Wiring harness test Disconnection or defective contact with connector
Specifications
No.
Readings
If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting
Resistance Ω
Between P02 (18) and J02 (7)
Below 1Ω
1
Below 1V
2
20 - 30V
3
Monitor panel • Prepare with ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Hold ignition switch in OFF position or HEAT position during troubleshooting. A.
Monitor panel test
PC400LC-7L
Voltage
At P02, between Ignition switch - OFF (18) and ground Ignition switch - HEAT
20-511 1
TROUBLESHOOTING 12 HEATER
E-2
UNIT DOES NOT WARM 2. When the starting switch is turned to the HEAT position, the heater unit is not warmed.
•
The preheater does not operate.
Relative information
• •
Check that the starting motor rotates normally. (If the starting motor does not rotate, carry out troubleshooting in “E-1 Engine does not crank”.)
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
A. 2.
Readings
Ignition switch test Internal disconnection
Resistance Ω
At H15, between Ignition switch - OFF (1) and (3) Ignition switch - HEAT
Above 1MΩ
1
Below 1Ω
2
Heater relay test Internal disconnection
Continuity and Resistance Ω
Ignition switch OFF HEAT
Heater relay
---
Between coil terminal and grounding
Continued
3
Between contact terminals
Below 1Ω
4
Continued
5
Intake air heater • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
4.
No.
Heater relay • With ignition switch in the OFF position. • Disconnect H15 and install T-adapter. • Hold ignition switch in OFF position or HEAT position during troubleshooting. A.
3.
Specifications
Ignition switch • With ignition switch in the OFF position. • Disconnect H15 and install T-adapter. • Hold ignition switch in OFF position or HEAT position during troubleshooting.
Intake air heater test Internal disconnection
Continuity
Intake air heater, between terminals
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
Wiring harness test Disconnection or defective contact with connector
20-512 1
Resistance Ω
Between H15 (3), J02, and heater relay terminal
Below 1Ω
6
Between starting motor terminal B and heater relay
Below 1Ω
7
Between heater relay and intake air heater
Below 1Ω
8
Between air heater and engine
Below 1Ω
9
PC400LC-7L
TROUBLESHOOTING
E-2
12 Electrical circuit diagram for engine preheating, starting, charging
PC400LC-7L
20-513 1
TROUBLESHOOTING
E-3
12
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK Failure information
Relative information
•
The auto engine warm-up device does not work.
•
The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C, and raise the engine rotation up to 1,200 rpm. The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more than 3 seconds, when the engine starting switch is in the ON position or after the engine is started. If the engine water temperature is below 10°C, the turbocharger protection function operates to keep the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.
•
Tools and Procedures
•
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Engine cooling water temperature signal • Turn the ignition switch ON for the trouble shooting
A.
Engine cooling water temperature signal fault
Monitor code 04107
Engine cooling water temperature (low temperature)
Compare the monitor indication with the actual engine cooling water temperate
1
If the display on the monitor panel is abnormal, carry out troubleshooting in “Engine water thermometer does not display normally. 2.
Engine controller A.
Engine controller test
20-514 1
If step1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E-4
12
E-4 AUTO-DECELERATOR DOES NOT OPERATE Failure information
Relative information
•
The auto-decelerator does not operate.
• • •
Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above this level. Check the display on the monitor panel while the engine is running. If the display on the monitor panel is abnormal, carry out troubleshooting in “*** is not displayed normally in monitoring function”.
---
Presumed cause and standard value
Cause
Standard value and references for testing Monitoring code
Item
Normal display
1
Boom RAISE signal fault
01900 Pressure switch 1
Boom RAISE
Lever operation: ON Lever NEUTRAL: OFF
2
Boom LOWER signal fault
01900 Pressure switch 1
Boom LOWER
Lever operation: ON Lever NEUTRAL: OFF
3
Arm RETRACT signal fault
01900 Pressure switch 1
Arm RETRACT
Lever operation: ON Lever NEUTRAL: OFF
4
Arm EXTEND signal fault
01900 Pressure switch 1
Arm EXTEND
Lever operation: ON Lever NEUTRAL: OFF
5
Bucket CURL signal fault
01901 Pressure switch 2
Bucket CURL
Lever operation: ON Lever NEUTRAL: OFF
6
Bucket DUMPING signal fault
01901 Pressure switch 2
Bucket DUMPING
Lever operation: ON Lever NEUTRAL: OFF
7
Swing signal fault
01900 Pressure switch 1
Swing
Lever operation: ON Lever NEUTRAL: OFF
8
Travel signal fault
01900 Pressure switch 1
Travel
Lever operation: ON Lever NEUTRAL: OFF
9
Service signal fault
01901 Pressure switch 2
Service
Lever operation: ON Lever NEUTRAL: OFF
10
Pump controller defective
As this is an internal failure, testing cannot be conducted. (If there is none of the causes listed in Item 1 through 9, the controller is judged as defective.
11
Engine controller defective
As this is an internal failure, testing cannot be conducted. (If there is none of the causes listed in Item 1 through 9, the controller is judged as defective.
PC400LC-7L
20-515 1
TROUBLESHOOTING
E-5
12
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE •
Relative information
---
Tools and Procedures
Failure information
• • • •
All the work equipment, swing and travel do not move.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse No. 9 fault
1.
Safety lock switch • With ignition switch in the OFF position. • Disconnect S14 and install T-adapter. • Hold ignition switch in OFF position. A.
2.
Readings
Resistance Ω
At S14, between Safety lock lever - Free (1) and (2) Safety lock lever - Lock
Below 1Ω
1
Above 1MΩ
2
PPC lock solenoid Internal disconnection, short circuit or ground fault
At V08, between (1) and (2)
20 - 60Ω
3
Resistance Ω
At V08, between (1) and grounding
Above 1MΩ
4
Above 1MΩ (Νο Continuity)
5
Assembled type diode D01 • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
4.
No.
PPC lock solenoid • With ignition switch in the OFF position. • Disconnect V08 and install T-adapter. • Hold ignition switch in OFF position. A.
3.
Safety lock switch test Internal disconnection
Specifications
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 4B.
Assembled type diode D01 Internal short
Resistance Ω
At D01, between (4) and (8)
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
B.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
20-516 1
Between FB1 (3) outlet and S14 (1)
Below 1Ω
6
Between S14 (2) and J02 - V01 (2)
Below 1Ω
7
Between V08 (1) to J13 and ground
Below 1Ω
8
Between FB1 (3) outlet and S14 (1) and grounding
Above 1MΩ
9
Between S14 (2) to J02 - V01 (2) and grounding
Above 1MΩ
10
Between S14 (2) and D01 (4) and grounding
Above 1MΩ
11
PC400LC-7L
TROUBLESHOOTING
E-5
12 Electrical circuit diagram for PPC lock solenoid
PC400LC-7L
20-517 1
TROUBLESHOOTING
E-6
12
E-6 ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE Failure information
Tools and Procedures
Relative information
• • • •
•
One-touch power max. function does not operate
•
If the one-touch power max. switch is pressed while the engine is running, the one-touch power max. monitor is displayed on the monitor panel. Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in the monitoring function. (Code No. 02200: Switch input 1)
•
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse No. 3 fault
1.
One touch power max. switch • With ignition switch in the OFF position. • Disconnect M23 and install T-adapter. • Hold ignition switch in OFF position. A.
2.
No.
Readings
Resistance Ω
At M23, One touch pwr. max. sw. - released between (1) and One touch pwr. max. sw. - Pressed (2)
Min. 1MΩ
1
Max. 1Ω
2
Max. 1Ω
3
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
B.
3.
One touch power max. switch test Internal disconnection
Specifications
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 2B.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Between FB1 (9) outlet and M23 (1)
Wiring harness test Contact with grounding circuit
Between FB1 (9) outlet and M23 (1) and grounding
Min. 1MΩ
4
Resistance Ω
Between FB1 (9) outlet and other related circuit and grounding
Min. 1MΩ
5
Max. 1V
6
20 - 30V
7
Pump controller • With ignition switch in the OFF position. • Disconnect C01 and install T-adapter • Keep ignition switch to the ON position for this test. A.
Pump controller test
20-518 1
Voltage
At C01, One touch pwr. max. sw. - released Between (11) One touch pwr. max. sw. - Pressed and ground
PC400LC-7L
TROUBLESHOOTING
E-6
12 Electrical circuit diagram related to one-touch power max. switch
PC400LC-7L
20-519 1
TROUBLESHOOTING
E-7
12
E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY MACHINE PUSH-UP FUNCTION DOES NOT OPERATE Machine push-up function does not operate normally.
Relative information
When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
(1)The machine push-up function does not operate.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Machine push-up switch • With ignition switch in the OFF position. • Disconnect M38 and install T-adapter. • Hold ignition switch in OFF position. Machine push-up switch A.
2.
Machine push-up switch test Internal disconnection
Resistance Ω
At M38, Low pressure position between (1) and High pressure position (2)
Below 1Ω
1
Above 1MΩ
2
Between M38 (2), J07 and V06 (2) and grounding
Below 1V
3
Between M38 (2) and D02 (3) and grounding
Below 1V
4
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the ON position for this test. A.
Wiring harness test Contact with 24V grounding circuit
20-520 1
Voltage
PC400LC-7L
TROUBLESHOOTING 12 MACHINE
E-7
PUSH-UP FUNCTION IS NOT TURNED OFF •
Machine push-up function does not operate normally.
Relative information
•
When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
Tools and Procedures
Failure information
• • • •
(2)The machine push-up function is not turned OFF.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse No. 2 fault
1.
Machine push-up switch • With ignition switch in the OFF position. • Disconnect M38 and install T-adapter. • Hold ignition switch in OFF position.
Specifications
No.
Readings
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 4B.
Machine push-up switch A.
2.
Below 1Ω
1
Above 1MΩ
2
Machine push-up solenoid Internal disconnection, short circuit or ground fault
At V06, between (1) and (2)
20 - 60Ω
3
Resistance Ω
At V06, between (2) and grounding
Above 1MΩ
4
Above 1MΩ (Νο Continuity)
5
Assembled type diode D02 • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
4.
Resistance Ω
At M38, Low pressure position between (1) and High pressure position (2)
Machine push-up solenoid • With ignition switch in the OFF position. • Disconnect V06 and install T-adapter. • Hold ignition switch in OFF position. A.
3.
Machine push-up switch test Internal disconnection
Assembled type diode D02 Internal short
Resistance Ω
At D02, between (3) and (7)
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
B.
Wiring harness test Disconnection or defective contact with connector Wiring harness test Contact with grounding circuit
PC400LC-7L
Resistance Ω
Resistance Ω
Between FB1 (2) outlet and M38 (1)
Below 1Ω
6
Between M38 (2) and J07 - V06 (2)
Below 1Ω
7
Between V06 (1) and ground
Below 1Ω
8
Above 1MΩ
9
Between M38 (2) to J07 - V06 (2) and grounding
Above 1MΩ
10
Between M38 (2) and D02 (3) and grounding
Above 1MΩ
11
Between FB1 (2) outlet and M38 (1) and related circuits and grounding
20-521 1
TROUBLESHOOTING
E-7
12 Electrical circuit diagram related to machine push-up solenoid
20-522 1
PC400LC-7L
TROUBLESHOOTING
E-7
12
MEMORANDUM
PC400LC-7L
20-523 1
TROUBLESHOOTING
E-8
12-
E-8 ATTACHMENT CIRCUIT DOES NOT CHANGE WHEN ATTACHMENT IS INSTALLED (1)When working mode A or E is selected, attachment circuit is not switched to crusher Attachment circuit does not change. circuit (reciprocation circuit). (2)When working mode B is selected, attachment circuit is not switched to breaker circuit (one-way circuit).
Relative information
If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or disconnection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected, however.
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
A.
2.
No.
Readings
Attachment return selection solenoid test Internal disconnection
At V12, between (1) and (2) Resistance Ω
20 - 60Ω
1
Above 1MΩ
2
At R20, between (3) and (5)
Below 1Ω
3
At R20, between (3) and (6)
Above 1MΩ
4
At V12, between (2) and grounding
Attachment return selection relay • With ignition switch in the OFF position. • Disconnect V06 and install T-adapter. • Hold ignition switch in OFF position. A.
3.
Specifications
Attachment return selection solenoid • With ignition switch in the OFF position. • Disconnect V12 and install T-adapter. • Hold ignition switch in OFF position.
Attachment return selection relay Internal disconnection, short circuit or ground fault
Resistance Ω
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test.
★ Hold ignition switch in the ON position for this test A.
B.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test Contact with 24V grounding circuit
Voltage
20-524 1
Between J03 (8) and R20 (3)
Below 1Ω
6
Between R20 (5) and V12 (2)
Below 1Ω
7
Between C03 (3), (13), (23) and V12 (1)
Below 1Ω
8
★ Between R20 (5) and V12 (2) and grounding
Below 1V
9
PC400LC-7L
TROUBLESHOOTING
E-8
12 Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid
PC400LC-7L
20-525 1
TROUBLESHOOTING
E-9
12
E-9 NO DISPLAY IN MONITOR PANEL AT ALL •
Relative information
---
Tools and Procedures
Failure information
• • • •
No display in monitor panel at all. When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse No. 12 fault
2.
Wiring harness • With ignition switch in the OFF position. • Disconnect P01 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
B.
3.
Specifications
No.
Readings
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 2B.
Wiring harness test Disconnection or defective contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
From P01 (1), (2) to J07 to FB1 (12)
Below 1Ω
1
From P01 (6), (7) to J04 and grounding
Below 1Ω
2
Above 1MΩ
3
Starting Switch At P01, between (1), (2) and ground ON
20 - 30V
4
Starting OFF
Below 1Ω
5
Between P01 (1), (2) to J07 to FB1 (12) outlet or related circuits and grounding
Monitor panel • With ignition switch in the OFF position. • Disconnect P01 and install T-adapter. • Keep ignition switch to the ON position for this test. Voltage A.
Monitor panel test Resistance Ω
20-526 1
switch
At P01, between (6), (7) and ground
PC400LC-7L
TROUBLESHOOTING
E-9
12 Electrical Circuit Diagram for Power Source in Monitor Panel
PC400LC-7L
20-527 1
TROUBLESHOOTING
E-10
12
E-10 PART OF DISPLAY ON MONITOR PANEL IS MISSING Failure information
•
Part of display on monitor panel is missing Part of the display in the monitor panel is missing during starting switch in ON.
Relative information
---
Cause
Standard value in normalcy and references for troubleshooting
★ Turn the starting switch ON during the troubleshooting. 1 Monitor panel LCD fault
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen becomes totally white) by the following switching operation, then the monitor panel is normal. • Switching operation: [/] + [A] (push switches simultaneously.)
2 Monitor panel defective
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
E-11 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL Failure information
•
Relative information
---
The monitor panels displays contents that have nothing to do with the model on which it is installed.
Cause
Standard value in normalcy and references for troubleshooting
★ Turn the starting switch in ON during the troubleshooting (monitoring). 1.
Model code signal fault (Internal failure)
Monitoring code
Item
Normal display
00200
Controller model code
PC400-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217]. 2.
Monitor panel defective
20-528 1
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E-12
12
E-12 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING •
The fuel level monitor red lamp lights up while the engine was running.
Relative information
• •
If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red. (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No.: 04200 Fuel level sensor)
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuel level lowered (system in normal condition)
2.
Fuel level sensor • With ignition switch in the OFF position. • Disconnect A60 and install T-adapter. • Hold ignition switch in OFF position.
Specifications
No.
Readings
Check fuel level in fuel tank. If insufficient, refill fuel.
Fuel level A. 3.
Resistance Ω
At A60, between (1) and grounding
FULL (Upper limit)
Approximately 12Ω
1
EMPTY (Lower limit)
85 - 110Ω
2
Below 1Ω
3
FULL (Upper limit)
Approximately 12Ω
4
EMPTY (Lower limit)
85 - 110Ω
5
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
4.
Fuel level sensor test Internal disconnection
Wiring harness test Contact with grounding circuit
Resistance Ω
Between P02 (2) and A60 (1)
Monitor panel • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Hold ignition switch in OFF position. Fuel level A.
Monitor panel test
Resistance Ω
At A60, between (2) and grounding
Electrical Circuit Diagram for Fuel Level Sensor
PC400LC-7L
20-529 1
TROUBLESHOOTING
E-13
12
E-13 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY •
Failure information
• • •
Tools and Procedures
Relative information
• • • •
Engine water temperature gauge does not display correctly
2.
While the engine water temperature is stabilized normally, the temperature gauge rises up to the red range (H).
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Engine water high temperature sensor • With ignition switch in the OFF position. • Disconnect TWH and install T-adapter. • Turn ignition switch ON or keep the engine running during troubleshooting. A.
2.
While the engine water temperature rises normally, the temperature gauge does not rise above the white range (C).
The signal of the engine water high temperature sensor for the water temperature gauge is received from the engine controller through the communication line. If the engine water high temperature sensor system becomes defective, error code [E934] may be displayed. Input from the engine water high temperature sensor (voltage and temperature) can be checked in the monitoring function. (Code No. 04106: Engine water sensor voltage Hi, Code No. 04102: Engine water temperature (High temperature))
Steps 1.
1.
Engine water high sensor test - Internal disconnection, short circuit, ground fault
Resistance Ω
At TWH, between (1) and (2)
3.5k - 90kΩ
1
At TWH, between (1) and grounding
Above 1MΩ
2
At TWH, between (2) and grounding
Above 1MΩ
3
Wiring harness • With ignition switch in the OFF position. • Disconnect CB2 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Hold ignition switch in the ON position during troubleshooting. A.
B.
C.
3.
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
Wiring harness test Contact with 24V circuit
Voltage
Between CB2 (27) and THW (1)
Below 1Ω
4
Between CB2 (29) and THW (2)
Below 1Ω
5
Between CB2 (39) and THW (2)
Below 1Ω
6
Above 1MΩ
7
Below 1V
8
Between CB2 (27) and TWH (1) and ground
★ Between CB2 (27) and TWH (1) and ground
Engine controller • With ignition switch in the OFF position. • Disconnect CB2 and install T-adapter. • Keep ignition switch to the OFF position for this test.
A.
4.
Wiring harness test Disconnection or contact with connector
Engine controller test
Monitor panel
20-530 1
Resistance Ω
At CB2, between (27) and (39)
3.5k - 90kΩ
9
At CB2, between (29) and (39)
3.5k - 90kΩ
10
At CB2, between (27) and grounding
Above 1MΩ
11
At CB2, between (29) and grounding
Above 1MΩ
12
At CB2, between (39) and grounding
Above 1MΩ
13
If causes 1 - 3 are not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E-13
12 Electrical circuit diagram related to engine water high temperature sensor
PC400LC-7L
20-531 1
TROUBLESHOOTING
E-14
12
E-14 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY Failure information
Tools and Procedures
Relative information
• • • •
•
Hydraulic oil temperature gauge does not display correctly
1.
Hydraulic oil temperature rises normally, but the display does not rise from the white range (C).
2.
Hydraulic oil temperature remains stable, but the display rises up the red range (H).
•
Input from the hydraulic oil temperature sensor can be confirmed in the monitor function. (Code No.: 04401 Hydraulic oil temperature)
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Hydraulic oil temperature sensor • With ignition switch in the OFF position. • Disconnect A61 and install T-adapter. • Turn ignition switch OFF. Engine cooling water temperature A.
2.
Hydraulic oil temperature sensor test Resistance Ω - Internal disconnection, short circuit, ground fault
At A61, between (1) and (2)
90 - 3.5kΩ
1
Above 1MΩ
2
Between P02 (12) and A61 (2)
Below 1Ω
3
Between P02 (13) and A61 (1)
Below 1Ω
4
Above 1MΩ
5
Below 1V
6
At P02, between (12) and (13)
90 - 3.5kΩ
7
At P02, between (12) and ground
90 - 3.5kΩ
8
10 - 100°C
At A61, between grounding
(2)
and
Wiring harness • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Hold ignition switch in the ON position during troubleshooting. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω Between P02 (12) and A61 (2) and ground
Wiring harness test Contact with 24V circuit
Voltage
★ Between P02 (12) and A61 (2) and ground
Monitor panel • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the OFF position for this test. Engine cooling water temperature A.
Monitor panel test
20-532 1
Resistance Ω
10 - 100°C
PC400LC-7L
TROUBLESHOOTING
E-14
12 Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC400LC-7L
20-533 1
TROUBLESHOOTING
E-15
12
E-15 FUEL GAUGE DOES NOT DISPLAY CORRECTLY Failure information
Tools and Procedures
Relative information
• • • •
•
Fuel gauge does not display correctly
1.
Though fuel was refilled, the display does not exceed the red range (E).
2.
Though the remaining fuel level is low, the display does not drop below the green range (F).
•
Input from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No.: 04200 Fuel sensor voltage)
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Fuel level sensor • With ignition switch in the OFF position. • Disconnect A60 and install T-adapter. • Turn ignition switch OFF during troubleshooting. Fuel level A.
2.
Fuel level sensor test Internal Resistance Ω disconnection, short circuit, ground fault
FULL (Upper limit) EMPTY (Lower limit)
At A60, between grounding
(1)
and
Approximately 12Ω
1
85 - 110Ω
2
Below 1Ω
3
Above 1MΩ
4
Below 1V
5
Approximately 12Ω
6
85 - 110Ω
7
Wiring harness • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Hold ignition switch in the ON position during troubleshooting. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω Between P02 (2) and A60 (1)
Wiring harness test Contact with grounding circuit
Resistance Ω Between P02 (2) and A60 (1) and ground
Wiring harness test Contact with 24V circuit
Voltage
★ Between P02 (2) and A60 (1) and ground
Monitor panel • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the OFF position for this test. Fuel level A.
Monitor panel test
Resistance Ω
FULL (Upper limit) EMPTY (Lower limit)
20-534 1
At P01, between (2) and ground
PC400LC-7L
TROUBLESHOOTING
E-15
12 Electrical Circuit Diagram for Fuel Level Sensor
PC400LC-7L
20-535 1
TROUBLESHOOTING
E-16
12
E-16 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY Failure information
Tools and Procedures
Relative information
• • • •
•
•
Though the swing lock switch was turned ON, the swing lock monitor does not light up.
2.
Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3)
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Swing lock monitor does not display correctly
1.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Swing lock switch • With ignition switch in the OFF position. • Disconnect X05 and install T-adapter. • Turn ignition switch OFF during troubleshooting. Swing lock switch A.
2.
Swing lock switch test Internal Resistance Ω disconnection, short circuit, ground fault
OFF
Above 1MΩ
1
Below 1Ω
2
From P02 (17) to J02 and X05and A60 (1)
Below 1Ω
3
From X05 (2) to J05 and grounding
Below 1Ω
4
From P02 (17) to J02 to X05 (1) and ground
Above 1MΩ
5
From P02 (17) to C02 (38) and ground
Above 1MΩ
6
★ From P02 (17) to J02 and X05 (1) and ground
Below 1V
7
★ From P02 (17) to C02 (38) and ground
Below 1V
8
ON
At X05, between (1) and (2)
Wiring harness • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Hold ignition switch in the ON position during troubleshooting. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
Wiring harness test Contact with 24V circuit
Voltage
Monitor panel • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the OFF position for this test. Swing lock switch A.
Monitor panel test
20-536 1
Voltage
OFF ON
At P01, between (17) and ground
20 − 30ς
9
Below 1V
10
PC400LC-7L
TROUBLESHOOTING
E-16
12 Electrical circuit diagram related to swing holding brake solenoid
PC400LC-7L
20-537 1
TROUBLESHOOTING
E-17
12
E-17 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED Failure information
When monitor switch is operated, nothing is displayed.
Relative information
---
Presumed cause and standard value in normalcy
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted.
Failure information
When monitor switch is operated, nothing is displayed.
(2) When LCD monitor adjustment switch is operated, mode selection screen is not displayed.
Relative information
---
Presumed cause and standard value in normalcy
Cause
(1) When mode selector switch is operated, working mode monitor is not displayed.
Cause
Standard value in normalcy and references for troubleshooting
Standard value in normalcy and references for troubleshooting
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted.
Failure information
When monitor switch is operated, nothing is displayed.
(3) When selector switch is operated, flow rate adjustment screen or flow rate selection screen is not displayed.
Relative information
---
Presumed cause and standard value in normalcy
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted.
Failure information
When monitor switch is operated, nothing is displayed.
(4) When maintenance switch is operated, item selection screen is not displayed.
Relative information
---
Presumed cause and standard value in normalcy
Cause
Cause
Standard value in normalcy and references for troubleshooting
Standard value in normalcy and references for troubleshooting
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted.
Failure information
When monitor switch is operated, nothing is displayed.
(5) When automatic deceleration switch is operated, automatic deceleration monitor is not displayed.
Relative information
When the automatic decelerator does not operate either, conduct the troubleshooting for E-4.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted.
Failure information
When monitor switch is operated, nothing is displayed.
(6) When travel speed selector switch is operated, travel speed monitor is not displayed.
Relative information
When the travel speed does not change either, conduct the troubleshooting for H-22.
Presumed cause and standard value in normalcy
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted.
Failure information
When monitor switch is operated, nothing is displayed.
(7) When wiper switch is operated, wiper monitor is not displayed.
Relative information
When the wiper does not operate either, conduct the troubleshooting for E-18.
Presumed cause and standard value in normalcy
20-538 1
Cause
Cause Monitor panel defective
Standard value in normalcy and references for troubleshooting
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
PC400LC-7L
TROUBLESHOOTING
E-17
12
MEMORANDUM
PC400LC-7L
20-539 1
TROUBLESHOOTING
E-18
12
E-18 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK WINDSHIELD WIPER DOES NOT WORK Failure information
Tools and Procedures
Relative information • • • •
•
Windshield wiper and window washer do not work.
•
Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3)
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
(1) The windshield wiper does not work.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Window rear limit switch • With ignition switch in the OFF position. • Disconnect W03 and install T-adapter. • Turn ignition switch OFF during troubleshooting. Front window A.
2.
Above 1MΩ
1
Below 1Ω
2
Continued
3
From P01 (9) and W04 (3)
Below 1Ω
4
From P01 (10) and W04 (1)
Below 1Ω
5
Above 1MΩ
6
20 - 30V
7
Below 1V
8
When retracted at rear
At W03, between (1) and (2)
Windshield wiper Continuity motor test - Internal and resistance value disconnection
At W04, between (3) and (1)
Wiring harness • With ignition switch in the OFF position. • Disconnect P01 and P02 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
B.
4.
When installed at front
Windshield wiper motor • With ignition switch in the OFF position. • Disconnect W03 and install T-adapter. • Turn ignition switch OFF or keep the engine running during troubleshooting. A.
3.
Window rear limit switch test - Internal Resistance Ω disconnection, short circuit, ground fault
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω From P02 (15) and W03 (2)
Monitor panel (Window rear limit switch system) • Turn the engine ignition switch OFF for preparations. • Disconnect P02 and install T-adapter. • Hold ignition switch in the ON position during the troubleshooting. Front window A.
5.
Monitor panel (Window rear limit switch system) test
When installed at front Voltage
When retracted at rear
At P02, between (15) and ground
Monitor panel (Windshield wiper motor system) • With ignition switch in the OFF position. • Disconnect P01 and install T-adapter. • Keep ignition switch to the ON position for this test. Windshield wiper switch A.
Monitor panel (Windshield wiper motor system) test
20-540 1
OFF Voltage
ON
Below 3V At P01, between (9) and ground Below 3V ↔ 20 At P01, between (10) and 30V (Constant ground cycle)
9 10
PC400LC-7L
TROUBLESHOOTING
E-18
12 Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch
PC400LC-7L
20-541 1
TROUBLESHOOTING 12 WINDSHIELD
E-18
WASHER DOES NOT OPERATE Windshield wiper and window washer do not work.
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse No. 4
2.
Windshield wiper motor • With ignition switch in the OFF position. • Disconnect A50 and install T-adapter. • Turn ignition switch OFF or keep the engine running during troubleshooting. A.
3.
(2) Windshield washer does not operate.
No.
Readings
Windshield wiper At A50, between (1) and (2) motor test - Internal Resistance Ω At A50, between (1) and ground disconnection
5 - 20Ω
1
Above 1MΩ
2
From FB1 (4) to J03 to J06 and A50 (1)
Below 1Ω
3
From FB1 (4) to J04 and P01 (3)
Below 1Ω
4
Above 1MΩ
5
Above 1MΩ
6
Above 1MΩ
7
Above 1MΩ
8
Wiring harness • With ignition switch in the OFF position. • Disconnect A50 and P01 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
Wiring harness test Disconnection or contact with connector
Resistance Ω
From FB1 (4) to J03 to J06 A50 (1) and grounding B.
Wiring harness test Contact with grounding circuit
From FB1 (4) to D02 (4) and to other relative circuits and Resistance Ω grounding From A50 (2) to J04 and P01 (3) and grounding From A50 (2) to D02 (8) and grounding
4.
Specifications
If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 3B.)
Monitor panel • With ignition switch in the OFF position. • Disconnect P01 and install T-adapter. • Keep ignition switch to the ON position for this test. Windshield wiper switch A.
Monitor panel test
20-542 1
Voltage
OFF ON
At P01, between (3) and ground
20 - 30V
9
Below 1V
10
PC400LC-7L
TROUBLESHOOTING
E-18
12 Electrical Circuit Diagram for Window Washer Motor
PC400LC-7L
20-543 1
TROUBLESHOOTING
E-19
12
E-19 ALARM BUZZER CANNOT BE CANCELLED •
The alarm buzzer cannot be cancelled.
Relative information
•
Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3)
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Alarm buzzer stop switch • With ignition switch in the OFF position. • Disconnect P03 and install T-adapter. • Turn ignition switch OFF. Alarm buzzer stop switch A.
2.
Release
Above 1MΩ
1
Depress
Below 1Ω
2
At P02 (16) and P03 (1)
Below 1Ω
3
From P03 (2) to J05 to grounding
Below 1Ω
4
★ Between P02 (16) and P03 (1) and grounding
Below 1V
5
20 - 30V
6
Below 1V
7
Alarm buzzer stop At P03, between (1) and switch test - Internal Resistance Ω (2) disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect P01, P02 and P03 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Voltage
Monitor panel • With ignition switch in the OFF position. • Disconnect P02 and install T-adapter. • Keep ignition switch to the ON position for this test. Alarm buzzer stop switch A.
Monitor panel test
20-544 1
Voltage
Release Depress
At P02, between (16) and ground
PC400LC-7L
TROUBLESHOOTING
E-19
12 Electrical circuit diagram related to alarm buzzer stop switch
PC400LC-7L
20-545 1
TROUBLESHOOTING
E-20
12
E-20 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION • •
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Boom Raise is not correctly displayed in monitor function Boom Raise is not correctly displayed in the monitor function on the monitor panel.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Boom RAISE PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S06 and install T-adapter. • Keep the engine running during troubleshooting. RH work equipment control lever A.
2.
NEUTRAL
Above 1MΩ
1
Boom RAISE
Below 1Ω
2
Between C03 (10) and S06 (2)
Below 1Ω
3
Boom RAISE PPC At S06, between (1) and hydraulic switch test - Resistance Ω (2) Internal disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C03 and S06 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Between S06 (1) and grounding
Below 1Ω
4
Wiring harness test Contact with grounding circuit
Resistance Ω Between C03 (10) and S06 (2) and grounding
Above 1MΩ
5
Below 1V
6
20 - 30V
7
Below 1V
8
Wiring harness test Contact with 24V circuit
Voltage
★ Between C03 (10) and S06 (2) and grounding
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Start the engine during troubleshooting. RH work equipment control lever A.
Pump controller test
20-546 1
Voltage
NEUTRAL Boom RAISE
At C03, between (10) and ground
PC400LC-7L
TROUBLESHOOTING
E-20
12 Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC400LC-7L
20-547 1
TROUBLESHOOTING
E-21
12
E-21 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION • •
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Boom LOWER is not correctly displayed in monitor function Boom LOWER is not correctly displayed in the monitor function on the monitor panel.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Boom LOWER PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S02 and install T-adapter. • Keep the engine running during troubleshooting. RH work equipment control lever A.
2.
NEUTRAL
Above 1MΩ
1
Boom LOWER
Below 1Ω
2
Between C03 (20) and S02 (2)
Below 1Ω
3
Boom LOWER PPC At S02, between (1) and hydraulic switch test - Resistance Ω (2) Internal disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C03 and S02 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Between S02 (1) and grounding
Below 1Ω
4
Wiring harness test Contact with grounding circuit
Resistance Ω Between C03 (20) and S02 (2) and grounding
Above 1MΩ
5
Below 1V
6
20 - 30V
7
Below 1V
8
Wiring harness test Contact with 24V circuit
Voltage
★ Between C03 (20) and S02 (2) and grounding
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Start the engine during the troubleshooting. RH work equipment control lever A.
Pump controller test
20-548 1
Voltage
NEUTRAL Boom LOWER
At C03, between (20) and ground
PC400LC-7L
TROUBLESHOOTING
E-21
12 Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
PC400LC-7L
20-549 1
TROUBLESHOOTING
E-22
12
E-22 “ARM IN” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION Failure information
•
Relative information
---
Arm IN is not displayed normally in monitoring function.
Cause
•
Arm IN is not displayed normally in monitoring function (special function) of monitor panel.
Standard value in normalcy and references for troubleshooting
1.
Arm IN PPC pressure sensor defective
The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for error code [E247].
2.
Pump controller defective
If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot be carried out since the defect is in the pump controller).
20-550 1
PC400LC-7L
TROUBLESHOOTING
E-23
12
E-23 “ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION • •
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Arm DUMPING is not correctly displayed in monitor function Arm DUMPING is not correctly displayed in the monitor function (special function) on the monitor panel.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Arm DUMPING PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S08 and install T-adapter. • Keep the engine running during troubleshooting. LH work equipment control lever A.
2.
NEUTRAL
Above 1MΩ
1
Arm DUMPING
Below 1Ω
2
Between C03 (40) and S08 (2)
Below 1Ω
3
Arm DUMPING PPC At S08, between (1) and hydraulic switch test - Resistance Ω (2) Internal disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C03 and S08 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Between S08 (1) and grounding
Below 1Ω
4
Wiring harness test Contact with grounding circuit
Resistance Ω Between C03 (40) and S08 (2) and grounding
Above 1MΩ
5
Below 1V
6
20 - 30V
7
Below 1V
8
Wiring harness test Contact with 24V circuit
Voltage
★ Between C03 (40) and S08 (2) and grounding
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Start the engine during the troubleshooting. LH work equipment control lever A.
Pump controller test
PC400LC-7L
Voltage
NEUTRAL Arm DUMPING
At C03, between (40) and ground
20-551 1
TROUBLESHOOTING
E-23
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-552 1
PC400LC-7L
TROUBLESHOOTING
E-24
12
E-24 “BUCKET CURL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION Failure information
Bucket CURL is not displayed normally in monitoring Bucket CURL is not displayed normally in monitoring function (special function. function) of monitor panel.
Relative information
---
Cause
Standard value in normalcy and references for troubleshooting
1.
Bucket CURL PPC pressure sensor The bucket CURL PPC pressure sensor may be defective. Carry out troubleshooting for error code [E248]. defective
2.
Pump controller defective
PC400LC-7L
If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot be carried out since the defect is in the pump controller).
20-553 1
TROUBLESHOOTING
E-25
12
E-25 “BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION • •
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Bucket DUMPING is not correctly displayed in monitor function. Bucket DUMPING is not correctly displayed in the monitor function (special function) on the monitor panel.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Bucket DUMPING PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S05 and install T-adapter. • Keep the engine running during troubleshooting. RH work equipment control lever A.
2.
NEUTRAL
Above 1MΩ
1
Bucket DUMPING
Below 1Ω
2
Between C03 (19) and S05 (2)
Below 1Ω
3
Bucket DUMPING At S05, between (1) and PPC hydraulic switch Resistance Ω (2) test - Internal disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C03 and S05 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Between S05 (1) and grounding
Below 1Ω
4
Wiring harness test Contact with grounding circuit
Resistance Ω Between C03 (19) and S05 (2) and grounding
Above 1MΩ
5
Below 1V
6
20 - 30V
7
Below 1V
8
Wiring harness test Contact with 24V circuit
Voltage
★ Between C03 (19) and S05 (2) and grounding
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Start the engine during the troubleshooting. RH work equipment control lever A.
Pump controller test
20-554 1
Voltage
NEUTRAL Bucket DUMPING
At C03, between (19) and ground
PC400LC-7L
TROUBLESHOOTING
E-25
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
PC400LC-7L
20-555 1
TROUBLESHOOTING
E-26
12
E-26 “SWING” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION Swing is not displayed normally in monitoring function.
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Swing is not displayed normally in monitoring function (special function) of monitor panel.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Swing left PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S07 and install T-adapter. • Keep the engine running during troubleshooting. LH work equipment control lever A.
2.
Swing left PPC At S07, between (1) and hydraulic switch test Resistance Ω (2) Internal disconnection
NEUTRAL
Min. 1MΩ
1
Left swing position
Max. 1Ω
2
NEUTRAL
Min. 1MΩ
3
Right swing position
Max. 1Ω
4
Swing right PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S03 and install T-adapter. • Keep the engine running during troubleshooting. RH work equipment control lever A.
3.
Swing right PPC At S03, between (1) and hydraulic switch test Resistance Ω (2) Internal disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C03, S07 and S03 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
4.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
Wiring harness test Contact with 24V circuit
Voltage
Between C03 (29) and S07 (2)
Max. 1Ω
5
Between C03 (29) and S03 (2)
Max. 1Ω
6
Between S07(1) and grounding
Max. 1Ω
7
Between S07(1) and grounding
Max. 1Ω
8
Between C03 (29) and S07 (2) and grounding
Min. 1MΩ
9
Between C03 (29) and S07 (2) and grounding
Min. 1MΩ
10
★ Between C03 (29) and S07 (2) and grounding
Max. 1V
11
★ Between C03 (29) and S03 (2) and grounding
Max. 1V
12
20 - 30V
13
Max. 1V
14
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Keep the engine running during the troubleshooting. LH work equipment control lever NEUTRAL A.
Pump controller test
20-556 1
Voltage
Left or right swing position
At C03, between (29) and ground
PC400LC-7L
TROUBLESHOOTING
E-26
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC400LC-7L
20-557 1
TROUBLESHOOTING
E-27
12
E-27 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION TRAVEL is not correctly displayed in monitor function TRAVEL is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Travel PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S30 and install T-adapter. • Keep the engine running during troubleshooting. Travel control lever A.
2.
NEUTRAL
Above 1MΩ
1
Forward or reverse
Below 1Ω
2
From C03 (39) to J01 to S30 (2)
Below 1Ω
3
From S30 (1) to J05 to grounding
Below 1Ω
4
From C03 (39) to J01 to S30 (2) and grounding
Above 1MΩ
5
From C03 (39) to A43 (2) and grounding
Above 1MΩ
6
★ From C03 (39) to J01 to S30 (2) and grounding
Below 1V
7
★ From C03 (39) and A43 (2) and grounding
Below 1V
8
Travel PPC hydraulic At S30, between (1) and switch test - Internal Resistance Ω (2) disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C03 and S30 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω
Wiring harness test Contact with 24V circuit
Voltage
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Keep the engine running during the troubleshooting. Travel control lever A.
Pump controller test
20-558 1
Voltage
NEUTRAL Forward or backward
At C03, between (39) and ground
20 - 30V
9
Below 1V
10
PC400LC-7L
TROUBLESHOOTING
E-27
12 Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC400LC-7L
20-559 1
TROUBLESHOOTING
E-28
12
E-28 “TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION • •
Travel Differential Pressure is not correctly displayed in monitor function Travel Differential Pressure is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
•
When pressure difference is created between the right and left travel PPC circuits (in steering), the travel differential mechanism is turned ON.
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Travel steering PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S31 and install T-adapter. • Keep the engine running during troubleshooting. Travel control lever A.
2.
NEUTRAL
Above 1MΩ
1
One side of right or left only
Below 1Ω
2
Between C02 (16) and S31 (2)
Below 1Ω
3
From S31 (1) to J05 to grounding
Below 1Ω
4
Above 1MΩ
5
Below 1V
6
20 - 30V
7
Below 1V
8
Travel steering PPC At S31, between (1) and hydraulic switch test Resistance Ω (2) Internal disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C02 and S31 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
3.
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Resistance Ω Between C02 (16) and S31 (2) and grounding
Wiring harness test Contact with 24V circuit
Voltage
★ From C02 (16) and S31 (2) and grounding
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Start the engine during the troubleshooting. Travel control lever NEUTRAL A.
Pump controller test
20-560 1
Voltage
One side of right or left only
At C03, between (39) and ground
PC400LC-7L
TROUBLESHOOTING
E-28
12 Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC400LC-7L
20-561 1
TROUBLESHOOTING
E-29
12
E-29 “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION • •
Relative information
---
Tools and Procedures
Failure information
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps 1.
Service is not correctly displayed in monitor function. Service is not correctly displayed in the monitor function (special function) on the monitor panel.
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Service (front) PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S10 and install T-adapter. • Keep the engine running during troubleshooting. Service pedal A.
2.
Service (front) PPC At S10, between (1) and hydraulic switch test Resistance Ω (2) Internal disconnection
NEUTRAL
Above 1MΩ
1
Operated to front
Below 1Ω
2
NEUTRAL
Above 1MΩ
3
Operated to rear
Below 1Ω
4
Service (rear) PPC hydraulic switch • With ignition switch in the OFF position. • Disconnect S11 and install T-adapter. • Keep the engine running during troubleshooting. Service pedal A.
3.
Service (rear) PPC At S10, between (1) and hydraulic switch test Resistance Ω (2) Internal disconnection
Wiring harness • With ignition switch in the OFF position. • Disconnect C02, S10 and S11 and install T-adapter. • Keep ignition switch to the OFF position for this test.
★ Have ignition switch ON for this test. A.
B.
C.
4.
Wiring harness test Disconnection or contact with connector
Between C02 (35) and S10 (2)
Below 1Ω
5
Resistance Ω Between C02 (35) and S11 (2)
Below 1Ω
6
Below 1Ω
7
Wiring harness test Contact with grounding circuit
Between C02 (35) and S10 (2) and grounding
Above 1MΩ
8
Resistance Ω
Between C02 (35) and S11 (2) and grounding
Above 1MΩ
9
Wiring harness test Contact with 24V circuit
★ Between C02 (35) and S10 (2) and grounding
Below 1V
10
Voltage
★ Between C02 (35) and S11 (2) and grounding
Below 1V
11
Between S10 (1) and grounding
Pump controller • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Start the engine during the troubleshooting. Service pedal A.
Pump controller test
20-562 1
Voltage
NEUTRAL At C02, between (35) and Operated to front or rear ground
20 - 30V Below 1V
PC400LC-7L
TROUBLESHOOTING
E-29
12 Electrical Circuit Diagram for Service PPC hydraulic Switch
PC400LC-7L
20-563 1
TROUBLESHOOTING
E-30
12
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING Failure information
Tools and Procedures
Relative information
• • • •
•
Travel alarm does not sound or does not stop sounding.
1.
The travel alarm does not sound while the machine is traveling.
2.
The alarm begins to sound when the machine is at a standstill.
---
Digital Volt Ohm Meter. T-adapter kit. Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the procedure. It is important to complete all steps and record information for final analyzing.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse No. 15
2.
Travel signal • Start the engine during troubleshooting (monitoring). A.
3.
No.
Readings
Monitoring code 01900
Item
Normal display
Travel
Control lever operated: ON Control lever NEUTRAL: OFF
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
B.
4.
Travel signal test Internal disconnection
Specifications
When fuse No. 15 is blown, there is a big possibility that ground fault occurred in the circuit. (See Step 3B.)
Between FB1 (15) outlet to J03 and A43 (1)
Below 1Ω
1
Between A43 (2) and J01 (19)
Below 1Ω
2
Above 1MΩ
3
Above 1MΩ
4
Wiring harness test Disconnection or contact with connector
Resistance Ω
Wiring harness test Contact with grounding circuit
Between FB1 (15) outlet to J03 and A43 and grounding Resistance Ω Between FB1 (15) outlet and other related circuit and grounding
Travel alarm • With ignition switch in the OFF position. • Disconnect C03 and install T-adapter. • Start the engine during the troubleshooting. A.
Travel alarm test
20-564 1
This is an internal failure, troubleshooting cannot be conducted. (If none of the causes listed in item 1 through 4 above is found, the travel alarm is judged as defective.)
PC400LC-7L
TROUBLESHOOTING
E-30
12 Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
PC400LC-7L
20-565 1
TROUBLESHOOTING
E-32
12
E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM ★ The control panel of the air conditioner constantly monitors the sensors and other devices in the system. When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially. ★ If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to the procedure for “Troubleshooting by self-diagnosis notice”, and then; • If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”. • If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE Self-diagnosis notice
Failure mode
E--
No failures
E11
Disconnection in recirculated air sensor
E12
Short-circuit in recirculated air sensor
E15
Disconnection in water temperature sensor
E16
Short-circuit in water temperature sensor
E18
Short-circuit in daylight sensor
E43
Abnormality in air outlet damper
E44
Abnormality in air mix damper
E45
Abnormality in recirculated and fresh air damper
★ Check the “Self-diagnosis notice” on the control panel according to the following procedure. •
How to display “Self-diagnosis notice”
1.
Turn the starting switch ON.
2.
Press OFF switch (1) and check that anything is not displayed on display monitor (2).
3.
4. •
•
•
Hold the UP switch (∧) and DOWN switch (∨) of temperature setting switch (3) simultaneously for 3 seconds or more. Check the “Self-diagnosis notice” displayed on display monitor (2). How to select “Self-diagnosis notice” If multiple “Self-diagnosis notices” are recorded, press the UP switch (∧) or DOWN switch (∨) of temperature setting switch (3) to select another notice. How to delete “Self-diagnosis notice” When reproducing the “Self-diagnosis notices” or after removing the cause of a failure, press the switches on both sides of recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the “Self-diagnosis notices” are deleted. Finishing display of “Self-diagnosis notice” To finish display of the “Self-diagnosis notice”, press OFF switch (1) or turn the starting switch OFF.
20-566 1
PC400LC-7L
TROUBLESHOOTING 12 E-32-E11
DISCONNECTION IN RECIRCULATED AIR SENSOR
Self-diagnosis notice
Trouble
E11 Contents of trouble
Action of control panel
Related information
Disconnection in the recirculated air sensor system is detected.
• •
Fixes the recirculated air temperature for control. When the following condition is satisfied, the operation returns to normalcy. + + +
--Circuit Diagnostic Procedures For Code [---]
No.
Readings
Recirculation air sensor test - Internal disconnection
Resistance Ω At THi, between (1) and (2)
300Ω − 430kΩ
1
Between M30 (12) and THi (2)
Max. 1Ω
2
Between M29 (11) and THi (1)
Max. 1Ω
3
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
3.
Specifications
Recirculated air sensor • Prepare with the ignition switch OFF • Disconnect THi connection and install T-adapter. • Keep the ignition switch in the OFF position for troubleshooting. A.
2.
Disconnection in recirculated air sensor
•
Steps 1.
E-32
Wiring harness test Disconnection or contact with connector
Air conditioner system
Resistance Ω
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE Self-diagnosis
Trouble
E12 Contents of trouble
Action of control panel
Related information
•
Short circuit in the recirculated air sensor system is detected.
• •
Fixes the recirculated air temperature for control. When the following condition is satisfied, the operation returns to normalcy. + + +
---
Steps 1.
Circuit Diagnostic Procedures For Code [---]
No.
Readings
Recirculation air sensor test - Internal disconnection
Resistance Ω At THi, between (1) and (2)
300Ω − 430kΩ
1
Between M30 (12) and THi (2)
Max. 1Ω
2
Between M29 (11) and THi (1)
Max. 1Ω
3
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
3.
Specifications
Recirculated air sensor • Prepare with the ignition switch OFF • Disconnect THi connection and install T-adapter. • Keep the ignition switch in the OFF position for troubleshooting. A.
2.
Short circuit in recirculated air sensor
Wiring harness test Disconnection or contact with connector
Air conditioner system
PC400LC-7L
Resistance Ω
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
20-567 1
TROUBLESHOOTING 12 E-32-E15
DISCONNECTION IN WATER TEMPERATURE SENSOR
Self-diagnosis notice
Trouble
E15 Contents of trouble
Action of control panel
Related information
Disconnection in water temperature sensor
•
Disconnection in the water temperature sensor system is detected.
• •
Ignores the warm-up control and fixes the engine water temperature at 60°C for control. When the following condition is satisfied, the operation returns to normalcy. + + +
---
Steps 1.
E-32
Circuit Diagnostic Procedures For Code [---]
Specifications
No.
Readings
Water temperature sensor • Prepare with the ignition switch OFF • Disconnect THw connection and install T-adapter. • Keep the ignition switch in the OFF position for troubleshooting. A.
2.
Water temperature sensor test - Internal disconnection
Resistance Ω At THw, between (1) and (2)
95Ω − 455kΩ
1
Between M30 (14) and THw (2)
Max. 1Ω
2
Between M29 (11) and THw (1)
Max. 1Ω
3
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
3.
Wiring harness test Disconnection or contact with connector
Air conditioner system
Resistance Ω
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR Self-diagnosis notice
Trouble
E16 Contents of trouble
Action of control panel
Related information
•
Short circuit in the water temperature sensor system is detected.
• •
Ignores the warm-up control and fixes the engine water temperature at 60×C for control. When the following condition is satisfied, the operation returns to normalcy. + + +
---
Steps 1.
Circuit Diagnostic Procedures For Code [---]
No.
Readings
Water temperature sensor test - Internal disconnection
Resistance Ω At THw, between (1) and (2)
95Ω − 455kΩ
1
Between M30 (14) and THw (2)
Max. 1Ω
2
Between M29 (11) and THw (1)
Max. 1Ω
3
Wiring harness • With ignition switch in the OFF position. • Keep ignition switch to the OFF position for this test. A.
3.
Specifications
Water temperature sensor • Prepare with the ignition switch OFF • Disconnect THw connection and install T-adapter. • Keep the ignition switch in the OFF position for troubleshooting. A.
2.
Short circuit in water temperature sensor
Wiring harness test Disconnection or contact with connector
Air conditioner system
20-568 1
Resistance Ω
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
PC400LC-7L
TROUBLESHOOTING 12 E-32-E18
E-32
SHORT IN DAYLIGHT SENSOR
Self-diagnosis notice
Trouble
E18 Contents of trouble
Action of control panel
Related information
Short circuit in daylight sensor
•
Short circuit in the daylight sensor system is detected.
• •
Assumes that the daylight sensor is not installed for control. When the following condition is satisfied, the operation returns to normalcy. + + +
---
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Daylight sensor
2.
Wiring harness • With ignition switch in the OFF position. • Disconnect M30 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
3.
Specifications
No.
Readings
The daylight sensor may be defective. Check it directly
Wiring harness test Disconnection or contact with connector
Resistance Ω
Between M30 (16) and P15 (2)
Max. 1Ω
1
Between M30 (3) and P15 (1)
Max. 1Ω
2
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
Air conditioner system
E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER Self-diagnosis notice
Trouble
E43 Contents of trouble
Action of control panel
Related information Steps
Trouble Abnormality in air outlet damper
•
Abnormality in air outlet servomotor system is detected.
• •
Stops the air outlet servomotor. When the following condition is satisfied, the operation returns to normalcy. + + +
★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Circuit Diagnostic Procedures For Code [---]
1.
Air outlet servo motor
2.
Wiring harness • With ignition switch in the OFF position. • Disconnect Mv1, M29 and M30 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
3.
Wiring harness test Disconnection or contact with connector
Air conditioner system
PC400LC-7L
Specifications
No.
Readings
The air outlet servo motor may be defective. Check it directly
Between Mv1 (1) and M30 (3)
Max. 1Ω
1
Between Mv1 (3) and M29 (11)
Max. 1Ω
2
Resistance Ω Between Mv1 (5) and M30 (9)
Max. 1Ω
3
Between Mv1 (6) and M29 (8)
Max. 1Ω
4
Between Mv1 (7) and M29 (9)
Max. 1Ω
5
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
20-569 1
TROUBLESHOOTING 12 E-32-E44
E-32
ABNORMALITY IN AIR MIX DAMPER
Self-diagnosis notice
Trouble
E44 Contents of trouble
Action of control panel
Related information
Abnormality in air mix damper
•
Abnormality in air mix servomotor system is detected.
• •
Stops the air mix servomotor. When the following condition is satisfied, the operation returns to normalcy. + + +
★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.
Steps
Circuit Diagnostic Procedures For Code [---]
1.
Air mix servo motor
2.
Wiring harness • With ignition switch in the OFF position. • Disconnect Mam, M29 and M30 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
3.
Specifications
No.
Readings
The air mix servo motor may be defective. Check it directly
Wiring harness test Disconnection or contact with connector
Air conditioner system
Between Mam (1) and M29 (11)
Max. 1Ω
1
Between Mam (3) and M30 (3)
Max. 1Ω
2
Resistance Ω Between Mam (5) and M30 (2)
Max. 1Ω
3
Between Mam (6) and M29 (4)
Max. 1Ω
4
Between Mam (7) and M29 (5)
Max. 1Ω
5
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER Self-diagnosis notice
Trouble
E45 Contents of trouble
Action of control panel
Related information
•
Abnormality in recirculated and fresh air servomotor system is detected.
• •
Stops the recirculated and fresh air servomotor. When the following condition is satisfied, the operation returns to normalcy. + + +
★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output
Steps 1.
Abnormality in recirculated and fresh air damper
shaft and break the motor coils. Circuit Diagnostic Procedures For Code [---]
2.
Fuse (in unit)
3.
Wiring harness • With ignition switch in the OFF position. • Disconnect Mrf, M29 and M33 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
4.
Specifications
No.
Readings
Recirculated and fresh air The recirculated and fresh air servo motor may be defective. Check it directly servo motor
Wiring harness test Disconnection or contact with connector
Air conditioner system
20-570 1
If the fuse (in unit) is broken, the circuit probably has a ground fault, etc. Check the related circuits.
Between Mrf (1) and M29 (6)
Max. 1Ω
1
Resistance Ω Between Mrf (3) and M29 (7)
Max. 1Ω
2
Between Mrf (7) and M33 (3)
Max. 1Ω
3
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPENT, Shop Manual, “Air conditioner”.
PC400LC-7L
TROUBLESHOOTING
E-32
12 Electrical Circuit Diagram for Air Conditioner
PC400LC-7L
20-571 1
TROUBLESHOOTING 12 E-32
E-32
- TROUBLESHOOTING BY FAILURE PHENOMENON
Trouble
•
Related information
---
Steps
The air conditioner does not operate.
Fuse No. 11
2.
Wiring harness • With ignition switch in the OFF position. • Disconnect M27, M29 and M30 and install T-adapter. • Keep ignition switch to the OFF position for this test. A.
B.
Wiring harness test Disconnection or contact with connector
Specifications
No.
Readings
If the fuse is broken, the circuit probably has a ground fault, etc. Refer to cause 3.
Resistance Ω
Between fuse (11) and M33 (3)
Max. 1Ω
1
Between M27 (14) and M30 (6)
Max. 1Ω
2
Between M33 (2) and chassis ground
Max. 1Ω
3
Between M29 (12) and chassis ground
Max. 1Ω
4
Min. 1Ω
5
Min. 1Ω
6
Wiring harness Between fuse (11) and M33 (3) and chassis ground Contact with ground Resistance Ω Between M27 (14) and M30 (6) and chassis ground circuit
Air conditioner unit • With ignition switch in the OFF position. • Disconnect M33 and install T-adapter. • Turn ignition switch to the ON position for this test. A.
4.
The air conditioner does not operate at all.
Circuit Diagnostic Procedures For Code [---]
1.
3.
1.
Voltage At M33, between (2) and (3) 20 - 30V 7 Air conditioner unit test If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective.
Control panel • With ignition switch in the OFF position. • Disconnect M33 and M29 and install T-adapter. • Turn ignition switch to the ON position for this test. A.
Control panel test
Voltage
Between M30 (6) and M29 (12)
20 - 30V
8 9
If the above voltage is normal and the air conditioner does not operate, the control panel is defective.
20-572 1
PC400LC-7L
TROUBLESHOOTING
E-32
12 Trouble
•
The air conditioner does not operate.
2.
Air does not come out (Air flow is insufficient).
Related information Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse (in unit)
2.
Blower relay • Prepare with ignition switch OFF. • Disconnect connector R30 and install T-adapter. • Keep ignition switch OFF. A.
3.
Readings
Blower relay (on coil Resistance Ω At R30, between (1) and (3) side) test
140 - 340Ω
1
Blower relay (on contact side) test
Voltage
At R30, between (4) and ground
20 - 30V
2
Power transistor • Prepare with ignition switch OFF. • Turn ignition switch ON and carry out troubleshooting. A.
5.
No.
Blower relay • Prepare with ignition switch OFF. • Disconnect connector R30 and install T-adapter. • Keep ignition switch OFF. A.
4.
Specifications
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
Power transistor test
Fan switch
Operate in rang of Low, If air flow can be changed with fan switch, power Medium and High transistor is normal.
3
Blower motor • Prepare with ignition switch OFF. • Disconnect connector NB and install T-adapter. • Turn ignition switch ON and carry out troubleshooting. A.
Blower motor test
Fan switch Voltage
ON
At MB, between (1) and (2)
20 - 30V
4
If the above voltage is normal and the blower motor does not rotate, the blower motor is defective. 6.
Wiring harness • Prepare with ignition switch in the OFF position. • Disconnect R30, R31, Mb, Ptr, M27, M29 and M30 and install T-adapters. • Keep ignition switch to the OFF position for this test. Between fuse 11 outlet, fuse in unit, R30 (3), R31 (1) and M30 (6) A.
7.
Wiring harness test Disconnection or contact with connector
Air conditioner unit
PC400LC-7L
Max. 1Ω
5
Between M29 (3) and R30 (1)
Max. 1Ω
6
Between M29 (12) and chassis ground
Max. 1Ω
7
Resistance Ω Between Mb (1) and R30 (4) Between Mb (2) and Ptr (3)
Max. 1Ω
8
Max. 1Ω
9 10
Between Ptr (1) and chassis ground
Max. 1Ω
Between Ptr (2) and M30 (7)
Max. 1Ω
11
Between Ptr (4) and M30 (8)
Max. 1Ω
12
If none of Steps 1 - 6 is the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-573 1
TROUBLESHOOTING
E-32
12 Trouble
•
The air conditioner does not operate.
3.
Air is not cooled (Cooling capacity is low).
Related information Steps
Circuit Diagnostic Procedures For Code [---]
1.
Fuse (in unit)
2.
Compressor relay • Prepare with ignition switch OFF. • Disconnect connector R31 and install T-adapter. • Keep ignition switch OFF. A.
3.
Specifications
No.
Compressor relay (on Resistance Ω At R31, between (1) and (2) coil side) test
140 - 340Ω
1
Compressor relay • Prepare with ignition switch OFF. • Disconnect connector R31 and install T-adapter. • Turn ignition switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position). A.
Compressor relay (on contact side) test
Voltage
At R31, between (4) and ground (Fan switch ON)
4.
Thermostat (Internal defect)
5.
High/Low pressure switch • Prepare with ignition switch OFF. • Disconnect connector P17 and install T-adapter. • Keep ignition switch OFF and carry out troubleshooting. A.
High/Low switch test
pressure
20 - 30V
The thermostat may be defective. Check it directly.
Resistance Ω At P17, between (1) and (2)
2 3
Max. 1Ω
4
6.
Compressor clutch
The compressor clutch may be defective. Check it directly.
5
7.
Compressor
The compressor may be defective. Check it directly.
6
8.
Wiring harness • Prepare with ignition switch in the OFF position. • Disconnect M30, M29, P17, R31, ST1and install T-adapters. • Keep ignition switch to the OFF position for this test.
A.
9.
Readings
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
Wiring harness test Disconnection or contact with connector
Air conditioner unit
20-574 1
Resistance Ω
Between M30 (4) and P17 (1)
Max. 1Ω
7
Between P17 (2) and chassis ground
Max. 1Ω
8
Between fuse 11 outlet, R31 (2), fuse in unit, R31 (1) and M30 (6)
Max. 1Ω
9 10
Between ST1 (1) and R31 (3)
Max. 1Ω
Between M29 (2) and ST1 (2)
Max. 1Ω
11
Between M29 (12) and chassis ground
Max. 1Ω
12
Between R31 (4) and M34 (1)
Max. 1Ω
13
If none of Steps 1 - 8 is the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC400LC-7L
TROUBLESHOOTING
E-32
12 Electrical Circuit Diagram for Air Conditioner
PC400LC-7L
20-575 1
TROUBLESHOOTING
E-32
12
MEMORANDUM
20-576 1
PC400LC-7L
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 12 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-605 H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW . . . . . 20-606 H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607 H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608 H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . 20-608 H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609 AUTO-DECELERATOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609 H-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609 FINE CONTROL MODE DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609 H-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610 BOOM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610 H-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611 ARM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611 H-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612 BUCKET MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612 H-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 20-612 H-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613 WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613 H-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614 WORK EQUIPMENT HAS BIG TIME LAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614 H-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT . . . . . . . . . . . . . . . . . 20-614 H-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614 H-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615 MACHINE PUSH-UP FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615 H-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY . . 20-615 H-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . 20-616 H-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616 H-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617 MACHINE SWERVES IN TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617 H-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618 MACHINE TRAVELS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618 H-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619 H-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED. . . . 20-620 H-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
PC400LC-7L
20-601 1
TESTING AND ADJUSTING
TABLE OF CONTENTS
TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620 H-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621 MACHINE DOES NOT SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621 H-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622 H-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623 EXCESSIVE OVERRUN WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623 H-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624 THERE IS BIG SHOCK WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624 H-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . 20-624 H-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625 SWING NATURAL DRIFT IS TOO BIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625 H-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626 ATTACHMENT CIRCUIT DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626 H-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . 20-626
20-602 1
PC400LC-7L
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 12
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
PC400LC-7L
20-603 1
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 12 ★ This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart (See Section 90 FOLDOUTs for complete hydraulic schematic). Use it as a reference material when troubleshooting the hydraulic and mechanical systems.
20-604 1
PC400LC-7L
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
12
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ★ Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Failure information
Phenomena occurring on machine
Relative information
Information on occurred failures and troubleshooting
Presumed cause and standard value
Cause
Standard value in normalcy and references for troubleshooting
1 2 3
Cause for presumed failure (The attached No. for filing and • The standard values in normalcy by which to judge “good” or “no good” about presumed causes. reference purpose only. It does • References for making judgement of “good” or “no good”. not stand for any priority)
4 5
PC400LC-7L
20-605 1
TROUBLESHOOTING
H-1
12
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW Failure information
All the work equipment lack power, or their travel and swing speeds are slow.
Relative information
Set the working mode at A mode for troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of unload valve
Control lever
Unload pressure
All control levers in NEUTRAL
4.12±1.0 MPa {42±10 kgf/cm2}(597±142 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling. Control lever
Main relief pressure
2
33.34 - 36.77 MPa {340 - 375kgf/cm2} Arm, DIGGING Improper adjustment or (4836 - 5333 psi) malfunctioning of main relief valve If the pressure does not return to normalcy even after the adjustment, malfunctioning of main relief valve or its internal failure is suspected. In that case, check the valve itself.
3
Malfunctioning of self pressure decompression valve
Presumed cause andstandard value in normalcy
★ Stop engine for preparations. Start troubleshooting at engine high idling. Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.84 - 3.43MPa {29 - 35kgf/cm2} (412 - 497 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling. 4
Improper adjustment or malfunctioning of PC valve
Oil pressure to be measured
Measurement condition
Oil pressure ratio
Pump delivery pressure
Swing lock: ON Arm: Digging relief
Approx. 0.6 (Approx. 3/5)
PC valve output pressure
1
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of PC valve or its internal failure is suspected. In that case, check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 5
Malfunctioning of LSEPC valve
Travel speed
Travel control lever
LS-EPC output pressure
Lo
NEUTRAL
Approx. 1.37MPa {Approx. 14 kgf/cm2} (199 psi)
Hi
OPERATED
0 MPa {0 kgf/cm2}
★ Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured 6
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure LS valve output pressure
All control levers in NEUTRAL Nearly equal pressure
Travel without load (control lever held at half stroke) 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of LS valve or its internal failure is suspected. In that case, check the valve itself. 7
Malfunctioning of servo Malfunctioning of servo piston is suspected. Check the piston itself. piston
8
Piston pump defective
20-606 1
If none of the above listed causes is detected, the piston pump is suspected of deteriorated performance, malfunctioning or internal failure.
PC400LC-7L
TROUBLESHOOTING
H-2
12
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS Failure information
The engine speed sharply drops or the engine stalls.
Relative information
Relative Information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Improper adjustment or malfunctioning of main relief valve
Control lever
Main relief pressure
Arm, DIGGING
33.34 - 36.77 MPa {340 - 375 kgf/cm2} (4835 - 5333 psi)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the main relief valve or its internal failure is suspected. In that case, check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 2
Improper adjustment or malfunctioning of PC valve
Oil pressure to be measured
Measurement condition
Oil pressure ratio
Pump delivery pressure
Swing lock: ON Arm: Digging relief
Approx. 0.6 (Approx. 3/5)
PC valve output pressure
1
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the PC valve or its internal failure is suspected. In that case, check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured 3
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure LS valve output pressure
All control levers in NEUTRAL
Travel without load (control lever held at half stroke)
Nearly equal pressure
1 Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 4
Orifice or filter in servo equipment clogged
The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself.
5
Malfunction of servo piston
The servo piston is suspected of malfunction. Check the piston itself.
PC400LC-7L
20-607 1
TROUBLESHOOTING
H-3
12
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE Failure information
No work equipment nor travel and swing functions can be set in motion.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of PPC lock solenoid valve
Safety lock lever
Solenoid output pressure
Locked
0 MPa {0 kgf/cm2} (0 psi)
Released
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling. 2
Malfunctioning of self pressure decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL position
2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)
3
Piston pump defective
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the following manner. • Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal condition.
4
Damper defective
It is presumed that the pump shaft does not rotate due to some internal failure of the damper. Check the damper itself.
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP An abnormal noise is heard from around the hydraulic pump.
Relative information
---
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Hydraulic oil level lowered
Make a visual check.
2
Quality of hydraulic oil bad
Air may have get mixed with the oil. Make a visual check.
3
Hydraulic tank cap breather clogged
It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside the tank. Make a visual check.
4
Hydraulic tank strainer clogged
It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction circuit. Make a visual check.
5
Piston pump defective
The piston pump is suspected of an internal failure. Check the pump itself.
20-608 1
PC400LC-7L
TROUBLESHOOTING
H-5
12
H-5 AUTO-DECELERATOR DOES NOT WORK Failure information
The auto-decelerator does not work.
Relative information
•
This troubleshooting mode is applied when the auto-decelerator does not work, while operating the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch only in the travel circuit -actually located inside PPC valve) Set the working mode at A mode for the troubleshooting.
• Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Travel control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Operation
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
Malfunctioning of travel PPC valve (shuttle valve)
H-6 FINE CONTROL MODE DOES NOT FUNCTION Failure information
The fine control mode poorly functions or its response is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
2
Malfunctioning of LS- EPC valve
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {Approx. 14 kgf/cm2} (Approx. 199 psi)
Hi
OPERATED
0 MPa {0 kgf/cm2} (0 psi)
Orifice in LS circuit clogged The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured 3
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure PC valve output pressure
All control levers in NEUTRAL
Travel without load (control lever held at half stroke)
Nearly equal oil pressure
1 Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 4
Malfunctioning of servo piston
PC400LC-7L
Malfunctioning of the servo piston is suspected. Check the piston itself.
20-609 1
TROUBLESHOOTING
H-7
12
H-7 BOOM MOVES SLOWLY OR LACKS POWER Failure information
The boom moves slowly or lacks power
Relative information
Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of right PPC valve (in boom circuit)
R.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Boom RAISE Boom LOWER
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
2
Malfunction of merge/ divide solenoid valve
Travel lever
Solenoid output pressure
Neutral
0 MPa {0 kgf/cm2} (0 psi)
Operated (Note)
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
3
Malfunctioning of merge/ divide valve (main and LS valves)
The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself.
4
Malfunctioning of boom control valve (spool)
The spool in the boom control valve (Lo - Hi) is presumed to malfunction. Check the valve itself.
5
Malfunctioning of boom control valve (pressure compensation valve)
The pressure compensation valve in the boom control valve (Lo ïHi) is presumed to malfunction. Check the valve itself.
6
Malfunctioning of boom control valve (regeneration valve)
The regeneration valve in the boom control valve (Lo) or the seal is presumed to malfunction. Check the valve itself.
7
Malfunctioning of boom control valve (lock valve)
The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the valve itself.
8
Malfunction of boom control valve (check valve)
The check valve in the boom control valve (Hi) is presumed to malfunction. Check the valve itself.
9
Malfunctioning of safety valve for lock valve or seal defective
The safety valve for the lock valve is presumed to malfunction, or the seal is suspected to be defective. Check the valve itself.
10
Malfunctioning of boom The suction valve (bottom side) in the boom control valve (Lo) is presumed to malfunction, or the seal is control valve (suction valve) or suspected to be defective. seal defective
11
Malfunctioning of boom The safety and suction valves (head side) in the boom control valve (Lo) are presumed to malfunction, or the control valve (safety and seal is suspected to be defective. Check those valves themselves. suction valves) or seal defective
12
Malfunctioning of LS shuttle valve (left travel, bucket and service valves)
LS shuttle valves in the left travel control valve, bucket control valve and service control valve are presumed to malfunction. Check those valves themselves.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 13
Boom cylinder defective
Boom cylinder
Amount oil leakage from cylinder
Raise relief
20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
20-610 1
PC400LC-7L
TROUBLESHOOTING
H-8
12
H-8 ARM MOVES SLOWLY OR LACKS POWER Failure information
The arm moves slowly, or lacks power.
Relative information
Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of left PPC valve (arm circuit)
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Arm DIGGING Arm DUMPING
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
Presumed cause and standard value in normalcy
★ Stop engine for preparations. Start troubleshooting at engine high idling. 2
Malfunctioning of merge/ divide solenoid valve
Travel lever
Solenoid output pressure
Neutral
0 MPa {0 kgf/cm2} (0 psi)
Operated (Note)
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
3
Malfunctioning of merge/ divide valve (main and LS valves)
4
Malfunctioning of arm control The spool in the arm control valve (Lo•Hi) is presumed to malfunction. Check the valve itself. valve (spool)
5
Malfunctioning of arm control valve (pressure compensation The pressure compensation valve in the arm control valve (Lo•Hi) is presumed to malfunction. Check the valve itself. valve)
6
Malfunctioning of arm control The generation valve in the arm control valve (Lo) is presumed to malfunction, or the seal is suspected to be valve (regeneration valve) defective. Check the valve itself.
7
Malfunctioning of arm control The safety and suction valves in the arm control valve (Lo•Hi) are presumed to malfunction, or the seal is valve (safety and suction suspected of defect. Check those valves themselves. valves) or seal defective
8
Malfunction of arm control valve (quick return valve)
The quick return valve in the arm control valve (Hi) is presumed to malfunction. Check the valve itself.
9
Malfunctioning of LS shuttle valve (right travel, boom, left travel, bucket and service valves)
LS shuttle valves in the right travel control valve, boom control valve, left travel control valve, bucket control valve and service valve are presumed to malfunction. Check those valves themselves.
10
Arm cylinder defective
The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. Arm cylinder
Amount oil leakage from cylinder
Digging relief
20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
PC400LC-7L
20-611 1
TROUBLESHOOTING
H-9
12
H-9 BUCKET MOVES SLOWLY OR LACKS POWER Failure information
The bucket moves slowly, or lacks power.
Relative information
Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
★ Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of right PPC valve (bucket circuit)
1
R.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Bucket DIGGING Bucket DUMPING
Above 2.75MPa {Above 28 kgf/cm2} (Above 398 psi)
2
Malfunctioning of bucket control valve (spool)
3
Malfunctioning of bucket control The pressure compensation valve in the bucket control valve is presumed to malfunction. Check the valve valve (pressure compensation valve) itself.
4
Malfunctioning of bucket control valve (safety and suction valves) or seal defective
The safety and suction valves in the bucket control valve are presumed to malfunction, or the seal is suspected to be defective. Check those valves themselves.
5
Malfunction of LS shuttle valve (service valve)
The LS shuttle valve in the service control valve is presumed to malfunction. Check the valve itself.
The spool in the bucket control valve is presumed to malfunction. Check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 6
Bucket cylinder defective
Bucket cylinder
Amount oil leakage from cylinder
Digging relief
20 cc/min
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION Work equipment does not move in its single operation (1) The boom does not move when operated independently. (2) The arm does not move when operated independently. (3) The bucket does not move when operated independently.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
2
Malfunctioning of PPC valve
Malfunctioning of work equipment control valve (spool)
20-612 1
Work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Operated
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
PC400LC-7L
TROUBLESHOOTING
H-11
12
H-11 WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST Failure information
Work equipment has a bit too fast hydraulic drift (1) Hydraulic drift of the boom is a bit too fast.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Boom cylinder defective
2
Boom control lever (lock valve) seal defective
The seal at lock valve in the boom control lever is suspected to be defective. Check the valve itself.
3
Seal at safety valve for lock valve defective
The seal at the safety valve in the lock valve (Lo) is suspected to be defective. Check the valve itself.
Boom cylinder
Amount oil leakage from cylinder
Raise relief
20 cc/min
Work equipment has a bit too fast hydraulic drift (2) Hydraulic drift of the arm is a bit too fast.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Arm cylinder defective
Arm cylinder
Amount oil leakage from cylinder
Digging relief
20 cc/min
2
Arm control valve (safety and suction valves) seal defective
The seal for safety and suction valves (bottom side) in the arm control valve (Lo•Hi) is suspected to be defective. Check the valve itself. (Whether the seal is defective or not may well be determined by changing for other safety and suction valves.)
3
Arm control valve (spool) seal defective
The seal for spool in the arm control valve (Lo•Hi) is suspected to be defective. Check the seal itself.
4
Arm control valve (pressure compensation valve) seal defective
The seal for pressure compensation valve (bottom side) in the arm control valve (Lo•Hi) is suspected to be defective. Check the seal itself.
Work equipment has a bit too fast hydraulic drift (3) Hydraulic drift of the bucket is a bit too fast.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Bucket cylinder defective
Bucket cylinder
Amount oil leakage from cylinder
Digging relief
20 cc/min
Bucket control valve (safety and suction valves) seal defective
The seal for the safety and suction valves (bottom side) in the bucket control lever is suspected to be defective. Check the seal itself. (Whether the seal is defective or not may well be determined by changing for other safety and suction valves.)
3
Bucket control valve (spool) seal defective
The seal for spool in the bucket control valve is suspected to be defective. Check the seal itself.
4
Bucket control valve (pressure compensation valve) seal defective
The seal for pressure compensation valve (bottom side) in the bucket control valve is suspected to be defective. Check the seal itself.
2
PC400LC-7L
20-613 1
TROUBLESHOOTING
H-12
12
H-12 WORK EQUIPMENT HAS BIG TIME LAG The work equipment has a big time lag.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of LS-EPC valve
1
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {14 kgf/cm2}(199 psi)
Hi
Operation
0 MPa {0 kgf/cm2} (0 psi)
2
Malfunctioning of control valve The regeneration valve in the control valve is presumed to malfunction. Check the valve itself. (regeneration valve) - with boom and arm only
3
Malfunctioning of control valves (safety & suction valve)
4
Malfunctioning of control valve (pressure compensation valve) The pressure compensation valve of the control valve is presumed to malfunction. Check the valve itself directly.
The safety and suction valves (boom : head side, arm and bucket : bottom side) of the control valve are presumed to malfunction. Check those valves themselves directly. (Whether they are defective or not may well be determined by changing them for other safety and suction valves.)
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
Control valve (pressure The seal for pressure compression valve in the control valve is suspected to be defective. Check the seal 1 compensation valve) seal defective itself.
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK One-touch power max. function does not work.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
2
Malfunctioning of 2-stage solenoid valve
Malfunctioning of main relief valve
20-614 1
Swing lock switch
Solenoid valve output pressure
OFF
0 MPa {0 kgf/cm2} (0 psi)
ON
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
The main relief valve of control valve is presumed to malfunction. Check the valve itself.
PC400LC-7L
TROUBLESHOOTING
H-15
12
H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK Failure information
The machine push-up function does not work
Relative information
When carrying out troubleshooting, set the working mode in A-mode.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Prepare with starting switch OFF, then run engine at high idling and carry out troubleshooting. 1
2
Malfunction of machine push-up solenoid valve
Malfunction of boom 2 control valve (safety-suction valve)
Machine push-up switch
Solenoid outlet pressure
OFF
Min. 2.75 MPa {Min. 28 kgf/cm2} (Min. 398 psi)
ON
0 MPa {0 kgf/cm2}
The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting side on the head side) may be malfunctioning. Check it directly.
H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY In a compound operation, work equipment with larger load tends to move slowly.
Relative information
---
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting The pressure compensation valve for the work equipment with larger load is presumed to malfunction. Check the valve itself.
1
Malfunctioning of pressure compensation valve for work equipment with larger load
PC400LC-7L
Combination of compound operation
Work equipment with larger load
Work equipment with smaller load
Boom RAISE + arm DIGGING
Boom
Arm
Boom RAISE + arm DUMPING
Arm
Boom
Boom RAISE + bucket DIGGING
Boom
Bucket
Arm DUMPING + bucket DIGGING
Arm
Bucket
Boom LOWER + arm DUMPING
Arm
Boom
20-615 1
TROUBLESHOOTING
H-17
12
H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information
If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
Presumed cause and standard value in normalcy
Failure information
Cause
1
Standard value in normalcy and references for troubleshooting
Malfunctioning of LS select valve The LS select valve of control valve is presumed to malfunction, or the seal is suspected to be defective. or seal defective Check the valve and seal themselves.
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY In a compound operation of swing + travel, the travel speed drops sharply.
Relative information
If the travel speed is slow in the single operation of travel, carry out the H-20 check first.
Presumed cause and standard value in normalcy
Failure information
Cause
1
20-616 1
Malfunctioning of LS shuttle valve (left travel and swing)
Standard value in normalcy and references for troubleshooting
The LS shuttle valve in the left travel control valve or the swing control valve is presumed to malfunction. Check both of them directly.
PC400LC-7L
TROUBLESHOOTING
H-19
12
H-19 MACHINE SWERVES IN TRAVEL Failure information
The machine tends to swerve while traveling.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of travel PPC valve
Travel control lever
PPC valve output pressure
Operated to Forward Operated to Reverse
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
Differential output between right and left sides
0.4 MPa {4 kgf/cm2} (56 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
2
Malfunctioning of self-pressure decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling. Oil Pressure ratio 3
Improper adjustment or malfunctioning of LS valve
Oil pressure to be measured
All control levers in NEUTRAL
Travel without load (control lever held at half stroke)
Pump delivery pressure LS valve output pressure
1 Nearly equal pressure
Approx. 0.6 (Approx. 3/5)
★ Stop engine for preparations. Start troubleshooting at engine high idling. 4
Malfunctioning of travel interlocking solenoid valve
Travel control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Operating one side only
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
5
Malfunctioning of travel interlocking valve
6
Malfunctioning of travel control The spool in the travel interlocking valve is presumed to malfunction. Check the spool itself. valve (spool)
The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 7
8
Malfunction of travel motor
Final drive defective
PC400LC-7L
Travel control lever
Amount of oil leakage from travel motor
Travel relief
40 l/min (10.56 gal/min)
The final drive is suspected of an internal failure. Check the inside of the final drive directly. (An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or metal chip or dust contained in the drained oil.)
20-617 1
TROUBLESHOOTING
H-20
12
H-20 MACHINE TRAVELS SLOWLY Failure information
The machine's travel speed is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1 Malfunctioning of travel PPC valve
Malfunctioning of 2 self-pressure decompression valve
Travel control lever
PPC valve output pressure
Operated to Forward Operated to Reverse
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
Output differential between right and left or front and rear
Below 0.4 MPa {Below 4 kgf/cm2} (56 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling. Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling. 3 Malfunctioning of LS-EPC valve
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {Approx. 14 kgf/cm2} (0.0199 psi)
Hi
Operated
0 MPa {0 kgf/cm2} (0 psi)
4 Malfunction of travel control valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool itself.
Malfunctioning of travel 5 control valve (pressure compensation valve)
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
6
Malfunctioning of travel control valve (suction valve)
Malfunctioning of LS shuttle 7 valve (bucket)
The suction valve in the travel control valve is presumed to malfunction. Check the valve itself. The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 7 Malfunction of travel motor
8 Final drive defective
20-618 1
Travel control lever
Amount of oil leakage from travel motor
Travel relief
40 l/min (10.56 gal/min)
The final drive is suspected of an internal failure. Check the inside of the final drive directly. (An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or metal chip or dust contained in the drained oil.)
PC400LC-7L
TROUBLESHOOTING
H-21
12
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER Failure information
The machine cannot be easily steered.
Relative information
Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of travel PPC valve (steering spool)
Travel control lever
PPC valve output pressure (steering)
NEUTRAL on both sides
0 MPa {0 kgf/cm2} (0 psi)
Operating one side only
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
2
3
Malfunctioning of travel interlocking solenoid valve
Travel control lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Operating one side only
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
Malfunctioning of travel interlocking The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself. valve
★ Stop engine for preparations. Start troubleshooting at engine high idling. 4
Malfunctioning of merge/ divide solenoid valve
Travel control lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
OPERATED
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
5
Malfunctioning of merge/ divide valve
The merge/divide valve of control valve is presumed to malfunction. Check the valve itself.
6
Malfunction of travel control valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool itself.
7
Malfunctioning of travel control valve (pressure compensation valve)
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
8
Malfunctioning of travel control valve (suction valve)
The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
9
Malfunctioning of LS shuttle valve (bucket)
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
10
Check valve seal defective at LS oil pressure pick-up port
The seal in the check valve of LS oil pressure pick-up port is suspected to be defective. Check the seal itself.
11
Malfunctioning of travel motor (safety valve)
The seal in the check valve of the travel motor is suspected to be defective. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the motors between forward and reverse, or right and left.)
12
Malfunctioning of travel motor (check valve)
The seal in the check valve of the travel motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the motors between forward and reverse, or right and left.)
PC400LC-7L
20-619 1
TROUBLESHOOTING
H-22
12
H-22 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED. Failure information
Travel speed does not shift, or it is slower or faster than preset speed.
Relative information
Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. Travel speed
Travel control lever
Monitoring [01500]
Lo
690mA Fine control (to the extent that the decelerator is released)
Mi
Presumed cause and standard value in normalcy
1
Malfunctioning of LS-EPC valve
740mA
Hi
0 mA
★ Stop engine for preparations. Start troubleshooting at engine high idling. Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {14 kgf/cm2}(0.0199 psi)
Hi
Operation
0 MPa {0 kgf/cm2} (0 psi)
★ Stop engine for preparations. Start troubleshooting at engine high idling. 2
3
Malfunctioning of travel speed solenoid valve
Malfunctioning of travel motor (speed shifting)
Travel speed
Travel control lever
Solenoid output pressure
Lo
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Hi
Operation
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
The travel motor is presumed to malfunction when shifting speed. Check the speed shifting portion directly.
H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) A track shoe does not turn (only on one side).
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Travel control valve (suction valve) seat defective
The suction valve seat in the travel control valve is suspected of defect. Check the seat itself.
2
Travel motor (safety valve) seat defective
The safety valve seat in the travel motor is suspected of defect. Check the seat itself.
3
Travel motor (check valve) seat defective
The check valve seat in the travel motor is suspected of defect. Check the seat itself.
4
Travel Motor speed
★ Stop engine for preparations. Start troubleshooting at engine high idling.
5
Final drive defective
20-620 1
Travel control lever
Amount of oil leakage from travel motor
Travel relief
40 l/min (10.56 gal/min)
The final drive is suspected of an internal failure. Check the inside of the final drive directly. (A failure inside the final drive may well be determined by an abnormal noise from within, abnormal heat generated or metal dust or chips contained in the drained oil.)
PC400LC-7L
TROUBLESHOOTING
H-24
12
H-24 MACHINE DOES NOT SWING Failure information
Machine does not swing (1) The machine swings neither to the right nor to the left.
Relative information
Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
2
Malfunctioning of swing holding brake solenoid valve
R.H. work equipment control lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Swing operated
2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction. (holding brake) Check it directly.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 3
Improper adjustment or malfunctioning of swing motor (safety valve)
Swing lock switch
L.H. work equipment control lever
Swing relief pressure
ON
Swing relief
27.95 - 32.85 MPa {285 - 335 kgf/cm2} (4,053 - 4,764 psi)
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 4
5
Swing motor defective
Swing machinery defective
L.H. work equipment control lever
Amount of oil leakage from swing motor
Swing relief
Below 11 l/min (2.9 gal/min)
The swing machinery is suspected of an internal failure. Check the inside of the swing machinery directly. (A failure inside the swing machinery may well be determined by an abnormal noise from within, abnormal heat generated or metal dust or chips contained in the drained oil.)
Machine does not swing (2) The machine does not swing in one direction.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of swing PPC valve
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Swing operated
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
2
Malfunctioning of swing control valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the spool itself.
3
Swing motor (suction valve) seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching if there is any change.)
4
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. Swing motor (check valve) seal (Whether the seal is defective or not may well be determined by swapping the right and left check valves and defective watching the result.)
PC400LC-7L
20-621 1
TROUBLESHOOTING
H-25
12
H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW Failure information
Swing acceleration is poor, or swing speed is slow (1) Swing acceleration is poor, or swing speed is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1
Malfunctioning of LS shuttle valve The LS shuttle valves for all the control valves are presumed to malfunction. Check them directly. (all LS shuttles)
2
Malfunctioning of swing
The swing holding brake portion of the swing motor is presumed to malfunction.
★ Stop engine for preparations. Start troubleshooting at engine high idling.
3
Improper adjustment or malfunctioning of swing motor (safety valve)
Swing lock switch
L.H. work equipment control lever
Swing relief pressure
ON
Swing relief
27.95 - 32.85 MPa {285 - 335 kgf/cm2} (4,053 - 4,764 psi)
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 4
5
Swing motor defective
Swing machinery defective
L.H. work equipment control lever
Amount of oil leakage from swing motor
Swing relief
Below11 l/min (2.9 gal/min)
Inside of the swing machinery is presumed to malfunction. Check itself. (Whether it is defective or not may well be determined by abnormal noise, abnormal generation of heat and the mixture of the metal particles in drain oil.)
Failure information
Swing acceleration is poor, or swing speed is slow. (2) Swing acceleration is poor only on one side, or swing speed is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of swing PPC valve
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Swing operated
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
2
Malfunctioning of swing control valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the valve itself.
3
Malfunctioning of swing control valve (pressure compensation valve)
The pressure compensation valve in the swing motor is presumed to malfunction. Check the valve itself.
4
Swing motor (suction valve) seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching the result.)
5
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. Swing motor (check valve) seal (Whether the seal is defective or not may well be determined by swapping the right and left check valves and defective watching the result.)
20-622 1
PC400LC-7L
TROUBLESHOOTING
H-26
12
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING Excessive overrun when stopping swing. (1) The work equipment overruns excessively when stopping swing.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling.
1
Improper adjustment or malfunctioning of swing motor (safety valve)
Swing lock switch
L.H. work equipment control lever
Swing relief pressure
ON
Swing relief
27.95 - 32.85 MPa {285 - 335 kgf/cm2} (4,053 - 4,764 psi)
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself.
★ Stop engine for preparations. Start troubleshooting at engine high idling. 2
Swing motor defective
L.H. work equipment control lever
Amount of oil leakage from swing motor
Swing relief
Below11 l/min (2.9 gal/min)
Failure information
Excessive overrun when stopping swing (2) Swing acceleration is poor only on one side, or swing speed is slow.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of swing PPC valve
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Swing operated
Above2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
2
Swing PPC slow return valve clogged
The PPC slow return valve is suspected of clogging. Check the valve itself. (Whether the valve is clogged or not may well be determined by swapping the right and left valves and watching the result.)
3
Malfunctioning of swing control valve (spool)
The spool in the swing control valve is resumed to malfunction. Check the valve itself.
4
Swing motor (suction valve) seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching the result.)
5
Swing motor (check valve) seal defective
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left check valves and watching the result.)
PC400LC-7L
20-623 1
TROUBLESHOOTING
H-27
12
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING There is a big shock caused when stopping a swing motion.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of swing PPC valve
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2}(0 psi)
Swing operated
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
The swing PPC slow return valve is presumed to malfunction. Check the valve itself. (Whether the valve malfunctions or not may well be determined by swapping the right and left valves and watching the result.)
2
Malfunctioning of swing PPC slow return valve
3
Malfunctioning of swing motor The swing motor shockless valve is presumed to malfunction. Check the valve itself. (shockless valve)
H-28 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING There is a big abnormal noise caused when stopping a swing motion.
Relative information
Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Malfunctioning of backpressure valve
The backpressure valve is presumed to malfunction. Check the valve itself.
2
Malfunction of swing motor (safety valve)
The safety valve in the swing motor is presumed to malfunction. Check the valve itself.
3
Malfunction of swing motor (suction valve)
The seal in suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left valves and watching the result.)
4
Swing machinery defective
The swing machinery is suspected of an internal failure. Check the inside of the machinery itself. (A failure inside the swing machinery may well be determined by monitoring abnormal noise, abnormal heat generated or metal dust or chips contained in the drained oil.)
20-624 1
PC400LC-7L
TROUBLESHOOTING
H-29
12
H-29 SWING NATURAL DRIFT IS TOO BIG Swing natural drift is too big. (1) When the swing holding brake is activated.
Failure information
•
When the swing lock switch is ON position, or the swing holding brake release switch is in the normal position, the swing brake is activated and the swing is fixed with a disc brake. Set the working mode in A mode for troubleshooting.
Relative information • Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Stop engine for preparations. Start troubleshooting at engine high idling. 1
2
Swing and holding brake solenoid valve malfunctioned
Swing motor (parking brake portion) malfunctioned
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Swing operated
2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)
The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that portion directly.
Swing natural drift is too big. (2) When the swing holding brake is released.
Failure information
• Relative information • Presumed cause and standard value in normalcy
R.H. work equipment control lever
Cause
When the swing holding brake release switch is in the emergency condition, the swing brake is released and the swing is retained only hydraulically. Set the working mode in A mode for troubleshooting. Standard value in normalcy and references for troubleshooting
1
Swing control valve (spool) malfunctioned
The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly.
2
Swing control valve (pressure compensation valve) malfunctioned
The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself directly.
3
Swing motor (safety valve) defective
The safety valve seal in the swing motor is suspected of defect. Check the valve itself directly.
4
Swing motor (suction valve) defective
The suction valve seal in the swing motor is suspected of defect. Check the valve itself directly.
5
Swing motor (check valve) defective
The check valve seal in the swing motor is suspected of defect. Check the valve itself directly.
6
Swing motor (shockless valve) The shockless valve in the swing motor is suspected of malfunction or the seal is suspected of defect. Check the malfunctioned or seal defective valve or seal itself directly.
PC400LC-7L
20-625 1
TROUBLESHOOTING
H-30
12
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE When attachment is installed Failure information
The return circuit of the attachment circuit does not change. •
Relative information
If an attachment is installed, the service circuit changes according to the selected working mode as shown below. 1) In mode A or E: The double acting circuit is selected and the safety valve is set to the low pressure. 2) In mode B: The single acting circuit is selected and the safety valve is set to the high pressure.
★ Setting of the safety valve on only port B side is changed. Port A is always set to the low pressure.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
★ Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 1
Malfunction of attachment return selector solenoid valve
Working mode
Solenoid valve output pressure
Mode E or A
0 MPa {0 kgf/cm2} (0 psi)
Mode B
2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
2
Malfunction of 2 attachment return selector valve
3
Malfunction of service 3 control valve The safety valve of the service control valve (on port B side) may have a (safety valve) malfunction. Check it directly.
The attachment return selector valve may have a malfunction. Check it directly.
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED When attachment is installed Failure information
Flow rate in attachment circuit cannot be adjusted.
Relative information
• •
If an attachment is installed, the flow rate in the service circuit changes according to the selected working mode. How to adjust the flow rate in modes A and E is different from that in mode B. For details, see OPERATION MANUAL.
Presumed cause and standard value in normalcy
Cause 1
Malfunction of attachment flow rate adjustment EPC valve
Standard value in normalcy and references for troubleshooting The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly.
★ Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 2
20-626 1
Malfunction of service PPC valve
Wiring harness connector Disconnect connector V30 of attachment flow rate adjustment EPC valve.
Service pedal
PPC valve output pressure
In NEUTRAL
0 MPa {0 kgf/cm2} (0 psi)
Operated
Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
PC400LC-7L
30
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 REMOVAL AND INSTALLATION OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10 SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 STRIPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21 STRIPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 ENGINE REAR SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28 HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30 ENGINE AND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 SWING MOTOR AND SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
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INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44 SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 TRAVEL MOTOR AND FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51 FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57 CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62 TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64 IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66 RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70 TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71 EXPANSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72 AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75 OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78 MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80 ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 REVOLVING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
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DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL . . . . . . . . . . . . . . 30-96 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98 CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103 WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104 TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115 OPERATOR’S CAB GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118 FRONT WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
PC400LC-7L
30-3 2
DISASSEMBLY AND ASSEMBLY 12
MEMORANDUM
30-4 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES SPECIAL TOOLS ● ●
Special tools that are deemed necessary for removal or installation of parts are listed. List of the special tools contains the following kind of information.
1.
Necessity: ■: Special tools which cannot be substituted, should always be used. ●:Special tools which are very useful if available, can be substituted with commercially available tools.
2.
Distinction of new and existing special tools: N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification.
3.
Circle mark (❍) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. ★ Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS ● ●
The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. Various symbols used in the REMOVAL Section are explained and listed below. WARNING! This mark indicates safety-related precautions which must be followed when doing the work.
★ This mark gives guidance or precautions when doing the procedure. [*1] This mark shows that there are instructions or precautions for installing parts. This mark shows oil or water to be drained.
INSTALLATION OF PARTS ● ● ●
Except where otherwise instructed, install parts is the reverse order of removal. Instructions and precautions for installing parts are shown with [*1] mark in the INSTALLATION Section, identifying which step the instructions are intended for. Marks shown in the INSTALLATION Section stand for the following. WARNING! This mark indicates safety-related precautions which must be followed when doing the work.
PC400LC-7L
30-5 2
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
★ This mark gives guidance or precautions when doing the procedure. This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil or water to be added.
SKETCHES OF SPECIAL TOOLS ●
Various special tools are illustrated for the convenience of local manufacture.
30-6 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS DURING OPERATION
12
PRECAUTIONS DURING OPERATION ★ Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or assembly) of units.
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK
●
If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, over them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws alternately. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. ★ Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1.
Hoses and tubes using sleeve nuts
● ● ● ● ● ● ● ● ● ●
2.
Nominal number
Plug (nut end)
02
07376-50210
07221-20210 (Nut), 07222-00210 (Plug)
03
07376-50315
07221-20315 (Nut), 07222-00312 (Plug)
04
07376-50422
07221-20422 (Nut), 07222-00414 (Plug)
05
07376-50522
07221-20522 (Nut), 07222-00515 (Plug)
06
07376-50628
07221-20628 (Nut), 07222-00616 (Plug)
10
07376-51034
07221-21034 (Nut), 07222-01018 (Plug)
12
07376-51234
07221-21234 (Nut), 07222-01219 (Plug)
Sleeve nut (elbow end) Use the two items below as a set
Split flange type hoses and tubes Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
PC400LC-7L
30-7 2
DISASSEMBLY AND ASSEMBLY 3.
PRECAUTIONS DURING OPERATION
If the part is not under hydraulic pressure, the following corks can be used:
Dimensions
Nominal number
Part Number
06
D
d
L
07049-00608
6
5
8
08
07049-00811
8
6.5
11
10
07049-01012
10
8.5
12
12
07049-01215
12
10
15
14
07049-01418
14
11.5
18
16
07049-01620
16
13.5
20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK ● ● ● ● ● ● ● ● ● ● ● ● ●
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press-fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
30-8 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12 PRECAUTIONS ● ● ●
●
PRECAUTIONS DURING OPERATION
WHEN COMPLETING THE OPERATIONS
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed air from the system after reassembling the parts. ★ For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
OTHER PRECAUTIONS To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are clean. ● To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when disassembling or assembling. ● Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be disassembled. ● Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling. ● Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that have failed. ● When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely. ● Do not use seal tape for the thread of the plug mounts or connections. ● If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits. ● When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air from piston pump. Remark After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed the air as follows after completion of installation. ●
A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.) ★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air inside the cylinder will cause damage to the piston packing. B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter. C. Raise the engine speed and repeat Step B to bleed the air. Repeat this procedure until no more air comes out from the plugs. D. After completing bleeding the air, tighten the plugs. Plug: 11.3 ± 1.5 Nm (8.33 ± 1.10 lbf ft) E. After repair or long storage, follow the same procedure.
PC400LC-7L
30-9 2
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST 12
Q'ty
Puller
■
1
Removal, installation of nozzle holder assembly
2
790-331-1110
Wrench
●
1
Tightening of cylinder head bolt
3
795-931-1100
Seal puller
■
1
Removal of engine seal
795-931-1210
Push tool
■
1
Part No.
1
4 ●
01050-31625
●
Bolt
■
3
●
01050-31645
●
Bolt
■
3
Push tool
■
1
●
5
795-931-1220
●
01050-31645 795T-521-1140
Engine assembly
A 6
7
30-10 2
B C
■
3
■
1
790-101-5221
●
Grip
■
1
●
01010-81225
●
Bolt
■
1
●
01050-31640
●
Bolt
■
3
Remover
■
1
●
795-471-1810
●
Plate
■
1
●
795-471-1820
●
Bolt
■
1
●
795-471-1830
●
Bracket
■
1
●
01435-01035
●
Bolt
■
3
●
Bolt
■
1
■
1
● 8
Bolt
Push tool
●
795-471-1800
Engine and hydraulic pump assembly
Part Name
01435-01025 795T-471-1550
Wrench
796-601-1110
Stopper
■
1
796-460-1210
Oil stopper
●
1
Adapter
●
796-770-1320
1
Sketch
Necessity
795-799-1170
Symbol
Component
New/remodel
Remark Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured). Remark Necessity: ■:............... Cannot be substituted, should always be installed (used) ●:................Extremely useful if available, can be substituted with commercially available part Remark New/remodel: N:..........Tools with new part numbers, newly developed for this model R:..........Tools with upgraded part numbers, remodeled from items already available for other models Blank:.... Tools already available for other models, used without any modification Remark Tools marked O in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF SPECIAL TOOLS).
Nature of work, remarks
Press fitting of engine rear seal
O Press fitting of engine front seal
N
Removal of fuel supply pump
O N
Removal, installation of nozzle tip Removal, installation of engine mount bolt Stopping of oil
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
Q'ty
Push tool
●
1
Removal of shaft
2 790-201-2350
Push tool
■
1
Removal of bearing
3 790-201-2510
Press fitting of bearing
Swing motor and swing machinery assembly
D
Part No.
4
Push tool
■
1
790-101-5401
Push tool kit
■
1
●
790-101-5531
●
Plate
1
●
790-101-5421
●
Grip
1
●
01010-51240
●
Bolt
Push tool
■
6 790-201-2770
Push tool
■
1
7 796T-626-1110
Push tool
■
1
796-627-1210
Wrench assembly
■
1
●
796-627-1220
●
Wrench
1
●
796-427-1140
●
Pin
3
●
01314-20612
●
Screw
Carrier roller assembly
■
1
790-101-2510
Block
●
1
791-122-1130
Plate
●
1
790-101-2550
Leg
●
2
Adapter
●
2
790-101-2570
Plate
●
4
790-101-2560
Nut
●
2
790-101-2102
Puller (294 kN {30 t})
■
1
790-101-1102
Pump
■
1
3 796-627-1020
Installer
■
1
791-430-3230
Installer
■
1
791-601-1000
Oil pump
■
1
791-630-1780
Installer
■
1
791-601-1000
Oil pump
■
1
791-575-1520
Installer
■
1
791-601-1000
Oil pump
■
1
791-685-8006
Compressor
■
1
791-635-3160
Extension
■
1
790-101-1600
Cylinder (686 kN {70 t})
■
790-101-1102
Pump
■
790-201-1500
Push tool kit
■
●
790-201-1660
●
Plate
1
●
790-101-5021
●
Grip
1
●
01010-50816
●
Bolt
1
F
Track roller assembly
G
Idler assembly
H
1
Recoil spring assembly
J 2
PC400LC-7L
Press fitting of bearing inner race O
Press fitting of bearing
Removal, installation of round nut
3
Push tool
2 790-101-2740
Press fitting of oil seal
Press fitting of bearing inner race
796T-627-1230
E
Nature of work, remarks
1
5 790-201-2870
1
Final drive assembly
Part Name
Sketch
Necessity
1 796T-627-1630
Symbol
Component
New/remodel
12
O
Pressing of bearing inner race
Installation of floating seal
Supply of oil
Disassembly, assembly of recoil spring assembly
1 Installation of dust seal
30-11 2
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
Remover and installer
■
1
Track shoe assembly
790-101-1300
Cylinder (980 kN {100 t})
■
1
790-101-1102
Pump
■
1
796-946-1310
Guide ∅21.8
Part No.
K
Part Name
796-946-2110
Guide ∅20.9 Guide ∅20.6
1
(For 723-46-45100, 723-46-45500) 796-946-1320
Guide
1
(For 723-46-40100, 723-46-40601) 796-946-1420 2 Control valve assembly
L
Guide ∅21.6
1
(For 723-46-42800) 796-946-2120
Guide
1
(For 723-46-44100) 796-946-2220
Guide Sleeve
1
(For 723-46-40100, 723-46-40601) 796-946-1430
Sleeve
1
(For 723-46-42800) 3
796-946-2130
Sleeve
1
(For 723-46-44100) 796-946-2230
Sleeve
1
(For 723-46-45100, 723-46-45500)
Center swivel joint assembly
30-12 2
M
Replacement of pressure compensation valve seal
1
(For 723-46-45100, 723-46-45500) 796-946-1330
Pulling out of master pin
1
(For 723-46-44100) 796-946-2210
Nature of work, remarks
1
(For 723-46-40100, 723-46-40601) 1
Sketch
Component
New/remodel
Q'ty
791-650-3000
Symbol
Necessity
12
790-101-2501
Push puller
●
790-101-2510
●
Block
1
●
790-101-2520
●
Screw
1
●
791-112-1180
●
Nut
1
●
790-101-2540
●
Washer
1
●
790-101-2630
●
Leg
2
●
790-101-2570
●
Plate
4
●
790-101-2560
●
Nut
2
●
790-101-2650
●
Adapter
2
■
1
Disassembly, assembly of center swivel joint assembly
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
1
790-102-4300
Wrench assembly
■
1
790-102-4310
Pin
■
2
Expander
●
1
796-720-1680
Ring (For boom and bucket)
●
1
07281-01589
Clamp (For boom and bucket)
●
1
796-720-1690
Ring (For arm)
●
1
07281-01919
Clamp (For arm)
●
1
790-201-1702
Push tool kit
■
1
1 790-502-1003 2
3 790-720-1000
4
Hydraulic cylinder assembly
N
●
790-201-1851
●
Push tool (For bucket)
1
5 ●
790-201-1861
●
Push tool (For boom)
1
●
790-101-5021
●
Grip
1
●
01010-50816
●
Bolt
6
Work equipment assembly
PC400LC-7L
P
Part Name
Sketch
■
Part No.
New/remodel
Q'ty
Cylinder repair stand
Symbol
Component
Necessity
12
Nature of work, remarks
Disassembly, assembly of hydraulic cylinder assembly Removal, installation of piston assembly
Installation of piston ring
Press fitting of bushing
1
790-201-1500
Push tool kit
●
790-101-5021
●
Grip
1
●
01010-50816
●
Bolt
1
●
790-201-1660
Plate (For bucket)
1
●
790-201-1670
●
Plate (For boom)
1
●
790-201-1680
●
Plate (For arm)
1
■
1
796-670-1100
Remover
●
796-670-1110
●
Sleeve
1
●
796-670-1120
●
Plate
1
●
796-670-1130
●
Screw
1
●
796-870-1110
●
Adapter
1
●
01643-33080
●
Washer
1
●
01803-13034
●
Nut
1
●
Press fitting of dust seal
1
790-101-4000
Puller (490 kN {50t}, long)
●
1
790-101-1102
Pump (294 kN {30t})
●
1
Removal of foot pin
30-13 2
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
Operatorís cab glass
30-14 2
■
1
Vacuum pump (100V)
■
1
799-703-1110
Vacuum pump (220V)
■
1
799-703-1120
Vacuum pump (240V)
■
1
799-703-1400
Gas leak tester
■
1
1
793-498-1210
Lifter (Suction cup)
■
2
2
20Y-54-13180
Adapter
■
2
Sketch
Service tool kit
799-703-1100
Part Name
New/remodel
799-703-1200
Part No.
Q
Y
Q'ty
Air conditioner assembly
Necessity
Component
Symbol
12
Nature of work, remarks
Collection and supply of air conditioner refrigerant
Removal and Installation of operatorís cab glass
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12 SKETCHES
SPECIAL TOOL LIST
OF SPECIAL TOOLS
Remark Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A6. Push tool
A8. Wrench
PC400LC-7L
30-15 2
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
D7. Push tool
E2. Push tool
30-16 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
CONTACT TERMINAL REMOVAL (HD30 TYPE) 1.
Obtain the correct removal tool according to the wire size used in the connector.
2.
With the rear insert part of the connector facing you, snap the removal tool over the wire of the contact terminal you will be removing.
Remark Using a removal tool that is too large or too small will hinder wire removal and may damage the connector or removal tool. Always use the correct removal tool size for the wire gauge you are servicing. 3.
In a straight line, carefully slid the removal tool along the wire and into the grommet until a contact resistance is felt.
Remark Do not pull on the wire or twist the tool when inserting removal tool into the grommet. Damage to the tool or connector may result.
4.
Once tool is fully inserted into the connector, carefully pull the removal tool and contact terminal-wire out of the connector.
5.
If contact terminal-wire will not come out, remove tool and reinsert removal tool again.
PC400LC-7L
30-17 2
DISASSEMBLY AND ASSEMBLY 12 STRIPING
CONNECTOR REPAIR PROCEDURES
INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or corroded sections of the wire being repaired referring to the Deutsch Table below. Deutsch Table Deutsch Terminal Part Number
Wire Gauge Range
Strip Length: mm (in)
0460 - 202 - 20141 0462 - 201 - 20141
20 AWG 20 AWG
3.96 - 5.53 (.156 -.218) 3.96 - 5.53 (.156 -.218)
0460 - 202 - 16141 0462 - 201 - 16141
16, 18 and 20 AWG 16, 18 and 20 AWG
6.35 - 7.92 (.250 -.312) 6.35 - 7.92 (.250 -.312)
0460 - 215 - 16141 0462 - 209 - 16141
14 AWG 14 AWG
6.35 - 7.92 (.250 -.312) 6.35 - 7.92 (.250 -.312)
0460 - 204 - 12141 0462 - 203 - 12141
12 and 14 AWG 12 and 14 AWG
5.64 - 7.21 (.222 -.284) 5.64 - 7.21 (.222 -.284)
0460 - 204 - 08141 0462 - 203 - 08141
8 and 10 AWG 8 and 10 AWG
10.92 - 12.47 (.430 -.492) 10.92 - 12.47 (.430 -.492)
0460 - 204 - 0490 0462 - 203 - 04141
6 AWG 6 AWG
10.92 - 12.47 (.430 -.492) 10.92 - 12.47 (.430 -.492)
Using wire insulation stripers, remove only the measured amount of insulation from the wire according to the size contact terminal listed in the “Strip Length” above.
Wire Inspection After stripping insulation from wire, inspect wire strands for: • Corrosion, straightness and uniformity • Broken or nicked wire strands are unexcitable and may cause high resistance in the circuit. • Do not twist or wrap the wire strands as this may cause wire strand breakage during the crimping process.
30-18 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12 CRIMPING
CONNECTOR REPAIR PROCEDURES
CONTACT TERMINAL (HD30 TYPE)
1.
After insulation has been striped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool #HDT48-00 and rotate until arrow is aligned with wire size to be crimped.
2.
Loosen locknut, turn adjusting screw in until it stops.
3.
Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut.
4.
Insert wire into contact terminal. Be sure contact terminal is centered between indicators.
5.
Close crimp tool handle until crimp cycle is completed.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Using the inspection hole in the contact terminal inspect the crimped contact terminal to ensure that all strands are in the crimped barrel.
Remark The tool must be readjusted for each type/size of contact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.
PC400LC-7L
30-19 2
DISASSEMBLY AND ASSEMBLY 12 INSERTION
OF CONTACT TERMINAL (HD30 TYPE)
1.
Grasp contact terminal approximately 25.2mm (1in) behind the crimped barrel.
2.
Holding connector with rear grommet facing you.
3.
Insert completed contact terminal straight into connector grommet until a positive stop is felt.
4.
Once contact terminal is in connector, a slight tug will confirm that the contact terminal is properly locked in place.
5.
For unused wire cavities, insert sealing plugs for full environmental sealing.
30-20 2
CONNECTOR REPAIR PROCEDURES
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12 CONTACT
TERMINAL REMOVAL (DT TYPE)
1.
Remove the wedge lock using needle nose pliers or a hooked shaped wire.
2.
Pull the wedge lock straight out and save for reinstallation.
3.
To remove the contact terminal gently pull the wire backwards while at the same time releasing the locking finger by pushing it away from the terminal with a small screwdriver.
4.
Hold the rear seal grommet in place and pull the contact terminal out of the connector.
PC400LC-7L
CONNECTOR REPAIR PROCEDURES
30-21 2
DISASSEMBLY AND ASSEMBLY 12 STRIPING
CONNECTOR REPAIR PROCEDURES
INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or corroded sections of the wire being repaired referring to the Deutsch Table below. Deutsch Table Deutsch Terminal Part Number
Wire Gauge Range
Strip Length: mm (in)
0460 - 202 - 20141 0462 - 201 - 20141
20 AWG 20 AWG
3.96 - 5.53 (.156 -.218) 3.96 - 5.53 (.156 -.218)
0460 - 202 - 16141 0462 - 201 - 16141
16, 18 and 20 AWG 16, 18 and 20 AWG
6.35 - 7.92 (.250 -.312) 6.35 - 7.92 (.250 -.312)
0460 - 215 - 16141 0462 - 209 - 16141
14 AWG 14 AWG
6.35 - 7.92 (.250 -.312) 6.35 - 7.92 (.250 -.312)
0460 - 204 - 12141 0462 - 203 - 12141
12 and 14 AWG 12 and 14 AWG
5.64 - 7.21 (.222 -.284) 5.64 - 7.21 (.222 -.284)
0460 - 204 - 08141 0462 - 203 - 08141
8 and 10 AWG 8 and 10 AWG
10.92 - 12.47 (.430 -.492) 10.92 - 12.47 (.430 -.492)
0460 - 204 - 0490 0462 - 203 - 04141
6 AWG 6 AWG
10.92 - 12.47 (.430 -.492) 10.92 - 12.47 (.430 -.492)
Using wire insulation stripers, remove only the measured amount of insulation from the wire according to the size contact terminal listed in the “Strip Length” above.
Wire Inspection After stripping insulation from wire, inspect wire strands for: • Corrosion, straightness and uniformity • Broken or nicked wire strands are unexcitable and may cause high resistance in the circuit. • Do not twist or wrap the wire strands as this may cause wire strand breakage during the crimping process.
30-22 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12 CRIMPING
CONNECTOR REPAIR PROCEDURES
CONTACT TERMINAL (DT TYPE)
1.
After insulation has been striped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool #HDT48-00 and rotate until arrow is aligned with wire size to be crimped.
2.
Loosen locknut, turn adjusting screw in until it stops.
3.
Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut.
4.
Insert wire into contact terminal. Be sure contact terminal is centered between indicators.
5.
Close crimp tool handle until crimp cycle is completed.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Using the inspection hole in the contact terminal inspect the crimped contact terminal to ensure that all strands are in the crimped barrel.
Remark The tool must be readjusted for each type/size of contact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.
PC400LC-7L
30-23 2
DISASSEMBLY AND ASSEMBLY 12 INSERTION
CONNECTOR REPAIR PROCEDURES
OF CONTACT TERMINAL (DT TYPE)
1.
Grasp the crimped contact terminal approximately 25.2mm (1in) behind the crimped barrel.
2.
Hold the connector with the rear grommet facing you and insert the completed wire into the connector.
3.
Push the contact terminal straight into the connector until a “click” is felt. A slight tug will confirm that the contact terminal is properly locked in place.
4.
Once all contact terminals are in place, insert the wedge lock with the arrow pointing toward exterior locking mechanism. The wedge lock will snap into place. Rectangular wedges are not oriented and may fit either way.
Remark As the connector receptacle is shown - use the same procedures for a plug.
30-24 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
ENGINE
12
ENGINE Remark Removal, installation, disassembly and assembly of the following components, see the ENGINE SHOP MANUAL.
AFTERCOOLER ALTERNATOR CYLINDER HEAD ENGINE FRONT SEAL ENGINE OIL COOLER ENGINE REAR SEAL FUEL INJECTION PUMP NOZZLE HOLDER NOZZLE TIP STARTING MOTOR THERMOSTAT TURBOCHARGER WATER PUMP
PC400LC-7L
30-25 2
DISASSEMBLY AND ASSEMBLY
RADIATOR
12
RADIATOR REMOVAL 1.
Remove cover (1).
2.
Drain the coolant. Coolant: Approximately 35 L (9.25 gal)
3.
Erect the engine hood according to the following procedure. A. Open engine hood (2) and sling it temporarily. ★ When slinging the engine hood, take care not to damage the rubber seal. B. Prepare M10 bolt [1]. ● When removing the radiator, L = 50 or longer. ● When removing the oil cooler, L = 70 or longer. C. Remove bolt (4). D. Remove pin (5) from the lower part of stay (3). E. Adjust the engine hood so that center hole A of stay (3) will be at the bolt (4). F.
Install stay (3) with bolt [1] and fix engine hood (2) vertically.
4.
Disconnect reservoir tank hose (6). ★ Disconnect the hose from the radiator.
5.
Disconnect radiator hoses (7), (8), and (9). [*1]
6.
Remove covers (10) and (11).
30-26 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
RADIATOR
12 7. Remove cover (12). 8.
Disconnect radiator hose (13). [*1]
9.
Remove 2 mount bolts (14).
10. Lift off radiator assembly (15). Radiator assembly: 30 kg (66.13 lb)
PC400LC-7L
30-27 2
DISASSEMBLY AND ASSEMBLY
RADIATOR
12 INSTALLATION ● ●
Carry out installation in the reverse order to removal. Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Coolant: Approximately 35 L (9.25 gal)
[*1] Radiator hose clamps (7): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm} (2.4 ± 0.36 lbf ft) (8): 4.4 ± 0.49 Nm {0.49 ± 0.05 kgm} (3.2 ± 0.36 lbf ft) (9), (13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} (6.4 ± 0.3 lbf ft)
30-28 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL COOLER
12
HYDRAULIC OIL COOLER REMOVAL 1.
Remove cover (1).
2.
Remove plug (2) of the hydraulic oil cooler drain hose to drain the hydraulic oil. ★ Before draining, open the hydraulic tank cap to release the pressure in the tank. Then, drain the oil through the cooler hose.
3.
Erect the engine hood according to the following procedure. A. Open engine hood (100) and sling it temporarily. ★ When slinging the engine hood, take care not to damage the rubber seal. B. Prepare M10 bolt [1]. C. Remove bolt (102). D. Remove pin (103) from the lower part of stay (101). E. Adjust the engine hood so that center hole A of stay (101) will be at the bolt (102). F.
4.
Install stay (101) with bolt [1] and fix engine hood (100) vertically.
Remove covers (3) and (4).
PC400LC-7L
30-29 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL COOLER
12 5. Remove hydraulic oil cooler tube mount bolts (5) and (6). 6.
Remove right and left hydraulic oil cooler mount bolts (7).
7.
Remove 3 hydraulic oil cooler-side mount bolts (8). ★ When removing 1 of the 3 bolts which is hidden behind cover B, pull cover B lightly. ★ Bolt [1] is used to fix the engine hood vertically.
8.
Remove the net on the outside of the hydraulic oil cooler.
9.
Lift off hydraulic oil cooler assembly (9). Hydraulic oil cooler: 50 kg (110 lb)
INSTALLATION ● ●
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
30-30 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
12
ENGINE AND HYDRAULIC PUMP
C
796-601-1110
Stopper
■
1
N
796-460-1210
Oil stopper
■
1
796-770-1320
Adapter
■
1
Part No.
Part Name
Sketch
Qíty
B
New/Remodel
Symbol
Necessity
SPECIAL TOOLS
REMOVAL WARNING! Disconnect the cable from the negative (–) terminal of the battery. WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. ★ Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1.
Remove the 4 engine undercovers.
2.
Remove the hydraulic tank strainer. Using tool C, stop the oil. ★ When not using tool C, remove the drain plug to drain the oil from the hydraulic tank and piping. Hydraulic tank: Approximately 335 L (88.5 gal)
3.
Drain the coolant. Coolant: Approximately 35 L (9.25 gal)
4.
Close the fuel stop valve of the fuel tank.
5.
Erect the engine hood according to the following procedure. A. Open engine hood (100) and sling it temporarily. ★ When slinging the engine hood, take care not to damage the rubber seal. B. Prepare M10 bolt [1]. C. Remove bolt (102). D. Remove pin (103) from the lower part of stay (101).
PC400LC-7L
30-31 2
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
E. Adjust the engine hood so that center hole A of stay (101) will be at the bolt (102). F.
Install stay (101) with bolt [1] and fix engine hood (100) vertically.
6.
Remove tube (1). [*1] ★ Remove the tube and bracket together.
7.
Disconnect clamp (2) and pipe (3). [*2] ★ Remove the clamp, pipe, and bracket (4) together.
8.
Disconnect fuel inlet hose (5) and fuel return hoses (6) and (7). [*3]
9.
Disconnect clamp (8) and radiator hoses (9), (10), and (11). [*4]
10. Remove covers (12) and (13). 11. Remove fan guard (14). ★ Bolt [1] is used to fix the engine hood vertically.
30-32 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
12 12. Loosen adjustment bolt (15) and remove belt (16). [*5] 13. Remove air conditioner compressor assembly (17). ★ Move the air conditioner compressor assembly toward the control valve top cover. 14. Disconnect fan (18). ★ Insert your hand through clearance A between the fan and the radiator and remove the 6 fan mount bolts in order, turning the fan with your foot.
15. Disconnect aftercooler hose (21) and heater hose (22). [*6]
16. Remove cover (23). 17. Disconnect radiator hose (24). [*4]
18. Disconnect heater hose (25).
PC400LC-7L
30-33 2
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
12 19. Disconnect the following 2 wiring connectors. ● (26): ERO2 (Various sensors) ● (27): ERO3 (Each injector and fuel supply pump) 20. Remove mount bolts (28) and bracket (29).
21. Open the main pump side cover. 22. Lift off covers (30) and (31) together. 23. Remove cover (32) and stay (33).
24. Disconnect the following 2 pump wiring connectors. ● (34): V22 (PC-EPC solenoid valve) Band color: Red ● (35): V21 (LS-EPC solenoid valve) Band color: White 25. Disconnect the following 10 hoses and 1 tube. ● (36): EPC basic pressure port hose (Band color: Yellow) ● (37): Rear pressure port hose (Band color: Yellow) ● (38): Rear pump discharge port hose ● (39): Front pump discharge port hose
30-34 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12 ● ● ● ● ●
ENGINE AND HYDRAULIC PUMP
(40): Drain port hose (41): Front load pressure input port hose (42): Rear load pressure input port hose (Band color: Red) (43): Front pressure input port hose (44): Pump suction port tube
26. Disconnect engine ground cable (46) from the rear of the hydraulic pump. 27. Using tool B, remove 4 front and rear engine mount bolts (47). [*7]
28. Lift off engine and hydraulic pump assembly (48). ★ Check that all the wires and pipes have been disconnected. Engine and hydraulic pump assembly: 1,700 kg (3,748 lb)
PC400LC-7L
30-35 2
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
12 INSTALLATION ●
Carry out installation in the reverse order to removal.
[*1] Hose clamp: 9.8 ± 0.5 Nm {0.1 ± 0.05 kgm} (7.2 ± 0.36 lbf ft) [*2] Clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} (7.7 ± 0.36 lbf ft) [*3] Fuel hoses (5), (6), and (7): 14.8 - 19.6 Nm {1.5 - 2.0 kgm} (10.9 - 14.4 lbf ft) [*4] Radiator hoses: (9): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}(2.4 ± 0.36 lbf ft) (10): 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}(3.2 ± 0.36 lbf ft) (11), (24):8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} (6.4 ± 0.36 lbf ft) [*5] ★ See TESTING AND ADJUSTING, Testing and adjusting air conditioner compressor belt tension or REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL in engine manual. [*6] Air aftercooler hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} (7.9 ± 0.73 lbf ft) [*7] Engine mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (607 - 759.6 lbf ft) ●
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. Coolant: Approximately 35 L (9.24 gal)
●
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Hydraulic oil: Approximately 335 L (88.4 gal)
●
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
30-36 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
SWING CIRCLE
12
SWING CIRCLE REMOVAL 1.
Remove the revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY.
2.
Sling swing circle assembly (1) by 3 points temporarily, remove 40 mount bolts, and lift off the swing circle assembly. [*1] Swing circle assembly: 600 kg (1,323 lb)
INSTALLATION ●
Carry out installation in the reverse order to removal.
[*1] Mating face of swing circle: Gasket sealant (LG-6)
Threads of swing circle mount bolt: Adhesive (LT-2)
Swing circle mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (608 - 759 lbf ft) Target: 927 Nm {94.5 kgm} (683.7 lbf ft) ★ When installing the swing circle to the track frame, bring soft zone mark S of the inner race and soft zone mark P of the outer race to the right side of the chassis as shown below. Quantity of grease in grease bath: Grease (G2-LI), 33 L (8.7 gal) (Use GLT2-LI for 50°C (138.2°F) specification)
PC400LC-7L
30-37 2
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12
SWING MOTOR AND SWING MACHINERY REMOVAL WARNING! Release the residual pressure in the hydraulic circuit. Refer to the Releasing of Residual Pressure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this manual. WARNING! Lower the work equipment to the ground for oil filler cap on the fuel tank to release the residual pressure inside the tank and move the safety lock lever to the LOCK position. 1.
Disconnect five swing motor hoses (1) through (5). ● (1): Between swing motor and control valve (MA port) ● (2): Between swing motor and control valve (MB port) ● (3): Suction hose (S port) ● (4): Drain hose (T port) ● (5): Swing brake releasing pilot hose (B port)
2.
Detach the swing motor and swing machinery assembly (6), using forcing screw [1] after removing the mount bolts. [*1]
3.
Lift and remove swing motor and swing machinery assembly (6). ★ When lifting the swing motor and swing machinery assembly for removal, do so slowly so that the hoses and other parts will not be damaged. ★ Take good care, when lifting the assembly, until the spigot joint portion is pulled out. Swing motor and swing machinery assembly: 550 kg (1,212 lb)
30-38 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12 INSTALLATION ●
Install in reverse order of removal.
[*1] Mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (608 - 759 lbf ft) ●
●
Refilling hydraulic oil Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again. Air bleeding Refer to the Air Bleeding of Various Parts section in the TESTING AND ADJUSTING chapter of this manual.
PC400LC-7L
30-39 2
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
Push tool
●
1
2
790-201-2350
Push tool
■
1
3
790-201-2510
Push tool
■
1
790-101-5401
Push tool kit
■
1
●
790-101-5531
●
Plate
1
●
790-101-5421
●
Grip
1
●
01010-51240
●
Bolt
1
D 4
Part Name
5
790-201-2870
Push tool
■
1
6
790-201-2770
Push tool
■
1
7
796T-626-1110
Push tool
■
1
Sketch
796T-627-1630
Part No.
New/Remodel
Qíty
1
Symbol
Necessity
12 SPECIAL TOOLS
N
O
DISASSEMBLY 1.
Draining oil Loosen the drain plug and drain the oil from the swing machinery case. Swing machinery case: Approximately 21 L (5.5 gal)
2.
Swing motor assembly A. Set the swing motor and swing machinery assembly on block [1]. B. Remove 10 mount bolts and lift off swing motor assembly (1). Swing motor assembly: 115 kg (254 lb)
3.
No. 1 sun gear Remove No. 1 sun gear (2).
30-40 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12 4. No. 1 carrier assembly A. Remove No. 1 carrier assembly (3).
B. Disassemble the No. 1 carrier assembly according to the following procedure. Remove snap ring (4), and then remove shaft (5), gear (6), bearing (7), thrust washer (8), and plate (9).
5.
Ring gear Remove the mount bolts and ring gear (10).
6.
No. 2 sun gear Remove No. 2 sun gear (11).
PC400LC-7L
30-41 2
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12 7. Bolt Remove holder mount bolt (12).
8.
No. 2 carrier assembly A. Lift of No. 2 carrier assembly (13).
B. Disassemble the No. 2 carrier assembly according to the following procedure. i. Push in pin (14) and drive out shaft (15) from carrier (16). ★ After removing the shaft, remove pin (14). ii.
Remove thrust washer (17), gear (18), bearing (19), and thrust washer (20).
iii. Remove plate (21).
9.
Shaft assembly A. Turn over case and pinion assembly (24) and remove 12 mount bolts (23) of cover assembly (22).
30-42 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12 B. Turn over case and pinion assembly (24) and set it on the press stand. Using push tool [2], D1 and the press, pull out pinion shaft assembly (25). ★ Set a wood block under the press so that the pinion shaft will not be damaged when it comes off. ★ A rough standard pressing force is 20 odd tons.
10. Disassemble the pinion shaft assembly (25) according to the following procedure. A. Using the push tool, remove cover assembly (22) and bearing (26) from shaft (27). ★ A rough standard pressing force is 30 tons. B. Remove oil seal (28) from cover (29).
11. Bearing Using multiple push tools [3], remove bearing (30) from case (31). ★ Push tool to be set contact with bearing: D2
PC400LC-7L
30-43 2
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12 ASSEMBLY ★ Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1.
Bearing Using push tool D3 and [4], press fit bearing (26) to case (31). ★ A rough standard pressing force is several tons.
2.
Cover assembly A. Using push tool D4, press fit oil seal (28) to cover (29). Periphery of oil seal: Gasket sealant (LG-6) ★ Take care that the gasket sealant (LG-6) will not stick to the oil seal lip and shaft assembly (22).
B. Install cover assembly (22) to case (31) and tighten mount bolts (23). ★ Match the oil path of cover (22) to the drilled hole of case (31). Cover fitting face: Gasket sealant (LG-6)
Mount bolt: 98 - 123 Nm {10 - 12.5 kgm} (73 - 90 lbf ft) Oil seal lip: Grease (G2-LI)
30-44 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 3.
SWING MOTOR AND SWING MACHINERY
Case assembly A. Turn over case assembly (32) and set it to shaft (27). Using push tools D5 and D6 [5], press fit the bearing inner race. ★ When setting the case assembly to the shaft, take care extremely not to damage the oil seal. ★ A rough standard pressing force is 30 tons.
B. Bearing Using too D7, press fit bearing (30). ★ Press both inner race and outer race of the bearing simultaneously. Do not press only the inner race. ★ A rough standard pressing force is 20 odd tons. ★ After press fitting the bearing, check that the case turns smoothly.
4.
No. 2 carrier assembly A. Assemble the No. 2 carrier assembly according to the following procedure. ★ There is a caulking mark made when the pin was inserted at the end of carrier side hole “a” and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i.
Install plate (21) to carrier (16).
ii.
Install bearing (19) to gear (18) and fit top and bottom thrust washers (17) and (20), and then set the gear assembly to carrier (16).
iii. Aligning the pin holes of shaft (15) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. ★ When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iv. Insert pin (14).
PC400LC-7L
30-45 2
DISASSEMBLY AND ASSEMBLY 12
SWING MOTOR AND SWING MACHINERY
★ When inserting the pin, do not set the 3 claws (parts “a”) on the periphery to the thin part of the carrier (part “b”). The thin part may be on the opposite side, however. Check each carrier and avoid setting a claw to the thin part. ★ After inserting the pin, caulk the pin part of the carrier. B. Install No. 2 carrier assembly (13).
5.
Bolt and O-ring A. Tighten bolt (12). Threads of mount bolt: Adhesive (LT-2)
Mount bolt: 343 - 427 Nm {34 - 43.5 kgm} (253 - 314 lbf ft) B. Fit the O-ring to case (31).
6.
No. 2 sun gear Install No. 2 sun gear (11).
7.
Ring gear Using the eyebolt (M12 x 1.75), install ring gear (10).
30-46 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12 ★ When installing ring gear (10), set its match mark (part “d”) and the projection of the case flange (part “c”) as shown in the at right figure.
★ Degrease the mating faces of ring gear (10) and case. ★ Never stick gasket sealant to the mating faces of ring gear (10) and case. Mount bolt: 245 - 309 Nm {25 - 31.5 kgm} (181 - 227 lbf ft) ★ Add engine oil (EO30-CD) at this time.
8.
No. 1 carrier assembly A. Assemble the No. 1 carrier assembly according to the following procedure. i.
Press fit shaft (5) to the carrier in the direction of the arrow until the snap ring groove is seen.
ii.
After installing snap ring (4), press back the shaft from the opposite side until the snap ring is fitted to face P of the carrier. At this time, take care not to press back too much.
iii. After installing plate (9), install thrust washer (8), bearing (7), gear (6), and snap ring (4).
PC400LC-7L
30-47 2
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
12 B. Install No. 1 carrier assembly (3).
9.
No. 1 sun gear assembly Install No. 1 sun gear (2).
★ Take care not to install the No. 1 sun gear upside down. ★ Install the No. 1 sun gear with the tooth (part “e”) down.
10. Swing motor assembly Install swing motor assembly (1) to ring gear (10). ★ When installing the swing motor assembly, set the relief valve (part f) and the projection of the case (part c) as shown in the following figure. ★ Degrease the mating faces of swing motor assembly (1) and ring gear (10). Mating faces of swing motor assembly (1) and ring gear (10): Gasket sealant (LG-6) Mount bolt: 98 - 123 Nm {10 - 12.5 kgm} (73 - 90 lbf ft) Swing motor assembly: 115 kg (254 lb)
30-48 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY ●
SWING MOTOR AND SWING MACHINERY
Refilling with oil Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-30K for extremely cold district) through the oil filler to the specified level. Swing machinery case: Approximately 21 L (5.5 gal)
PC400LC-7L
30-49 2
DISASSEMBLY AND ASSEMBLY
SPROCKET
12
SPROCKET REMOVAL 1.
Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Swing work equipment 90°, push up chassis with work equipment and place block [1] between track frame and track shoe.
3.
Remove mount bolts and lift off sprocket (1). [*1] Sprocket: 70 kg (154.3 lb)
INSTALLATION ●
Install in reverse order of removal.
[*1] Thread of sprocket mount bolt: Gasket sealant (LG-6) Sprocket mount bolt: 640 - 785 Nm {65 - 80 kgm} (472 - 578 lbf ft)
30-50 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR AND FINAL DRIVE
12
TRAVEL MOTOR AND FINAL DRIVE REMOVAL 1.
Remove the sprocket. For details, see Removal of sprocket. WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank.
2.
Remove cover (1).
3.
Disconnect drain hose (2), travel speed selector hose (3), and motor hoses (4) and (5). ★ Remove the nipples, too.
4.
Remove the 24 mount bolts and lift off the final drive assembly (6). [*1] ★ Take care extremely not to damage the nipple sealing faces of the hose joints. ★ When slinging the final drive assembly, do not use the tap hole for the cover. Final drive assembly: 700 kg (1544 lb)
INSTALLATION ●
Carry out installation in the reverse order to removal.
[*1] Mount bolt: 490 - 608 Nm {50 - 62 kgm} (362 - 448 lbf ft) ●
●
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
PC400LC-7L
30-51 2
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12
FINAL DRIVE
1
E
1
Wrench assembly
●
796-627-1220
●
Wrench
1
●
796-427-1140
●
Pin
3
●
01314-20612
●
Screw
3
796T-627-1230
Push tool
■
1
790-101-2510
Block
●
1
791-122-1130
Plate
●
1
790-101-2550
Leg
●
2
2 790-101-2740
Adapter
●
2
790-101-2570
Plate
●
4
790-101-2560
Nut
●
2
790-101-2102
Puller (30 tons)
■
1
790-101-1102
Pump
■
1
Installer
■
1
3 796-627-1020
Sketch
■
796-627-1210
New/Remodel
Part Name
Qíty
Part No.
Necessity
Symbol
SPECIAL TOOLS
O
DISASSEMBLY 1.
Draining oil Remove the drain plug to drain the oil from the final drive case. Final drive case: Approximately 11L (3 gal)
2.
Cover A. Place the final drive on block [1] and remove the mount bolts and cover (1). B. Using eyebolt [2], remove cover (1).
30-52 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 3. Spacer Remove spacer (2).
4.
No. 1 carrier assembly A. Remove No. 1 carrier assembly (3).
B. Disassemble the No. 1 carrier assembly according to the following procedure.
5.
i.
Push in pin (5) to drive out shaft (6) from carrier (7). ★ After removing the shaft, remove pin (5).
ii.
Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11).
No. 1 sun gear shaft Remove spacer (4), No. 1 sun gear (12), and No. 2 sun gear (13).
PC400LC-7L
30-53 2
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 6. Thrust washer Remove thrust washer (14).
7.
No. 2 carrier assembly A. Sling No. 2 carrier assembly (15) with wires, etc. and remove it.
B. Disassemble No. 2 carrier assembly according to the following procedure.
8.
i.
Push in pin (16) to drive out shaft (17) from carrier (18). ★ After removing the shaft, remove pin (16).
ii.
Remove thrust washer (19), gear (20), bearing (21), and thrust washer (22).
Nut A. Remove lock plate (23).
30-54 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 B. Using tool E1, remove nut (24).
9.
Hub assembly A. Using eyebolts [3], remove hub assembly (25) from the travel motor.
B. Disassemble hub assembly (25) according to the following procedure. i.
Remove bearing (26) from hub (32).
ii.
Remove floating seal (27) from hub (32).
PC400LC-7L
30-55 2
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 iii. Remove bearings (28) and (29) from hub (32).
C. Remove floating seal (30) from travel motor (31).
D. Using puller [4], remove bearing (34) and collar (33) together. ★ You can remove bearing (34) and collar (33) without using puller [4] in some cases.
30-56 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 ASSEMBLY ★ Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1.
Hub assembly A. Using the push tool, press fit bearings (28) and (29) to hub (32).
B. Using tool E3, install floating seal (27) to hub (32). ★ Thoroughly degrease and dry the O-ring and O-ring fitting surface of the floating seal before installing. ★ After installing the floating seal, check that its slant is less than 1 mm. ★ After installing the floating seal, thinly apply engine oil to the sliding surfaces.
C. Install collar (33) and bearing (34) to travel motor (31).
D. Using tool E3, install floating seal (30) (which is hidden and not seen behind tool E3) to travel motor (31). ★ Thoroughly degrease and dry the O-ring and O-ring fitting surface of the floating seal before installing. ★ After installing the floating seal, check that its slant is less than 1 mm. ★ After installing the floating seal, thinly apply engine oil to the sliding surfaces.
PC400LC-7L
30-57 2
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 E. Using eyebolts [3], set hub assembly (25) to the travel motor. Using the push tool, lightly hit the bearing to press fit it.
2.
Nut Install the nut according to the following procedure. A. Rotate the hub 2 - 3 turns. B. Using tool E2, press the bearing inner race. ★ Pressing force: 29.4 - 38.3 kN {3.0 - 3.9 tons} C. While the bearing is pressed, rotate the hub at least 5 turns in 1 direction. D. Release the pressing force. E. Press the bearing again. ★ Pressing force: 14.7 - 18.6 kN {1.5 - 1.9 tons} F.
Under the condition in E above, measure dimension “a”.
G. Measure thickness “b” of nut (24). H. Obtain a - b = c. I.
Using tool D1, tighten nut (24) until dimension “c” is as follows. ★ Dimension “c”: c +0.07 -0.03 mm
30-58 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 J.
Using push-pull gauge [5], measure the rotating force of the hub in its revolving direction on the motor case. ★ Rotating force: Max. 765 N {78 kg} (171.9 lbf) ★ The rotating force means the maximum force at the tangent to the bolt circle at the beginning of rotation.
K. Install lock plate (23), fitting it to the motor spline. Threads of mount bolt: Adhesive (LT-2)
Mount bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} (48.8 ± 5.4 lbf ft)
3.
No. 2 carrier assembly A. Assemble the No. 2 carrier assembly according to the following procedure. ★ There is a caulking mark made when the pin was inserted at the end of carrier side hole “h” and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i.
Install bearing (21) to gear (20) and fit top and bottom thrust washers (19) and (22), and then set the gear assembly to carrier (18).
ii.
Aligning the pin holes of shaft (17) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. ★ When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers.
iii. Insert pin (16). ★ After inserting the pin, caulk the pin part of the carrier. ★ After assembling the carrier assembly, check that the gear (20) turns smoothly.
PC400LC-7L
30-59 2
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 B. Install No. 2 carrier assembly (15). ★ Install No. 2 carrier assembly (15) so that the 4 gear shaft ends will be in the 4 hollows at the motor case end.
4.
Thrust washer Install thrust washer (14).
5.
No. 2 sun gear Install spacer (4) and No. 2 sun gear (13).
6.
No. 1 carrier assembly A. Assemble the No. 1 carrier assembly according to the following procedure. ★ There is a caulking mark made when the pin was inserted at the end of carrier side hole “h” and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i.
30-60 2
Install bearing (10) to gear (9) and fit top and bottom thrust washers (8) and (11), and then set the gear assembly to carrier (7).
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
12 ii.
Aligning the pin holes of shaft (6) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. ★ When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers.
iii. Insert pin (5). ★ After inserting the pin, caulk the pin part of the carrier. ★ After assembling the carrier assembly, check that the gear (9) turns smoothly.
B. Install No. 1 carrier assembly (4).
7.
No. 1 sun gear shaft Install No. 1 sun gear shaft (12).
8.
Spacer Install spacer (2).
9.
Cover Using eyebolts [2], install cover (1) and tighten the mount bolts. Cover mount face: Gasket sealant (LG-6)
Mount bolt: 98 - 123 Nm {10 - 12.5 kgm} (72 - 90 lbf ft) ●
Refilling with oil ★ Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W30K for extremely cold district) through the oil filler. Final drive case: Approximately 11 L (2.9 gal) ★ After installing the final drive assembly to the chassis, check the oil level again at the specified position.
PC400LC-7L
30-61 2
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
12
CARRIER ROLLER ★ Only precautions for assembling the carrier roller assembly are explained below.
F
■
1
2 791-601-1000
Oil pump
■
1
Part Name
Sketch
Installer
Part No.
New/Remodel
Qíty
1 791-430-3230
Symbol
Necessity
SPECIAL TOOLS
Carrier roller assembly: 35 kg (78 lb)
ASSEMBLY ●
Press fitting of support (2) A. The threads of shaft (1) must be in the range of the following figure. B. Press fitting dimension of shaft: (Shown in the following figure) C. Using push tool [1], press fit support (2) to shaft (1). At this time, apply press fitting force of at least 79 kN {8.1 tons}.
●
Floating seal ★ When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. ★ Be sure to use the installer F to insert the floating seal assembly in the housing. ★ After installing the floating seal, check that its slant is less than 1 mm and its projection “a” is 5 - 7 mm.
Carrier roller ★ Using tool F, apply the standard pressure to the oil filler to check the seal for air leakage. ★ Keep the following standard pressure for 10 seconds and check that the pointer of the gauge does not lower. Standard pressure:. . . . . . 0.1 MPa {1 kg/cm2} (14.2 psi) ●
30-62 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
12 ★ Using tool F, fill the carrier roller assembly with oil and tighten the plug. Carrier roller: 170 - 180 cc (EO30-CD)
PC400LC-7L
30-63 2
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
12
TRACK ROLLER ★ Only precautions for assembling the track roller assembly are explained below.
G
■
1
2 791-601-1000
Oil pump
■
1
Part Name
Sketch
Installer
Part No.
New/Remodel
Qíty
1 791-630-1780
Symbol
Necessity
SPECIAL TOOLS
Track roller assembly: 80 kg (176 lb)
ASSEMBLY ●
Floating seal ★ When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. ★ Be sure to use the installer G to insert the floating seal assembly in the housing. ★ After installing the floating seal, check that its slant is less than 1 mm and its projection “a” is 5 - 7 mm.
Track roller ★ Using tool G, apply the standard pressure to the oil filler to check the seal for air leakage. ★ Keep the following standard pressure for 10 seconds and check that the pointer of the gauge does not lower. Standard pressure:. . . . . . 0.1 MPa {1 kg/cm2} (14.2 psi) ★ Using tool G, fill the track roller assembly with oil and tighten the plug. ●
Track roller: 280 - 310 cc (EO30-CD)
Plug: 10 - 20 Nm {1 - 2 kgm} (7.37 - 14.7 lbf ft)
30-64 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
IDLER
12
IDLER
Installer
■
1
791-601-1000
Oil pump
■
1
Part Name
Sketch
791-575-1520
Part No.
New/Remodel
Qíty
H
Necessity
Symbol
SPECIAL TOOLS
DISASSEMBLY 1.
Remove nut (1) and pull out bolt (2) to remove support (3).
2.
Remove floating seal (4) from support (3) and idler (5).
3.
Pull out idler (5) from shaft and support assembly (6). ★ Idler is filled with oil of 345 ± 10 cc. Drain it or spread cloths to soak it at this time.
4.
Remove floating seal (7) on the opposite side from idler (5) and shaft and support assembly (6).
5.
Remove nut (8), pull out bolt (9), and then remove support (10) from shaft (11).
PC400LC-7L
30-65 2
DISASSEMBLY AND ASSEMBLY
IDLER
12 6. Remove bushing (12) from idler (5).
ASSEMBLY 1.
Press fit bushings (12) (on both sides) to idler (5).
2.
Fit the O-ring and install support (10) to shaft (11) with bolt (9) and tighten nut (8).
★ Install the shaft with the UP mark up.
3.
Using tool H, install floating seal (7) to idler (5) and shaft and support assembly (6).
30-66 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
IDLER
12 ★ When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. ★ Be sure to use the installer H to insert the floating seal assembly in the housing. ★ After installing the floating seal, check that its slant is less than 1 mm and its projection “a” is 9 - 11 mm.
4.
Install shaft and support assembly (6) to idler (5).
5.
Similarly, using too H, install floating seal (4) to idler (5) and support (3).
PC400LC-7L
30-67 2
DISASSEMBLY AND ASSEMBLY
IDLER
12 ★ Coat the sliding surface of the floating seal with oil and take care that dirt will not stick to it. ★ Degrease the floating seal and the O-ring contact surfaces. 6.
Fit the O-ring, set support (3), install bolt (2), and tighten nut (1).
7.
Add oil and tighten the plug. Quantity of oil: Approximately 345 ± 10 cc (EO-30CD)
Plug: 130 - 180 Nm {13 - 18 kgm} (96 - 132 lbf ft)
30-68 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
12
RECOIL SPRING
Compressor
■
1
1
791-635-3160
Extension
■
1
790-101-1600
Cylinder (686 kN {70 t})
■
3
j
790-101-1102
Pump
■
3
790-201-1500
Push tool kit
2
●
790-201-1660
●
Plate
●
790-101-5021
●
Grip
●
01010-50816
●
Bolt
Part No.
Part Name
Sketch
Qíty
791-685-8006
Symbol
New/Remodel
Necessity
SPECIAL TOOLS
1
Recoil spring (Excluding idler): 900 kg (1985 lb)
DISASSEMBLY 1.
Remove piston assembly (2) from recoil spring assembly (1).
2.
Disassembly of recoil spring assembly A. Set tool J1 to recoil spring assembly (1). WARNING! Since the installed load of the spring is large and dangerous, set the tool securely.
Installed load of spring: 239.037 kN {24,375 kg} (53,738 lbf) B. Apply oil pressure gradually to compress the spring and remove lock plate (3) and nut (4). ★ Compress the spring to a degree that you can loosen the nut. ★ Release the oil pressure gradually to reduce the spring tension to 0 (zero). ★ Free length of spring: 845.3 mm (33.2 in) C. Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from spring (5). 3.
Disassembly of piston assembly A. Remove lock plate (11) from piston (10), and then remove valve (12). B. Remove snap ring (13), U-packing (14), and ring (15).
PC400LC-7L
30-69 2
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
12 ASSEMBLY 1.
Assembly of piston assembly A. Install ring (15) and U-packing (14) to piston (10) and secure them with snap ring (13). B. Tighten valve (12) temporarily and secure it with lock plate (11).
2.
Assembly of recoil spring assembly A. Using tool J2, install dust seal (9) to cylinder (7).
B. Install cylinder (7), collar (8), and yoke (6) to spring (5), and then set them to tool J1. Sliding parts of cylinder: Grease (G2-LI)
C. Apply oil pressure gradually to compress the spring and tighten nut (4) so that installed length of the spring will be “a”, and then secure it with lock plate (3). ★ Installed length of spring “a”: Approximately 690 mm D. Remove recoil spring assembly (1) from tool J1. 3.
Install piston assembly (2) to recoil spring assembly (1). Sliding parts of piston: Grease (G2-LI)
Wear ring: Grease (G2-LI)
★ Install the piston assembly so that the position of the valve will be on outside. ★ Supply 320 cc of grease (G2-LI) to the cylinder, bleed air, and check that the grease flows out of the grease hole.
30-70 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
12
TRACK SHOE
K
791-650-3000
Remover and installer
■
790-101-1300
Cylinder (980 kN {100 t})
■
790-101-1102
Pump
■
Sketch
New/Remodel
Part Name
Qíty
Part No.
Necessity
Symbol
SPECIAL TOOLS
EXPANSION 1.
Start the engine and set the master pin to above the idler.
2.
Remove track shoes (2) on the right and left sides of master pin (1). [*1]
3.
Lower the work equipment to the ground and loosen lubricator (3) to slacken the track shoe. [*2] WARNING! Since the internal pressure of the adjustment cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not come out sufficiently, move the machine forward and in reverse.
4.
Using tool K, remove master pin (1). [*3]
5.
Move the master pin forward and set block [1] under the track shoe in front of the idler.
6.
Pull out pusher K.
7.
Move the machine in reverse slowly to expand the track shoe. [*4]
PC400LC-7L
30-71 2
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
12 INSTALLATION ●
Carry out installation in the reverse order to expansion.
[*1] Mount bolt: Anti-seizure compound (MARUZEN MOLYMAX No. 2 or equivalent)
Mount bolt: Tighten the 4 bolts first to 392 ± 39 Nm {40 ± 4 kgm} (289 ± 28 lbf ft). Check that the mating faces are fitted, then retighten each bolt by 120° ± 10°. [*2] ★ Adjust the tension of the track shoe. For detail, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension. Lubricator: 58.8 - 88.3 Nm {6 - 9 kgm} (43.3 - 65.1 lbf ft)
[*3] ★ Using the tool, press fit the master pin so that its projection “a” will be as follows. ● Dimension “a”: 4.4 ± 2 mm Supply grease to the space between the bushing and pin so that filling rate will be 100%. Grease: NIGUTAITE LYK-2 manufactured by NIPPON GREASE CO., LTD. or equivalent
Apply grease to the contact faces of dust seal (5) and bushing (4) (all over the end face of the dust seal or bushing) (parts marked Q). Do not apply grease to the pars marked X, however. R: Detail of regular pin position M: Detail of master pin position (Pins are not inserted, however) [*4] Set the track shoe and sprocket (4) as shown in the following figure (on both right and left sides).
30-72 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
12
AIR CONDITIONER UNIT
Service tool kit
■
1
799-703-1100
Vacuum pump (100V)
■
1
799-703-1110
Vacuum pump (220V)
■
1
799-703-1120
Vacuum pump (240V)
■
1
799-703-1400
Gas leak tester
■
1
Part Name
Sketch
799-703-1200
Part No.
New/Remodel
Qíty
Q
Necessity
Symbol
SPECIAL TOOLS
REMOVAL WARNING! Disconnect the cable from the negative (–) terminal of the battery. 1.
Swing the upper structure by 90°.
2.
Open the engine hood.
3.
Connect tool Q to cap [1] and collect the air conditioner refrigerant.
4.
Remove rear covers (1), (2), (3), and (4).
5.
Remove duct (5), cover (6), and plate (7).
6.
Remove plate (8) and duct (9). ★ Remove the duct lock clip.
7.
Remove ducts (10) and (11).
PC400LC-7L
30-73 2
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
12 8. Disconnect connectors D01 (12), D02 (13), C09 (14), R22 (15), R20 (16), and K19 (17). 9.
Remove and sling controller (18).
10. Remove plate (19). 11. Disconnect air conditioner unit connectors M27 (20) and M33 (21).
12. Remove the air conditioner unit undercover. ★ Part A
13. Remove mount bolt (24) and connector (25). [*1] 14. Disconnect heater hoses (22) and (23) and air conditioner tube (26). [*1] ★ Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.
15. Remove the 7 mount bolts and air conditioner unit assembly (27).
30-74 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
12 INSTALLATION ●
Carry out installation in the reverse order to removal. ★ When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them. ★ When connecting each air conditioner hose, check that the O-ring is fitted to the joint. ★ Check that each O-ring is free from flaw and deterioration.
[*1] ★ Apply compressor oil (ND-OIL8) to the threads of the refrigerant pipe joints and tighten each nut with double spanner. Hose clamp (M6 bolt): 8 - 12 Nm {0.8 - 1.2 kgm} (5.9 - 8.8 lbf ft) Hose screw of M16 x 1.5: 12 - 15 Nm {1.2 - 1.5 kgm} (8.8 - 11.0 lbf ft) Hose screw of M22 x 1.5: 20 – 25 Nm {2.0 – 2.5 kgm} (14.7 - 18.4 lbf ft) Hose screw of M24 x 1.5: 30 – 35 Nm {3.0 – 3.5 kgm} (22.1 - 25.8 lbf ft) ●
Charging air conditioner with refrigerant gas Using tool Q, charge the air conditioner circuit with refrigerant (HFC R134a) from the compressor. ★ Quantity of refrigerant: 950 ± 50 g
PC400LC-7L
30-75 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
12
OPERATOR’S CAB REMOVAL WARNING! Disconnect the cable from the negative (–) terminal of the battery. 1.
Remove rear covers (1), (2), (3), and (4).
2.
Remove duct (5), cover (6), and plate (7).
3.
3. Remove plate (8), duct (9) and the element. ★ Remove the duct lock clip.
4.
Remove clip (10) and disconnect cab wiring connectors M45 (11), H08 (12), and H09 (13).
5.
Remove air conditioner connector plate (14).
6.
Disconnect connectors M71 (15), H10 (16), H11 (17), and H12 (18).
7.
Disconnect upper and lower duct joints (19) and (20).
8.
Remove controller sub-plate (21) and incline it against the air conditioner.
30-76 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
12 9. Remove cover (22) and floor mat (23).
10. Move right console (24) into the cab. 11. Remove monitor panel undercover (25).
12. Disconnect cab wiring connector W04 (26) (Wiper motor). 13. Remove ducts (27) and (28). ★ Both (27) and (28) are two in number. ★ Cut the tie-wrap on the monitor wiring harness. 14. Remove cover (29) and monitor assembly (30).
15. Disconnect radio antenna (31). 16. Remove clip (32) and take wiring harness (33) out of grommet (34).
PC400LC-7L
30-77 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
12 17. Take grommet (35) out of the right front of the cab. 18. Disconnect the windshield washer hose from (36). 19. Remove 4 mount bolts (37) and 5 mount bolts (38). ★ Check the types of the bolts. ★ In the initial period, 7 mount bolts (38) are used.
20. Using lever block [1], lift off operator's cab assembly (39). Operator's cab assembly: 300 kg (662 lb)
21. When starting the engine while the operator's cab is removed (for transportation, etc.), use the following brackets. A. Bracket (41) for controller (40), Part No.: 208-53-13920
B. Bracket (42) for monitor panel assembly (30) Part No.: 208-53-13910
INSTALLATION ●
Carry out installation in the reverse order to removal.
30-78 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
MONITOR
12
MONITOR REMOVAL WARNING! Disconnect the cable from the negative (–) terminal of the battery. 1.
Remove cover (1) and disconnect wiring connector P15 of air conditioner sunlight sensor (2). ★ Raise and remove the cover.
2.
Remove the 3 mount screws and monitor assembly (3). ★ Disconnect monitor panel wiring connectors P01, P02, and P70 before removing the monitor assembly.
INSTALLATION ●
Carry out installation in the reverse order to removal.
PC400LC-7L
30-79 2
DISASSEMBLY AND ASSEMBLY
PUMP CONTROLLER
12
PUMP CONTROLLER REMOVAL WARNING! Disconnect the cable from the negative (–) terminal of the battery. 1.
Remove covers (1), (2), and (3).
2.
Disconnect pump controller wiring connectors C01 (4), C02 (5), and C03 (6).
3.
Remove the 4 mount bolts and pump controller assembly (7).
INSTALLATION ●
Carry out installation in the reverse order to removal.
30-80 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
ENGINE CONTROLLER
12
ENGINE CONTROLLER REMOVAL WARNING! Disconnect the cable from the negative (–) terminal of the battery. 1.
Open the right side cover (cooler).
2.
Remove bracket (1).
3.
Remove the 4 mount bolts and engine controller assembly (2).
4.
Disconnect engine controller wiring connectors CB1 (3), CB2 (4), and CB3 (5).
INSTALLATION ●
Carry out installation in the reverse order to removal.
PC400LC-7L
30-81 2
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME
12
REVOLVING FRAME REMOVAL WARNING! Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position. 1.
Remove the work equipment assembly. For details, see WORK EQUIPMENT.
2.
Remove the counterweight assembly. For details, see COUNTERWEIGHT.
3.
Disconnect 4 boom cylinder hoses (1). ★ Plug the hoses to stop oil.
4.
Sling boom cylinder assembly (2) temporarily.
5.
Remove plate (3) and pin (4) and lift off boom cylinder assembly (2). ★ Remove the boom cylinder on the opposite side similarly. Boom cylinder assembly: 360 kg (794 lb)
30-82 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME
12 6. Disconnect 7 hoses (5) – (11). ● (5): Center swivel joint (Port D) – Swing motor (Port T) ● (6): Center swivel joint (Port D) – Hydraulic tank ● (7): Center swivel joint (Port E) – Solenoid valve ● (8): Center swivel joint (Port B) – Control valve left travel (Port B2) ● (9): Center swivel joint (Port D) – Control valve right travel (Port B5) ● (10): Center swivel joint (Port A) – Control valve left travel (Port A2) ● (11):Center swivel joint (Port C) – Control valve right travel (Port A5) 7.
Pull out pin (12) on the center swivel joint side and disconnect the lock plate from the center swivel joint.
8.
Remove 29 mount bolts (13), leaving 3 each at the front and rear sides.
9.
Using a lever block, sling the revolving frame assembly temporarily, balancing it in each direction. ★ Put wood liners to the rear side of the frame. ● Rough standard length of sling: Front: 8 m in total Rear: 6 m ● If the engine hood interferes with the sling, erect the engine hood, referring to RADIATOR.
10. Remove the remaining 6 bolts and lift off revolving frame assembly (14). [*1] WARNING! When removing the revolving frame assembly, take care that it will not interfere with the center swivel joint assembly. Revolving frame assembly: 10,000 kg (22,047 lb)
PC400LC-7L
30-83 2
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME
12 INSTALLATION ●
Carry out installation in the reverse order to removal.
[*1] ●
Match the soft zone point (P) of the outer race and the soft zone point (S) of the inner race. Mating face of swing circle: Gasket sealant (LG-6)
Threads of revolving frame mount bolt: Adhesive (LT-2)
Revolving frame mount bolt 1. Tighten the bolts marked with A (at 4 places) according to the following steps 1) – 3). 1) Tighten each bolt to 392 Nm {40 kgm} (289 lbf ft) first. 2) Then, tighten the bolt by 90° ± 5°. • Make a mark on the bolt head with a marker pen (to check the angle). 3) The tightening torque of the bolt tighten in 2) above must be 1,176 Nm {120 kgm} (867 lbf ft) or larger. 2. Tighten each bolt 208-25-71230 which is not marked with A according to above steps 1) – 3). If the tightening torque reaches 2,254 Nm {230 kgm} (1662 lbf ft) before completing the above steps and the tightening angle is 35° – 95°, however, stop tightening.
★ Marks P and S are the soft zone points. ● Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. ● Bleeding air Bleed air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
30-84 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
12
COUNTERWEIGHT REMOVAL 1.
Set eyebolt [1] to counterweight assembly (1).
2.
Remove 4 mount bolts (2). [*1] ★ Check where shims have been used.
3.
Lift off counterweight assembly (1). [*2] ★ When lifting off the counterweight, take care not to strike it against the engine, radiator and cooler assembly, etc. Counterweight assembly: 9,500 kg (20,944 lb)
INSTALLATION ●
Carry out installation in the reverse order to removal. ★ If heat insulation cover (3) of the engine compartment is flattened, replace it.
[*1] Threads of mount bolt: Adhesive (LT-2)
Mount bolt: 3,430 - 4,212 Nm {350 - 430 kgm} (2,530 - 3106 lbf ft) [*2] ★ Installation and adjustment of counterweight 1) Adjust the level difference from the exterior parts (horizontal clearance) with shims. ● Kinds of shim thickness: 0.5 mm, 1 mm 2) Insert the shims so that the clearance between the door and counterweight and that between the revolving frame and counterweight will be 10 ± 5 mm evenly.
PC400LC-7L
30-85 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
12
HYDRAULIC TANK REMOVAL 1.
Remove 3 lower covers (1).
2.
Drain the oil from the hydraulic tank. Capacity of hydraulic tank: Approximately 335 L (88.5 gal)
3.
Open engine hood (2) and remove control valve top cover (3).
4.
Remove cover (4).
5.
Disconnect drain hoses (5) and (6).
6.
Disconnect block (7).
7.
Disconnect drain hoses (8), (9), and (10).
8.
Disconnect 2 clamps (11).
9.
Remove side cover (12).
30-86 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
12 10. Remove sensor (13). 11. Disconnect suction tube (14). 12. Sling the hydraulic tank assembly temporarily and remove 6 mount bolts (15).
13. Lift off hydraulic tank assembly (16). Hydraulic tank assembly: 200 kg (441 lb)
INSTALLATION ● ●
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Capacity of hydraulic tank: Approximately 335 L (88.5 gal) Quantity of oil in tank (Center of oil level gauge): 248 L (65.5 gal)
●
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
PC400LC-7L
30-87 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
12
HYDRAULIC PUMP
Oil stopper
●
1
796-770-1320
Adapter
●
1
Part Name
Sketch
796-460-1210
Part No.
New/Remodel
Q’ty
C
Necessity
Symbol
SPECIAL TOOLS
REMOVAL WARNING! Disconnect the cable from the negative (–) terminal of the battery. WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. ★ Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1.
Remove 2 lower covers (1).
2.
Remove the hydraulic tank strainer. Using tool C, stop the oil. ★ When not using tool C, remove the drain plug to drain the oil from the hydraulic tank and piping. Capacity of hydraulic tank: Approximately 335 L (88.5 gal)
3.
Drain the oil from the flywheel housing.
4.
Open the main pump side cover.
5.
Open the engine hood.
6.
Lift off covers (2) and (3) together.
7.
Remove cover (4).
8.
Remove stay (5).
30-88 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
12 9. Disconnect the following 2 pump wiring connectors. ● (6): V22 (PC-EPC solenoid valve) Band color: Red ● (7): V21 (LS-EPC solenoid valve) Band color: White 10. Disconnect the following 10 hoses and 1 tube. ● (8): EPC basic pressure port hose (Band color: Yellow) ● (9): Rear pump pressure input port hose (Band color: Red) ● (10): Rear pump discharge port hose ● (11): Front pump discharge port hose ● (12): Drain port hose ● (13): Front load pressure input port hose ● (14): Rear load pressure input port hose (Band color: Red) ● (15): Front pump pressure input port hose ● (16): Pump suction port tube
11. Sling hydraulic pump assembly (18) temporarily and remove 12 mount bolts (17).
12. Lift off hydraulic pump assembly (18). [*1] Hydraulic pump assembly: 255 kg (563 lb)
PC400LC-7L
30-89 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
12 INSTALLATION ●
Carry out installation in the reverse order to removal.
[*1] Hydraulic pump involute spline: Anti-friction compound (LM-G)
Mating face of hydraulic pump case: Gasket sealant (LG-6)
●
Refilling with oil Flywheel housing drain plug: 42.1 - 70.6 Nm {4.3 - 7.2 kgm} (31 - 52 lbf ft) Add oil through the oil filler to the specified level.
●
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Capacity of hydraulic tank: Approximately 335 L (88.5 gal) Quantity of oil in tank (Center of oil level gauge): 248 L (65.5 gal)
●
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
30-90 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
12
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT REMOVAL 1.
Remove the hydraulic pump assembly. Refer to the HYDRAULIC PUMP section.
2.
Remove snap ring (1) and then remove spacer (2).
3.
Pry off oil seal (3) with a screwdriver. [*1] ★ When attempting to pry off the seal, do not damage the shaft.
INSTALLATION ●
Install in reverse order of removal.
[*1] Oil seal lip portion: Grease (G2-LI)
Oil seal outer circumference: Grease (G2-LI)
★ Coat the oil seal outer circumference thinly with grease. ★ Press-fit oil seal (3), using tool.
PC400LC-7L
30-91 2
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12
CONTROL VALVE REMOVAL WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank and set the safety lock lever to the LOCK position. ★ Put tags to the disconnected hoses and tubes to prevent a mistake in reconnecting them. 1.
Open engine hood (1).
2.
Remove control valve top cover (2).
3.
Remove partition covers (3), (4), and (5) between the engine and control valve.
4.
Remove the control valve bottom cover.
5.
Disconnect the 2 wiring connectors and 8 hoses. ● (6): A51 (Front pump pressure sensor) ● (7): A52 (Rear pump pressure sensor) ● (8): Port PS hose (Hose band: Yellow-Blue) ● (9): Port PST hose (Hose band: Brown) ● (10): Port PPS2 hose (Rear pump, red) ● (11): Port PR hose (Solenoid) ● (12): Port PR hose (Pump, yellow) ● (13): Port PP1 hose (Front pump) ● (14): Port PP2 hose (Rear pump) ● (15): Port T hose (Oil cooler)
6.
Disconnect the following 4 control valve hoses: ● (16): Port PPS1 hose (Front pump) ● (17): Port PLS2 hose (Hose band: Red) ● (18): Port PLS1 hose ● (19): Port PX1 hose (Hose band: Blue)
7.
Remove relay bracket (20) and clamp (21).
8.
Disconnect drain hose (22). (To tank)
9.
Disconnect the following 6 left PPC hoses. ● (23): In order from top Bucket CURL (Hose band: White) Left travel REVERSE Boom RAISE (Hose band: Green) Left SWING (Hose band: Red) Right travel REVERSE (Hose band: Blue) Arm DUMP (Hose band: Yellow)
30-92 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
10. Disconnect 4 boom hoses (24). 11. Remove boom tube clamps (25) and (26).
12. Disconnect port TSW hose (27) (Swing motor port S). 13. (28): In order from top Remove port A-1 tube (Boom Hi bottom side). Remove port A1 tube (Bucket bottom side). Disconnect port A2 hose (Swivel joint port A). After removing the hoses from ports B, remove port A3 tube (Boom bottom side). Remove port A4 hose (Swing motor port MB). Disconnect port A5 hose (Swivel joint port C). Remove port A6 tube (Arm head side). 14. (29): In order from top Disconnect port B-1 hose (Arm Hi bottom side). Disconnect port B1 hose (Bucket head side). Disconnect port B2 hose (Swivel joint port B). Remove port B3 tube (Boom head side). Remove port B4 hose (Swing motor port MA). Disconnect port B5 hose (Swivel joint port D). Remove port B6 tube (Arm bottom side). 15. Disconnect the following 6 right PPC hoses. ● (30): Bucket DUMP (Hose band: Black) ● (31): Left travel FORWARD (Hose band: Red) ● (32): Boom LOWER (Hose band: Brown) ● (33): Right SWING ● (34): Right travel FORWARD (Hose band: Green) ● (35): Arm IN (Hose band: Blue)
PC400LC-7L
30-93 2
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12 16. Disconnect the following 3 control valve hoses. ★ Do not disconnect hose C. ● (36): Port BP5 hose (To solenoid) ● (37): Port PX2 hose ● (38): Port TS hose
17. Sling control valve assembly (40) temporarily and remove 3 mount bolts (39).
18. Lift off control valve assembly (40). Control valve assembly: 250 kg (552 lb)
30-94 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12 INSTALLATION ● ●
●
Carry out installation in the reverse order to removal. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
PC400LC-7L
30-95 2
DISASSEMBLY AND ASSEMBLY 12 REPLACEMENT
CONTROL VALVE
PROCEDURE FOR PRESSURE COMPENSATION VALVE
SEAL Remark Only precautions for assembling the pressure compensation valve assembly and control valve assembly are explained below.
796-946-1310
Guide ➆21.8
(For 723-46-40100, 723-46-40601) 1
796-946-2110
Guide ➆20.9
(For 723-46-44100) 796-946-2210
Guide ➆20.6
(For 723-46-45100, 723-46-45500) 796-946-1320
Guide
(For 723-46-40100, 723-46-40601) 796-946-1420 2 L
Guide 21.6
(For 723-46-42800) 796-946-2120
Guide
(For 723-46-44100) 796-946-2220
Guide
(For 723-46-45100, 723-46-45500) 796-946-1330
Sleeve
(For 723-46-40100, 723-46-40601) 796-946-1430 3
Sleeve
(For 723-46-42800) 796-946-2130
Sleeve
(For 723-46-44100) 796-946-2230
Sleeve
(For 723-46-45100, 723-46-45500)
30-96 2
Sketch
New/Remodel
Part Name
Q’ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
1 1 1 1 1 1 1 1 1 1 1
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12 ★ Since there many types of the pressure compensation valves, make a mark on each valve to indicate from where it was removed. 1.
Remove piston (2), plug (3), and spring (4) from pressure compensation valve (1).
2.
Remove seal (5) and O-ring (6) from piston (2). ★ There many types of the pistons. ★ Clean the pressure compensation valve thoroughly. Then, using the tool, install seals as shown in the figure.
3.
Fit O-ring (6) to piston (2).
4.
Set tool L1 to piston (2) and push it in with your hand slowly so that seal (5) will expand evenly. ★ You may push in the seal to the flat part of the tool first, and then install the tool to the piston and push in the seal further.
5.
Set tool L2 to piston (1) for other seal (3) and push it in with your hand slowly so that seal (3) will expand evenly. ★ You may push in the seal to the flat part of the tool first, and then install the tool to the piston and push in the seal further.
6.
Install correcting tool L3 to piston (1) for about 1 minute to fit seals (2) and (3). ★ Check that the seal are not projected or broken.
7.
Fit plug (3) and spring (4) to piston (2) and assemble pressure compensation valve (1). ★ If these parts are difficult to install, do not push them in forcibly, but install them to correcting tool L3 to fit the seals, and then install them to the piston. ★ After assembling, push the piston with your hand and check that it is returned by only the spring force.
PC400LC-7L
30-97 2
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12 ASSEMBLY ● ●
●
Apply engine oil to the sliding surfaces of the parts before installing. When installing spools (7) and (10) in the valve chamber, direct drilled holes (8) and (11) toward cylinder ports (9) and (12).
Install filters (13) to the bottom of ports PLS1 and PLS2 as shown at right.
30-98 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12 ● Control valve top and bottom covers Mating faces of control valve top and bottom covers: SEALEND 242 or equivalent ★ Use 2 washers (W2) each for only 2 places of the control valve top cover. ● Tighten the mount bolts of the control valve top and bottom covers in the following order. (A → D → C → B) Mount bolt of control valve top and bottom covers: 156.9 - 176.5 Nm {16 - 18 kgm} (115.7 - 130.1 lbf ft) ●
Merge-divider valve Mating face of merge-divider valve: SEALEND 242 or equivalent
●
Tighten the mount bolts of the merge-divider valve similarly to those of the control valve covers. Mount bolt of merge-divider valve: 156.9 - 176.5 Nm {16 - 18 kgm} (115.7 - 130.1 lbf ft)
●
Tighten the mount bolts of the boom Hi check valve, quick return valve, lock valve, and arm plate similarly to those of the control valve covers. Mount bolt of boom Hi check valve, quick return valve, lock valve, and arm plate: 58.8 - 73.6 Nm {6 - 7.5 kgm} (43.3 - 54.2 lbf ft)
PC400LC-7L
30-99 2
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12 Mount bolts of back-pressure valve, boom Hi check valve, quick return valve, lock valve and arm plate: 58.8 - 73.6 Nm {6 - 7.5 kgm} (43.3 - 54.2 lbf ft) ●
●
Pressure compensation valve ★ When installing each pressure compensation valve, check the mark made when it was removed. Main relief valve assembly After installing the main relief valve to the control valve, see TESTING AND ADJUSTING, Testing and adjusting oil pressures in work equipment, swing, and travel circuits.
30-100 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT REMOVAL WARNING! Replace the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, release of remaining pressure in hydraulic circuit. ★ Mark all the piping with tags to prevent mistakes in the mount position when installing.
1.
Disconnect six hoses (1) through (6) between travel motor and center swivel joint. ● (1): Center swivel joint (T port) – Left travel motor (T port) ● (2): Center swivel joint (T port) – Right travel motor (T port) ● (3): Center swivel joint (B port) – Left travel motor (PA port) ● (4): Center swivel joint (D port) – Right travel motor (PB port) ● (5): Center swivel joint (A port) – Left travel motor (PB port) ● (6): Center swivel joint (C port) – Right travel motor (PA port)
2.
Disconnect nine hoses (7) through (15). ● (7): Center swivel joint (E port) – Left travel motor (P port) ● (8): Center swivel joint (E port) – Right travel motor (P port) ● (9): Center swivel joint (D port) – swing motor (T port) ● (10): Center swivel joint (D port) – Hydraulic tank ● (11): Center swivel joint (E port) – solenoid valve ● (12): Center swivel joint (B port) – Left travel control valve (B2 port) ● (13): Center swivel joint (D port) – Right travel control valve (B5 port) ● (14): Center swivel joint (A port) – Left travel control valve (A2 port) ● (15): Center swivel joint (C port) – Right travel control valve (A5 port)
3.
Pull out pin (16) on the side of center swivel joint and remove the jam plate from the center swivel joint.
4.
Remove four mount bolts (17).
5.
Remove center swivel joint assembly (18). [*1] Center swivel joint assembly: 40 kg (89 lb)
PC400LC-7L
30-101 2
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
12 INSTALLATION ●
Install in reverse order of removal.
[*1]
●
●
Install the center swivel joint facing in the direction shown in the diagram. (The diagram shows the machine as seen from above) Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air Bleed the air from the travel motor. For details see TESTING AND ADUSTING, Air Bleeding of Various Parts.
30-102 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
M
1
Push puller
●
790-101-2510
●
Block
1
●
790-101-2520
●
Screw
1
●
791-112-1180
●
Nut
1
●
790-101-2540
●
Washer
1
●
790-101-2630
●
Leg
2
●
790-101-2570
●
Plate
4
●
790-101-2560
●
Nut
2
●
790-101-2650
●
Adapter
2
Sketch
●
790-101-2501
New/Remodel
Part Name
Q’ty
Part No.
Necessity
Symbol
12 SPECIAL TOOLS
DISASSEMBLY 1.
Remove cover (1).
2.
Remove snap ring (2).
3.
Using tool M, pull out swivel rotor (4) and ring (3) from swivel shaft (5).
4.
Remove seal (6) from swivel shaft (5).
5.
Remove O-ring (7) and slipper seal (8) from swivel rotor (4).
ASSEMBLY 1.
Assemble slipper seal (8) and O-ring (7) to swivel rotor (4).
2.
Assemble seal (6) in swivel shaft (5).
3.
Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install. Contact surface of rotor, shaft: Grease (G0-LI or G2-LI)
●
When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring.
4.
Install ring (3) and secure with snap ring (2).
5.
Install O-ring and cover (1). Mount bolt: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
PC400LC-7L
30-103 2
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT PPC VALVE
12
WORK EQUIPMENT PPC VALVE ★ Only precautions for assembling the work equipment PPC valve assembly are explained below.
ASSEMBLY ●
Work equipment PPC valve assembly ★ Install springs (11❈) with the small-diameter (inside diameter) end on the shim (12) side. ★ Springs (10❈) having different number of turns are used for the following hydraulic ports. Take care when installing them. Installed height: 31.9 mm (Common to all springs) Installed load: P1, P2: 35.3 N {3.6 kg} (7.9 lbf) P3, P4: 21.6 N {2.2 kg} (4.85 lbf) ★ The position of each port is stamped on the underside of valve body. Piston (8): Grease (G2-LI)
★ When installing pistons (8), apply grease to their outside and the inside of the valve body holes. Mount bolt of plate (5): 11.8 - 14.7 Nm {1.2 - 1.5 kgm} (8.7 - 10.8 lbf ft) Sliding parts of joint (4): 2 - 4 cc of Grease (G2-LI)
Female threads of body (A): Adhesive (LT-2)
★ Apply a drop (about 0.02 g) of LOCTITE to each of the 2 threaded parts of the body as shown in the figure, and then tighten joint (4). Joint (4): 39 - 49 Nm {4 - 5 kgm} (28.7 - 36.1 lbf ft) ★ Observe the tightening torque of the joint. Contact parts of piston and disc (2): Grease 0.3 - 0.8 cc (G2-LI) Nut (1): 69 - 88 Nm {7 - 9 kgm} (51.8 - 64.9 lbf ft) ★ When installing disc (2), adjust the play to 0.5 - 3mm at 200 mm from the turning center of the lever.
30-104 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
TRAVEL PPC VALVE
12
TRAVEL PPC VALVE DISASSEMBLY ★ Only precautions for assembling the travel PPC valve assembly are explained below.
ASSEMBLY ●
Travel PPC valve assembly ★ Insert shim (3) of the thickness and quantity checked when disassembled. Standard shim thickness: 0.3 mm ★ Since spring (4) is not symmetric vertically, install it with the small-diameter (inside diameter) end on the shim side. Periphery of piston (7) and inside of hole of body (1): Grease (G2-LI)
Sliding part of shaft (13) (4 – 8 cc), contact parts of lever (12) and piston (7), and contact part of pin of lever (26) and plate (24) (0.3 – 0.8 cc): Grease (G2-LI) ★ Use the inserting jig described in KES.D.07177 to insert bushing (19). ★ Use the inserting jig described in KES.D.04025 to insert spring pin (25).
PC400LC-7L
30-105 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
Qíty
1
790-502-1003
Cylinder repair stand
■
1
790-102-4300
Wrench assembly
■
1
790-102-4310
Pin
■
2
790-720-1000
Expander
●
1
796-720-1680
Ring (For boom and bucket)
●
1
07281-01589
Clamp (For boom and bucket)
●
1
796-720-1690
Ring (For arm)
●
1
07281-01919
Clamp (For arm)
●
1
790-201-1702
Push tool kit
■
1
●
790-201-1851
●
Push tool (For bucket)
1
●
790-201-1861
●
Push tool (For boom)
1
●
790-201-1871
●
ï Push tool (For arm)
1
●
790-101-5021
●
Grip
1
●
01010-50816
●
Bolt
1
2 3
4
N 5
6
Part Name
790-201-1500
Push tool kit
1
●
790-101-5021
●
Grip
1
●
01010-50816
●
Bolt
1
●
790-201-1660
●
Plate (For bucket)
1
●
790-201-1670
●
Plate (For boom)
1
●
790-201-1680
●
Plate (For arm)
1
Sketch
Part No.
New/Remodel
Symbol
Necessity
SPECIAL TOOLS
DISASSEMBLY 1.
Piston rod assembly A. Remove the piping from the cylinder assembly. B. Remove the mount bolts and disconnect cylinder head assembly (1). C. Pull out piston rod assembly (2). ★ Put a container under the cylinder to receive oil.
30-106 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
12 D. Disassemble the piston rod assembly according to the following procedure. i.
Set piston rod assembly (2) to tool N1.
ii. Remove piston assembly lock screw (3). ★ This work is common to the boom, arm, and bucket cylinders. Screw size: M12 x Pitch 1.75
★ If screw (3) is so caulked that you cannot remove it, tighten it temporarily and tap the threads on it, and then remove it.
iii. Using tool N2, remove piston assembly (4). ● When not using tool N2, loosen the piston assembly by using the drilled holes (Ø10: 2 places) (in which the pins of N2 are inserted in the figure at right).
PC400LC-7L
30-107 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
12 iv. Remove plunger (5). ● Perform this work for only the boom and arm cylinder. v.
Remove collar (6). ● Perform this work for only the boom and arm cylinder.
vi. Remove head assembly (7).
vii. Remove cap (8), 11 balls (9), and plunger (10). ● Perform this work for only the arm cylinder. ★ Since cap (8) is made of nylon, tighten a screw into it and pull it with pliers.
2.
Disassembly of piston assembly A. Remove rings (11). B. Remove wear rings (12). C. Remove piston ring (13). D. Remove the O-ring and backup rings (14).
3.
Disassembly of cylinder head assembly A. Remove the O-ring and backup ring (15). B. Remove snap ring (16) and dust seal (17). C. Remove rod packing (18). D. Remove buffer ring (19). E. Remove snap ring (21). F.
Remove bushing (20).
30-108 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
12 ASSEMBLY ★ Take care not to damage the packings, dust seals, O-rings, etc. ★ Clean the all parts. After installing them, cover the piping ports and pin holes to prevent dirt from entering. ★ Do not insert each backup ring forcibly, but warm it in water at 50 60°C (122 - 140°F) and then insert it. 1.
Assembly of cylinder head assembly A. Using tool N5, press fit bushing (20). B. Install buffer ring (19). C. Install rod packing (18). D. Using tool N6, install dust seal (17) and secure it with snap ring (16). E. Install backup ring and O-ring (15). F.
2.
Install snap ring (21).
Assembly of piston assembly A. Using tool N3, expand piston ring (13). ★ Set piston ring (13) to tool N3 and turn the handle 8 - 10 times to expand the piston ring. B. Set tool N4 and contract piston ring (13).
C. Install backup ring and O-ring (14). D. Install wear ring (12). E. Install ring (11). ★ Do not increase the closed gap of the ring too much. Ring groove: Grease (G2-LI)
PC400LC-7L
30-109 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
12 3. Piston rod assembly A. Set the piston rod to tool N1. B. Install cylinder head assembly (7) to the piston rod. C. Fit the O-ring and backup ring to collar (6), and then install them. ● Perform this work for only the boom and arm cylinders. D. Install plunger (5). ● Perform this work for only the boom and arm cylinders.
E. Set plunger (10) to the piston rod. Install 11 balls (9) and secure them with cap (8). ★ After installing the plunger, check that it has a little play at its end. ● Perform this work for only the arm cylinder.
F.
Assemble piston assembly (4) according to the following procedure. ● When reusing the rod and piston assembly (4). i.
Tighten piston assembly (4). Then, using tool N2, tighten piston assembly (4) until the screw holes are aligned. ★ Remove the burrs from the threads with a file. Go to D. ● When replacing either or both of the rod and piston assembly (4) with new ones. ★ Make a mark of the cushion plug position on the end of the rod having the bottom cushion. ● Perform this work for only the arm cylinder. ii.
Using the tool, tighten piston assembly (4) until it reaches the end of the rod. Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} (216 ± 21.6 lbf ft) ★ ●
30-110 2
After tightening the piston, check that plunger (5) has some play. Perform this work for only the boom and arm cylinders.
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
12 iii. Make a screw hole to install screw (3). ★ Apply a drill to the V-groove of the threaded parts of piston (4) and rod (2) and make a hole. ★ When making a hole on the cylinder (arm cylinder) having the bottom cushion, make it around the cushion plug. ● • Dimensions of screw hole (mm) Tap drill diameter
Tap to be used
10.3
12 x 1.75 Tap drill hole depth
Tapping depth
Bucket/Boom
27
20
Arm
36
29
iv. Tighten screw (3). ★ Clean the parts thoroughly and remove metal chips, dirt, etc. Threads of screw: Adhesive (LOCTITE No. 262)
Screw: 58.9 - 73.6 Nm {6 - 7.5 kgm} (43.4 - 54.2 lbf ft) v.
Caulk the threaded part by 4 places with a punch.
G. Install piston rod assembly (2). ★ Set the abutment joint of the ring at a side and insert the piston rod, aligning it with the cylinder tube. ★ After inserting the piston rod, check that the ring is not broken or removed, and then insert to the end.
PC400LC-7L
30-111 2
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
12 H. Tighten the mount bolts of cylinder head assembly (7). Mount bolt: Bucket: 530 ± 78.5 Nm {54.0 ± 8 kgm} (390 ± 57.8 lbf ft) Arm: 892 ± 137 Nm {91.0 ± 14 kgm}(657 ± 101 lbf ft) Boom: 530 ± 78.5 Nm {54.0 ± 8 kgm} (390 ± 57.8 lbf ft) I.
Install the piping.
30-112 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12
WORK EQUIPMENT
P
1
Remover
●
796-670-1110
●
Sleeve
1
●
796-670-1120
●
Plate
1
●
796-670-1130
●
Screw
1
●
796-870-1110
●
Adapter
1
●
01643-33080
●
Washer
1
●
01803-13034
●
Nut
1
790-101-4000
Puller (490 kN {50t}, long)
●
1
790-101-1102
Pump (294 kN {30t})
l
1
Sketch
●
796-670-1100
New/Remodel
Part Name
Q’ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
REMOVAL WARNING! Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position. WARNING! See TESTING AND ADJUSTING, Releasing residual pressure in hydraulic circuit. 1.
Disconnect grease hose (1).
2.
Sling boom cylinder assembly (2) temporarily and remove lock bolt and nut (3). [*1]
3.
Remove plate (4) and head pin (5). [*2] ★ Check the quantity and positions of the inserted shims.
4.
Start the engine and retract the piston rod. ★ Bind the rod with wires, etc. so that it will not be extracted and lower it onto a stand or put a wood block to the bottom side so that the cylinder will not lower. When putting the wood block, remove the grease fitting on the bottom side. ★ Disconnect the boom cylinder on the opposite side similarly. ★ When slinging the boom cylinder, if the sling interferes with the work equipment lamp, remove the work equipment lamp.
PC400LC-7L
30-113 2
DISASSEMBLY AND ASSEMBLY 5.
Disconnect intermediate connector A42 (6) for the work equipment lamp.
6.
Disconnect 3 arm cylinder hoses (7) and 2 bucket cylinder hoses (8). ★ Put oil stopper plugs and secure the hoses to the valve side with ropes.
7.
Sling work equipment assembly (12) temporarily.
8.
Remove cover (9), plate (10), and foot pin (11) to disconnect work equipment assembly (12). [*3]
WORK EQUIPMENT
When removing with tool P Remove plate (10). Sling and set tool P and remove foot pin (11) to disconnect work equipment assembly (12). ★ Check the quantity and positions of the inserted shims. ●
9.
Move the machine in reverse to remove work equipment assembly (12). Work equipment assembly: 7,400 kg (16,315 lb)
30-114 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12 INSTALLATION ●
Carry out installation in the reverse order to removal.
[*1] ★ Tighten the locknut so that clearance “a” between the plate and nut will be 0.5 - 1.5 mm.
[*2] Inside wall of bushing before assembling pin: Anti-friction composition (LM-P) Greasing after assembling pin: Grease (LM-G)
WARNING! When aligning the pin holes, never insert your fingers in them. ★ Adjust the shim thickness so that clearance “b” between cylinder rod (12) and plate (4) will be 1.5 mm or less. Standard shim: 1.0, 2.0 mm [*3] Inside wall of bushing before assembling pin: Anti-friction composition (LM-P) Greasing after assembling pin: Grease (LM-G)
WARNING! When aligning the pin holes, never insert your fingers in them.
● ●
★ Adjust the shim thickness so that clearance “c” between boom (13) and bracket (14) will be 1 mm or less. Standard shim: 2.0, 2.5, 3.0, 3.5 mm Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part. Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
PC400LC-7L
30-115 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12
OPERATOR’S CAB GLASS
1.
Right side window glass
2.
Left side rear window glass
3.
Door lower window glass
4.
Front window glass
5.
Front window assembly (Front window glass + Front frame)
6.
Both-sided adhesive tape
7.
Center trim seal
★ Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) – (4) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) For the procedure for replacing the front window assembly, see FRONT WINDOW.
30-116 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
Y
Lifter (Suction cup)
■
2
20Y-54-13180
Adapter
■
2
Part name
Part No.
Sketch
793-498-1210
2
Part No.
New/Remodel
Q'ty
1
Symbol
Necessity
12 SPECIAL TOOLS
Part name
Remarks
Yokohama M-300
Metal primer
Yokohama G-200
Glass primer
20Y-54-39850
Sikaflex 256HV
Adhesive
20Y-54-51531
Two-sided tape (DAM)
REMOVAL ★ Remove the window glass to be replaced according to the following procedure. 1.
Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet) (8).
★ If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it. (The figure to the right shows the operator's cab of a wheel loader.) ★ If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. ★ Widening the cut with a screwdriver, cut the adhesive and bothsided adhesive tape with knife [4]. (The figure to the right shows the operator's cab of a wheel loader.) 2.
Remove the window glass.
PC400LC-7L
30-117 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12 INSTALLATION 1.
Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. ★ Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.) (The figure to the right shows the operator's cab of a wheel loader.)
2.
Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. ★ If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. ★ Clean the all black part on the back side of the window glass. ★ After cleaning the sticking surfaces, leave them for at least 5 minutes to dry. (The figure to the right shows the operator's cab of a wheel loader.)
3.
Apply primer (10). ★ The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. ★ Use the primer within 2 hours after unpacking it. ★ Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is packed.) A. Stir the primers for paint and glass sufficiently before using them. ★ If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) B. When reusing primer brush (11), wash it in white gasoline. ★ After washing the brush, check it again for dirt and foreign matter. ★ Prepare respective brushes for the paint primer glass primer.
30-118 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12 C. Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator's cab (8) which will be coated with the adhesive. Paint primer: Yokohama M-300 or equivalent
★ Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
★ Parts to be coated with primer: Apply the primer all over dimension (a). ● Dimension to apply primer (a): 25 mm
★ In addition to the above parts, apply the primer to right side window glass (1) and door lower window glass (3). ● Range to apply primer additionally for right side window glass (1): (b) ● Range to apply primer additionally for door lower window glass (3): (c) ★ After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. Remark Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
PC400LC-7L
30-119 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12 D. Evenly apply glass primer to the sticking surfaces of window glass (9). Glass primer: Yokohama G-200 or equivalent
★ Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
★ Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (6) and operator's cab (8). ★ Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. ★ After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. Remark Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
4.
Stick both-sided adhesive tape (P/N 20Y-54-51531) (6) along the inside edge of the glass sticking section. ★ Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before sticking the glass. ★ When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. ★ Take that the both-sided adhesive tape will not float at each corner of the window frame. ★ When sticking both-sided adhesive tape (6) around a frame, do not lap its finishing end over the starting end but make clearance e of about 5 mm between them.
A. Stick both-sided adhesive tape (6) for right side window glass (1).
30-120 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12
OPERATOR’S CAB GLASS
★ Stick both-sided adhesive tape (6a) additionally for right side window glass (1). ● Positions to stick additional both-sided adhesive tape for right side window glass: (f): 50 mm (g): 90 mm (h): 250 mm
B. Stick both-sided adhesive tape (6) for left side rear window glass (2) as shown in the figure.
C. Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the figure.
★ Stick both-sided adhesive tape (6b) additionally for door lower window glass (3). ★ Positions to stick additional both-sided adhesive tape for door lower window glass: (j): 110 mm (k): 90 mm (m): 200 mm
PC400LC-7L
30-121 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12 D. Stick both-sided adhesive tape (6) for front window glass (4) as shown in the figure.
★ Stick both-sided adhesive tape (6c) of the lower side of the front window glass along the outside edge of the lower line, differently from other both-sided adhesive tapes (6). (If it is stuck along the inside, it will be seen through the transparent part of the glass.)
5.
Position the new window glass. A. Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. B. Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line n. ★ Stick tapes [6] to the right, left, and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. C. Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass. ★ Do not remove the tapes left on the window glass and operator's cab before installing the window glass.
30-122 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY 12
6.
OPERATOR’S CAB GLASS
★ When positioning front window glass (4), set its horizontal position to the frame width and set its vertical position so that height difference (p) between it and the frame top will be 3 mm.
Apply adhesive. ★ Use Sikaflex 256HV adhesive ★ The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. ★ Keep the adhesive in a dark place where the temperature is below 25°C (77°F). ★ Never heat the adhesive higher than 30°C (86°F). ★ When reusing the adhesive, remove the all hardened part from the nozzle tip. A. Break aluminum seal of the outlet of adhesive cartridge and install the nozzle. B. Cut the tip of the adhesive nozzle (14) so that dimensions (q) and (r) will be as follows. • Dimension (q): 10 mm • Dimension (r): 15 mm
C. Set adhesive cartridge (12) to caulking gun [7]. ★ An electric caulking gun is more efficient.
PC400LC-7L
30-123 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12 D. Remove the release tape of the both-sided adhesive tape on the glass side. E. Apply adhesive (15) to the outside of both-sided adhesive tape (6) of the operator's cab.
★ Apply adhesive (15) to dimensions (s) and (t) of both-sided adhesive tape (6) of operator's cab (8). • Dimension (s): 10 mm • Dimension (t): 15 mm ★ Apply adhesive (15) higher than both-sided adhesive tape (6). ★ Apply the adhesive evenly.
★ Apply adhesive (15) additionally for additional both-sided adhesive tape (6a) of the right side window glass and additional both-sided adhesive tape (6b) of door lower window glass.
30-124 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12 7. Install the window glass. A. Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. ★ Since the window glass cannot be removed and stuck again, stick it very carefully. ★ Stick the glass within 5 minutes after applying the adhesive. B. After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. ★ Press the corners of the window glass firmly.
★ You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup Y1.
★ After installing front window glass (4), fill the clearances between it and center trim seal (16) with caulking material in range (s) to dimensions (t) and (u). After applying the primer to glass (4) of section A – A, apply adhesive as caulking material. • Caulking dimension (t): 2 mm • Caulking dimension (u): 5 mm ★ When caulking, mask the glass side and form the adhesive with a rubber spatula as shown in the figure. ★ Wipe off projected adhesive. Glass primer: Yokohama G-200
Adhesive: Sikaflex 256HV
PC400LC-7L
30-125 2
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS
12 8. Fix the window glass. A. After installing right window glass (1) to the operator's cab, insert stopper rubbers Y2 to 2 places (v) at the bottom of the glass to fix the glass.
B. Using styrene foam blocks [9] and rubber bands [10], fix the window glass and both-sided adhesive tape to fit them completely. 9.
After installing the window glass, remove the primer and adhesive from the operator's cab and window glass. ★ Using white gasoline, wipe off the adhesive before it is dried up. ★ When cleaning the glass, do not give an impact to it.
10. Protect the stuck window glass. A. Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20°C (68°F) and humidity of 60%). B. After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually.
30-126 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
FRONT WINDOW WARNING! Lower the work equipment to the ground and stop the engine. ★ To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below.
REMOVAL 1.
Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides).
2.
Remove left corner blocks (1) and (2) and right corner block (3). [*1]
3.
Remove left striker bolt (4), right striker bolt (5), left corner block bracket, and right corner block bracket (7). [*2]
4.
Install left striker bolt (4) to the operator's cab again and tighten it lightly. ★ This bolt will be used to hang the pull-up assist cable in step 8.
5.
Release the rear locks.
6.
Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the both sides of the front window through the portion from which the corner blocks were removed in step 3 (the portion where the rail is open) and hold them.
7.
Remove rollers (8) and (9) under the both sides of the front window.
PC400LC-7L
30-127 2
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
12 8. Remove left lower pin (10). [*3] ★ If left lower pin (10) is removed, plate (12) at the end of pull-up assist cable (11) comes off. ★ Hang plate (12) on the left striker bolt. WARNING! The return load of 58.8 N {6 kg} (13.2 lbf) is applied to the rear of the operator's cab. Accordingly, take care when removing left lower pin (10) to disconnect pull-up assist cable (11).
9.
Put out the bottom of front window assembly (13) through the rail opening portion and lower it gradually.
10. Lower front window assembly (13) completely. ★ Do not let the front window assembly touch the monitor.
30-128 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
12 11. Twist front window assembly (13) to the right and left to remove both upper rollers (14) and (15) from the rails, and then remove front window assembly (13).
PC400LC-7L
30-129 2
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
12 INSTALLATION Carry out installation in the reverse order to removal. [*1] [*2] ● Adjust opening and closing of the front window assembly according to the following procedure. ●
1.
Open and close the front window to check that it does not interfere with the rails and the rollers are not hitch.
2.
If there is any problem in opening or closing of the front window, loosen the mount bolts of roller adjustment brackets (16) and (17) and adjust the condition of the front window, and then tighten the mount bolts again. Mount bolt: 98 Nm {1.0 kgm} (72.2 lbf ft)
30-130 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
12 3. Raise the front window assembly and fix it with the rear locks (on both sides). ★ Check that the locks in the rear of the operator's cab are applied securely. 4.
Install right corner block (3) and fix right corner block bracket (7) with right striker bolt (5). ★ Tighten the striker bolt securely after adjusting it in step 6. ★ Install the right corner block so that there will be no level difference at part (a). ★ Install the right corner block so that level difference (b) between the rail and right corner block (3) at part PF will be 0 - 1.0 mm. Check that the right corner block is not projected from the rail at the rolling surface of the roller. ★ Secure roller clearance (c) at part PJ.
PC400LC-7L
30-131 2
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
12 5. Install left corner blocks (1) and (2) and secure left corner bracket (6) with left striker bolt (4). ★ Tighten the striker bolt securely after adjusting it in step 6. ★ Install the left corner blocks so that there will be no level difference at 2 part (d). ★ Secure roller clearance (e).
6.
Tighten left striker bolt (4) and right striker bolt (5) at roughly right positions so that front window glass (18) will be fitted to cab-side trim seal (19).
30-132 2
PC400LC-7L
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
12
7.
Open and close the front window assembly and check the working condition of both locks (20) and (21). A. If both locks do not work normally, move the striker bolts toward the rear of the cab and tighten them again. B. After moving the striker bolts, check the fitness of the front window glass and cab-side trim seal which was checked in step 6. C. Repeat the work in 1) and 2) until the fitness of the front window and the working condition of both locks (20) and (21) are acceptable, and then tighten the striker bolts.
8.
After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak into the cab.
9.
Adjust the “opening” lock of the front window assembly. A. After adjusting the “closing” lock of the front window in steps 6 and 7, raise the front window assembly to the ceiling. B. Check the working condition of both front window assembly “opening” locks in the rear of the operator's cab. C. If the locks do not work normally, move both striker plates (22) in the rear of the operator's cab forward and in reverse and fix them at places where the locks work normally.
PC400LC-7L
30-133 2
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
12 10. Adjust the front window stoppers. A. After adjusting “closing” lock of the front window assembly in step 9, check the contact of both front window stoppers (23). B. If both stoppers (23) do not contact normally, adjust and fix them at places where they contact normally.
11. Check the latching effort of the front window assembly. A. After finishing steps 6 - 10, check that latching efforts of both locks (20) and (21) are even. ★ Check the latching efforts on both “closing” side (in the front of the operator's cab) and “opening” side (in the rear of the operator's cab). [*3] Left lower pin: 27 - 34 Nm {2.75 - 3.47 kgm} (20 - 25 lbf ft) Mount bolt: Adhesive (LT-2)
30-134 2
PC400LC-7L
90
OTHERS
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 HYDRAULIC DIAGRAM SHEET 1/2 (PART 2 OF 4) FOLDOUT 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5 HYDRAULIC DIAGRAM SHEET 1/2 (PART 3 OF 4) FOLDOUT 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7 HYDRAULIC DIAGRAM SHEET 1/2 (PART 4 OF 4) FOLDOUT 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9 HYDRAULIC DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11 HYDRAULIC DIAGRAM SHEET 2/2 (PART 2 OF 4) FOLDOUT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13 HYDRAULIC DIAGRAM SHEET 2/2 (PART 3 OF 4) FOLDOUT 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15 HYDRAULIC DIAGRAM SHEET 2/2 (PART 4 OF 4) FOLDOUT 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19 ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19 ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21 ELECTRICAL DIAGRAM SHEET 2/5 (PART 1 OF 1) FOLDOUT 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23 ELECTRICAL DIAGRAM SHEET 3/5 (PART 1 OF 1) FOLDOUT 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25 ELECTRICAL DIAGRAM SHEET 4/5 (PART 1 OF 2) FOLDOUT 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27 ELECTRICAL DIAGRAM SHEET 4/5 (PART 2 OF 2) FOLDOUT 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29 ELECTRICAL DIAGRAM SHEET 5/5 (PART 1 OF 2) FOLDOUT 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31 ELECTRICAL DIAGRAM SHEET 5/5 (PART 2 OF 2) FOLDOUT 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33 M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17 . . . . . . . . . . . . 90-35 M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18 . . . . . . . . . . . . 90-37 E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19 . . . . . . . . . . . . 90-39 E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20 . . . . . . . . . . . . 90-41 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21 . . . . . . . . . . 90-43 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 2 OF 4) FOLDOUT 22 . . . . . . . . . . 90-45 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 3 OF 4) FOLDOUT 23 . . . . . . . . . . 90-47 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 4 OF 4) FOLDOUT 24 . . . . . . . . . . 90-49
PC400LC-7L
90-1
OTHERS 12
MEMORANDUM
90-2
PC400LC-7L
OTHERS
HYDRAULIC
12
HYDRAULIC
HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1
PC400LC-7L
90-3
OTHERS
HYDRAULIC
MEMORANDUM
90-4
PC400LC-7L
OTHERS 12 HYDRAULIC
PC400LC-7L
HYDRAULIC
DIAGRAM SHEET 1/2 (PART 2 OF 4) FOLDOUT 2
90-5
OTHERS
HYDRAULIC
MEMORANDUM
90-6
PC400LC-7L
OTHERS 12 HYDRAULIC
PC400LC-7L
HYDRAULIC
DIAGRAM SHEET 1/2 (PART 3 OF 4) FOLDOUT 3
90-7
OTHERS
HYDRAULIC
MEMORANDUM
90-8
PC400LC-7L
OTHERS 12 HYDRAULIC
PC400LC-7L
HYDRAULIC
DIAGRAM SHEET 1/2 (PART 4 OF 4) FOLDOUT 4
90-9
OTHERS
HYDRAULIC
MEMORANDUM
90-10
PC400LC-7L
OTHERS 12 HYDRAULIC
PC400LC-7L
HYDRAULIC
DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5
90-11
OTHERS
HYDRAULIC
MEMORANDUM
90-12
PC400LC-7L
OTHERS 12 HYDRAULIC
PC400LC-7L
HYDRAULIC
DIAGRAM SHEET 2/2 (PART 2 OF 4) FOLDOUT 6
90-13
OTHERS
HYDRAULIC
MEMORANDUM
90-14
PC400LC-7L
OTHERS 12 HYDRAULIC
PC400LC-7L
HYDRAULIC
DIAGRAM SHEET 2/2 (PART 3 OF 4) FOLDOUT 7
90-15
OTHERS
HYDRAULIC
MEMORANDUM
90-16
PC400LC-7L
OTHERS 12 HYDRAULIC
PC400LC-7L
HYDRAULIC
DIAGRAM SHEET 2/2 (PART 4 OF 4) FOLDOUT 8
90-17
OTHERS
HYDRAULIC
MEMORANDUM
90-18
PC400LC-7L
OTHERS
ELECTRICAL
12
ELECTRICAL
ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9
PC400LC-7L
90-19
OTHERS
ELECTRICAL
MEMORANDUM
90-20
PC400LC-7L
OTHERS
ELECTRICAL
ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10
PC400LC-7L
90-21
OTHERS
ELECTRICAL
MEMORANDUM
90-22
PC400LC-7L
OTHERS 12 ELECTRICAL
PC400LC-7L
ELECTRICAL
DIAGRAM SHEET 2/5 (PART 1 OF 1) FOLDOUT 11
90-23
OTHERS
ELECTRICAL
MEMORANDUM
90-24
PC400LC-7L
OTHERS
ELECTRICAL
ELECTRICAL DIAGRAM SHEET 3/5 (PART 1 OF 1) FOLDOUT 12
PC400LC-7L
90-25
OTHERS
ELECTRICAL
MEMORANDUM
90-26
PC400LC-7L
OTHERS 12 ELECTRICAL
PC400LC-7L
ELECTRICAL
DIAGRAM SHEET 4/5 (PART 1 OF 2) FOLDOUT 13
90-27
OTHERS
ELECTRICAL
MEMORANDUM
90-28
PC400LC-7L
OTHERS 12 ELECTRICAL
PC400LC-7L
ELECTRICAL
DIAGRAM SHEET 4/5 (PART 2 OF 2) FOLDOUT 14
90-29
OTHERS
ELECTRICAL
MEMORANDUM
90-30
PC400LC-7L
OTHERS 12 ELECTRICAL
PC400LC-7L
ELECTRICAL
DIAGRAM SHEET 5/5 (PART 1 OF 2) FOLDOUT 15
90-31
OTHERS
ELECTRICAL
MEMORANDUM
90-32
PC400LC-7L
OTHERS 12 ELECTRICAL
PC400LC-7L
ELECTRICAL
DIAGRAM SHEET 5/5 (PART 2 OF 2) FOLDOUT 16
90-33
OTHERS
ELECTRICAL
MEMORANDUM
90-34
PC400LC-7L
OTHERS 12 M
ELECTRICAL
CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17
PC400LC-7L
90-35
OTHERS
ELECTRICAL
MEMORANDUM
90-36
PC400LC-7L
OTHERS 12 M
ELECTRICAL
CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18
PC400LC-7L
90-37
OTHERS
ELECTRICAL
MEMORANDUM
90-38
PC400LC-7L
OTHERS 12 E CIRCUIT
PC400LC-7L
ELECTRICAL
(ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19
90-39
OTHERS
ELECTRICAL
MEMORANDUM
90-40
PC400LC-7L
OTHERS 12 E CIRCUIT
PC400LC-7L
ELECTRICAL
(ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20
90-41
OTHERS
ELECTRICAL
MEMORANDUM
90-42
PC400LC-7L
OTHERS 12 P CIRCUIT
PC400LC-7L
ELECTRICAL
(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21
90-43
OTHERS
ELECTRICAL
MEMORANDUM
90-44
PC400LC-7L
OTHERS 12 P CIRCUIT
PC400LC-7L
ELECTRICAL
(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 2 OF 4) FOLDOUT 22
90-45
OTHERS
ELECTRICAL
MEMORANDUM
90-46
PC400LC-7L
OTHERS 12 P CIRCUIT
PC400LC-7L
ELECTRICAL
(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 3 OF 4) FOLDOUT 23
90-47
OTHERS
ELECTRICAL
MEMORANDUM
90-48
PC400LC-7L
OTHERS 12 P CIRCUIT
PC400LC-7L
ELECTRICAL
(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 4 OF 4) FOLDOUT 24
90-49
OTHERS
ELECTRICAL
MEMORANDUM
90-50
PC400LC-7L
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