SEBM033007
MACHINE MODEL
SERIAL No.
PC400-7 PC400LC-7 PC450-7 PC450LC-7
50001 and up 50001 and up 20001 and up 20001 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
PC400, 400LC, PC450, 450LC-7 mount the SAA6D125E-3 engine. For details of the engine, see the 125-3 Series Engine Shop Manual.
© 2005 All Rights Reserved Printed in Japan 09-05 (01)
00-1 (7)
GENERAL
CONTENTS No. of page
01 GENERAL ............................................................................................................................
01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................
10-1
20 TESTING AND ADJUSTING ......................................................................... 20-1 30 DISASSEMBLY AND ASSEMBLY
..................................................... 30-1
90 OTHERS ................................................................................................................................
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90-1
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SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWORD
GENERAL
FOREWORD GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
k
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
5
Oil, water
Places where oil, water or fuel must be added, and the capacity.
6
Drain
Places where oil or water must be drained, and quantity to be drained.
a
4
3 2
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
LT-1A
790-129-9030
LT-1B
790-129-9050
LT-2
09940-00030
LT-3
790-129-9060 (Set of adhesive and hardening agent)
LT-4
790-129-9040
Holtz MH 705
790-126-9120
Three bond 1735
790-129-9140
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
LG-1
790-129-9010
LG-5
790-129-9080
LG-6
790-129-9020
LG-7
790-129-9070
Three bond 1211
790-129-9090
Three bond 1207B
419-15-18131
Adhesives
Gasket sealant
00-10
Q’ty
Container
Main applications, features
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. 20 g Polyethylene Used for plastics (except polyethylene, (2 pcs.) container polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and nonmetal. • Features: Polyethylene Resistance to heat and chemicals 50 g container • Used for anti-loosening and sealant purpose for bolts and plugs. • Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene (max. strength after 30 minutes) 2g container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high 50 cc container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. 200 g Tube • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type 1 kg Tube • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case 150 g
Tube
FOREWORD
Molybdenum disulphide lubricant
Komatsu code
Part No.
Q’ty
Container
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
Various
Various
G2-LI
G2-CA
Grease
Primer
Adhesive
Caulking material
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381
SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
Various
Various
400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can 400 g 16 kg
400 g 16 kg
Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type
• Used for normal temperature, light load bearing at places in contact with water or steam. • Used for heavy load portion
• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects Bellows type on microorganisms, animals, and plants. Can
20 ml
Glass container
20 ml
Glass container
22M-54-27230
20 ml
Glass container
22M-54-27240
150 ml
Can
22M-54-27250
20 ml
Glass container
22M-54-27210
320 ml
Ecocart (Special container)
• Used as primer for cab side (Using limit: 4 months)
417-926-3910
417-926-3910
320 ml
Polyethylene container
20Y-54-39850
310 ml
Polyethylene container
417-926-3920
320 ml
Polyethylene container
20Y-54-55130
333 ml
Polyethylene container
22M-54-27220
333 ml
Cartridge
• Used as primer for glass side (Using limit: 4 months)
Adhesive for cab glass
Category
COATING MATERIALS
• Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190
1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5
16 18 20 22 24
24 27 30 32 36
235 – 285 320 – 400 455 – 565 610 – 765 785 – 980
23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100
27 30 33 36 39
41 46 50 55 60
1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630
118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Tightening torque
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12
Tightening torque
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
mm
mm
14 20 24 33 42
Varies depending on type of connector.
Tightening torque (Nm {kgm})
Norminal No.
02 03, 04 05, 06 10, 12 14
Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010
{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
mm
mm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
Tightening torque (Nm {kgm})
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5
{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}
Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
10 0 2 24 0 4 43 0 6 77 0 12
6 8 10 12
1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
802 10 0 2 12 0 2 24 0 4 36 0 5
6 8 10 12 14
0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
kgm
301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9
1 / 16 1/8 1/4 3/8 1/2 3/4 1
0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.20 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference)
Range
Target
34 – 54 {3.5 – 5.5}
44 {4.5}
–
9 — – 18UN 16
14.3
34 – 63 {3.5 – 6.5}
44 {4.5}
14
–
–
22
54 – 93 {5.5 – 9.5}
74 {7.5}
–
11 — – 16UN 16
17.5
24
59 – 98 {6.0 – 10.0}
78 {8.0}
18
–
–
04
27
84 – 132 {8.5 – 13.5}
103 {10.5}
22
13 — – 16UN 16
20.6
05
32
128 – 186 {13.0 – 19.0}
157 {16.0}
24
1 – 14UNS
25.4
06
36
177 – 245 {18.0 – 25.0}
216 {22.0}
30
3 1 — – 12UN 16
30.2
(10)
41
177 – 245 {18.0 – 25.0}
216 {22.0}
33
–
–
(12)
46
197 – 294 {20.0 – 30.0}
245 {25.0}
36
–
–
(14)
55
246 – 343 {25.0 – 35.0}
294 {30.0}
42
–
–
02
03
00-14
19
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
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
2 Color White & Red
—
Code
—
WB
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
3
4
Auxiliary
Color White & Black
—
Code
—
WL
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
Color White & Blue
—
Code
—
—
Color White & Green
—
—
Code
—
—
—
Color
—
—
—
WG
RY
Black & Red Red & Yellow RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
5 Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
6 Red & Blue Yellow & White Green & Blue
n n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches 1 mm = 0.03937 in
(A)
00-16
0
1
2
3
4
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6
7
8
9
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
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
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
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
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
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
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
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
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {
}.
Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
04-05
01 GENERAL SPECIFICATION DRAWINGS ......................................................................................................................01- 2 SPECIFICATIONS ........................................................................................................................................01- 4 WEIGHT TABLE............................................................................................................................................01- 8 FUEL, COOLANT AND LUBRICANTS .........................................................................................................01- 12
PC400/450(LC)-7
01-1
GENERAL
SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS DIMENSIONS
WORKING RANGES
01-2
PC400/450(LC)-7
GENERAL
SPECIFICATION DRAWINGS
DIMENSIONS Fixed gauge specification Item
Unit
PC400-7
PC400LC-7
PC450-7
PC450LC-7
A
Overall length
mm
11,940
11,940
12,040
12,040
B
Overall height
mm
3,635
3,635
3,660
3,660
C
Overall width
mm
3,340
3,440
3,340
3,340
D
Track shoe width
mm
600
700
600
600
E
Height of machine cab
mm
3,265
3,265
3,265
3,265
F
Tail swing radius
mm
3,645
3,645
3,645
3,645
G
Track overall length
mm
5,055
5,355
5,055
5,355
H
Length of track on ground
mm
4,020
4,350
4,020
4,350
Min. ground clearance
mm
555
550
555
550
Unit
PC400-7
PC400LC-7
PC450-7
PC450LC-7
Variable gauge specification Item A
Overall length
mm
11,940
11,940
12,040
12,040
B
Overall height
mm
3,635
3,635
3,660
3,660
C
Overall width
mm
3,490
3,490
3,490
3,490
D
Track shoe width
mm
600
600
600
600
E
Height of machine cab
mm
3,265
3,265
3,265
3,265
F
Tail swing radius
mm
3,645
3,645
3,645
3,645
G
Track overall length
mm
5,055
5,355
5,055
5,355
H
Length of track on ground
mm
4,020
4,350
4,020
4,350
Min. ground clearance
mm
685
685
685
685
Unit
PC400-7
PC400LC-7
PC450-7
PC450LC-7
WORKING RANGES Working range A
Max. digging reach
mm
12,025
12,025
12,005
12,005
B
Max. digging depth
mm
7,820
7,820
7,790
7,790
C
Max. digging height
mm
10,915
10,915
10,925
10,925
D
Max. vertical wall depth
mm
6,870
6,870
6,600
6,600
E
Max. dumping height
mm
7,565
7,565
7,625
7,625
F
Min. dumping height
mm
—
—
—
—
G
Max. reach at ground level
mm
11,820
11,820
11,800
11,800
PC400/450(LC)-7
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS PC400-7, PC400LC-7 PC400-7 Machine model
PC400LC-7
Variable gauge spec.
Fixed gauge spec.
Serial Number m3
Weight of machine
kg
1.4
1.4
41,200
42,400
42,200
43,500
Max. digging depth
mm
7,820
7,820
Max. vertical wall depth
mm
6,870
6,870
Max. digging reach
mm
12,025
12,025
Max. reach at ground level
mm
11,820
11,820
Max. digging height
mm
10,915
10,915
Max. dumping height
mm
7,565
7,565
Max. digging force
kN {kg}
256.0 {26,100}
256.0 {26,100}
(using power max. function)
kN {kg}
(274.6 {28,000})
(274.6 {28,000})
Swing speed
rpm
9.1
9.1
Swing max. slope angle
deg.
20
20
Travel speed
km/h
Lo: 3.0, Mi: 4.4, Hi: 5.5
Lo: 3.0, Mi: 4.4, Hi: 5.5
Gradeability
deg.
35
35
Working ranges Performance
Variable gauge spec.
50001 and up
Bucket capacity
kPa {kg/cm }
77.7{0.79}
79.9 {0.82}
73.9 {0.75}
65.3 {0.67}
[mm]
[600]
[600]
[700]
[700]
Overall length (for transport)
mm
11,940
11,940
11,940
11,940
Overall width
mm
3,340
3,490
3,440
3,490
Overall width of track
mm
3,340
2,990
3,440
2,990
Overall width of track when extended
mm
—
3,490
—
3,490
Overall height (for transport)
mm
3,635
3,635
3,635
3,635
Overall height to top of machine
mm
3,265
3,265
3,265
3,265
Ground clearance of upper structure
mm
1,320
1,320
1,320
1,320
Min. ground clearance
mm
555
685
555
685
Tail swing radius
mm
3,645
3,645
3,645
3,645
Min. swing radius of work equipment
mm
4,735
4,735
4,735
4,735
Height of work equipment
mm
9,210
9,210
9,210
9,210
Length of track on ground
mm
4,020
4,020
4,020
4,020
Track gauge
mm
2,740
2,890
2,740
2,890
Height of machine cab
mm
3,265
3,265
3,265
3,265
Ground pressure [standard shoe width]
Dimensions
Fixed gauge spec.
2
at min. swing radius
: The “Mi” mode is on the multi-monitor specification machine only
01-4
PC400/450(LC)-7
GENERAL
SPECIFICATIONS
Machine model
PC400-7
PC400LC-7
Serial Number
50001 and up
mm l {cc}
SAA6D125E-3 4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler 6 – 125 × 150 11.045 {11,045}
kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
246.4/1,850 {330/1,850} 1,334/1,400 {136/1,400} 1,930 1,000 203 {151}
Model Type
Performance
Engine
No. of cylinders – bore × stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption
Starting motor Alternator Battery
24V, 7.5 kW 24V, 35A 12V, 110 Ah × 2 ALW-4
Carrier roller
2 on each side 7 on each side
8 on each side
Track shoe
Assembly-type triple grouser, 45 on each side
Assembly-type triple grouser, 48 on each side
Hydraulic motor Control valve Hydraulic pump
Track roller
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type
Type × No. Delivery Set pressure
HPV190+190, variable displacement, piston type x2 l /min
345 × 2
MPa {kg/cm2}
37.8 {380}
Type × No.
6-spool type + 1-spool type × 1
Control method
Hydraulic
Travel motor
KMV200ADT-2, Variable displacement, piston type (with brake valve, parking brake): × 2
Swing motor
KMF230ABE-5, Fixed displacement piston type (with safety valve, holding brake, reverse rotation preventive valve): × 1
Type
Boom
Arm
Bucket
Double-acting piston
Double-acting piston
Double-acting piston
Inside diameter of cylinder
mm
160
185
160
Diameter of piston rod
mm
110
120
110
Stroke
mm
1,570
1,820
1,270
Max. distance between pins
mm
3,830
4,325
3,140
Min. distance between pins
mm
2,260
2,505
1,870
Hydraulic tank Hydraulic filter Hydraulic cooler
PC400/450(LC)-7
Closed box type Tank return side CF40-1 (Air cooled)
01-5
GENERAL
SPECIFICATIONS
PC450-7, PC450LC-7 PC450LC-7 Machine model
PC450LC-7
Variable gauge spec.
Fixed gauge spec.
Performance
Working ranges
Serial Number
20001 and up
Bucket capacity
m3
Operating weight
kg
1.4
1.4
42,700
44,000
43,700
44,600
Max. digging depth
mm
7,790
7,790
Max. vertical wall depth
mm
6,600
6,600
Max. digging reach
mm
12,005
12,005
Max. reach at ground level
mm
11,800
11,800
Max. digging height
mm
10,925
10,925
Max. dumping height
mm
7,625
7,625
kN {kg}
258.9 {26,400}
258.9 {26,400}
(275.5 {28,300})
(275.5 {28,300})
Max. digging force (using power max. function) Swing speed
rpm
9.1
9.1
Swing max. slope angle
deg.
17
17
Travel speed
km/h
Lo: 3.0, Mi: 4.4, Hi: 5.5
Lo: 3.0, Mi: 4.4, Hi: 5.5
Gradeability
deg.
35
35
Ground pressure [standard shoe width]
kPa {kg/cm2} [mm]
80.5 {0.82} [600]
82.9 {0.85} [600]
76.5 {0.78} [600]
78.1 {0.80} [600]
Overall length (for transport)
mm
12,040
12,040
12,040
12,040
Overall width
mm
3,340
3,490
3,340
3,490
Overall width of track
mm
3,340
2,990
3,340
2,990
—
3,490
—
3,490
Overall width of track when extended
Dimensions
Variable gauge spec.
Fixed gauge spec.
Overall height (for transport)
mm
3,660
3,660
3,660
3,660
Overall height to top of machine
mm
3,265
3,265
3,265
3,265
Ground clearance of upper structure
mm
1,320
1,320
1,320
1,320
Min. ground clearance
mm
555
685
555
685
Tail swing radius
mm
3,645
3,645
3,645
3,645
Min. swing radius of work equipment
mm
4,805
4,805
4,805
4,805
Height of work equipment
mm
9,230
9,230
9,230
9,230
Length of track on ground
mm
4,020
4,020
4,350
4,350
Track gauge
mm
2,740
2,890
2,740
2,890
Height of machine cab
mm
3,265
3,265
3,265
3,265
at min. swing radius
: The “Mi” mode is on the multi-monitor specification machine only
01-6
PC400/450(LC)-7
GENERAL
SPECIFICATIONS
Machine model
PC450-7
PC450LC-7
Serial Number
20001 and up
Model
SAA6D125E-3
Type
4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler
No. of cylinders – bore × stroke
mm
6 – 125 × 150
l {cc}
11.045 {11,045}
Flywheel horsepower
kW/rpm {HP/rpm}
246.4/1,850 {330/1,850}
Max. torque
Nm/rpm {kgm/rpm}
1,334/1,400 {136/1,400}
Max. speed at no load
rpm
1,930
Min. speed at no load
rpm
4,000
Min. fuel consumption
g/kWh {g/HPh}
203 {151}
Performance
Engine
Piston displacement
Starting motor
24V, 7.5 kW
Alternator
24 V, 35 A
Battery
12V, 110 Ah × 2 ALW-4
Carrier roller
2 on each side
Track roller
Hydraulic pump
Type × No.
Control valve
Type × No.
Hydraulic motor
Track shoe
Travel motor
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type
Delivery Set pressure
7 on each side
8 on each side
Assembly-type triple grouser,
Assembly-type triple grouser,
45 on each side
48 on each side
HPV190+190, ariable displacement, piston type × 2 l /min
345 × 2
MPa {kg/cm2}
37.8 {380} 6-spool type + 1-spool type × 1
Control method
Hydraulic
KMV200ADT-2, Variable displacement, piston type (with brake valve, parking brake): × 2
Swing motor
KMF230ABE-5, Fixed displacement piston type × 2 (with safety valve, holding brake, reverse rotation preventive valve): × 1
Cylinder type
Boom
Arm
Bucket
Double-acting piston
Double-acting piston
Double-acting piston
Inside diameter of cylinder
mm
160
185
160
Outside diameter of piston rod
mm
110
130
110
Stroke
mm
1,570
1,985
1,270
Max. distance between pins
mm
3,830
4,740
3,140
Min. distance between pins
mm
2,260
2,755
1,870
Hydraulic tank Hydraulic filter Hydraulic cooler
PC400/450(LC)-7
Closed box type Tank return side CF40-1 (Air cooled)
01-7 (3)
GENERAL
WEIGHT TABLE
WEIGHT TABLE PC400-7, PC400LC-7
k This weight table is for use when handling components or when transporting the machine. Unit: kg Machine model
PC400-7
Serial Number
PC400LC-7 50001 and up
Engine assembly
1,500
1,500
• Engine
1,150
1,150
• Damper
14.7
14.7
• Hydraulic pump
210
210
Radiator, oil cooler assembly
195
195
Hydraulic tank, filter assembly (excluding hydraulic oil)
198
198
Fuel tank (excluding fuel)
251
251
3,297
3,297
Operator's cab
279
279
Operator's seat
35
35
Counterweight
9,220
9,500
Swing machinery (including swing motor)
526
526
Control valve (with service valve)
257
257
Swing motor
105
105
Travel motor
208 × 2
208 × 2
40
40
Revolving frame
Center swivel joint Fixed gauge specification
Variable gauge specification
Fixed gauge specification
Variable gauge specification
• Track frame assembly
10,173
11,367
10,965
11,934
• Track frame
5,506
6,766
6,077
7,096
• • Center frame
—
3,229
—
3,229
• • Crawler frame
—
1,754 × 2
—
1,921 × 2
• Swing circle
605 × 2
605 × 2
• Idler
230 × 2
230 × 2
• Idler cushion
338 × 2
338 × 2
• Carrier roller
32 × 4
32 × 4
• Track roller
72 × 14
72 × 16
• Final drive (including travel motor)
722 × 2
722 × 2
01-8 (4)
PC400/450(LC)-7
GENERAL
WEIGHT TABLE
Unit: kg Machine model
PC400-7
Serial Number
PC400LC-7 50001 and up
Track shoe assembly • Standard triple grouser shoe (600 mm)
4,470
4,760
• Standard triple grouser shoe (700 mm)
4,890
5,210
• Wide triple grouser shoe (800 mm)
5,320
5,670
• Wide triple grouser shoe (900 mm)
—
6,130
Boom assembly
3,290
3,290
Arm assembly
1,374
1,374
Bucket assembly
1,366
1,366
355 × 2
355 × 2
Arm cylinder assembly
510
510
Bucket cylinder assembly
280
280
Link assembly
258
258
92 + 20 × 2 + 73 + 27 + 54
92 + 20 × 2 + 73 + 27 + 54
Arm pin
17 + 23
17 + 23
Bucket pin
38 × 2
38 × 2
Link pin
34 × 2
34 × 2
Boom cylinder assembly
Boom pin
PC400/450(LC)-7
01-9
GENERAL
WEIGHT TABLE
PC450-7, PC450LC-7 Unit: kg Machine model
PC450-7
PC450LC-7
Serial Number
20001 and up
Engine assembly
1,500
1,500
• Engine
1,150
1,150
• Damper
14.7
14.7
• Hydraulic pump
210
210
Radiator oil cooler assembly
195
195
Hydraulic tank, filter assembly (excluding hydraulic oil)
198
198
Fuel tank (excluding fuel)
251
251
3,402
3,402
Operator’s cab
279
279
Operator’s seat
35
35
Counterweight
9,220
9,220
Swing machinery
526
526
Control valve
257
257
Swing motor
105
105
Travel motor
208 × 2
208 × 2
40
40
Revolving frame
Center swivel joint Fixed gauge specification
Variable gauge specification
Fixed gauge specification
Variable gauge specification
• Track frame assembly
10,462
11,697
11,269
12,244
• Track frame
5,506
6,766
6,077
7,096
• • Center frame
—
3,229
—
3,229
• • Crawler frame
—
1,754 × 2
—
1,921 × 2
• Swing circle
605
605
• Idler
230 × 2
230 × 2
• Idler cushion
338 × 2
338 × 2
• Carrier roller
32 × 4
32 × 4
• Track roller
81 × 6, 72 × 8
81 × 8, 72 × 8
722 × 2
722 × 2
• Final drive (including travel motor)
01-10
PC400/450(LC)-7
GENERAL
WEIGHT TABLE
Unit: kg Machine model
PC450-7
Serial Number
PC450LC-7 20001 and up
Track shoe assembly • Standard triple grouser shoe (600 mm)
4,470
4,760
• Standard triple grouser shoe (700 mm)
4,890
5,210
—
—
Boom assembly
3,380
3,380
Arm assembly
1,622
1,622
Bucket assembly
1,941
1,941
355 × 2
355 × 2
Arm cylinder assembly
580
580
Bucket cylinder assembly
280
280
Link assembly
258
258
92 + 20 × 2 + 73 + 27 + 54
92 + 20 × 2 + 73 + 27 + 54
Arm pin
17 + 23
17 + 23
Bucket pin
38 × 2
38 × 2
Link pin
34 × 2
34 × 2
• Wide triple grouser shoe (800 mm)
Boom cylinder assembly
Boom pin
PC400/450(LC)-7
01-11
GENERAL
FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
01-12
PC400/450(LC)-7
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE RELATED PARTS ..................... 10- 2 RADIATOR • OIL COOLER • AFTERCOOLER ................................ 10- 3 POWER TRAIN ....................................... 10- 4 FINAL DRIVE .......................................... 10- 6 SPROCKET ............................................. 10- 7-1 SWING MACHINERY .............................. 10- 8 SWING CIRCLE ...................................... 10- 10 TRACK FRAME AND RECOIL SPRING . 10- 12 IDLER ...................................................... 10- 14 CARRIER ROLLER ................................. 10- 16 TRACK ROLLER ..................................... 10- 17 TRACK SHOE ......................................... 10- 18 HYDRAULIC PIPING DRAWING ............ 10- 22 HYDRAULIC TANK.................................. 10- 24 HYDRAULIC PUMP ................................ 10- 26 LS(PC)-EPC VALVE ................................ 10- 44 VARIABLE VOLUME VALVE .................. 10- 47 CONTROL VALVE ................................... 10- 50 MAIN RELIEF VALVE .............................. 10- 64 CLSS ....................................................... 10- 66 SELF PRESSURE REDUCING VALVE... 10- 69 SWING MOTOR ...................................... 10- 72 CENTER SWIVEL JOINT ........................ 10- 80 TRAVEL MOTOR..................................... 10- 82 TRAVEL JUNCTION VALVE.................... 10- 93 VALVE CONTROL ................................... 10- 95 TRAVEL PPC SHUTTLE VALVE ............. 10- 96 WORK EQUIPMENT • SWING PPC VALVE ................................................ 10-100 TRAVEL PPC VALVE .............................. 10-104 SERVICE PPC VALVE ............................ 10- 111 SOLENOID VALVE .................................. 10- 112 PPC ACCUMULATOR............................. 10- 114 RETURN OIL FILTER ............................. 10- 115 BOOM HYDRAULIC DRIFT PREVENTION VALVE........................ 10- 116 ARM HYDRAULIC DRIFT PREVENTION VALVE ................................................ 10-121 QUICK RETURN VALVE......................... 10-125 LIFT CHECK VALVE................................ 10-127 ATTACHMENT CIRCUIT SELECTOR VALVE................................................ 10-128 HOLDING VALVE .................................... 10-130 HYDRAULIC CYLINDER......................... 10-136 WORK EQUIPMENT ............................... 10-138 PC400/450(LC)-7
AIR CONDITIONER .................................10-144 ENGINE CONTROL .................................10-145 ELECTRONIC CONTROL SYSTEM........10-151 MONITOR SYSTEM.................................10-178 7-SEGMENT MONITOR SYSTEM........ 10-197-1 SENSOR ..................................................10-198
10-1 (4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE RELATED PARTS
ENGINE RELATED PARTS
1. 2. 3. 4.
Drive plate Torsion spring Stopper pin Friction plate
10-2
5. 6. 7. 8.
Damper assembly Muffler Rear engine mount Front engine mount
Outline • The damper assembly is a wet type. Oil capacity: 1.3 l
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RADIATOR • OIL COOLER • AFTERCOOLER
RADIATOR • OIL COOLER • AFTERCOOLER
1. 2. 3. 4. 5. 6. 7. 8. 9.
Oil cooler Radiator Radiator cap Reservoir tank Net Shroud Radiator inlet hose Radiator outlet hose Aftercooler
PC400/450(LC)-7
10. Condenser 11. Fuel cooler
Specifications Radiator : ALW-4 Oil cooler : CF40-1
10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
POWER TRAIN
1. 2. 3. 4. 5. 6.
Idler Center swivel joint Control valve Final drive Travel motor (KMV 200ADT-2) Engine (SAA6D125-3E)
10-4
7. 8. 9. 10. 11. 12.
Hydraulic pump (HPV190+190) Travel speed solenoid valve Swing brake solenoid valve Swing machinery Swing motor (KMF230ABE-5) Swing circle
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FINAL DRIVE
FINAL DRIVE
10-6
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FINAL DRIVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Level plug Drain plug No. 1 planetary gear (No. of teeth: 43) No. 1 sun gear (No. of teeth: 10) No. 2 sun gear (No. of teeth: 18) No. 1 planetary carrier No. 2 planetary carrier Cover Ring gear (No. of teeth: 98) Sprocket Floating seal Travel motor No. 2 planetary gear (No. of teeth: 38)
Specification Reduction ratio: – 10 + 98 × 18 + 98 = –68.600 10 18
Unit: mm No.
Check item
14
Backlash between No. 1 sun gear and No. 1 planetary gear
15
Criteria
Remedy
Standard clearance
Clearance limit
0.15 – 0.54
1.10
Backlash between No. 1 planetary gear and ring gear
0.18 – 0.66
1.30
16
Backlash between No. 2 planetary carrier and motor
0.06 – 0.24
—
17
Backlash between No. 2 sun gear and No. 2 planetary gear
0.15 – 0.51
1.00
18
Backlash between No. 2 planetary gear and ring gear
0.17 – 0.60
1.20
19
Backlash between No. 2 planetary carrier and No. 2 sun gear
0.15 – 0.54
—
20
Amount of wear on sprocket tooth
21
Width of sprocket tooth
PC400/450(LC)-7
Replace
Repair limit: 6 Standard size
Repair limit
90
87
Rebuild or replace
10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SPROCKET
SPROCKET
Unit: mm No.
Check item
1
Wear of tooth tip
2
Thickness of tooth root
3
Width of tooth
4
Wear of tooth shape
10-7-1 (6)
Criteria
Remedy
Standard size
Repair limit
355
343
20.8
14.8
90
87
Build-up welding or replace
Repair limit: 6 (measure with sprocket tooth shape)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
a The above drawing is reduced to 61%. Enlarge it to 164% to return it to the full scale and make a copy on an OHP sheet.
PC400/450(LC)-7
10-7-2 (6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MACHINERY
SWING MACHINERY
10-8
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MACHINERY
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Swing pinion (No. of teeth: 13) Cover Case No. 2 planetary gear No. 2 sun gear Ring gear No. 1 sun gear Swing motor Oil level gauge No. 1 planetary gear No. 1 planetary carrier No. 2 planetary carrier Drain plug
Specification Reduction ratio: 19 + 68 × 16 + 68 = 24.039 19 16
Unit: mm No.
Check item
14
Backlash between swing motor shaft and No. 1 sun gear
15
Criteria
Remedy
Standard clearance
Clearance limit
0.18 – 0.28
—
Backlash between No. 1 sun gear and No. 1 planetary gear
0.15 – 0.51
1.00
16
Backlash between No. 1 planetary gear and ring gear
0.17 – 0.60
1.10
17
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.40 – 0.75
1.20
18
Backlash between No. 2 sun gear and No. 2 planetary gear
0.16 – 0.55
1.00
19
Backlash between No. 2 planetary gear and ring gear
0.17 – 0.60
1.10
20
Backlash between coupling and swing pinion
0.08 – 0.25
—
21
Backlash between swing pinion and swing circle
0.00 – 1.21
2.00
22
Clearance between plate and coupling
0.57 – 1.09
—
Standard size
Repair limit
0
—
23
Wear of swing pinion surface contacting with oil seal
PC400/450(LC)-7
Replace
150 –0.100
Apply hard chrome plating, recondition, or replace
10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 84) 2. Ball 3. Swing circle outer race
Specifications 84 = –6.462 13 Amount of grease: 33 l (G2-LI) Reduction ratio: –
a. Inner race soft zone “S” position b. Outer race soft zone “S” position
Unit: mm No.
4
Check item Axial clearance of bearing (when mounted on chassis)
10-10
Criteria
Remedy
Standard clearance
Repair limit
0.5 – 1.6
3.2
Replace
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING
1. 2. 3. 4. 5. 6. 7. 8. 9.
Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard
10-12
•
The dimensions and the number of track rollers depend on the model, but the basic structure is not different.
•
Number of track rollers Model
Q’ty
PC400-7, 450-7
7
PC400LC-7, 450LC-7
8
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK FRAME AND RECOIL SPRING
Standard shoe Model
PC400-7
PC400LC-7
PC450-7
PC450LC-7
Shoe width
600 mm
700 mm
600 mm
600 mm
Link pitch
228 mm
228 mm
228 mm
228 mm
46 (Pieces)
46 (Pieces)
49 (Pieces)
49 (Pieces)
Item
No. on track (one side)
Unit: mm No.
10
11
Check item
Vertical width of idler guide
Criteria
Remedy
Standard size
Tolerance
Repair limit
Track frame
123
+2 –1
127
Idler support
120
±0.5
118
Track frame
266
+3 –1
271
Idler support
261
—
259
Horizontal width of idler guide
Standard size 12
Rebuild or replace
Recoil spring
PC400/450(LC)-7
Repair limit
Free length × OD
Installation length
Installation load
Free length
Installation load
795 × 241
648
173.3 kN {17,680 kg}
—
138.56 kN {14,140 kg}
Replace
10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
IDLER
IDLER
10-14
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm No.
1
Check item Outside diameter of protruding
Criteria
Remedy Repair limit
Standard size 704
—
2
Outside diameter of tread
660
648
3
Depth of tread
22
28
4
Total width
202
—
5
Width of tread
48.5
—
6
Clearance between shaft and bushing
Standard size 95
7
Interference between idler and bushing
Standard size 102.6
PC400/450(LC)-7
Tolerance Shaft
Hole
–0.120 –0.207
+0.360 +0.220
Tolerance Shaft
Hole
+0.087 +0.037
–0.027 –0.079
Rebuild or replace
Standard clearance 0.340 –0.507 Replace bushing Standard interference 0.064 –0.149
10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CARRIER ROLLER
CARRIER ROLLER
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
175
—
Outside diameter of tread
148
134
3
Width of tread
50.3
—
4
Thickness of tread
32
25
5
Width of flange
19
—
1
Outside diameter of flange
2
6
Interference between shaft and bushing
7
Interference between roller and bushing
8
Axial clearance of roller
10-16
Standard size
Tolerance
Standard Interference Replace interference limit
Shaft
Hole
50
–0.250 –0.270
+0.099 –0.032
0.218 – 0.369
—
57
+0.117 +0.087
+0.040 0
0.047 – 0.177
—
Standard clearance
Clearance limit
0.5 – 0.7
—
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK ROLLER
TRACK ROLLER
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
240
—
Outside diameter of inner flange (double flange)
237
—
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
—
1
Outside diameter of outer flange
2
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
Standard size 80
11
Interference between roller and bushing
Standard size 87.6
PC400/450(LC)-7
Tolerance Shaft
Hole
Standard clearance
–0.250 –0.350
+0.174 +0.029
0.279 – 0.524
Tolerance Shaft
Hole
+0.108 +0.008
–0.006 –0.036
Rebuild or replace
Clearance limit 1.5
Standard Interference interference limit 0.014 – 0.144
Replace bushing
—
10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE TRACK SHOE
a P portion shows the link of bushing press-fitting end.
10-18
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
Unit: mm No. 1
Check item
Criteria
Link pitch
2
Bushing outside diameter
3
Thickness of bushing metal
4
Link height
5
Thickness of link metal (bushing press-fitting portion)
6 7
Standard size
Repair limit
228.9
231.9
Standard size
When turned
71.5
66.5
12
7
Standard size
Repair limit
129
119
34.5
24.5
Shoe bolt pitch
144
Adjust or replace
Repair or replace
Replace
76.2
9 Link
11
Inside width
106
Overall width
51.6
Tread width
44.8
12
Protrusion of pin
4.4
13
Protrusion of regular bushing
5.25
14
Overall length of pin
252
15
Overall length of bushing
16
Thickness of spacer
17 18
Reverse or replace
184
8
10
Remedy
Press-fitting force
19
Repair or replace
Adjust or replace
164.5 —
Bushing
118 – 304 kN {12 – 31 ton}
Regular pin
176 – 451 kN {18 – 46 ton}
Master pin
137 – 284 kN {14 – 29 ton}
—
: Dry type track link PC400/450(LC)-7
10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
Unit: mm No.
Check item a. Regular link Shoe bolt
20
b. Master link
Criteria Tightening torque (Nm {kgm}) Triple shoe
22
23
Interference between bushing and link
Interference between regular pin and link
Clearance between regular pin and bushing
Interference between master pin and bushing
25
—
—
—
PC400-7, PC450-7: 46 PC400LC-7, PC450LC-7: 49 Standard size
Tolerance
Standard interference
Hole
71
+0.494 +0.454
+0.074 0
0.380 – 0.494
47
+0.235 +0.085
–0.218 –0.280
0.303 – 0.515
Standard size
Standard size
Standard size
Tolerance Shaft
Hole
+0.235 +0.085
+0.915 +0.415 Tolerance
Shaft
Hole
+0.03 0
–0.218 –0.280 Tolerance
Shaft
Hole
–0.2 –0.4
+0.915 +0.415
Retighten
—
Shaft
47
10-20
120±10 Lower limit torque (Nm {kgm})
47
Clearance between master pin and bushing
393±39 {40±4} Additinal tightening angle (deg.)
47
24
Additinal tightening angle (deg.)
Tightening torque (Nm {kgm})
No. of shoes (each side)
21
Remedy
Standard clearance 0.180 – 0.830
Adjust or replace
Standard interference 0.218 – 0.310 Standard clearance 0.615 – 1.315
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRACK SHOE
TRIPLE GROUSER SHOE
Unit: mm No.
Check item
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
PC400/450(LC)-7
17.5 23.5
10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Bucket cylinder Arm cylinder Boom cylinder Swing motor Control valve Oil cooler Hydraulic filter Hydraulic pump L.H. travel motor Hydraulic tank Multi-pattern selector valve L.H. PPC valve Safety lever (electric type) Center swivel joint R.H. PPC valve Travel PPC valve Attachment circuit selector valve Holding valve Accumulator Solenoid valve assembly 20A. PPC lock solenoid 20B. Travel junction solenoid 20C. Pump merge/divider solenoid 20D. Travel speed solenoid 20E. Swing brake solenoid 20F. Machine push-up solenoid 20G. 2-stage relief solenoid
10-22
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC400/450(LC)-7
HYDRAULIC PIPING DRAWING
10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC TANK
HYDRAULIC TANK
1. 2. 3. 4. 5. 6. 7. 8.
Oil filler cap Breather Hydraulic tank Sight gauge Strainer Filter element Strainer Bypass valve
Specifications Tank capacity: 335 l Amount of oil inside tank: 248 l Pressure valve • Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} • Suction cracking pressure: 0 – 0.49 kPa {0 – 0.005 kg/cm2} • Bypass valve set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm2} Breather • Intake valve set pressure: 2.0 ± 0.3 kPa {0.02 ± 0.003 kg/cm2} • Exhaust valve set pressure: 98 ± 14.7 kPa {1.0 ± 0.15 kg/cm2}
10-24
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
HYDRAULIC PUMP HPV190+190
1. 2. 3. 4. 5. 6. 7.
Front main pump Rear main pump LS valve PC valve LS-EPC valve PC-EPC valve Variable volume valve
IM ISIG PAF PFC PAR PRC PBF PD1F PENF PBR PD2F PD2R
: : : :
PC mode selector current LS set selector current Front pump delivery Front pump delivery pressure detection : Rear pump delivery : Rear pump delivery pressure detection : Front pump pressure input : Case drain port : Front pump control pressure detection : Rear pump pressure input : Drain plug : Drain plug
PENR : Rear pump control pressure detection port PLSF : Front load pressure input PLSFC: Front load pressure detection port PLSR : Rear load pressure input PLSRC: Rear load pressure detection port PS : Pump suction PLSCR: LS set selector pressure detection port PM : PC set selector pressure detection port PEPC : EPC basic pressure input PDIR : Air bleeder PEPB : EPC basic pressure detection port
Outline • This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.
10-26 (4)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
Shaft (Front) Cradle Case (Front) Rocker cam Shoe Piston
PC400/450(LC)-7
7. 8. 9. 10. 11. 12.
HYDRAULIC PUMP
Cylinder block Valve plate End cap Shaft (Rear) Case (Rear) Servo piston
10-27
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Function
Structure
•
•
•
The rotation and torque transmitted to the pump shaft are converted into hydraulic energy, and pressurized oil is discharged according to the load. It is possible to change the discharge amount by changing the swash plate angle.
• •
• •
10-28
HYDRAULIC PUMP
Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
Operation 1) Operation of pump i Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle is called the swash plate angle.) ii Center line X of rocker cam (4) maintains swash plate angle in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F – E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in. iii If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)
PC400/450(LC)-7
10-29 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
2) Control of discharge amount • If the swash plate angle becomes larger, the difference between volumes E and F becomes larger and discharge amount Q increases. • Swash plate angle is changed by servo piston (12). • Servo piston (12) moves in a reciprocal movement ( ) according to the signal pressure from the PC and LS valves. This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides in a rotating movement in direction of arrow. • With servo piston (12), the area receiving the pressure is different on the left and the right, so main pump discharge pressure (self pressure) PP is always brought to the chamber receiving the pressure at the small diameter piston end. • Output pressure Pen of the LS valve is brought to the chamber receiving the pressure at the large diameter end. The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
10-30
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
LS VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Plug Locknut Sleeve Spring Seat Spool Piston Sleeve
PA PP PDP PLP PLS PPL PSIG
: : : : : : :
Pump port Pump port Drain port LS control pressure output port LS pressure input port PC control pressure input port LS mode selection pilot port
PA PA2 PDP PM PPL
: : : : :
Pump port Pump pressure pilot port Drain port PC mode selector pressure pilot port PC control pressure output port
PC VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Servo piston assembly Plug Pin Spool Retainer Seat Cover Wiring
PC400/450(LC)-7
10-31
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
Function (1) LS valve The LS valve detects the load and controls the discharge amount. This valve controls main pump discharge amount Q according to differential pressure PLS (=PP – PLS) [called the LS differential pressure] (the difference between main pump pressure PP and control valve outlet port pressure PLS). Main pump pressure PP, pressure PLS {called the LS pressure} coming from the control valve output, and pressure PSIG {called the LS selector pressure} from the proportional solenoid valve enter this valve. The relationship between discharge amount Q and differential pressure PLS, (the difference between main pump pressure PP and LS pressure PLS) (= PP – PLS) changes as shown in the diagram at the right according to LS pressure selector current PSIG of the LS-EPC valve. When PSIG changes between 0 and 1A, the set pressure of the spring changes according to this, and the selector point for the pump discharge amount changes at the rated central valve between 1.2 2.6 MPa {12 27 kg/cm2}. (2) PC valve When the pump discharge pressure PP1 (selfpressure) and PP2 (other pump pressure) are high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. In other words, If the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount Q is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The controller senses the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set value, the command current to the PCEPC valve solenoid from the controller increases according to the drop in the engine speed to reduce the pump swash plate angle.
10-32 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
OPERATION
(1) LS valve 1) When control valve is at neutral position • The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the inlet port of the control valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The size of this LS pressure PLS + force Z of spring (4) and the main pump pressure (self pressure) PP determines the position of spool (6). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC valve for the LS valve entering port G also changes the position of spool (6). (The set pressure of the spring changes). • Before the engine is started, servo piston (12) is pushed to the right. (See the diagram on the right) • When the engine is started and the control lever is at the neutral position, LS pressure PLS is 0 MPa {0 kg/cm2}. (It is interconnected with the drain circuit through the control valve spool.)
of the piston, so the swash plate is moved to the minimum angle by the difference in the area of the piston (12).
At this point, spool (6) is pushed to the right, and port C and port D are connected. Pump pressure PP enters the large diameter end of the piston from port K and the same pump pressure PP also enters port J at the small diameter end PC400/450(LC)-7
10-33
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
2) Operation in increase direction for pump discharge amount • When the difference between the main pump pressure PP and LS pressure PLS, in other words, LS differential pressure PLS, becomes smaller (for example, when the area of opening of the control valve becomes larger and pump PP drops), spool (6) is pushed to the left by the combined force of LS pressure PLS and the force of spring (4). • When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC valve is connected to the drain port, so circuit D – K becomes drain pressure PT. (The operation of the PC valve is explained later).
10-34
•
HYDRAULIC PUMP
For this reason, the pressure at the large diameter end of servo piston (12) becomes drain pressure PT, and pump pressure PP enters port J at the small diameter end, so servo piston (12) is pushed to the right. Therefore, the swash plate moves in the direction to make the discharge amount larger. If the output pressure of the EPC valve for the LS valve enters port G, this pressure creates a force to move piston (7) to the right. If piston (7) is pushed to the right, it acts to make the set pressure of spring (4) weaker, and the difference between PLS and PP changes when ports D and E of spool (6) are connected.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
3) Operation in decrease direction for pump discharge amount • The following explains the situation if the servo piston (12) moves to the right (the discharge amount becomes smaller). When LS differential pressure PLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (6) to the right. • When spool (6) moves, main port pressure PP flows from port C and port D and from port K, it enters the large diameter end of the piston. • Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end of servo piston (12), servo piston (12) is pushed to the right.
PC400/450(LC)-7
• •
HYDRAULIC PUMP
As a result, the swash plate moves in the direction to make angle smaller. If LS selection pressure PSIG enters port G, it acts to make the set pressure of spring (4) weaker.
10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
4) When servo piston is balanced • Let us take the area receiving the pressure at the large diameter end of the piston as A1, the area receiving the pressure at the small diameter end as A0, and the pressure flowing into the large diameter end of the piston as Pen. If the main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS pressure PLS are balanced, and the relationship is A0 × PP = A1 × Pen, servo piston (11) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the opening of the throttle from port D to port E and from port C to port D of spool (6) is approximately the same.)
10-36 (1)
•
•
HYDRAULIC PUMP
At this point, the relationship between the area receiving the pressure at both ends of piston (12) is A0 : A1 = 1:2, so the pressure applied to both ends of the piston when it is balanced becomes PP : Pen = 2:1. The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is adjusted so that it is determined when PP – PLS = 2.6 MPa {27 kg/cm2 }. However, if PSIG (the output pressure of 0 2.9 MPa {0 30 kg/cm2} of the EPC valve of the LS valve) is applied to port G, the balance stop position will change in proportion to pressure PSIG between PP – PLS = 2.6 1.2 MPa {27 12 kg/cm2}.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
(2) PC Valve 1) When pump controller is normal a. When the load on the actuator is small and pump pressures PP1 and PP2 are low i) Movement of PC-EPC solenoid (1) • The command current from the pump controller flows to PC-EPC solenoid (1).This command current acts on the PC-EPC valve and outputs the signal pressure. When this signal pressure is received, the force pushing piston (2) is changed. • On the opposite side to the force pushing this piston (2) is the spring set pressure of springs (4) and (6) and pump pressure PP1 (self pressure) and PP2 (other pump pressure) pushing spool (3). Piston (2) stops at a position where the combined force pushing spool (3) is balanced, and the pressure (pressure of port C) output from the PC valve changes according to this position.
PC400/450(LC)-7
HYDRAULIC PUMP
•
The size of command current X is determined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed. a Other pump pressure This is the pressure of the pump at the opposite end. For the F pump, it is the R pump pressure For the R pump, it is the F pump pressure
10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ii) Action of spring • The spring load of springs (4) and (6) in the PC valve is determined by the swash plate position. • If piston (9) moves to the right, spring (6) is compressed, and if it moves further to the right, spring (6) contacts seat (5) and is fixed in position. In other words, the spring load is changed by piston (9) extending or compressing springs (4) and (6).
10-38
•
HYDRAULIC PUMP
If the command circuit input to PC-EPC valve solenoid (1) changes further, the force pushing piston (2) changes, and the spring load of springs (4) and (6) also changes according to the valve of the PC-EPC valve solenoid command current.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
•
•
•
HYDRAULIC PUMP
Port C of the PC valve is connected to port E of the LS valve (see (1) LS valve). Self pressure PP1 enters port B and the small diameter end of servo piston (9), and other pump pressure PP2 enters port A. When pump pressures PP1 and PP2 are small, spool (3) is on the left. At this point, port C and D are connected, and the pressure entering the LS valve becomes drain pressure PT. If port E and port G of the LS valve are connected (see (1) LS valve), the pressure entering the large diameter end of the piston from port J becomes drain pressure PT, and servo piston (9) moves to the left. In this way, the pump discharge amount moves in the direction of increase. As servo piston (9) moves further, springs (4) and (6) expand and the spring force becomes weaker. When the spring force becomes weaker, spool (3) moves to the right, so the connection between port C and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of piston (9) to the left is stopped. In other words, the stop position for piston (9) (= pump discharge amount) is decided at the point where the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing force created by the pressures PP1 and PP2 acting on the spool (3) are in balance.
PC400/450(LC)-7
10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
b. When load on actuator is large and pump discharge pressure is high • When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing spool (3) to the right becomes larger and spool (3) moves to the position in the diagram above. When this happens, as shown in the diagram above, part of the pressurized oil from port B flows out through port C where the LS valve is actuated to port D, and the pressurized oil flowing from port C to the LS valve becomes approximately half of main pump pressure PP. • When port E and port G of the LS valve are connected (see (1) LS valve), the pressure from port J enters the large diameter end of servo piston (9), and servo piston (9) stops.
10-40
•
•
HYDRAULIC PUMP
If pump discharge pressure PP and PP2 increases further and spool (3) moves further to the right, main pump pressure PP1 flows to port C and acts to make the discharge amount the minimum. When piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the left, port C and port B are disconnected and port C and port D are interconnected. As a result, the pressure at port C (= J) drops, and piston (9) stops moving to the right. The position in which piston (9) stops when this happens is further to the right than the position when pump pressures PP1 and PP2 are low.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
The relation of average pump pressure (PP1 + PP2)/2 and the position of servo piston (9) forms a bent line because of the doublespring effect of springs (4) and (6). The relationship between average pump pressure (PP1 + PP2)/2 and pump discharge amount Q is shown in the figure at the right.
•
If command voltage X sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/2, and pump discharge amount Q is proportional to the pushing force of the PCEPC valve solenoid and moves in parallel. In other words, the pushing force of PC-EPC solenoid (1) is added to the force pushing to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and Q moves from to in accordance with the increase in X.
PC400/450(LC)-7
HYDRAULIC PUMP
10-41
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
2) When pump controller is abnormal and emergency pump drive switch is ON a. When load on main pump is light • If there is a failure in the pump controller, turn emergency pump drive switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery. But if the current is used as it is, it is too large, so use the resistor to control the current flowing to PC-EPC valve solenoid (1). • When this is done, the current becomes constant, so the force pushing piston (2) is also constant. • If the main pump pressure PP1 and PP2 are low, the combined force of the pump pressure and the force of PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left.
10-42
•
HYDRAULIC PUMP
At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the discharge amount larger.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
b. When main pump load is heavy • In the same way as in the previous item, when the emergency pump drive switch is ON, the command current sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. • If main pump pressures PP1 and PP2 increase, spool (3) moves further to the right than when the main pump load is light, and is balanced at the position in the diagram above (See Fig. P). • In this case, the pressure from port B flows to port C, so servo piston (9) moves to the right (to make the discharge amount smaller) by the same mechanism as explained in item 2)-b, and stops at a position to the right of the position when the load on the pump is light (See Fig. Q). In other words, even when the emergency pump drive switch is ON, the curve for the pump pressure PP and discharge amount Q is determined as shown in PC400/450(LC)-7
HYDRAULIC PUMP
the diagram for the valve of the current sent to the PC-EPC valve solenoid through the resistor. The curve when the emergency pump drive switch is ON is curve , which is to the left of curve for when the pump controller is normal.
10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LS(PC)-EPC VALVE
LS(PC)-EPC VALVE
1. 2. 3. 4.
Body Spool Spring Rod
10-44
5. Coil 6. Plunger 7. Connector
PSIG : To LS(PC) valve PT : To tank PEPC: From self-reducing pressure valve
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LS(PC)-EPC VALVE
Function • •
The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. When it receives signal current i from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS valve.
Operation 1. When signal current is 0 (coil de-energized) • When there is no signal current flowing from the controller to coil (5), coil (5) is de-energized. • For this reason, spool (2) is pushed to the left in the direction of the arrow by spring (3). • As a result, port PEPC closes and the pressurized oil from the main pump does not flow to the LS valve. At the same time, the pressurized oil from the LS valve passes from port PSIG(PM) through port PT and is drained to the tank.
PC400/450(LC)-7
10-45
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LS(PC)-EPC VALVE
2. When signal current is very small (coil energized) • When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated which pushes plunger (6) to the left. • Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port PEPC to port PSIG(PM). • When the pressure at port PSIG(PM) rises and the load of spring (3) + the force acting on surface a of spool (2) becomes greater than the propulsion force of plunger (6), spool (2) is pushed to the right. The circuit between port PEPC and port PSIG(PM) is shut off, and at the same time, port PSIG(PM) and port PT are connected. • As a result, spool (2) is moved up or down until the propulsion force of plunger (6) is balanced with the load of spring (3) + pressure of port PSIG(PM). • Therefore, the circuit pressure between the EPC valve and the LS valve is controlled in proportion to the size of the signal current.
3. When signal current is maximum (coil energized) • When the signal current flows to coil (5), coil (5) is energized. • When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. • For this reason, spool (2) is completely pushed to the left by push pin (4). • As a result, the maximum flow of pressurized oil from port PEPC flows to port PSIG(PM), and the circuit pressure between the EPC valve and LS valve becomes the maximum. At the same time, port PT closes and stops the oil from flowing to the tank.
10-46 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
VARIABLE VOLUME VALVE
VARIABLE VOLUME VALVE
1. 2. 3. 4.
Block Plug Spring Piston
PC400/450(LC)-7
PM : To PC valve PT : To tank PEPC: From self-reducing pressure valve
10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
VARIABLE VOLUME VALVE
Function •
This stabilizes the EPC output pressure.
Operation •
The output pressure from EPC flows to port PM, and when the propulsion force of piston (4) becomes larger than the load of spring (3), piston (4) is pushed to the left and the volume at port PM increases. When the propulsion force of piston (4) becomes less than the load on spring (3), piston (4) is pushed to the right and the volume at port PM goes down.
10-48
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE 1. 2. 3. 4. 5. 6. 7. 8. 9.
6-spool valve Cover 1 Cover 2 Pump merge-divider valve Back pressure valve Boom lock valve Boom, arm Hi valve Quick return valve Boom Hi check valve
A1 A2 A3 A4 A5 A6 A-1 A-2 B1 B3 B4 B5 B6 B-1 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
: : : : : : : : : : : : : : : : : : : : : : : :
10-50
To bucket cylinder bottom o left travel motor To boom cylinder bottom To swing motor To right travel motor To arm cylinder head To boom cylinder bottom To attachment To bucket cylinder head To bottom cylinder head To swing motor To right travel motor To arm cylinder bottom To arm cylinder bottom From bucket PPC valve From bucket PPC valve From left travel PPC valve From left travel PPC valve From boom PPC valve From boom PPC valve From swing PPC valve From swing PPC valve From right travel PPC valve From right travel PPC valve
CONTROL VALVE
Outline • This control valve consists of a 7-spool valve (6 spool valve + boom • arm Hi valve). A merge-divider valve, back-pressure valve, boom hydraulic drift prevention valve, quick return valve, and Hi valve check valve are installed to it. • Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the assembly, the assembly is small in size and easy to maintain. • Since one spool of this control valve is used for one work equipment unit, its structure is simple.
P11 P12 BP1 PB5 PLS1 PLS2 PP1 PP2 PPS1 PPS2 PR PS PST PX1 PX2 SA SB T T1 TS TSW
: From arm PPC valve : From arm PPC valve : Boom RAISE PPC output pressure : From 2-stage safety valve solenoid valve : To rear pump control : To front pump control : To rear pump control : To front pump control : From rear main pump : From front main pump : To solenoid valve, PPC valve, EPC valve : From pump merge-divider solenoid valve : From travel junction valve : From 2-stage solenoid valve : From 2-stage solenoid valve : Pressure sensor fitting port : Pressure sensor fitting port : To tank : To tank : To tank : To swing motor
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
7-spool valve (1/9)
PC400/450(LC)-7
10-51
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(2/9)
10-52
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(3/9)
1. Unload valve 2. Pressure compensation valve (Arm OUT) 3. Pressure compensation valve (Right travel reverse) 4. Pressure compensation valve (Left swing) 5. Pressure compensation valve (Boom RAISE) 6. Pressure compensation valve (Left travel reverse) 7. Pressure compensation valve (Bucket CURL) 8. Pressure compensation valve (Boom RAISE)
PC400/450(LC)-7
9. 10. 11. 12. 13. 14.
Pressure compensation valve (Arm IN) Pressure compensation valve (Bucket DUMP) Pressure compensation valve (Left travel forward) Pressure compensation valve (Boom LOWER) Pressure compensation valve (Right swing) Pressure compensation valve (Right travel forward) 15. Pressure compensation valve (Arm IN) 16. Main relief valve
10-53
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(4/9)
1. 2. 3. 4. 5.
Spool (Arm) Spool (Right travel) Spool (Swing) Spool (Boom) Spool (Left travel)
6. 7. 8. 9. 10.
Spool (Bucket) Spool (Boom Hi) Spool (Arm Hi) Unload valve Main relief valve Unit: mm
No.
Check item Standard size
11
Spool return spring
Remedy
Criteria Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
54.2 × 34.8
51.2
416.5 N {42.5 kg}
—
333.2 N {34 kg}
12
Spool return spring
54.6 × 34.8
51.2
429.9 N {42.9 kg}
—
336.1 N {34.3 kg}
13
Spool return spring
54.5 × 34.8
51.2
393 N {40.1 kg}
—
314.6 N {32.1 kg}
14
Spool return spring
54.9 × 24.2
51.2
251 N {25.1 kg}
—
201.0 N {20.5 kg}
15
Spool return spring
57.2 × 32.8
51
416 N {42.5 kg}
—
333.2 N {34.0 kg}
10-54
If damaged or deformed, replace spring
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(5/9)
1. 2. 3. 4. 5. 6. 7. 8.
Safety-suction valve (Arm OUT) Suction valve (Right travel reverse) Suction valve (Boom RAISE) Suction valve (Left travel reverse) Safety-suction valve (Boom Hi) Safety-suction valve (Arm IN) Safety-suction valve (Bucket DUMP) Suction valve (Left travel forward)
9. 10. 11. 12. 13. 14. 15. 16.
Safety-suction valve (2-stage) (Boom LOWER) Suction valve (Right travel forward) Safety-suction valve (Arm IN) LS shuttle valve (Arm, right travel) LS select valve LS shuttle valve (Boom, left travel, bucket) LS check valve Pressure relief plug Unit: mm
No.
Check item
Remedy
Criteria Standard size
17
Check valve spring
PC400/450(LC)-7
Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
11.5 × 4.6
8.5
1.5 N {0.15 kg}
—
1.2 N {0.12 kg}
If damaged or deformed, replace spring
10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(6/9)
1. 2. 3. 4.
Unload valve Main relief valve Safety valve (Boom RAISE) Lift check valve
10-56
ARM CONTROL VALVE
R. H. TRAVEL CONTROL VALVE
5. Safety-suction valve 6. Spool 7. Pressure compensation valve (OUT) 8. LS shuttle valve 9. Pressure compensation valve (IN) 10. Safety-suction valve 11. Check valve for regeneration circuit
12. Suction valve 13. Spool 14. Pressure compensation valve (Reverse) 15. LS shuttle valve 16. Pressure compensation valve (Forward) 17. Suction valve
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm No.
Check item
Remedy
Criteria Standard size
18
Regeneration valve spring
Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
31.5 × 10.3
19.5
6.2 N {0.6 kg}
—
4.9 N {0.5 kg}
19
Piston return spring
36.9 × 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
20
Piston return spring
36.9 × 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
PC400/450(LC)-7
If damaged or deformed, replace spring
10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(7/9)
SWING CONTROL VALVE 1. Spool 2. Pressure compensation valve (Left) 3. LS select valve 4. Pressure compensation valve (Right)
10-58
ARM CONTROL VALVE
L. H. TRAVEL CONTROL VALVE
5. Suction valve 6. Spool 7. Pressure compensation valve (RAISE) 8. Hydraulic drift prevention valve 9. LS shuttle valve 10. Pressure compensation valve (Lower) 11. Safety-suction valve 12. Check valve for regeneration circuit
13. Pump merge-divider valve (Travel junction valve) 14. Return spring 15. Suction valve 16. Spool 17. Pressure compensation valve (Reverse) 18. LS shuttle valve 19. Pressure compensation valve (Forward) 20. Suction valve
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm No.
Check item
Remedy
Criteria Standard size
21
Regeneration valve spring
Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
31.5 × 10.3
19.5
6.2 N {0.6 kg}
—
4.9 N {0.5 kg}
—
14.0 N {1.4 kg}
22
Piston return spring
48.1 × 10.8
28
17.5 N {1.8 kg}
23
Piston return spring
36.9 × 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
24
Spool return spring
30.7 × 20.5
23
50.0 N {5.1 kg}
—
40.0 N {4.1 kg}
PC400/450(LC)-7
If damaged or deformed, replace spring
10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(8/9)
BOOM, ARM HI VALVE
BUCKET CONTROL VALVE 1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11. 12. 13.
Safety-suction valve Spool Pressure compensation valve (CURL) LS shuttle valve Pressure compensation valve (DUMP) Safety-suction valve
Boom Hi spool Pressure compensation valve (Boom RAISE) Boom Hi check valve Quick-return valve Pressure compensation valve (Arm IN) Arm Hi spool Safety-suction valve Unit: mm
No.
Check item Standard size
14
15
Piston return spring
Piston return spring
10-60
Remedy
Criteria Repair limit
Installed length
Installed load
48.1 × 10.8 36.9 × 11.1
Free length × OD
Free length
Installed load
28
17.5 N {1.8 kg}
—
14.0 N {1.4 kg}
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
If damaged or deformed, replace spring
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
(9/9)
1. 2. 3. 4. 5. 6. 7. 8.
Unload valve Main relief valve Pump merge-divider valve (Main) Return spring Pump merge-divider valve (For LS) Return spring Valve (Sequence valve) Spring (Sequence valve)
10-62
9. 10. 11. 12. 13. 14. 15. 16.
LS bypass plug Screw Poppet Spring (Pressure reducing valve pilot) Spring (Pressure reducing valve main) Valve (Pressure reducing valve) Spring (Safety valve) Ball
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm No.
Check item
Remedy
Criteria Standard size
17
Check valve spring
Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
11.5 × 4.6
8.5
1.5 N {0.15 kg}
—
1.2 N {0.12 kg}
—
125.5 N {12.8 kg}
18
Spool return spring
46.6 × 21.8
3.3
156.8 N {16.0 kg}
19
Spool return spring
64.5 × 32.3
63
177.5 N {18.1 kg}
—
142.0 N {14.5 kg}
20
Sequence valve spring
70.9 × 18.0
59
199.8 N {20.4 kg}
—
160.0 N {16.3 kg}
PC400/450(LC)-7
If damaged or deformed, replace spring
10-63
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MAIN RELIEF VALVE
MAIN RELIEF VALVE
1. Spring 2. Poppet
Function •
The relief valve set pressure is set to 2 stages. When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.
Operation • •
The relief valve set pressure is determined by the installed load of spring (1). (First stage) It is unnecessary to set the first and second stage individually. The second stage is set when the first stage is set.
1. When pilot pressure P is OFF: Low-pressure setting The set pressure is determined by the installed load of spring (1). 2. When pilot pressure P is ON: High-pressure setting In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter (d1) so the set pressure becomes higher.
10-64 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
CLSS OUTLINE OF CLSS
Features
Structure
•
CLSS stands for Closed Center Load Sensing System, and has the following features.
•
1) Fine control not influenced by load 2) Control enabling digging even with fine control 3) Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations 4) Energy saving using variable pump control
•
10-66 (1)
The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. The main pump body consists of the pump itself, the PC valve and LS valve.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
Basic principle 1) Control of pump swash plate • The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure PLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. (LS pressure PLS = Pump discharge pressure PP – LS pressure PLS)
•
If LS differential pressure PLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.
PC400/450(LC)-7
10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
2) Pressure compensation • A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. • When two actuators are operated together, this valve acts to make pressure difference P between the upstream (inlet port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure).
10-68
CLSS
In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of opening S1 and S2 of each valve.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE Function •
This value reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves, PPC valves, etc.
Operation 1. When engine is stopped • Poppet (11) is pressed by spring (12) against the seat and port PR is not connected to TS. • Valve (14) is pressed by spring (13) against the left side and port P2 is connected to PR. • Valve (7) is pressed by spring (8) against the left side and port P2 is not connected to A2.
PC400/450(LC)-7
10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
2. When in neutral or load pressure P2 is low (When the boom is lowered and arm is at the IN position and they are moving down under their own weight) Note: When load pressure A2 is lower than selfpressure reducing valve output pressure PR. •
•
Valve (7) receives the force of spring (8) and PR pressure (which is 0 MPa {0 kg/cm2} when the engine is stopped) in the direction to close the circuit between ports P2 and A2. If the hydraulic oil flows in port P2, the fdx P2 pressure becomes equal to the total force of spring (8) and the value of area of ød × PR pressure, then the area of the pass between ports P2 and A2 is adjusted so the P2 pressure will be kept constant above the PR pressure. If the PR pressure rises above the set level, puppet (11) opens and the hydraulic oil flows from the PR port through orifice “a” in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice “a” in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.
3. When load pressure P2 is high • If load pressure A2 rises and the pump discharge increases because of operation of the work equipment, the fdx P2 pressure rises higher than the total of the force of spring (8) and the value of ød × PR pressure, and then valve (7) moves to the right stroke end. • As a result, the area of the pass between ports P2 and A2 increases and the pass resistance lowers and the loss of the engine power is reduced. • If the PR pressure rises above the set pressure, poppet (11) opens and the hydraulic oil flows from the PR port through orifice “a” in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice “a” in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.
10-70 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
4. When abnormal high pressure is generated • If the PR pressure on the self-pressure reducing valve rises abnormally high, ball (16) separates from the seat against the force of spring (15) and the hydraulic oil flows from output port PR to TS. Accordingly, the PR pressure lowers. By this operation, the hydraulic devices (PPC valves, solenoid valves, etc.) are protected from abnormal pressure.
PC400/450(LC)-7
10-71 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
SWING MOTOR KMF230ABE-5
Specifications B S T MA MB
: From swing lock solenoid valve : From control valve : To tank : From control valve : From control valve
Model
KMF230ABE-5
Theoretical displacement
229.4 cm³/rev
Safety valve set pressure Rated revolving speed Brake release pressure
10-72
27.9 +0.5 +0 MPa {285 +0.5 kg/cm2} +0 1,413 rpm 1.9 ± 0.4 MPa {19 ± 4 kg/cm2}
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6. 7.
Brake spring Drive shaft Spacer Case Disc Plate Brake piston
10-74
8. 9. 10. 11. 12. 13. 14.
Housing Piston Cylinder block Valve plate Reverse prevention valve Center shaft Center spring
SWING MOTOR
15. Safety valve 16. Check valve 17. Shuttle valve
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
Unit: mm No.
Check item
Criteria
Remedy
Standard size 18
19
Check valve spring
Shuttle valve spring
PC400/450(LC)-7
Free length × OD
Repair limit
Installed length
Installed load
66.5 × 25.6 24.5 × 11.6
Free length
Installed load
45
6.96 N {0.71 kg}
—
5.59 N {0.57 kg}
14.5
7.45 N {0.76 kg}
—
5.98 N {0.61 kg}
If damaged or deformed, replace spring
10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
RELIEF VALVE 1. Outline The relief portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). 2. Function When the swing is stopped, the outlet port circuit of the motor from the control valve is closed, but the motor continues to rotate under inertia, so the pressure at the output side of the motor becomes abnormally high, and this may damage the motor. To prevent this, the abnormal high pressure oil is relieved to port S from the outlet port of the motor (high-pressure side) to prevent any damage. 3. Operation 1) When starting swing • When the swing control lever is operated to swing right, the pressure oil from the pump passes through the control valve and is supplied to port MA. As a result, the pressure at port MA rises, the starting torque is generated in the motor, and the motor starts to rotate. The oil from the outlet port of the motor passes from port MA through the control valve and returns to the tank. (Fig. 1) 2) When stopping swing • When the swing control lever is returned to neutral, the supply of pressure oil from the pump to port MA is stopped. With the oil from the outlet port of the motor, the return circuit to the tank is closed by the control valve, so the pressure at port MB rises. As a result, rotation resistance is generated in the motor, so the braking effect starts. • If the pressure at port MB becomes higher than the pressure at port MA, it pushes shuttle valve A (4) and chamber C becomes the same pressure as port MB. The oil pressure rises further until it reaches the set pressure of relief valve (1). As a result, a high braking torque acts on the motor and stops the motor. (Fig.2) • When relief valve (1) is being actuated, the relief oil and oil from port S passes through check valve B (3) and is supplied to port MA. This prevents cavitation at port MA.
10-76 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
Operation of swing lock 1. When swing lock solenoid valve is deactivated When the swing lock solenoid valve is deactivated, the pressurized oil from the main pump is shut off and port B is connected to the tank circuit. As a result, brake piston (7) is pushed down by brake spring (1), discs (5) and plates (6) are pushed together, and the brake is applied.
2. When swing lock solenoid valve is activated When the swing lock solenoid valve is activated, the valve is switched and the pressure oil from the main pump enters port B and flows to brake chamber a. The pressure oil entering chamber a overcomes brake spring (1) and pushes brake piston (7) up. As a result, discs (5) and plates (6) are separated and the brake is released.
PC400/450(LC)-7
10-77 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
REVERSAL PREVENTION VALVE Outline diagram
1. 2. 3. 4. 5. 6. 7.
Valve body Spool (MA side) Spring (MA side) Plug Spool (MB side) Spring (MB side) Plug
Explanation of effect
10-78
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SWING MOTOR
Outline This valve reduces the swing back generated in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. This is effective in preventing spillage of the load and reducing the cycle time when stopping the swing (the positioning ability is good and it is possible to move swiftly to the next job.
Operation 1. When brake pressure is being generated at port MB • Pressure MB passes through the notch and goes to chamber d, spool (5) pushes spring (6) according to the difference in area D1 > D2, moves to the left, and MB is connected to e. When this happens, pressure MA is below the set pressure of spring (3), so spool (2) does not move. For this reason, the pressure oil is closed by spool (2), and the braking force is ensured.
2. After motor stops • The motor is reversed by the closing pressure generated at port MB. (1st reversal) When this happens, reversal pressure is generated at port MA. Pressure MA goes to chamber a, so spool (2) pushes spring (3) and moves to the right, and MA is connected to B. At the same time, b is connected to f through the drill hole in spool (5), so the reversal pressure at port MA is bypassed to port T to prevent the 2nd reversal.
PC400/450(LC)-7
10-79 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
A1 A2 C1 B2 D1 E
: To L.H. travel motor port PB : From control valve port A2 : To R.H. travel motor port PA : From control valve port B2 : To R.H. travel motor port PB : To L.H. and R.H. travel motors port P
T2 T1 D2 B1 C2
: To tank : From L.H. and R.H. travel motors port T : From control valve port B5 : To L.H. travel motor port PA : From control valve port A5
Unit: mm No.
Check item
6
Clearance between rotor and shaft
10-80
Criteria
Remedy
Standard Size
Standard clearance
Repair limit
80
—
—
If damaged or deformed, replace spring
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
TRAVEL MOTOR KMV280ADT
Port T (to tank) Port PA (from control valve) Port PB (from control valve) Port PI (from travel speed solenoid valve)
10-82
Specifications Model: Theoretical delivery
KMV200ADT Min 130 cm3/rpm Max 200 cm3/rpm Brake releasing pressure: 1.0 ± 0.4 MPa {10 ± 4 kg/cm2} Travel speed switching pressure: 2 +4 0.8 +0.4 –0.1 MPa {8 –1 kg/cm } (Differentical pressure)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6. 7.
Output shaft Motor case Piston Cylinder Valve plate End cover Slow return valve
PC400/450(LC)-7
8. 9. 10. 11. 12. 13. 14.
Regulator piston Plate Disc Check valve spring Check valve Counterbalance valve Spool return spring
TRAVEL MOTOR
15. 16. 17. 18. 19. 20.
Safety valve Rgegulator valve Spring Brake spring Brake piston Check valve
10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
Unit: mm No.
Check item
Criteria
Remedy
Standard size 21
Spool return spring
22
Check valve spring
23
Regulator piston spring
10-84
Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
62.52 × 32.0
42.0
426.6N {43.5 kg}
—
341.3 N {32.2 kg}
62.5 × 20.0
39.0
3.04 N {0.31 kg}
—
2.45 N {0.25 kg}
55.0× 9.0
50.0
98.1 N {10 kg}
—
78.5 N {8 kg}
Replace spring if damaged or deformed
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
Operation of moter 1) At low speed (motor swash plate angle at maximumu)
•
• •
The solenoid valve is de-energized, so the pilot pressure oil from the main pump does not flow to port P For this reason, regulator valve (16) is pushed down by spring (17). The main pressure oil from the control valve pushes check valve (20), goes to end cover (6), in regulator valve (16) and acts also on chamber b. When this happens, the propulsion force of regulator piston (8) acts in a downward direction.
PC400/450(LC)-7
•
As a result, valve plate (5) and cylinder block (4) move in the maximum swash plate angle direction, the motor capacity becomes maximum, and the system is set to low speed.
10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
2) At high speed (motor swash plate angle at minimum)
• • • •
When the solenoid valve is energized, the pilot pressure oil from the main pump flows to port P, and pushes regulator valve (16) up. As a result, the oil in chamber b is drained inside the case, and acts on chamber a via regulator valve (16). Because of this, the propulsion force of the pressure oil at chamber a of regulator piston (8) acts in a upward direction. As a result, valve plate (5) and cylinder block (4) move in the minimum swash plate angle direction, the motor capacity becomes minimum, and the system is set to hign travel speed.
10-86
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
PARKING BRAKE 1. When starting to travel
Operation •
•
When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (13), opens the circuit to the parking brake, and flows into chamber e of brake piston (19). It overcomes the force of spring (18), and pushes piston (19) to the right. When this happens, the force pushing plate (9) and disc (10) together is lost, so plate (9) and disc (10) separate and the brake is released.
PC400/450(LC)-7
10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
2. When stopping travel
Operation •
•
•
• •
When the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber e of brake piston (19) passes through the throttle of slow return valve (7) until spool (13) of the counterbalance valve returns to neutral. When spool (13) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from the throttle f of brake piston (19) and brake piston (19) is pushed fully to the left by spring (18). As a result, plate (9) and disc (10) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return
10-88
valve (7) when the brake piston returns, and this ensures that the brake is applied after the machine stops.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
Operation of brake valve • The brake valve consists of a check valve (1), counterbalance valve (2), and safety valve (3) in a circuit as shown in the diagram on the right. • The function and operation of each component is as given below. 1) Counterbalance valve, check valve Function • When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount).
Operation when pressurized oil is supplied • When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open check valve (12a) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (12b) and spool (13), so the pressure at the supply side rises.
PC400/450(LC)-7
10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
TRAVEL MOTOR
The pressurized oil at the supply side flows from orifice E1 in spool (13) and orifice E2 in the piston to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure, spool (13) is pushed to the right. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate.
Operation of brake when traveling downhill • If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber S1 through orifices E1 and E2 will also drop. When the pressure in chamber S1 drops below the spool switching pressure, spool (13) is returned to the left by spring (14), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. 2) Safety valve (2-direction operation, 2-stage set safety valve) Function • When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve. However, the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment.
10-90 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) • When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. • If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [x/4 (D12 – D2) × pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the opposite side.
2) When stopping travel (low-pressure setting) • When the travel lever is placed at neutral, the pressure in chamber PA drops and counterbalance valve spool (13) returns to the neutral position. While the counterbalance valve spool (13) is returning to the neutral position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left, and the set load becomes smaller. Because of this, the set pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing speed. [Set pressure of safty valve] When starting or traveling: When stopping: High-pressure setting Low-pressure setting 40.2 MPa {410 kg/cm2}
PC400/450(LC)-7
27.5 MPa {27.5 kg/cm2}
10-91
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL MOTOR
3) When pressure in chamber MA has become high (when rotating counterclockwise) • When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia.
•
If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [x/4 (D3 2 – D1 2) × pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the opposite side.
Operation of mechanism for varying set pressure 1) When starting travel (high-pressure setting) • When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (19), and opens the pilot circuit to the safety valve. The oil passes from chamber G to passage H and flows into chamber J, pushes the piston to the right, and compresses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a large drawbar pull is made available.
10-92
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE Function • This valve connects both travel circuits to each other so that the hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. • When the machine is steered, outside pilot pressure PST closes the travel junction valve to secure high steering performance.
PC400/450(LC)-7
Operation When pilot pressure is turned ON • If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (14), travel junction spool (13) moves to the left stroke end and the junction circuit between port PTL (Left travel circuit) and PTR (Right travel circuit) is closed.
10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
When pilot pressure is turned OFF • If pilot pressure PST from the solenoid valve is 0, travel junction spool (13) is pressed by the force of spring (14) against the right side and the pass between ports PTL and PTR is open.
10-94
•
TRAVEL JUNCTION VALVE
If the oil flow rates in both travel motors become different from each other, the oil flows through the route between port PTL, travel junction spool (13), and port PTR so that the oil flow rates will be equalized again.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
VALVE CONTROL
VALVE CONTROL
Lever positions 1. 2. 3. 4. 5. 6. 7.
Travel PPC valve Service PPC valve Service pedal L.H. travel lever R.H. travel lever R.H. PPC valve R.H. work equipment control lever
PC400/450(LC)-7
8. 9. 10. 11. 12. 13.
Solenoid valve Accumulator Control valve Hydraulic pump Junction box L.H. work equipment control lever 14. L.H. PPC valve
(1) Hold (2) Boom “RAISE” (3) Boom “LOWER” (4) Bucket “DUMP” (5) Bucket “CURL” (6) Hold (7) Arm “IN” (8) Arm “OUT”
(9) Swing “RIGHT” (10) Swing “LEFT” (11) Neutral (12) Travel “REVERSE” (13) Travel “FORWARD”
10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC SHUTTLE VALVE
TRAVEL PPC SHUTTLE VALVE Function •
•
If boom RAISE or arm IN are operated when the machine is traveling, the stroke of the spools for the boom and arm is controlled by the travel PPC pressure and this limits the flow of oil to the boom and arm cylinders. When the boom and arm stroke is controlled, the travel PPC pressure passes through the circuit inside the control valve to actuate the system.
Operation 1. When travel is at neutral • Stroke limit signal chambers a and b are connected to the travel PPC valve through orifices (5) and (6) in pistons (3) and (4) inside the travel spring case, and the is drained. • When arm IN is operated, spool (1) moves to the right by stroke (st0) to a point where it contacts the end face of spring case (2). • When boom RAISE is operated, spool (9) moves to the left by stroke (st3) to a point where it contacts the end face of spring case (10).
10-96
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC400/450(LC)-7
TRAVEL PPC SHUTTLE VALVE
10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC SHUTTLE VALVE
2. When travel is operated • When the travel lever is operated to right REVERSE (or FORWARD), the right (REVESE (or FORWARD) PPC pressure pushes spool (7) to the left (or right). • Spool (7) pushes piston (3), orifice (5) closes, and stroke limit signal chamber a is shut off from the drain circuit of the travel PPC valve. • At the same time, the right REVERSE (or FORWARD) PPC pressure passes through orifice (6) in piston (4), acts on the right end face of piston (8), and pushes piston (8) to the left. • If arm IN is operated, spool (1) moves to the right, but the maximum stroke of the spool is limited by the amount of movement st2 of piston (8) and becomes st1. • If boom RAISE is operated, spool (9) tries to move to the left, but the travel PPC pressure enters stroke control signal chamber b, so the spool does not move.
10-98
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC400/450(LC)-7
TRAVEL PPC SHUTTLE VALVE
10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT • SWING PPC VALVE
WORK EQUIPMENT • SWING PPC VALVE
P T
: From self pressure reducing valve : To tank
10-100
P1 P2 P3 P4
: Left PPC: Arm OUT / Right PPC: Boom LOWER : Left PPC: Arm IN / Right PPC: Boom RAISE : Left PPC: Swing LEFT / Right PPC: Bucket CURL : Left PPC: Swing RIGHT / Right PPC: Boom LOWER
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
Spool Metering spring Centering spring Piston Disc Nut (For connection of lever)
7. 8. 9. 10. 11.
WORK EQUIPMENT • SWING PPC VALVE
Joint Plate Retainer Body Filter
Unit: mm No.
Check item
Criteria
Remedy
Standard size 12
Centering spring (For P3 and P4)
Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
42.4 × 15.5
34
17.1 N {1.8 kg}
—
13.7 N {1.4 kg}
13
Centering spring (For P1 and P2)
44.4 × 15.5
34
29.4 N {3.0 kg}
—
23.5 N {2.4 kg}
14
Metering spring
26.5 × 8.2
24.9
16.7 N {1.7 kg}
—
13.7 N {1.4 kg}
PC400/450(LC)-7
If damaged or deformed, replace spring
10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT • SWING PPC VALVE
Operation 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1)
2) During fine control (neutral o fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P1. When this happens, spool (1) moves up or down so that force of metering spring (2) is balanced with the pressure at port P1. The relationship in the position of spool (1) and body (10) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change untill retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to position where the pressure in chamber A (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced.
10-102
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT • SWING PPC VALVE
3) During fine control (when control lever is returned) • When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil.
4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D.
PC400/450(LC)-7
10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
TRAVEL PPC VALVE
P T P1 P2
: From self pressure reducing valve : To tank : Left reverse : Left forward
10-104
P3 P4 P5 P6
: Right reverse : Right forward : Travel signal : Steering signal
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5.
Plate Body Piston Collar Metering spring
PC400/450(LC)-7
6. 7. 8. 9. 10.
TRAVEL PPC VALVE
Centering spring Valve Damper Steering signal Steering signal valve spring
10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
Unit: mm No.
Check item
Criteria Standard size
1
Metering spring
Remedy Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
26.5 × 8.15
24.7
16.7 N {1.7 kg}
—
13.7 N {1.4 kg}
2
Centering spring
48.1 × 15.5
32.5
108 N {11 kg}
—
86.3 N {8.8 kg}
3
Steering signal spring
12.8 × 7.3
8.5
8.8 N {0.9 kg}
—
7.1 N {0.72 kg}
10-106
If damaged or deformed, replace spring
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
Travel signal/Steering function • •
Travel signal If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5. Steering signal If the operation quantities of both levers are different from each other as in the steering operation, the higher one of the PPC output pressures on both sides is output as the steering signal. Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neutral. Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation 1. While in NEUTRAL The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not output.
PC400/450(LC)-7
10-107
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
2. While travelling straight (The following drawing shows the circuit for traveling straight forward.) While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal valve is kept in neutral and the steering signal (Port P6) is not output.
10-108
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
3. When steered or pivot-turned (The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.) If the operation quantities of both levers are different from each other as in the steering operation (If the difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal. In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2. The pressure in right spring chamber (l) is P4. If (P4 – P2) × (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.
PC400/450(LC)-7
10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRAVEL PPC VALVE
4. When pivot-turned (The following drawing shows the circuit for left reverse and right forward operation.) While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and outputs the steering signal (port P6).
10-110
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SERVICE PPC VALVE
SERVICE PPC VALVE a Refer to the section WORK EQUIPMENT • SWING PPC VALVE for function of this valve. 1. 2. 3. 4. 5. 6. 7. 8. T P P1 P2
Spool Metering spring Centering spring Piston Lever Plate Retainer Body : : : :
To tank From main pump Port Port
Unit: mm No.
Check item
Criteria
Remedy
Standard size 9
10
Centering spring
Metering spring
PC400/450(LC)-7
Free length × OD
Repair limit
Installed length
Installed load
33.9 × 15.3 22.7 × 8.1
Free length
Installed load
28.4
124.5 N {12.7 kg}
—
100 N {10.2 kg}
22
16.7 N {1.7 kg}
—
13.7 N {1.4 kg}
If damaged or deformed, replace spring
10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
SOLENOID VALVE PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid valves
1. 2. 3. 4. 5. 6. 8.
PPC lock solenoid valve Travel junction solenoid valve Merge-divider solenoid valve Travel speed solenoid valve Swing brake solenoid valve Machine push-up solenoid valve 2-stage relief solenoid valve
10-112
T A1 A2 A3 A4 A5 A6
: To tank A8 : To main valve (2-stage relief : To No. 1 pump (CO valve) valve) : To main valve (Travel junc- P1 : From main pump tion valve) ACC : To accumulator : To main valve (Merge-divider valve) : To both travel motors : To swing motor : To 2-stage safety valve at boom cylinder head
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
1. 2. 3. 4. 5. 6.
Connector Moving core Coil Spool Block Spring
Operation WHEN SOLENOID IS TURNED OFF •
Since the signal current does not flow from the controller, solenoid (3) is turned off. Accordingly, spool (4) is pressed by spring (6) against the left side. By this operation, the pass from P to A is closed and the hydraulic oil from the main pump does not flow into the actuator. At this time, the oil from the actuator is drained through ports A and T into the tank.
WHEN SOLENOID IS TURNED ON •
The signal current flows from the controller to solenoid (3), and the latter is turned on. Accordingly, spool (4) is pressed against to the right side. By this operation, the hydraulic oil from the main pump flows through port P and spool (4) to port A, then flows into the actuator. At this time, port T is closed and the oil does not flow into the tank.
PC400/450(LC)-7
10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC ACCUMULATOR
PPC ACCUMULATOR 1
1. 2. 3. 4. 5. 6.
2
Gas plug Shell Poppet Holder Bladder Oil port
3
Specifications Gas capacity: 300 cc (for PPC) 4
5
6
SBP00290
10-114
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
RETURN OIL FILTER
RETURN OIL FILTER FOR BREAKER
1. 2. 3. 4. 5.
Drain plug Element Case Head cover Relief valve
PC400/450(LC)-7
Specifications Rated pressure : 6.9 MPa {70 kg/cm2} Flow : 200 l/min. Relief valve cracking pressure: 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2} Filter mesh size : 6 µm Filtering area : 4,570 cm2
10-115
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BOOM HYDRAULIC DRIFT PREVENTION
BOOM HYDRAULIC DRIFT PREVENTION VALVE Function •
When the boom lever is not being operated, these valves act to prevent the oil at the boom bottom from leaking from spool (1) and prevent the boom from moving down.
Operation 1. Boom RAISE When the boom RAISE is operated, the main pressure oil acts in the left direction on ringshaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When it overcomes the force of spring (4), poppet (5) moves to the left. In addition, the main pressure oil acts in the right direction on seat diameter d3 of valve (6). When it overcomes the force of spring (4), valve (6) moves to the right. As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.
10-116
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC400/450(LC)-7
BOOM HYDRAULIC DRIFT PREVENTION
10-117
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BOOM HYDRAULIC DRIFT PREVENTION
2. Boom at HOLD • When the boom is raised and the control lever is returned to the HOLD position, the oil that has flowed into the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of valve (6). • Valve (6) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. As a result, the boom is held in position.
10-118
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC400/450(LC)-7
BOOM HYDRAULIC DRIFT PREVENTION
10-119
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BOOM HYDRAULIC DRIFT PREVENTION
3. Boom LOWER • When boom LOWER is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the boom flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B goes to port A and flows to the control valve.
10-120
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ARM HYDRAULIC DRIFT PREVENTION
ARM HYDRAULIC DRIFT PREVENTION VALVE (If equipped) Function •
When the arm lever is not being operated, these valves act to prevent the oil at the arm head from leaking from spool (1) and prevent the arm from moving down.
Operation 1. Arm DUMP When the arm DUMP is operated, the main pressure oil acts in the left direction on ringshaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When it overcomes the force of spring (4), poppet (5) moves to the left. As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.
PC400/450(LC)-7
10-121
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ARM HYDRAULIC DRIFT PREVENTION
2. Arm at HOLD • When the arm DUMP is operated and the control lever is returned to the HOLD position, the oil that has flowed into the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at the head of the arm cylinder are shut off. • At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the head of the arm cylinder are shut off. • In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of valve (6). As a result, the arm is held in position.
10-122
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ARM HYDRAULIC DRIFT PREVENTION
3. Arm IN • When arm IN is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber b inside the poppet is drained through orifice c. The oil at the head end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B goes to port A and flows to the control valve.
PC400/450(LC)-7
10-123
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
4. When abnormally high pressure is generated • If abnormally high pressure is generated in the boom cylinder bottom circuit, the hydraulic oil in port B pushes check valve (6) open, then safety valve (3) operates.
10-124
•
ARM HYDRAULIC DRIFT PREVENTION
If the hydraulic drift prevention valve for the arm cylinder head circuit is installed (optional), the hydraulic oil in the boom cylinder bottom circuit or that in the arm cylinder head circuit, having higher pressure, pushes check valve (6) open, then safety valve (3) operates.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
QUICK RETURN VALVE
QUICK RETURN VALVE Function When arm OUT is operated, this valve reduces the pressure loss of the large amount of oil returning from the cylinder bottom. Operation 1. Arm at OUT When arm OUT is operated, the pilot pressure from the PPC valve pushes pilot spool (1), and the pressure oil from chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port A, the pressure at port A and acts on ring -shaped area C (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) moves to the left and the pressure oil from port A goes to port B. From port B, the oil is drained directly to the tank.
PC400/450(LC)-7
10-125
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
QUICK RETURN VALVE
2. Arm at HOLD The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at the bottom end of the arm acts in the right direction on ring-shaped area C (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) is closed by the total of this force and the force of spring (3), so port A and port B are shut off.
10-126
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LIFT CHECK VALVE
LIFT CHECK VALVE Function This valve applies back pressure to the drain circuit to prevent generation of negative pressure on the hydraulic devices for the work equipment (motors, cylinders, etc.) Operation 1. While engine is stopped Any oil is not supplied from the pump to the selfpressure reducing valve and valve (1) is pressed by only the force of spring (2) toward the right and drain circuit “a” of the control valve is connected through orifice “b” of valve (1) to port T.
2. While engine is running • Output pressure PR of the self-pressure reducing valve is applied through the control valve to spring chamber “c” of the back pressure valve. • Output pressure PR applied to spring chamber “c” is applied to the left end of valve (1) (area of ød) to push valve (1) to the right. • At this time, pressure PA of drain circuit “a” of the control valve is applied to the right end of valve (1) (area of ød1) to push valve (1) to the left. • Valve (1) is balanced so that the back pressure PA will be as follows. PA = {(Area of ød) × PR + Force of spring (2)} / (Area of ød1)
PC400/450(LC)-7
10-127
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE
1. Spool 2. Spring
: To control valve V : To hydraulic tank T ATT : To attachment ACC: To accumulator P1 : From attachment circuit selector solenoid valve TS : To hydraulic tank Unit: mm
No.
Check item
Criteria Standard size
3
Spool return spring
10-128
Remedy Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
132.0 × 29
114.5
833 N {85.0 kg}
—
666 N {68.0 kg}
Replace spring if any damages or deformations are found
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE
Function When a breaker is installed, the return oil from the breaker does not pass through the main valve, but returns directly to the hydraulic tank. When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected. Operation 1. When attachment other than breaker is installed Spool (1) is pushed fully to the left by the force of spring (2), ATT port and port V are interconnected, and ATT port and port T are shut off, so the attachment and main valve are interconnected.
2. When breaker is installed When the pilot pressure from the attachment circuit selector solenoid valve overcomes the force of spring (2), the spool (1) moves fully to the right. ATT port and port V are shut off and ATT port and port T are interconnected, so the oil returning from the breaker does not pass through the main valve, but passes through port T and returns directly to the hydraulic tank.
PC400/450(LC)-7
10-129
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HOLDING VALVE
HOLDING VALVE Downward movement prevention valve (For boom and arm)
: From control valve V : To hydraulic tank T CY : To hydraulic cylinder PI : From PPC valve PCY : Fror pressure pickup and equalizer circuits
10-130
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1. 2. 3. 4. 5. 6.
HOLDING VALVE
Pilot spool Spring (1st stage of spool) Spring (2nd stage of spool) Safety valve Check valve Spring
Unit: mm No.
Check item
Criteria
Remedy
Standard size 7
Check valve spring
Repair limit
Free length × OD
Installed length
Installed load
Free length
Installed load
20.8 × 12.2
13.5
12.7 N {1.3 kg}
—
9.8 N {1.0 kg}
—
47.0 N {4.8 kg}
8
Spool return spring
41.1 × 9.6
35
58.8 N {6.0 kg}
9
Spool return spring
41.9 × 25.8
41
78.4 N {8.0 kg}
—
62.7 N {6.4 kg}
10
Spool return spring
43.2 × 25.4
41
125.4 N {12.8 kg}
—
100.4 N {10.2 kg}
PC400/450(LC)-7
If damaged of deformed, replace spring
10-131
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HOLDING VALVE
Function If the piping between the main valve and a work equipment cylinder bursts, this valve prevents the oil from flowing back from the work equipment cylinder to prevent sudden fall of the work equipment. Operation 1. When the work equipment is in neutral [When piping is normal] • Check valve (5) is closed by the work equipment cylinder holding pressure applied through port CY to chamber “b”. • When the work equipment is in neutral, no pilot pressure is applied from the PPC valve to port Pi. Accordingly, pilot spool (1) is moved to the left end by the force of springs (2) and (3), then chambers “a” and “b” are shut of from each other. • By this operation, oil does not flow between the main valve and the work equipment cylinder, thus the work equipment cylinder held. • If the pressure in the work equipment cylinder rises abnormally high, work equipment cylinder holding pressure Pb operates safety valve (4). • In the downward movement prevention valves for the boom, chambers “b” of both of them are connected through ports PCY. Accordingly, even if the leakages are different between both valves, the pressures in both chambers “b” become the same. [When piping bursts] Even if piping A between the main valve and work equipment cylinder bursts, chamber “a” is shut off from chamber “b” as in the case where the piping is normal. Accordingly, the work equipment cylinder is held.
10-132 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HOLDING VALVE
2. When oil is sent from main valve to cylinder [When piping is normal] • If pressure Pa of the oil sent from the main valve to chamber “a” is higher than the total of pressure Pb in chamber “b” connected to the work equipment cylinder and the force of spring (6), check valve (5) opens and chambers and the oil flows from the main valve to the work equipment cylinder. [When piping bursts] • If piping A between the main valve and the work equipment cylinder bursts, the oil in chamber “a” flows out through the burst part and pressure Pa in chamber “a” lowers. • If Pa lowers below the total of pressure Pb in chamber “b” and the force of spring (6), check valve (5) closes and chambers “a” and “b” are shut off from each other. Accordingly, pressure Pb in the cylinder is held and the work equipment does not fall suddenly.
PC400/450(LC)-7
10-133 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HOLDING VALVE
3. When oil is returned from work equipment cylinder to main valve [When piping is normal] • The work equipment cylinder holding pressure is applied to chamber “b” and check valve (5) closes. • The pilot pressure from the PPC valve is applied to port Pi. If it is higher than the force of spring (2) (area of 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.
10-134
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-136
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC CYLINDER
Unit: mm No.
Check item Cylinder
1
2
3
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing
Clearance between cylinder bottom support pin and bushing
PC400/450(LC)-7
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
Boom
110
–0.036 –0.090
+0.261 +0.047
0.083 – 0.351
0.412
Arm
120
–0.036 –0.090
+0.263 +0.048
0.084 – 0.353
0.412
Bucket
100
–0.036 –0.090
+0.257 +0.047
0.083 – 0.347
0.447
Boom
110
–0.036 –0.090
+0.169 +0.100
0.136 – 0.259
—
Arm
110
–0.036 –0.090
+0.169 +0.100
0.136 – 0.259
—
Bucket
100
–0.036 –0.090
+0.187 +0.097
0.133 – 0.277
—
Boom
100
–0.036 –0.090
+0.190 +0.070
0.106 – 0.280
—
Arm
110
–0.036 –0.090
+0.195 +0.099
0.135 – 0.285
—
Bucket
100
–0.036 –0.090
+0.187 +0.097
0.133 – 0.277
—
Replace bushing
Replace pin or bushing
10-137
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
10-138
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm No.
Check item
1
Clearance between connecting pin and bushing of revolving frame and boom
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
120
–0.036 –0.090
+0.173 +0.101
0.137 – 0.263
1.0
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
PC400/450(LC)-7
Replace
Adjust shims
10-139
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
1. Dimension of arm
10-140
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm Model PC400-7
PC450-7
No. 1
–0.036 –0.090
ø110 +0.1 +0 /
–0.036 –0.090
2
ø129.3 +1.5 +0 / 126 ± 1.2
ø129.3 +1.5 +0 / 126 ± 1.2
3
–0.3 ø355 +0.5 +0 / 351 –0.8
–0.3 ø355 +0.5 +0 / 351 –0.8
4
ø120 +0.1 +0 /
–0.036 –0.090
ø120 +0.1 +0 /
–0.036 –0.090
5
514.8
570.6
6
195
208.2
7
1,038
1,132.2
8
3,375
3,375
9
2,977.5
2,975.1
10
502
506.8
11
720
720
12
719
719
13
537.1
537.1
14
1,850
1,817
15 16 17
18
ø110 +0.1 +0 /
ø100 +0.1 +0 /
–0.036 –0.090
ø371 +1 +0 / 370 ± 0.5 ø100 +0.1 +0 /
–0.036 –0.090
ø100 +0.1 +0 /
–0.036 –0.090
ø371 +1 +0 / 370 ± 0.5 ø100 +0.1 +0 /
–0.036 –0.090
Arm as individual part
355 –0.5
355 –0.5
When pressfitting bushing
370
370
Min.
1,870
1,870
Max.
3,140
3,140
–0
–0
19
PC400/450(LC)-7
10-141
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
2. Dimension of bucket
10-142
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm Model PC400-7
PC450-7
1
534.1 ± 0.5
534.1 ± 0.5
2
56.3 ± 0.5
56.3 ± 0.5
3
96° 1’
94° 14’
4
537.1
537.1
5
1,839
1,806
6
190
198
7
—
—
8
62° 1’
46° 1’
A
ø140.1 +0.1 +0
ø140.1 +0.1 +0
B
ø130 +0.063 –0
ø130 +0.063 –0
C
ø100 +0.1 +0
ø100 +0.1 +0
371 +1 +0
371 +1 +0
No.
9
10 A
57
58
B
72
72
12
144
144
13
562.5 +0.5 –2.5
562.5 +0.5 –2.5
14
ø26
ø26
A
ø165
ø165
B
—
—
16
ø230
ø230
17
146.1
135.5
18
137.6
142.0
19
R115
R115
20
R85
R85
21
410 ± 1
410 ± 1
22
64
64
11
15
PC400/450(LC)-7
10-143 (3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AIR CONDITIONER
AIR CONDITIONER AIR CONDITIONER PIPING
1. 2. 3. 4. 5. 6. 7. 8.
Hot water pickup piping Receiver tank Hot water return piping Condenser Air conditioner compressor Refrigerant piping Air conditioner unit Duct
10-144
A. Fresh air B. Recirculated air C. Hot air/cold air
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
ENGINE CONTROL 1. Operation of system Starting engine • When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
Engine speed control • The fuel control dial sends signal voltages to the engine controller according to its angle. The engine controller sends drive signals to the supply pump according to the signal voltages received from the fuel control dial and controls the fuel injection pump to control the engine speed.
Stopping engine • When the engine controller detects that the starting switch is at the OFF position, it cuts the signal to the supply pump drive solenoid to stop the engine.
PC400/450(LC)-7
10-145 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
2. Components of system Fuel control dial 1. 2. 3. 4. 5. 6.
Knob Dial Spring Ball Potentiometer Connector
Function •
•
The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine controller. The hatched area in the graph on the right is the abnormality detection area and the engine speed is set at low idling.
10-146
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
3. Engine controller
Input and output signals
PC400/450(LC)-7
10-147
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CN1 [CN-E11] Pin No.
ENGINE CONTROL
CN2 [CN-E12] Signal name
Input/ Output
CN1-1 POWER (+24V constant) CN1-2 POWER (+24V constant) CN1-3 Model selection 1 CN1-4 GND CN1-5 NC CN1-6 NC CN1-7 GND
Pin No. CN2-1 GND
Input
CN2-2 NC CN2-3 NC
Input
CN2-4 RS232C_1RX CN2-5 NC
Output
Input
CN2-8 NC CN2-9 Sensor 5V power supply 2
CN1-10 GND CN1-11 NC
Input
CN2-10 Fuel control dial CN2-11 S_NET_SHIELD GND
CN1-14 NC CN1-15
Engine oil pressure switch (For high pressure)
CN1-16 Memory clear
Output Input Input Input Input
CN1-17 Model selection 3 CN1-18 NC
Input Output
CN1-19 Key switch (ACC) CN1-20 Starting switch (C)
Input Input
Engine oil pressure switch (For low CN1-21 pressure)
Input
CN1-22 Auto deceleration signal CN1-23 Model selection 2
Input Input
CN1-24 NC
Output
Input Input
CN2-6 NC CN2-7 NC
CN1-8 GND CN1-9 NC
CN1-12 NC CN1-13 Key switch (ACC)
Input/ Output
Signal name
Input Input Output Input
CN2-12 CAN_SHIELD CN2-13 NC
Output
CN2-14 RS232C_1TX CN2-15 G_SHIELD (GND)
Output
CN2-16 Ne_SHIELD (GND) CN2-17 Fuel temperature sensor
Input
CN2-18 NC CN2-19 Sensor 5V power supply 1
Input Output
CN2-20 Boost pressure sensor
Input
CN2-21 S_NET (+)
Input/ Output
CN2-22 CAN0_L
Input/ Output
CN2-23 NC CN2-24 FWE_switch CN2-25 G pulse (–)
Input Input
CN2-26 Ne pulse (–) CN2-27 Coolant temperature sensor (High)
Input Input
CN2-28 NC CN2-29 Analog GND
Input
CN2-30 NC
Input
CN2-31 S_NET (+)
Input/ Output
CN2-32 CAN0_H
Input/ Output
CN2-33 NC
10-148 (1)
CN2-34 GND (232C_GND) CN2-35 G pulse (+)
Input
CN2-36 Ne pulse (+) CN2-37 Coolant temperature sensor (Low)
Input Input
CN2-38 NC
Input
CN2-39 Analog GND CN2-40 Common rail pressure sensor
Input
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE CONTROL
CN3 [CN-E13] Pin No.
Signal name
Input/ Output
CN3-1 Power supply for power CN3-2 Power supply for power CN3-3 NC CN3-4 NC CN3-5 Injector #3 (+)
Output
CN3-6 Injector #2 (+) CN3-7 NC
Output Input
CN3-8 Output mode selection 1 (Test mode) CN3-9 Lever neutral flag (Test mode)
Input Input
CN3-10 Engine rotation pulse output CN3-11 Power GND
Output Input
CN3-12 Supply pump 1 (+) CN3-13 Supply pump 2 (+)
Output Output
CN3-14 Injector #1 (+) CN3-15 Injector #3 (–)
Output Output
CN3-16 Injector #2 (–) CN3-17 NC
Output Input
CN3-18 Output mode selection 2 (Test mode) CN3-19 NC
Input Input
CN3-20 Q command output CN3-21 Power supply for power
Output
CN3-22 Supply pump 1 (–) CN3-23 Supply pump 2 (–)
Output Output
CN3-24 Injector #1 (–) CN3-25 Injector #6 (+)
Output Output
CN3-26 Injector #4 (+) CN3-27 NC
Output Output
CN3-28 Auto deceleration flag (Test mode) CN3-29 NC
Input Input
CN3-30 GND CN3-31 Power GND CN3-32 Power GND CN3-33 Injector #5 (–)
Output
CN3-34 Injector #5 (+) CN3-35 Injector #6 (–)
Output Output
CN3-36 Injector #4 (–) CN3-37 NC
Output Output
CN3-38 Auto deceleration control (Test mode) CN3-39 NC
Input Input
CN3-40 GND
PC400/450(LC)-7
10-149
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM CONTROL FUNCTIONS
a For the self-diagnosis function, see “TROUBLE SHOOTING”
PC400/450(LC)-7
10-151
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
TOTAL SYSTEM DIAGRAM
10-152 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PC400/450(LC)-7
ELECTRONIC CONTROL SYSTEM
10-153
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
1. Engine and Pump control function
10-154
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
Function •
The operator can set the work mode switch on the monitor panel to mode A, E, or B (or L) and select proper engine torque and pump absorption torque according to the type of work. • The engine throttle and pump controller detects the speed of the engine governor set with the fuel control dial and the actual engine speed and controls them so that the pump will absorb all the torque at each output point of the engine, according to the pump absorption torque set in each mode. : The L mode is on the multi-monitor specification machine only.
PC400/450(LC)-7
10-155
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
1) Control method in each mode Mode A, Mode E • Matching point in mode A: Rated speed
•
Mode A
246.3 kW/1,850 rpm {331 HP/1,850 rpm}
Mode E
213.3. kW/1,720 rpm {286 HP/1,720 rpm}
If the pump load increases and the pressure rises, the engine speed lowers. At this time, the controller lowers the pump discharge so that the engine speed will be near the full output point. If the pressure lowers, the controller increases the pump discharge so that the engine speed will be near the full output point. By repeating these operations, the controller constantly uses the engine near the full output point.
10-156
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Mode B / (Mode Mode
•
L) Mode B
Mode
Partial output point
82%
Mode B
194.9 kW/1,730 rpm {261 HP / 1,730 rpm}
Mode
L
ELECTRONIC CONTROL SYSTEM
L
61%
150.8 kW/1,250 rpm {202 HP / 1,250 rpm}
At this time, the controller keeps the pump absorption torque along the constant horsepower curve and lower the engine horsepower by the composite control of the engine and pump. By this method, the engine is used in the low fuel consumption area. : The L mode is on the multi-monitor specification machine only.
PC400/450(LC)-7
10-157
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
2) Function to control pump during travel • When the travel is operated in A operation, or E or B working mode, the working mode stays as it is, and the pump absorption torque and engine speed rise to A travel mode.
•
If the machine travels in mode L, the working mode and engine speed do not change, but the pump absorption torque is increased. : The L mode is on the multi-monitor specification machine only.
3) Function to control when emergency pump drive switch is turned ON • Even if the controller or a sensor has a trouble, the functions of the machine can be secured with pump absorption torque almost equivalent to mode E by turning on emergency pump drive switch (10). In this case, a constant current flows from the battery to the EPC valve for PC and the oil pressure is sensed by only the EPC valve for PC.
10-158
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
2. Pump/Valve control function
Function •
The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
PC400/450(LC)-7
10-159
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
1) LS control function • The change point (LS set differential pressure) of the pump discharge in the LS valve is changed by changing the output pressure from the LSEPC valve to the LS valve according to the operating condition of the actuator. • By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved. 2) Cut-off function • When the cut-off function is turned on, the PCEPC current is increased to near the maximum value. • By this operation, the flow rate in the relief state is lowered to reduce fuel consumption. • Operating condition for turning on cut-off function Condition •
The average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm2} and the one-touch power maximizing function is not turned on
The cut-off function does not work, however, while the machine is travelling in mode A or the arm crane operation width swing lock switch is turned on. 1) 2-stage relief function • The relief pressure in the normal work is 34.8 MPa {355 kg/cm2}. If the 2-stage relief function is turned on, however, the relief pressure rises to about 37.2 MPa {380 kg/cm2}. By this operation, the hydraulic force is increased further. • Operating condition for turning on 2-stage relief function
Condition • • • • • •
Condition During travel When swing lock switch is turned on When boom is lowered When one-touch power maximizing function is turned on When L mode is operated
Relief pressure 34.8 MPa {355 kg/cm2} 37.2 MPa {380 kg/cm2}
: The L mode is on the multi-monitor specification machine only.
10-160
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
3. One-touch power maximizing/machine push-up function
Function • •
Power can be increased for a certain time by operating the left knob switch. When the machine push-up switch is operated, the boom pushing force is increased.
PC400/450(LC)-7
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
1) One-touch power maximizing function • When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 7% to increase the digging force. • If the left knob switch is turned on in working mode “A” or “E”, each function is set automatically as shown below.
Working mode A, E
Engine/Pump control Matching at rated output point
2-stage relief function 34.8 MPa {355 kg/cm2} 37.2 MPa {380 kg/cm2}
Operation time
Software cut-off function
Automatically reset at 8.5 sec
Cancel
2) Machine push-up function • Operate switch (1) to increase the boom pushing force when digging ditches or holes on hard ground.
Switch
OFF
ON
10-162
2-stage safety valve function Setting of safety valve at boom cylinder 14.7 MPa {150 kg/cm2} Setting of safety valve at boom cylinder 28.4 MPa {290 kg/cm2}
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
4. Auto-deceleration function
Function •
•
If all the control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is automatically lowered to the medium level to reduce fuel consumption and noise. If any lever is operated, the engine speed rises instantly to the set level.
PC400/450(LC)-7
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
Operation WHEN CONTROL LEVERS ARE SET IN NEUTRAL •
If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,300 rpm) for 4 seconds, the engine speed lowers to the second deceleration level (about 1,300 rpm) and keeps at that level until any lever is operated again.
WHEN ANY CONTROL LEVER IS OPERATED •
If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly to the level set with the fuel control dial.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
5. Auto-warm-up/Overheat prevention function
Function •
After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the engine. If the coolant temperature rises too high during work, the pump load is reduced to prevent overheating.
PC400/450(LC)-7
10-165 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
1) Auto-warm-up function • After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the engine. Operating condition (All)
Operated
Coolant temperature: Below 30°C. Engine speed: Max. 1,200 rpm
Engine speed: Max. 1,200 rpm
Resetting condition (Any one) Auto Manual
Reset
Coolant temperature: Above 30°C Auto-warm-up operation time: Min. 10 minutes
2) Overheat prevention function • If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to prevent overheating.
Operating condition
Coolant temperature: Above 105°C
Operating condition Coolant temperature: Above 102°C
Operating condition Coolant temperature: Above 100°C
Operating condition Coolant temperature: Above 95°C
10-166 (1)
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec. or longer
•
Operation/Remedy Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds
Operation/Remedy Work mode: Mode A, E, OR B Engine speed: Keep as is. Monitor alarm lamp: Lights up. Lower pump discharge. Operation/Remedy Work mode: Mode A Engine speed: Keep as is. Lower pump discharge.
Operation/Remedy Work mode: Travel Engine speed: Keep as is. Lower travel speed.
This function is turned on when the coolant temperature rises above 95°C.
Resetting condition Coolant temperature: Below 105°C Fuel control dial: Return to low idle position once. • Under above condition, controller is set to condition before operation of function. (Manual reset) Resetting condition Coolant temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition Coolant temperature: Below 100°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition Coolant temperature: Below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
6. Swing control function
Function The swing lock and swing holding brake functions are installed.
PC400/450(LC)-7
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1) Swing lock and swing holding brake functions • The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake function (automatic) is used to prevent hydraulic drift after the machine stops swinging. • Swing lock switch and swing lock/holding brake Lock switch
Lock lamp
Function
OFF
OFF
Swing holding brake
ON
ON
Swing lock
ELECTRONIC CONTROL SYSTEM
2) Quick hydraulic oil warm-up function when swing lock switch is turned on • If swing lock switch (4) is turned on, the pump-cut function is cancelled and the relief pressure rises from 34.8 MPa {355 kg/cm2} to 37.2 MPa {380 kg/cm2}. If the work equipment is relieved under this condition, the hydraulic oil temperature rises quickly and the warm-up time can be shortened.
Operation If swing lever is set in neutral, swing brake operates in about 7 sec. If swing lever is operated, brake is released and machine can swing freely. Swing lock operates and machine is locked from swinging. Even if swing lever is operated, swing lock is not reset and machine does not swing.
: Operation of swing holding brake release switch
•
If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing, the swing lock can be reset with the swing holding brake release switch. Swing holding brake release switch Swing lock switch Swing brake
ON (When control has trouble) ON
OFF
OFF (When controller is normal) ON
Swing Swing Swing lock is lock is lock is turned on canceled turned on
OFF Swing holding brake is turned on
a Even if the swing holding brake release switch is turned on, if the swing lock switch is turned on, the swing brake is not released. a If the swing lock is reset, swinging is stopped by only the hydraulic brake of the safety valve. Accordingly, if swinging is stopped on a slope, the upper structure may drift hydraulically.
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PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
7. Travel control function
Function •
The pumps are controlled and the travel speed is changed manually or automatically, to secure proper travel performance matched to the type of work and jobsite during travel.
PC400/450(LC)-7
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
1) Pump control function during travel • If the machine travels in a work mode other than mode A, the work mode and the engine speed are kept as they are and the pump absorption torque is increased. a For details, see ENGINE/PUMP COMPOSITE CONTROL FUNCTION. 1. Travel speed change function i) Manual change with travel speed switch If the travel speed switch is changed between Lo, ( Mi), and Hi, the governor/ pump controller controls the pump capacity and motor capacity at each gear speed as shown at right to change the travel speed. Travel speed switch Pump capacity (%) Motor capacity Travel speed (km/h)
Lo (Low speed)
( Mi) (Middle Speed)
Hi (High speed)
90
82
100
Max.
Max.
Min.
3.2
4.5
5.5
ii)
Automatic change according to engine speed If the fuel control dial is used to set the engine speed to less than 1,200 rpm: • When traveling in Lo, it will not switch even when set to Hi or Mi. • When traveling in Hi or Mi, it will switch automatically to Lo. iii) Automatic changes according to pump discharge pressure When traveling with the travel speed switch set to Hi or Mi, it the load increases, such as when traveling uphill, and the travel pressure goes above 3.23 MPa {330 kg/cm2} for more than 0.5 sec, the travel motor capacity will automatically change to low speed (equivalent to Lo). (The travel speed switch will stay at Hi or Mi.) After continuing to travel in Lo, if the load increases, such as when traveling on level ground or traveling downhill, and the travel pressure goes below 18.6 MPa {190 kg/cm2} for more than 0.5 sec, the travel motor capacity will automatically change and will return to Hi or Mi. : The “Mi” mode is on the multi-monitor specification machine only.
10-170
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
8. ATT flow control, circuit selector function (if equipment)
Function This function is available only with the ATT specification. The function acts as follows according to the flow command and working mode from the monitor. 1) It throttles the ATT PPC pressure and controls the flow when the pedal is fully depressed. 2) In mode B and the other modes, it switches to ATT single acting (B) or double acting (other modes). : The ATT flow control adjustment function is on the multi-monitor specification machine only.
PC400/450(LC)-7
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
9. System component parts 1) Engine revolution sensor
1. 2. 3. 4.
Sensor Locknut Wiring harness Connector
Function •
•
The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine throttle and pump controller. A magnet is used to sense the gear teeth. Each time a gear tooth passes in front of the magnet, a current is generated.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
2) PPC oil pressure switch
1. Plug 2. Switch 3. Connector Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) Pressure: 0.3 ± 0.5 MPa {3.0 ± 0.5 kg/cm2} Function •
The junction block has 7 pressure switches, which check the operating condition of each actuator by the PPC pressure and transmit it to the engine throttle and pump controller.
PC400/450(LC)-7
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
3) Pump pressure sensor
1. Sensor 2. Connector Function •
The pump pressure sensor is installed to the inlet circuit of the control valve. It converts the pump discharge pressure into a voltage and transmits it to the engine throttle and pump controller.
Operation • •
• •
The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance, then converts the change of the resistance into a voltage and transmits it to the amplifier (voltage amplifier). The amplifier, amplifies the received voltage and transmits it to the engine throttle and pump controller. Relationship between pressure P (MPa {kg/cm2}) and output voltage (V) is as follows. V = 0.08 [0.008] × P + 0.5
10-174 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
Pump controller
PC400/450(LC)-7
10-175
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
Input and output signals CN-1
CN-2
Pin No.
Signal name
Input/ Output
1
NC
2 3
R pump pressure sensor NC
4 5
NC NC
6 7
NC NC
Input
8 9
F boom pressure sensor NC
Input
10 11
Signal GND Knob SW
12 13
NC Buchet CURL PPC pressure sensor
14 15
NC NC
16 17
NC Starting switch (Terminal C)
18 19
NC Arm IN PPC pressure sensor
20 21
NC NC
22 23
POT_PWR Starting switch (terminal ACC)
24
NC
10-176 (1)
Input
Pin No.
Input/ Output
Signal name
1
NC
2 3
Swing emergency switch NC
Input Input
4 5
232C_RxD NC
Input
6 7
NC Model selection 4
8 9
Attachment circuit selector signal NC
Input Output
Input
10 11
NC NC
Input
12 13
CAN shield Model selection 5
Input
14 15
232C_TxD NC
Input
16 17
Travel steering signal pressure SW Model selection 3
Input
18 19
NC Auto deceleration signal
20
NC
21
S_NET
Input/ output
22
CAN0_L
Input/ output
Output Input
Input Output Input Input Output
23
NC
24 25
FWE_SW NC
26 27
NC Model selection 2
28 29
NC GND (pulse GND)
30 31
NC GND (S_NET GND)
32
CAN0_H
33
NC
34
GND (232C GND)
35
Service valve pressure switch
Input
36 37
NC Model selection switch 1
Input
38 39
Swing lock switch GND (pulse GND)
Input
40
Engine speed sensor
Input
Input
Input
Input/ output
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
CN-3 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Signal name VB (controller power) VIS (solenoid power) SOL_COM (solenoid common gnd) Battery relay drive NC LS-EPC Travel junction SOL NC NC Boom RAISE pressure SW VB (controller power) VIS (solenoid power) SOL_COM (solenoid common gnd) KEY_SIG NC PC-EPC Pump merge/divider solenoid Heater relay drive Bucket DUMP pressure switch Boom LOWER pressure switch GND (controller GND) NC SOL_COM (solenoid common gnd) KEY_SIG NC Service flow adjustment EPC (1) Travel Hi/Lo selector solenoid 2-stage relief solenoid Swing pressure switch Arm IN pressure switch NC GND (controller GND) GND (controller GND) NC NC NC Swing parking brake solenoid NC Travel pressure switch Arm OUT pressure switch
PC400/450(LC)-7
Input/ Output Input Input Output Output Output Input Input Input Input Input Input Output Output Output Input Input Input Input Input Output Output Output Input Input Input Input
Output Input Input
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MONITOR SYSTEM
•
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)
10-178
•
The monitor panel also has various mode selector switches and functions to operate the machine control system.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
1. Monitor panel
Outline •
The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.
PC400/450(LC)-7
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MONITOR SYSTEM
Input and output signals CN-1 Pin Signal name No. 1 Key ON 2 Key ON 3 Washer motor output 4 Starting signal 5 Limit switch (W) 6 GND 7 GND 8 VB + 9 Wiper motor (+) 10 Wiper motor (-) 11 Buzzer ON signal 12 Limit switch (P)
CN-2 Pin Signal name No. 1 Engine coolant temperature 2 Fuel level 3 Radiator coolant level 4 (Hydraulic oil level) 5 Air cleaner clogging 6 NC 7 Engine oil pressure 8 Engine oil level
Input/ output Input Input Output Input Input
Input Output Output Input Input
Input/ output Input Input Input Input Input Input Input Input
9 N/W signal
Input/ Output
10 N/W signal
Input/ Output
11 12 13 14 15 16 17 18 19 20
Battery charge Hydraulic oil temperature (analog) GND (for analog signal) Buzzer drive Limit SW (window) Buzzer cancel Swing lock Preheat Light switch N/W GND
10-180 (1)
CN3 Pin No. 1 2 3 4 5 6 7 8
Signal name NC NC NC NC NC NC RS230C CTS RS230C RXD
Input/ output Input Input Input Input Input Input Input Input
9 RS230C RXD
Input/ Output
10 RS230C RXD
Input/ Output
11 BOOTSW 12 NC 13 GND
Input Input
14 CAN (SHIELD)
Input
15 CAN (+) 16 CAN (-)
Input Input
Input Input Input Input Input Input Input Input
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Wiper motor Preheating monitor Swing lock monitor Engine coolant temperature monitor Hydraulic oil temperature gauge Engine coolant temperature gauge Working mode monitor Service monitor Travel speed monitor Fuel gauge
PC400/450(LC)-7
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Fuel level monitor Hydraulic oil temperature monitor Power max. monitor Auto-deceleration monitor Radiator coolant level caution Battery charge caution Engine oil pressure caution Engine oil level caution Air cleaner clogging Maintenance time warning caution
10-181 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MONITOR ITEMS AND DISPLAY Symbol
Display item
Swing lock
Preheating
Power Max
Display method
Swing lock switch
Swing holding brake release switch
Swing lock monitor
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Continuous set time
Preheating monitor status
Up to 30 sec.
ON
From 30 sec. to 40 sec.
Flashes
More than 40 sec.
OFF
Power Max. switch status
Power Max. monitor status
Being pressed
Lights up but goes out after approx. 9 sec when kept pressed
Not being pressed
Flashes
Engine coolant temperature Hydraulic oil temperature
See gauge display on the next page
Fuel level
10-182 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Gauge
Engine coolant temperature (°C)
Hydraulic oil temperature (°C)
Fuel level (l)
PC400/450(LC)-7
MONITOR SYSTEM
Range
Temperature, volume
Indicator
A1
105
Red
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
467
Green
C2
381
Green
C3
295
Green
C4
147.5
Green
C5
114
Green
C6
80.5
Red
Buzzer sound
10-183 (1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
Checks before starting (caution lamps all light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed.
Symbol
Display item
Check before starting item
When engine is stopped
When engine is running
Engine oil pressure
q
—
When abnormal, lights up and buzzer sounds
Battery charge
q
—
Lights up when abnormal
Radiator coolant level
q
Lights up when abnormal
When abnormal, lights up and buzzer sounds
Engine oil level
q
Lights up when abnormal
—
Air cleaner clogging
q
—
Lights up when abnormal
Maintenance
Lights up when there is a warning. Lights up for only 30 sec. after key is turned ON, then goes out.
The problems that have occurred are displayed in order from the left. When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed. Condition of hydraulic oil
Color of symbol
Low temperature (below B6 or equivalent)
Black on white background
Normal (B6 – B2)
No display
High temperature (below B2)
White on red background
10-184 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Display category
Symbol
Display item
Wiper
MONITOR SYSTEM
Display range
INT
ON
Display method
OFF
Displays set condition
Working mode
Displays set mode
Travel speed
Displays set speed
Monitor
Auto-deceleration
Service meter
PC400/450(LC)-7
Service meter indicator
ON
OFF
When service meter is working
Displays actuation status
Lights up when service meter is working
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
SWITCHES
1. 2. 3. 4. 5. 6. 7. 8. 9.
Selector switch Selector switch Display brightness, contrast adjustment switch Control switch Window washer switch Wiper switch Maintenance switch Travel speed selector switch Auto-deceleration switch
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PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
Working mode selector switch The condition of the machine changes according to the switch that is pressed (A, E, L, B). It is possible to check the condition on the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right.
•
Selector switch This is used when making detailed settings in each working mode. (For details, see ATTACHMENT FLOW CONTROL FUNCTION for modes A and E.)
•
Maintenance switch Check the condition of the maintenance items. (For details, see MAINTENANCE FUNCTION.)
•
Auto-deceleration switch Each time the auto-deceleration switch is pressed, the auto-deceleration function is switched ON/OFF. Use the auto-deceleration monitor display to check the present condition. When the working mode switch is operated to switch the working mode, it is automatically set to ON.
•
•
Travel speed selector switch Each time the travel speed selector switch is pressed, the travel speed changes. Lo o Hi o Lo …… Use the travel speed monitor display to check the present condition. The relationship between the set speed and the monitor display in the table on the right. Wiper switch Each time the wiper switch is pressed, the wiper setting changes OFF o INT o ON o OFF o …… Use the wiper monitor display to check the present condition. The relationship between the wiper setting and the monitor display is as shown in the table on the right.
PC400/450(LC)-7
MONITOR SYSTEM
Switch that is pressed
Display
Working mode status after setting
[A]
A
A mode (default)
[E]
E
E mode
[L]
L
Heavy-lift mode
[B]
B
Swing priority mode
Display
Setting
Crawler symbol + Lo
Low speed (default)
Crawler symbol + Mi
Medium speed
Crawler symbol + Hi
High speed
Display
Setting
Wiper actuation status
None
OFF
Stowing stopped or now stowing
Wiper symbol + INT
INT
Intermittent actuation
Wiper symbol + ON
ON
Continuous actuation
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.
•
Control switch This is used for control when using the maintenance function or select function. (For details, see each function.)
•
Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For details, see each function.)
10-188
MONITOR SYSTEM
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
SELECT MODE FUNCTION •
•
This is used when setting the flow in each working mode. It is possible to make the setting when genuine attachment piping is installed and the initial value setting function on the service menu has been used to set to ATTACHMENT INSTALLED. It is possible to check on the working mode monitor if this function can be set. Working mode
Monitor display
A mode
[A] + crusher symbol
E mode
[E] + crusher symbol
B mode
[B] + flow symbol
MEHOD OF USE a Carry out the setting on the normal screen 1. A mode, E mode 1) Press select switch (1) on the monitor to move to the adjustment screen. 2) Press control switch (2) to select the flow level. Control switch
Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
3) After completing the level selection, press input confirmation switch (3). The selection flow level is confirmed and the screen moves to the normal screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. a Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right.
PC400/450(LC)-7
Flow level
Flow (L/min.)
8
530
7
430
6
370
5
300
4
230
3
165
2
100
1
30
Remarks Default
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
2. B mode 1) Press select switch (1) on the monitor to move to the screen for selecting the 3-stage flow level. 2) Press control switch (2), or input [01] – [03] with the numeral 10-key pad to choose one on the three flow levels.
No.
10-key pad operation
01
02
03
3) After completing the level selection, press input confirmation switch (3). The selected flow level is selected. a Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the operator screen. This function can be used to return to the previously set flow. 4) After the flow level is confirmed, the screen changes to the screen shown in the diagram on the right. With this screen, it is possible to make fine adjustment to the flow. 5) Press control switch (2) and select the flow level. Control switch
No.
Flow level (L/min.)
01
230
02
190
03
150
Remarks Default
Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
10-190
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
6) After completing the level selection, press input confirmation switch (3). The selected flow level is confirmed and the screen moves to the operator screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. a Before the input confirmation switch is pressed, the flow level is not confirmed, se press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right. 7) Check the set value with the working mode monitor. The relationship between the display level and the set value is as shown in the table on the right, and it is possible to check the level of the flow that can be set.
PC400/450(LC)-7
MONITOR SYSTEM
Flow level
When flow is 140 l/ min.
When flow is 220 l/ min.
When flow is 300 l/ min.
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
10-191
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
MAINTENANCE FUNCTION When the maintenance time for replacement, inspection, or filling has approached for the 10 maintenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the starting switch is turned ON to remind the operator to perform lubrication maintenance. a Maintenance items No.
Item
Replacement interval (hours)
01
Engine oil
500
02
Engine oil filter
500
03
Fuel filter
500
04
Hydraulic filter
1000
05
Hydraulic tank breather
500
06
Corrosion resistor
1000
07
Damper case oil
1000
08
Final case oil
2000
09
Machinery case oil
1000
10
Hydraulic oil
5000
a The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the ramaining time. The relationship is as shown in the table below. Display
Condition
None
Remaining time for maintenance for all items is more than 30 hours
Notice display (black symbol displayed on yellow background)
There is one or more items with less than 30 hours remaining time for maintenance
Warning display (wiper symbol displayed on red background)
There is one or more items with less than 0 hours remaining time for maintenance
10-192 (1)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
METHOD OF CHECKING STATUS MAINTENANCE ITEMS a Operate as follows when on the operator screen. 1. Press maintenance switch (1) and switch to the maintenance list display screen. a The maintenance items are displayed as symbols on the screen. 2. Press control switch (2), or use the 10-key pad to input the number (01 – 10) of the maintenance item to select the item. a The cursor moves and the item is highlighted. a The display method is the same as described on the previous page (relationship between remaining time and caution display). If the remaining time is less than 30 hours, the item is displayed in yellow, and if it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION 1. After completing the selection, press input confirmation switch (3). The screen will change to the maintenance reset screen. 2. Use the maintenance reset screen to check the content, and if there is any problem, press input confirmation switch (3) to move to the check screen. If the wrong item is selected, press return switch (4) to return to the maintenance list screen. 3. Check the content on the check screen, and if there is no problem, press input confirmation switch (3) to reset the maintenance time. After the reset is completed, the screen returns to the maintenance list display screen. To check the remaining time, or if the wrong item is selected, press return switch (4) to return to the maintenance list screen. a The check screen shows the symbol for the maintenance item and the set time in large letters. a The background color of the symbol for the item where the maintenance item was reset is the same as the background of the screen, so it is possible to check that it has been reset.
PC400/450(LC)-7
10-193
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION This function is used to adjust the brightness and contrast of the display.
ADJUSTMENT METHOD a Operate as follows when on the operator screen. 1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen. a Relationship between menu symbol and content. No.
Symbol
Content
01
Return mark
Return
02
Contrast
03
Brightness
2. Press control switch (2), or use the 10-key pad to input the number (00 – 02) to select either contrast or brightness. After completing the selection, press input confirmation switch (3) and return to the adjustment screen. Then press return switch (4) or use the 10-key pas to set to [00] and press input confirmation switch (3) to return to the normal screen. 3. Press control switch (2) and adjust the brightness and contrast as desired. Control switch
Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
10-194
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
SERVICE METER CHECK FUNCTION •
•
When the starting switch is at the OFF position, keep return switch (1) and control switch (2) of the monitor pressed at the same time, and the service meter is shown on the display. This display is shown only while the two switches are being pressed. When the switches are released, the display goes out. Note that it takes 3 – 5 seconds after the switches are pressed for the service meter display to appear.
DISPLAY LCD CHECK FUNCTION •
•
On the password input screen or on the normal screen, if monitor return switch (1) and working mode (A) switch are kept pressed at the same time, all the LCD display will light up and the whole screen will become white, so the display can be checked. If any part of the display is black, the LCD is broken.
PC400/450(LC)-7
10-195
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MONITOR SYSTEM
USER CODE DISPLAY FUNCTION •
•
•
If there is any problem in operating the machine, the user code is displayed on the monitor to advise the operator of the steps to take. This code display appears on the operator screen. On the operator screen, the user code is displayed on the portion for the hydraulic oil temperature gauge.
If more than one user code is generated at the same time, the user codes are displayed in turn for 2 seconds each to display all the user codes.
10-196
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
While the user code is being displayed, if the input confirmation switch is pressed, the service code and failure code can be displayed.
•
If there is more than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed. Even i f service codes/f ailure codes have occurred, if they did not cause the user code to be displayed, this function does not display them.
•
If the telephone number has been set using the telephone number input on the service menu, it is possible to switch on the service code/failure code and display the telephone symbol and telephone number. For details of inputting and setting the telephone number, see SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING AND ADJUSTING section.
PC400/450(LC)-7
MONITOR SYSTEM
10-197 (4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
SJP08775 OR 08931
•
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)
10-197-1 (4)
•
The monitor panel also has various mode selector switches and functions to operate the machine control system.
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
1. Monitor panel
OUTLINE • The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode). The switches are flat sheet switches.
INPUT AND OUTPUT SIGNALS CN-P01 Pin No.
CN-P02 Signal name
Pin No.
Signal name
1
Key switch (Battery)
1
Engine water temperature
2
Key switch (Battery)
2
Fuel
3
Washer motor output
3
Radiator water level
4
Key switch (Terminal C)
4
NC
5
Wiper contact W
5
Air cleaner clogging sensor
6
GND
6
NC
7
GND
7
Engine oil pressure sensor
8
VB + (24 V)
8
Engine oil level sensor
9
Wiper motor (+)
9
Network signal
10 Wiper motor (–)
10 Network signal
11 (Buzzer ON signal input)
11 Charge level
12 Wiper contact P
12 NC 13 GND (For analog signal) 14 NC 15 Wind limit switch 16 Buzzer cancel 17 Swing lock 18 Preheating 19 Limit switch 20 Network (GND)
PC400/450(LC)-7
10-197-2 (4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
Display section of monitor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Service meter display Coolant temperature gauge Coolant temperature caution Digital meter display (Service code and user code are displayed when trouble occurs Fuel level caution Fuel level gauge Engine oil level caution lamp Preheating pilot lamp Swing holding brake pilot lamp Oil maintenance pilot lamp Battery charge caution lamp Air cleaner clogging caution lamp Engine oil pressure caution lamp
10-197-3 (4)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
Monitored items and display Symbol
PC400/450(LC)-7
Displayed item
Display range
When engine is stopped
While engine is running
Engine oil pressure
Max. 1,500 rpm Max. 0.05 MPa {0.5 kg/cm²} Min. 1,500 rpm Max. 0.15 MPa {1.5 kg/cm²}
Lights when normal. (Goes off when engine is started.)
Flashes and buzzer sounds when abnormal.
Air cleaner clogging
When clogged
Goes off.
Flashes when abnormal.
Charge level
When charge is abnormal
Lights when normal. (Goes off when engine is started.)
Flashes when abnormal.
Engine oil level
Below low level
Flashes when abnormal.
Goes off.
Packing (Swing lock)
When swing is locked
Lights up when swing is locked. Flashes when swing holding brake release switch is turned on.
Oil maintenance
See "OIL MAINTENANCE FUNCTION" on next page.
Preheating
When preheated
Coolant temperature
Flashes at 102°C or higher. Flashes and buzzer sounds at 105°C or higher.
Fuel level
Flashes when below low level.
Lights up for 30 sec. when starting switch is set to HEAT. Then, flashes for 10 sec. to indicated completion of preheating.
10-197-4 (4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
Oil maintenance function 1. Function and operation At a set time after the engine oil is replaced, the oil maintenance function is turned on to notify the operator by the LED lamp on the monitor panel that it is time to replace the oil. The function to indicate the phone number of the place to make contact for service on the LCD unit is installed, too. 1) Check of elapsed time Nothing is displayed normally until point B shown in the figure at right after this function is reset. If the key is turned on with the buzzer cancel switch processed (for 2.5 seconds), however, the elapsed time is displayed on the service meter section. 2) Display of replacement of oil If time passes point B after this function is reset, the elapsed time is displayed on the service meter section and the LED flashes when the key is turned on. 2. Setting of time interval 1) The time interval is set in the interval setting mode. It can be set to "125h", "250h", "500h", "Not set", or "Demo-mode". The default is "Not set". 2) To enter the interval setting mode, press and hold the clock switch for 2.5 seconds. 3) If the buzzer cancel switch is pressed in the interval setting mode, the clock display section changes to "—" o "125" o "250" o "500" o "d" in order. ("—" corresponds to "Not set" and "d" corresponds to "Demomode".) 4) To save the time interval, set a desired time (mode) on the monitor panel and press and hold the clock switch for 2.5 seconds.
10-197-5 (4)
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
3. Timing and contents of display 1) When replacement of oil is displayed 2) The elapsed time is displayed for 10 seconds after all segments are turned on. Phone number is displayed for the next 10 seconds. If the phone number has not been input, however, the elapsed time is displayed for 20 seconds after all segments are turned on. 3) When elapsed time is checked The elapsed time is displayed for 10 seconds after all segments are turned on. 4. Resetting elapsed time 1) When the replacement of oil and elapsed time are displayed, press the buzzer cancel switch 10 seconds after all segments are turned on (while the elapsed time is disp l aye d) and h ol d f or 3 se con ds. Th e elapsed time is reset. After this operation, "0h" is displayed for 1 second. 2) When the set time is changed, the elapsed time is reset to "0h". 5. Demo-mode 1) In the demo-mode, the time is set to 250h, the elapsed time is set to 240h, and replacement of oil is displayed when the key is turned on. The elapsed time does not increase, however. The time can be reset in this mode. Turn on the key 3 times in this mode, and the time interval is automatically set to "Not set" at the 4th time and after. The elapsed time is set to "0h" and counting of elapsed time is started.
PC400/450(LC)-7
10-197-6 (4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
Mode selector switches 1. 2. 3. 4.
•
There are 4 sets of the mode selector switches on the switch section. Each time one switch is pressed, the machine condition changes. The current condition is indicated by the lighting of the LED above the switch.
•
The initial setting of only the work mode after the starting switch is turned on can be changed. a For how to change the setting, see "Work mode default setting mode" in TROUBLESHOOTINGDisplay and special functions of monitor panel.
10-197-7 (4)
Travel speed switch Auto-deceleration switch Wiper switch Work mode selector switch (Including setting switch)
Operations table of switch section a The bold letters are the positions of the switches reset when the starting switch is turned on. Item
Operation
Work mode
A↔E↔B
Auto-deceleration
ON ↔ OFF
Wiper Travel speed
OFF ↔ Intermittent ↔ ON Hi ↔ Lo
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSOR
SENSOR •
The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the chassis ground. Name of sensor
Type of sensor
When normal
When abnormal
Engine oil level
Contact
ON (closed)
OFF (open)
Engine oil pressure
Contact
OFF (open)
ON (closed)
Hydraulic oil temperature
Resistance
—
—
Coolant temperature
Resistance
—
—
Fuel level
Resistance
—
—
Contact type
OFF (open)
ON (closed)
Air cleaner clogging
10-198
PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSOR
Engine oil level sensor 1. 2. 3. 4.
Connector Bracket Float Switch
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
Engine oil pressure sensor (For low pressure)
Coolant temperature sensor Hydraulic oil temperature sensor
1. Thermistor 2. Body 3. Tube
PC400/450(LC)-7
4. Tube 5. Wire 6. Connector
10-199
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SENSOR
Fuel level sensor 1. 2. 3. 4.
Float Connector Cover Variable resistor
Air cleaner clogging sensor
10-200
PC400/450(LC)-7
20 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2 STANDARD VALUE TABLE FOR CHASSIS .................................................................................................. 20-3 TESTING AND ADJUSTING ...................................................................................................................... 20-101 TROUBLESHOOTING ................................................................................................................................ 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims. k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving. k When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. k Be careful not to get caught in the fan, fan belt or other rotating parts. PC400/450(LC)-7
20-1 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Item
Machine model
PC400, 400LC-7 PC450, 450LC-7
Engine
SAA6D125E-3
Measurement condition
Unit
Standard value
Permissible value
1,930 ± 50
1,930 ± 50
1,000 ± 25
1,000 ± 25
1,850
1,850
kPa {mmHg}
Min 107 {Min. 800}
87 {650}
°C
Max. 700
Max. 700
Max. 4.0
6.0
Max. 1.0
2.0
0.33
—
0.71
—
Min. 2.9 {Min. 30} (150 – 200)
2.0 {20} (150 – 200)
Max. 1.18 {Max. 120}
1.96 {200}
0.39 – 0.69 {4.0 – 7.0}
0.21 {2.1}
0.34 – 0.64 {3.5 – 6.5}
0.18 {1.8}
High idling Engine speed
Low idling
rpm
Rated speed Intake air pressure
At rated output
Exhaust gas pressure
All speed range (intake air temp: 20°C) At sudden acceleration
Bosch index
Exhaust gas color At high idling Valve clearance (normal temperature)
Intake valve mm Exhaust valve
Compression pressure
Oil temperature: 40 – 60°C (Engine speed)
Blow-by pressure
(Coolant temperature: within operating range) At rated output
MPa {kg/cm2}
(rpm) kPa {mmH2O}
(Coolant temperature: within operating range) At high idling Oil pressure
At high idling
(SAE30) (SAE10W)
MPa {kg/cm2}
At low idling
(SAE30)
Min. 0.15 {Min. 1.5}
0.08 {0.8}
At low idling
(SAE10W)
Min. 0.1 {Min. 1.0}
0.07 {0.7}
Oil temperature
All speed range (inside oil pan)
°C
90 – 120
120
Fan, alternator belt tension
Deflection when pressed with finger force of approx. 58.8 N {6 kg}
mm
Approx. 13
Approx. 13
Air conditioner compressor belt tension
Deflection when pressed with finger force of approx. 58.8 N {6 kg}
mm
14 – 16
14 – 16
20-2 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS PC400, 400LC-7 PC450, 450LC-7
Applicable model
Engine speed
Category
Item
Measurement conditions
Standard value
Permissible value
1,930 ± 100
1,930 ± 100
1,830 ± 100
1,830 ± 100
1,300 ± 100
1,300 ± 100
9.5 ± 0.5
9.5 ± 0.5
85 ± 10
85 ± 10
85 ± 10
85 ± 10
85 ± 10
85 ± 10
85 ± 10
85 ± 10
115 ± 12
115 ± 12
Max. 10
Max. 15
Boom control lever
15.7 ± 4.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
Arm control lever
15.7 ± 4.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
24.5 ± 5.9 {2.5 ± 0.6}
Max. 39.2 {Max. 4.0}
74.5 ± 18.6 {7.6 ± 1.9}
Max. 107.6 {Max. 11}
2 pumps at relief
• Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idling • Arm in relief condition
At 2-pump relief + one touch power up
• Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idling • Arm relief + One-touch power max. switch in ON condition
Speed when autodeceleration is operated
• Engine at high idling • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition
Unit
rpm
Spool stroke
Boom control valve Arm control valve Bucket control valve
mm
Swing control valve
Operating effort of control levers
Travel of control levers
Travel control valve Boom control lever Arm control lever Bucket control lever Swing control lever Travel control lever
• Engine stopped • At center of control lever grip • Max. reading up to stroke end (excepting lever play in NEUTRAL position)
mm
Play of control levers
Bucket control lever Swing control lever
Travel control
PC400/450(LC)-7
Lever Pedal
• Hydraulic oil temperature: Within operation range • Engine at high idling • Hydraulic oil temperature: Within operating range • At center of control lever grip • Max. reading up to stroke end
N {kg}
20-3 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
Applicable model Category
Item
Unload pressure
Measurement conditions
Unit
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Hydraulic pump output pressure with all control levers in NEUTRAL position
Hydraulic pressure
Arm
Bucket
LOWER
• Hydraulic oil temperature: Within operation range • Engine at high idling
(1)
{42 ± 10}
{42 ± 10}
34.81 +1.47 –0.98
33.34 – 36.77 (35.79 – 39.23)
At lowpressure setting
18.14 ± 0.98
16.67 – 19.61
{185 ± 10}
{170 – 200}
At highpressure setting
31.38 ± 1.47
29.2 – 33.34
{320 ± 15}
{300 – 340}
34.81 +1.47 –0.98
33.34 – 36.77
Travel
20-4
4.2 ± 1.0
{340 – 375 (365 – 400)}
• Working mode: A mode • Hydraulic pump output pressure with all measurement circuits relieved • Values inside parenthesis: Hydraulic oil pressure with onetouch power max. switch in ON mode (reference only)
• Hydraulic oil temperature: Within operation range • Engine at high idling • Self-reducing pressure valve output pressure with all control levers in NEUTRAL position
• Hydraulic oil temperature: Within operation range • Engine at high idling LS differential pressure • Working mode: A mode • Traveling speed: Hi • Hydraulic oil pump pressure – LS pressure
4.2 ± 1.0
+15 {355 +15 –10 (380 –10 )}
Swing
Control circuit source pressure
Permissible value
(37.27 +1.47 –0.98 )
RAISE
Boom
Standard value
MPa {kg/cm2}
(37.27 +1.47 –0.98 ) +15 {355 +15 (380 –10 –10 )} 34.81 +1.47 –0.98 (37.27 +1.47 –0.98 ) +15 {355 –10 (380 +15 –10 )} +1.47 30.89 –2.45 {315 +15 –25 } 37.27 +2.94 –0.98 {380 +30 –10 }
(35.79 – 39.23) {340 – 375 (365 – 400)}
33.34 – 36.77 (35.79 – 39.23) {340 – 375 (365 – 400)}
27.95 – 32.85 {285 – 335} 35.79 – 40.70 {365 – 415}
3.24 ± 0.2 {33 ± 2}
2.84 – 3.43 {29 – 35}
When all control levers in NEUTRAL position
4.2 ± 1.0 {42 ± 10}
4.2 ± 1.0 {42 ± 10}
When traveling at half stroke (without load)
2.65 ± 0.1 {27 ± 1}
2.65 ± 0.1 {27 ± 1}
PC400/450(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
Applicable model Category
Item
Swing brake angle
Measurement conditions
Unit
Standard value
Permissible value
• Hydraulic oil temperature: Within operating range • Bucket: Empty • Engine at high idling • Working mode: A mode • Swing circle misalignment amount when stopping after one turn
deg. (mm)
PC400: Max. 120 PC450: Max. 130
PC400: Max. 150 PC450: Max. 160
3.7 ± 0.4
Max. 4.6
5.4 ± 0.5
Max. 6.4
sec.
33.0 ± 3.3
Max. 38
mm
0
0
90° • Hydraulic oil temperature: Within operation range • Bucket: Empty • Engine at high idling • Working mode: A mode • Time required for passing points 90 and 180 degrees from starting point
sec.
180°
Swing
Time taken to start swing
Time taken to swing
Hydraulic drift of swing
PC400/450(LC)-7
• Hydraulic oil temperature: Within operating range • Bucket: Empty • Engine at high idling • Working mode: A mode • Time required for 5 more turns after making initial one turn
• Hydraulic oil temperature: Within operation range • Engine stopped • Keeping upper structure transverse on slope of 15 degrees • Notching a mating mark on inner and outer races of swing circle • Mating mark misalignment amount during 5 minutes
20-5 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
Applicable model
Swing
Category
Item
Leakage from swing motor
Measurement conditions
Unit
Standard value
Permissible value
l/min
Max. 5.5
Max. 11
STD: 63.2 ± 12.6 LC: 67.3 ± 13.5
STD: 42.0 – 80.0 LC: 45.0 – 84.5
STD: 45.1 ± 6.8 LC: 48.1 ± 7.2
STD: 31.5 – 55.0 LC: 34.0 – 58.0
Hi
STD: 34.5 ± 35 LC: 36.7 ± 3.6
STD: 28.0 – 41.5 LC: 32.0 – 44.0
Lo
24.0 ± 4.8
18.9 – 31.0
17.1 ± 2.6
14.4 – 21.0
13.1 – 1.3
11.7 – 15.1
Max. 200
Max. 300
• Hydraulic oil temperature: Within operation range • Engine at high idling • Swing lock switch: ON • Leakage amount for one minute during swing relief
Lo
Travel speed (Idle travel)
Travel
Travel speed (Actual travel)
Travel deviation
20-6 (1)
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required for track shoes to make 5 turns after making one initial idle turn
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Flat ground • Time required for traveling 20 m after 10 m trial run
Mi
Mi
sec.
sec.
Hi
• Hydraulic oil temperature: Within operation range • Engine at idling • Working mode: A mode • Travel speed: Lo • Solid and flat ground • Swerving amount while traveling 20 m (X) after initial 10 m trial run.
mm
PC400/450(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
Applicable model Category
Measurement conditions
Unit
Standard value
Permissible value
Hydraulic drift of travel
• Hydraulic oil temperature: Within operating range • Engine stopped • Parking machine on slope 12 degrees with sprocket facing upslope • Sliding distance for 5 minutes
mm
0
0
l/min
Max. 20
Max. 40
Whole work equipment (tooth tip fall amount)
PC400: Max. 600 PC450: Max. 700
PC400: Max. 900 PC450: Max. 1,050
Boom cylinder (cylinder retraction amount)
PC400: Max. 25 PC450: Max. 29
PC400: Max. 38 PC450: Max. 44
PC400: Max. 85 PC450: Max. 100
PC400: Max. 128 PC450: Max. 150
PC400: Max. 30 PC450: Max. 35
PC400: Max. 45 PC450: Max. 53
Travel
Item
Hydraulic drift of work equipment
Work equipment
Leakage of travel motor
Arm cylinder (cylinder extension amount)
Bucket cylinder (cylinder retraction amount)
PC400/450(LC)-7
• Hydraulic oil temperature: Within operating range • Engine at high idling • Travel: Lock sprocket. • Oil leakage amount for one minute with traveling in relief condition
• Hydraulic oil temperature: Within operation range • Flat and level ground • Work equipment in measurement posture as illustrated above • Bucket load: 3,060 kg • Engine stopped • Work equipment control lever in NEUTRAL position • Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting
mm
20-7 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
20-8 (1)
RAISE Bucket
PC400: 4.0 ± 0.4 PC450: 4.2 ± 0.4
PC400: Max. 4.8 PC450: Max. 5.0
LOWER
Arm
Service limit value
PC400: 2.9 ± 0.3 PC450: 2.8 ± 0.3
PC400: Max. 3.4 PC450: Max. 3.3
CURL
Work equipment speed
Work equipment
Boom
Standard value for new machine
PC400: 4.3 ± 0.4 PC450: 4.7 ± 0.5
PC400: Max. 5.0 PC450: Max. 5.4
DUMP
Item
3.6 ± 0.4
Max. 4.3
CURL
Category
3.6 ± 0.4
Max. 4.3
DUMP
Applicable model
2.9 ± 0.3
Max. 3.5
Measurement conditions
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required from raise stroke end till bucket touches ground
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required from dumping stroke end to digging stroke end
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Time required from dumping stroke end to digging stroke end
Unit
sec.
PC400/450(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
Applicable model Category
Item
Time lag
Work equipment
Boom
Arm
Internal leackage
Bucket
Cylinders
Center swivel joint
PC400/450(LC)-7
Measurement Condition
• Hydraulic oil temperature: Within operation range • Engine at low idling • Working mode: A mode • Time required from raise stroke end till bucket touches ground and pushes up machine front
• Hydraulic oil temperature: Within operation range • Engine at low idling • Working mode: A mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again
Unit
Standard value
Permissible value
sec.
Max. 3.0
Max. 3.6
PC400: Max. 3.0 PC450: Max. 4.0
PC400: Max. 3.6 PC450: Max. 4.6
Max. 3.0
Max. 5.0
4.5
20
10
50
sec.
• Hydraulic oil temperature: Within operation range • Engine at low idling • Working mode: A mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again • Hydraulic oil temperature: Within operation range • Engine at high idling • Leakage amount for one minute with cylinder or travel to be measured in relief condition
cc/min
20-9 (1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
Applicable model
Performance of hydraulic pump
Performance in compound operation
Category
20-10 (1)
Item
Swerving amount in simultaneous operation of work equipment and travel
Hydraulic pump delivery
Measurement Condition • Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Traveling speed: Lo • Flat and level ground • Swerving amount (X) when traveling 20 m after initial trial run of 10 m
See next page
Unit
Standard value
Permissible value
mm
Max. 400
Max. 440
l/min
See next page
PC400/450(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
PC400, 400LC-7 PC450, 450LC-7
Applicable model Category
Item
Measurement Condition
Unit
Standard value
Permissible value
Performance of hydraulic pump
Discharge amount of hydraulic pump (A mode)
• Pump speed: At 1,950 rpm, PC current 280 mA
Check point
As desired a a
Test pump discharge pressure (MPa {kg/cm2})
Discharge pressure of other pump (MPa {kg/cm2})
P1
P2
Average pressure (MPa {kg/cm2}) P1+P2 2
Standard value for discharge amount Q (l/min)
Judgement standard lower limit Q (l/min)
See graph
See graph
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC400/450(LC)-7
20-11 (1)
TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE ...................................................... 20-102 MEASURING ENGINE SPEED .................................................................................................................. 20-104 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................ 20-105 MEASURING EXHAUST TEMPERATURE ................................................................................................ 20-106 MEASURING EXHAUST GAS COLOR ...................................................................................................... 20-107 ADJUSTING VALVE CLEARANCE ............................................................................................................ 20-108 MEASURING COMPRESSION PRESSURE.............................................................................................. 20- 110 MEASURING BLOW-BY PRESSURE ........................................................................................................ 20- 112 MEASURING ENGINE OIL PRESSURE .................................................................................................... 20- 113 HANDLING OF FUEL SYSTEM DEVICES................................................................................................. 20- 114 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM .................................................................. 20- 114 MEASURING FUEL PRESSURE ............................................................................................................... 20- 115 BLEEDING AIR FROM FUEL CIRCUIT ..................................................................................................... 20- 116 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE .................................................................................... 20- 118 ADJUSTING ENGINE SPEED SENSOR ................................................................................................... 20- 119 TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION ........................................ 20-120 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................ 20-121 MEASURING CLEARANCE OF SWING CIRCLE BEARING..................................................................... 20-122 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................. 20-123 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....................................................................................................... 20-124 MEASURING BASIC PRESSURE IN CONTROL CIRCUIT ....................................................................... 20-128 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ................................... 20-129 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.................................... 20-132 MEASURING SOLENOID VALVE OUTPUT PRESSURE.......................................................................... 20-137 MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................... 20-140 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES................................................ 20-142 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT ................................... 20-143 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT.............................................................. 20-145 MEASURING OIL LEAKAGE...................................................................................................................... 20-146 BLEEDING AIR FROM EACH PART.......................................................................................................... 20-149 TESTING PROCEDURE OF DIODE .......................................................................................................... 20-152 SPECIAL FUNCTIONS OF MONITOR PANEL .......................................................................................... 20-153 SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL ............................................................... 20-179-2 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER ................................................. 20-180 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM .......... 20-181 PM-CLINIC SERVICE ................................................................................................................................. 20-183
PC400/450(LC)-7
20-101 (7)
TESTING AND ADJUSTING
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
Measuring intake air pressure (boost pressure)
A
799-201-2202 Boost gauge kit
1
–101 – 200 kPa {–760 – 1,500 mmHg}
Measuring exhaust temperature
B
799-101-1502 Digital thermometer
1
–99.9 – 1,299°C
1 799-201-1502 Handy smoke meter
1
Measuring exhaust gas color
Part No.
Part name
C 2
Adjusting valve clearance
D
E 2 3
Measuring blow-by pressure
Measuring engine oil pressure
Measuring fuel pressure
F
Smoke meter
1
Commercially available
Feeler gauge
1
Air intake side: 0.35 mm, Exhaust side: 0.57 mm
1
0 – 6.9 MPa {0 – 70 kg/cm2}
795-471-1410 Adapter
1
6217-71-6112
Gasket
1
795-799-1170
Puller
1
799-101-5002 Hydraulic tester
1
(Pressure gauge): 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester
1
(Pressure gauge): 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester
1
(Pressure gauge): 0.98MPa {10 kg/cm2}
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
1
2 799-401-2320 Hydraulic tester Measuring clearance of swing circle bearing Measuring and adjusting oil pressures in work equipment, swing, and travel circuits
Commercially available
J 1 k 2
1 Measuring basic pressure in control circuit
L 2
Testing and adjusting oil pressure in pump PC control circuit
20-102 (1)
For 125E-3 engine
1
1
H
Pollution level: 0 – 70 % (With standard color) (Pollution level × 1/10 Bosch index)
799-201-1504 Blow-by checker
1
G
Remarks
Commercially available
1 795-502-1590 Compression gauge Measuring compression pressure
Q’ty
Testing/Adjusting item
symbol
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
1 M 2
Dial gauge
1 1
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
1
799-101-5220 Nipple
2
07002-11023
2
O-ring
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
1
799-101-5220 Nipple
2
07002-11023
2
O-ring
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
1
799-101-5220 Nipple
4
07002-11023
4
O-ring
Same as G
with magnet Same as G
(Size): 10 × 1.25 mm
Same as G1
Same as K2
Same as G
PC400/450(LC)-7
1 Testing and adjusting pressure in pump LS control circuit
N 2
Part No.
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
1
799-101-5220 Nipple
4
07002-11023
O-ring
4
Differential pressure gauge
1
3 799-401-2701 1 Measuring solenoid valve output pressure
P 2
Measuring PPC valve output pressure
Q
1
Part name
Q’ty
Testing/Adjusting item
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
symbol
TESTING AND ADJUSTING
Remarks
Same as G1
Same as M2
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
1
799-401-3100 Adapter
1
(Size): 02
799-401-3200 Adapter
1
(Size): 03
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
1
2 970-301-1740 Joint
1
Same as G1
Same as G1 (Size): PF1/4 + PT1/4
Measuring oil leakage
R
Commercially available
Testing wear of sprocket
—
799-627-1120 Wear gauge
1
Measuring coolant and oil temperatures
—
799-101-1502 Digital thermometer
1
Measuring operating effort and pressing force
—
79A-264-0021 Push-pull scale
1
0 – 294 N {0 – 30 kg}
79A-264-0091 Push-pull scale
1
0 – 490 N {0 – 50 kg}
Measuring stroke and hydraulic drift
—
Commercially available
Scale
1
Measuring work equipment speed
—
Commercially available
Stopwatch
1
Measuring voltage and resistance
—
Commercially available
Tester
1
Measuring cylinder
1
Same as B
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connectors and electric circuit diagram of each system.
PC400/450(LC)-7
20-103 (1)
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
MEASURING ENGINE SPEED 1. Turn the starting switch ON and set the monitor panel to “Monitoring”. a For the operating method, see “Special functions of monitor panel”. • Monitoring code: 01002 Engine Speed 01006 Engine Speed a Code 01002 is information of the engine controller and code 01006 is information of the pump controller. The engine speed can be measured with either of those codes. a The engine speed is displayed in rpm.
4) Measuring 2-pump relief + one-touch power maximizing speed (near rated speed): i) Start the engine and set the fuel control dial in the high idling position (MAX). ii) Set the working mode switch in the Amode position. iii) While relieving the arm circuit by moving the arm in, keep pressing the one-touch power maximizing switch. a The one-touch power maximizing function is reset automatically in about 8.5 seconds even if the switch is kept held. Accordingly, measure the engine speed in that period. 5) Measuring auto-deceleration speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Turn the auto-deceleration switch ON. 3) Set the work equipment control and swing control levers in neutral. a The engine speed lowers to a certain level about 5 seconds after all the levers are set in neutral. This level is the autodeceleration speed.
2. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 3. Measure the engine speed under each measurement condition. 1) Measuring low idling speed: i) Start the engine and set the fuel control dial in the low idling position (MIN). ii) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed. 2) Measuring high idling speed: i) Start the engine and set the fuel control dial in the high idling position (MAX). ii) Set the working mode switch in the Amode position. iii) Turn the auto-decelerator switch OFF. iv) Set the work equipment control, swing control, and travel levers in neutral. 3) Measuring 2-pump relief speed: i) Start the engine and set the fuel control dial in the high idling position (MAX). ii) Set the working mode switch in the Amode position. iii) Relieve the arm circuit by moving the arm in.
20-104 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) a Measuring instruments for intake air pressure (boost pressure) Symbol
Part No.
A
799-201-2202
Part Name Boost gauge kit
a When installing and removing the measuring instruments, take care not to touch a hot part of the engine.
4. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 5. Set the working mode switch in the A-mode position. 6. While running the engine at high idling, relieve the boom circuit by raising the boom and measure the intake air pressure (boost pressure).
1. Open the engine hood and remove intake air pressure pick-up plug (1).
7. After finishing measurement, remove the measuring instruments and return the removed parts. 2. Install nipple [1] of boost gauge kit A and connect gauge [2].
3. Run the engine at a medium or higher speed and drain the oil from the hose. a Insert the connecting parts of the gauge and hose about a half and open the self-seal on the hose side repeatedly, and the oil will be drained. a If Pm kit A is available, you may drain the oil by using the air bleeding coupling (790-2611130) in the kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil.
PC400/450(LC)-7
20-105 (1)
TESTING AND ADJUSTING
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE a Measuring instrument of exhaust gas temperature Symbol
Part No.
B
799-101-1502
Part Name Digital thermometer
k Install and remove the measuring instrument after the exhaust manifold is cooled.
5. Procedure for measuring exhaust temperature periodically for preventive maintenance (Pm Clinic), etc. 1) Set the working mode switch in the A-mode position. 2) Run the engine at high idling, relieve the arm circuit by moving the arm in, and measure the exhaust temperature. a Measure the exhaust temperature after it is stabilized.
1. Open the engine hood and remove exhaust temperature pick-up plug (1).
6. After finishing measurement, remove the measuring instruments and return the removed parts. 2. Install sensor [1] of digital thermometer B and connect them to meter [2]. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part.
3. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 4. Procedure for measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. a Set the digital thermometer in the PEAK mode.
20-106 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR a Measuring instrument of exhaust gas color Symbol C
Part No.
Part Name
1
799-101-9000
Handy smoke checker
2
Commercially available
Smoke meter
k When installing and removing the measuring instruments, take care not to touch a hot part. a If an air source and an electric power source are not available in the field, use handy smoke checker C1. When recording official data, use smoke meter C2. 1. Measuring with handy smoke checker C1 1) Stick a sheet of filter paper to C1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Run the engine and raise engine coolant temperature to operating range. 4) Accelerate the engine suddenly or run it at high idling and operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.
5) Remove the filter paper and compare it with the attached scale. 6) After finishing measurement, remove the m ea su ri ng i ns tr um ent an d re tur n the removed parts. 2. Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of exhaust pipe (1) and fix it to the exhaust pipe with a clip.
PC400/450(LC)-7
2) Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter C2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. 3) Connect the power cable to a receptacle of AC 100 V. a Before connecting the cable, check that the power switch of the smoke meter is turned off. 4) Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. 5) Turn on the power switch of smoke meter C2.
6) Run the engine and raise engine coolant temperature to operating range. 7) Accelerate the engine suddenly or run it at high idling and press the accelerator pedal of smoke meter C2 and collect the exhaust gas into the filter paper. 8) Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. 9) After finishing measurement, remove the me as ur in g in str u men t a nd r etu r n t he removed parts.
20-107 (1)
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE a Adjusting instrument for valve clearance Symbol
Part No.
D
Commercially available
the compression top dead center. In this case, rotate the crankshaft one more turn.
Part Name Feeler gauge
1. Open the engine hood and remove all cylinder head covers (1). a Remove all the intermediate clamps of the fuel high-pressure tube and disconnect the sleeve nuts on the common rail side and injector side, and you can remove the cylinder head covers. a Use ring wrenches (on the market) for highpressure pipes to disconnect and connect the fuel high-pressure tubes. a Remove the air intake connector, too, from the top of the No. 1 cylinder head cover. a After removing the head covers, tighten the sleeve nuts temporarily so that the fuel highpressure tubes will not interfere with the rocker arms.
5. Insert feeler gauge D in clearance “b” between rocker arm (3) and crosshead (4) and adjust the valve clearance with adjustment screw (5). a With the feeler gauge inserted, turn the adjustment screw to a degree that you can move the filler gauge lightly. 6. Fix adjustment screw (5) and tighten locknut (6). 3 Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm} a After tightening the locknut, check the valve clearance again.
2. Remove the belt protection covers (2 pieces) and loosen the fan belt and alternator belt. 3. Remove the radiator undercover. 4. Rotate the crankshaft forward to bring the stamped “1.6TOP” line “a” of the damper to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Crank the crankshaft with the crank pulley mounting bolt (width across flats: 24 mm) only in the forward direction so that the bolt will not be loosened. a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at
20-108 (1)
7. Turn the crankshaft forward by 120° each time and repeat steps 2 – 5 for each cylinder according to the firing order. • Firing order: 1 – 5 – 3 – 6 – 2 – 4
PC400/450(LC)-7
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
8. After finishing adjustment, return the removed parts.
3 Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} a After tightening the sleeve nuts permanently, tighten the clamp bolts of the fuel high-pressure tubes permanently. 3 Fuel high-pressure tube sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm} 3 Fuel high-pressure tube clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3 Air intake connector clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm} a Adjust the belt tension. For details, see TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION.
PC400/450(LC)-7
20-109 (1)
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE a Measuring instruments for compression pressure Symbol 1 E
2 3
Part No.
Part Name
795-502-1590
Compression gauge
795-471-1410
Adapter
6217-71-6112
Gasket
795-799-1170
Puller
k When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. 1. Run the engine and warm up the engine oil temperature to 40 – 60°C.
4. Install adapter E2 and connect it to compression gauge E1. 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2. Open the engine hood and remove cover (1) of the cylinder head to be measured. a Remove all the intermediate clamps of the fuel high-pressure tube and disconnect the sleeve nuts on the common rail side and injector side, and you can remove the cylinder head cover. a Use ring wrenches (on the market) for highpressure pipes to disconnect and connect the fuel high-pressure tubes. a Remove the air intake connector, too, from the top of the No. 1 cylinder head cover. 5. Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. 6. Remove the engine undercover and disconnect engine intermediate connectors ER02 and ER03.
3. Using puller E3, remove injector (2). a Loosen the nuts of the wiring harness alternately. a After removing the injector, tighten the sleeve nut temporarily so that the fuel highpressure tube will not interfere with the rocker arm.
20-110 (1)
k If the connectors are not disconnected, the engine starts during measurement, and that is dangerous. Accordingly, be sure to disconnect the connectors. k Cover the connectors on the controller side (chassis side) with a vinyl sheet, etc. to prevent electric leakage and grounding fault.
7. Turn the starting switch ON and prepare the monitor panel for measuring engine speed. a See MEASURING ENGINE SPEED.
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
8. Crank the engine with the starting motor and measure the compression pressure. a Measure the pressure when the pointer of the gauge is stabilized. a While measuring the compression pressure, measure the engine speed, too, and check that it is in the measurement condition range. 9. After finishing measurement, remove the measuring instruments and return the removed parts. 3 Injector holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 3 Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} a After tightening the sleeve nuts permanently, tighten the clamp bolts of the fuel high-pressure tubes permanently. 3 Fuel high-pressure tube sleeve nut: 39.2 – 49.0 Nm {4 – 5 kgm} 3 Fuel high-pressure tube clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3 Air intake connector clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm}
PC400/450(LC)-7
20-111 (1)
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE a Measuring instrument for blow-by pressure Symbol
Part No.
F
799-201-1504
Part Name Blow-by checker
1. Remove the engine undercover. 2. Install nozzle [1] of blow-by checker F to blow-by hose (1) and connect it to gauge [2] by the hose.
3. Run the engine and raise engine coolant and hydraulic oil temperatures to operating range. 4. Run the engine at high idling and measure the blow-by pressure under the following condition. • Work equipment mode: A • Swing lock switch: ON (High pressure relief) • Work equipment, swing, and travel circuits: Relieve by moving arm in. a Read the blow-by checker when its pointer is stabilized.
5. After finishing measurement, remove the measuring instruments and return the removed parts.
20-112 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE a Measuring instruments for engine oil pressure Symbol
G
1 2
Part No.
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-401-2320
Hydraulic tester
1. Open the engine hood and remove oil pressure pick-up plug (1) from the engine cylinder block.
5. After finishing measurement, remove the measuring instruments and return the removed parts.
2. Install nipple [1] of hydraulic tester G1 and connect it to hydraulic tester G2.
3. Run the engine and raise engine coolant temperature to operating range. 4. Measure the engine oil pressure at low idling and high idling.
PC400/450(LC)-7
20-113 (1)
TESTING AND ADJUSTING
HANDLING OF FUEL SYSTEM DEVICES RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
HANDLING OF FUEL SYSTEM DEVICES a Precautions for testing and adjusting fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and adjusting the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. a Precautions for replacing fuel filter cartridge Always use a Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than a Komatsu genuine filter is used, the fuel system may have trouble. So never use any thing but a Komatsu genuine filter.
20-114 (1)
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM a Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Fuel supply pump High-pressure circuit: Fuel supply pump – Common rail – Fuel injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following.
k Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE a Measuring instruments for fuel pressure Symbol
H
1 2
Part No.
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-401-2320
Hydraulic tester
3. Run the engine at high idling and measure the fuel pressure. a If the fuel pressure is in the following range, it is normal. 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
a Measure only the fuel pressure in the low-pressure circuit from the feed pump to the fuel filter and fuel supply pump.
k Since the pressure in the high-pressure circuit from the fuel supply pump to the common rail and fuel injector is very high, it cannot be measured. 1. Open the engine hood and remove fuel pressure pick-up plug (1).
4. After finishing measurement, remove the measuring instruments and return the removed parts.
2. Install nipple [1] of hydraulic tester H1 and connect them to hydraulic tester H2.
PC400/450(LC)-7
20-115 (1)
TESTING AND ADJUSTING
BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
a If fuel is used up or if a fuel circuit device is removed and installed, bleed air from the fuel circuit according to the following procedure. a Open the engine hood. 1. Remove fuel filter (1) and fill it with fuel and install it again. a Fill the fuel filter with clean fuel and take care that dirt will not enter it. a Add fuel through inlet ports (1a) (8 places) of the filter. Since hole (1b) is the outlet port (clean side), do not add fuel through it. a If clean fuel is not available, do not remove the filter but fill it with the fuel from the fuel tank by operating the priming pump.
20-116 (1)
2. Remove plug (2a) of the fuel filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the plug hole and install the plug. 3 Plug: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
PC400/450(LC)-7
TESTING AND ADJUSTING
BLEEDING AIR FROM FUEL CIRCUIT
3. Remove air bleed plug (2b) of the fuel filter and operate priming pump (3). a Operate the priming pump until the fuel flows out of the plug hole and install the plug. 3 Air bleed plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} 4. Loosen air bleeder (4) of the fuel supply pump and operate priming pump (3) 90 – 100 times. a Operate the priming pump until fuel flows from air bleeder (2b) and tighten the air bleeder. Then operate the priming pump several more times, until it becomes heavy. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm} 5. Start the engine with the starting motor. a Air in the high-pressure circuit is automatically bled when the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 2.
PC400/450(LC)-7
20-117 (1)
TESTING AND ADJUSTING
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE k Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, inspect it for fuel leakage according to the following procedure. a Clean and degrease the engine and the parts around it in advance so that you can inspect it easily for fuel leakage.
9. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. a If any fuel leakage is not detected, inspection is completed.
1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. 2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. 3. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 4. Run the engine at low idling. 5. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 6. Run the engine at high idling. 7. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 8. Run the engine at high idling and load it. a Relieve the oil by moving the arm in.
20-118 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR a Adjust the engine speed sensor for the pump controller according to the following procedure. a The engine G speed sensor and engine Ne speed sensor for the engine controller cannot be adjusted. a Open the engine hood and remove engine speed sensor (1) before adjusting it and check that its tip is free from steel chips and flaws, and then install it again.
1. Screw in sensor (1) until its tip touches the tooth tip of flywheel ring gear (2). 2 Threads: Hydraulic sealant 2. Return sensor (1) by 1/2 – 2/3 turns. a Adjust clearance “a” between the sensor tip and gear tooth tip to 0.75 – 1.00 mm. 3. Secure sensor (1) with nut (3). 3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}
4. After finishing adjustment, check that the monitor panel displays the engine speed normally in the monitoring mode. a For the operating method, see “Special functions of monitor panel”. a Monitoring code: 01006 (Engine speed)
PC400/450(LC)-7
20-119 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION Testing 1. Open the engine hood and remove belt protection covers (2 pieces).
Adjusting a If the deflection is abnormal, adjust it according to the following procedure.
2. Press the intermediate point between alternator pulley and fan pulley with a finger and measure deflection “a” of the belt. a Deflection “a” when pressing force is approximately 58.8 N {approximately 6 kg}: 13 mm
1. Loosen bolts and nuts (1), (2), and (3). 2. Turn nut (4) to move alternator (5) and adjust the belt tension. a If nut (4) is • Tightened clockwise, the belt tension is decreased. • Loosened counterclockwise, the belt tension is increased. a Check breakage of the pulleys, wear of the V-grooves and V-belts, and contact of the belts and V-grooves. a If a belt is lengthened to the adjustment limit, cut, or cracked, replace it with a new belt. 3. Tighten nuts and bolts (3), (2), and (1). a If a V-belt is replaced, readjust its tension after 1 operating hour.
20-120 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION Testing 1. Open the engine hood and remove belt protection covers (2 pieces).
Adjusting a If the deflection is abnormal, adjust it according to the following procedure.
2. Press the intermediate point between air conditioner compressor pulley and crank pulley with a finger and measure deflection “a” of the belt. a Deflection “a” when pressing force is approximately 58.8 N {approximately 6 kg}: 14 mm – 16 mm
1. Loosen bolts (1) and (2). 2. Move compressor (3) to adjust the belt tension. a Check breakage of the pulleys, wear of the V-grooves and V-belts, and contact of the belts and V-grooves. a If a belt is lengthened to the adjustment limit, cut, or cracked, replace it with a new belt. 3. Tighten bolts (2) and (1). a If a V-belt is replaced, readjust its tension after 1 operating hour.
PC400/450(LC)-7
20-121 (1)
TESTING AND ADJUSTING
MEASURING CLEARANCE OF SWING CIRCLE BEARING
MEASURING CLEARANCE OF SWING CIRCLE BEARING a Measuring instrument for clearance of swing circle bearing Symbol
Part No.
J
Commercially available
Part Name
4. Set the arm at almost right angle to the ground and lower the boom until the track shoe at the front end of the machine rises. a At this time, the front end of the upper structure rises and the rear end lowers.
Dial gauge
a When measuring the clearance of the swing circle bearing on the actual machine, observe the following procedure.
5.
Under this condition, read dial gauge J. a Dial gauge J indicates the clearance of the bearing.
k While measuring, do not put your hands or foot under the undercarriage.
1. Fix dial gauge J to outer race (1) or inner race (2) of the swing circle and apply the probe to the end face of inner race (2) or outer race (1) on the opposite side. a Set dial gauge J on the front or at rear side of the machine.
6. Return the machine to the position of step 2 and check that dial gauge J indicates 0 again. a If dial gauge J does not indicate 0, repeat steps 3 – 5.
2. Set the work equipment in the maximum reach position and set the bucket tip at the height of the revolving frame bottom. a At this time, the front end of the upper structure lowers and the rear end rises. 3. Set the dial gauge to 0 point.
20-122 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. Run the engine at low idling and move the machine forward by the length of track on ground and stop slowly. 2. Place square bar [1] on the track shoe between idler (1) and 1st carrier roller (2). a As the square bar [1], use angle iron which has less deflection. 3. Measure maximum distance “a” between square bar [1] and track shoe. • Standard maximum distance “a” : 10 – 30 mm
PC400/450(LC)-7
Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. 1. When tension is too high Loosen valve (3) to discharge the grease.
k Since the valve may jump out because of the high-pressure grease, do not loosen it more than 1 turn.
2. When tension is low Add grease through valve (3). a If the track shoe is not tensed well, drive the machine forward and in reverse slowly.
20-123 (1)
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS a Testing and adjusting instruments for oil pressure in work equipment, swing, and travel circuits Symbol 1 K 2
Part No.
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
a The oil pressure in work equipment, swing, and travel circuits can be checked with the monitoring function of the monitor panel (For the operating method, see “Special functions of monitor panel”). • Monitoring code: 01100 F Pump Pressure 01101 R Pump Pressure • The pump oil pressure is displayed in 1 MPa {1 kg/cm2, 1 PSI).
2) Install nipple K2 and connect it to oil pressure gauge [1] of hydraulic tester K1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.
3) Run the engine and raise the hydraulic oil temperature to the operating range. Measuring 1. Preparation work
k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1) Open the pump room cover and remove oil pressure pick-up plugs (1) and (2). • (1): Front pump discharge pressure pickup plug • (2): Rear pump discharge pressure pickup plug
20-124 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TESTING AND ADJUSTING
2. Combination of pump, actuator, and valve a When the oil from the pumps is divided, the front pump and rear pump act independently on each actuator. Note that different actuators relieve different valves. a When the work equipment circuit or swing circuit is relieved singly, the oils of the pumps are merged. When the travel circuit is relieved singly, the oils of the pumps are divided. a The actuators in the table are arranged in the order when the control valve is seen from the front of the machine (and an attachment is installed to the service valve). Pump
Actuator
Valve relieved
(F unload valve) (F main relief valve)
Front
Service
Safety valve for service
Boom Hi Arm Hi
F main relief valve
Bucket
F main relief valve
Left travel
F main relief valve
Boom
RAISE: F main relief valve LOWER: Safety-suction valve
a If the one-touch power maximizing switch is released, the valve is relieved at low pressure. If the former is pressed, the lower is relieved at high pressure. a If the swing lock switch is turned ON, the 2stage relief valve is kept turned ON and the valve is relieved at high pressure. Accordingly, keep the swing lock switch turned OFF. 5. Measuring swing circuit relief pressure 1) Start the engine and turn the swing lock switch ON. 2) Run the engine at high idling and relieve the swing circuit and measure the oil pressure. a The pressure measured when the swing motor safety valve is relieved is indicated. a The swing motor relief pressure is lower than the main relief valve. 6. Measuring travel circuit relief pressure 1) Start the engine and lock the travel mechanism.
k Set pin [2] between the sprocket and track frame to lock the travel mechanism securely.
(Pump merge-divider valve) (Travel junction valve) (Self-pressure reducing valve)
Rear
Swing
Swing motor safety valve
Right travel
R main relief valve
Arm Lo
R main relief valve
(R unload valve) (R main relief valve) (Centralized safety valve) (Back pressure valve)
3. Measuring unload pressure 1) Start the engine. 2) Run the engine at high idling and set all the control levers in neutral and measure the oil pressure. a The pressure measured when the unload valve is unloaded is indicated.
2) Run the engine at high idling and relieve the travel circuit and measure the oil pressure. a The pressure measured when the main relief valve is relieved is indicated. The travel circuit is always relieved at high pressure.
4. Measuring work equipment circuit relief pressure 1) Start the engine and move the cylinder to be measured to the stroke end. 2) Run the engine at high idling and relieve the cylinder and measure the oil pressure. a The pressure measured when the main relief valve is relieved is indicated.
PC400/450(LC)-7
20-125 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
Adjusting a The unload valve cannot be adjusted. 1. Adjusting main relief pressure a If the relief pressure of the work equipment circuit and/or travel circuit is abnormal, adjust main relief valves (3) and (4) according to the following procedure. • (3): Front main relief valve • (4): Rear main relief valve a When adjusting the main relief valve on the front pump side, remove the control valve top cover. a When adjusting the main relief valve on the rear pump side, remove the control valve undercover (if the covers are installed). a Adjust only the low relief pressure of the main relief valve. (If the low relief pressure is adjusted, the high relief pressure is adjusted automatically.) a The low relief pressure is the pressure applied when the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the selector port.
1) Disconnect pilot hose (5). 2) Fixing holder (6), loosen locknut (7). 3) Turn holder (6) to adjust the pressure. a If the holder is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} 4) Fixing holder (6), tighten locknut (7). 3 Locknut: 49.0 – 58.8 Nm {5 – 6 kgm}
20-126 (1)
5) Connect pilot hose (5). 6) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above. 2. Adjustment of boom LOWER relief pressure (High-pressure setting side) a If the high relief pressure of the boom LOWER circuit is abnormal, adjust the high pressure setting side of boom LOWER safetysuction valve (8) according to the following procedure. a The high relief pressure is the pressure applied when the machine push-up switch is turned ON and the pilot pressure is not applied to the selector port.
1) Disconnect pilot hose (9). 2) Fixing holder (10), loosen locknut (11). 3) Turn holder (10) to adjust the pressure. a If the holder is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of holder: Approx. 25.3 MPa {Approx. 258 kg/cm2} 4) Fixing holder (10), tighten locknut (11). 3 Locknut: 93 – 123 Nm {9.5 – 12.5 kgm}
PC400/450(LC)-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
4. Adjusting swing relief pressure a If the relief pressure of the swing circuit is abnormal, adjust swing motor safety valve (14) according to the following procedure.
5) Connect pilot hose (9). 6) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above. a If the high pressure setting side is adjusted, the low pressure setting side changes. Accordingly, adjust the low pressure setting side. 3. Adjustment of boom LOWER relief pressure (Low-pressure setting side) a If the low relief pressure of the boom LOWER circuit is abnormal or the high pressure setting side was adjusted, adjust the low pressure setting side of boom LOWER safety-suction valve according to the following procedure. a The low relief pressure is the pressure applied when the machine push-up switch is turned OFF and the pilot pressure is applied to the selector port. 1) Disconnect pilot hose (9). 2) Fixing holder (12), loosen locknut (13). 3) Turn holder (12) to adjust the pressure. a If the holder is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of holder: Approx. 25.3 MPa {Approx. 258 kg/cm2} 4) Fixing holder (12), tighten locknut (13). 3 Locknut: 78 – 93 Nm {8.0 – 9.5 kgm} 5) Connect pilot hose (9). 6) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.
PC400/450(LC)-7
1) Fixing adjustment screw (15), loosen locknut (16). 2) Turn adjustment screw (15) to adjust the pressure. a If the adjustment screw is • Turned to the right, pressure rises. • Turned to the left, pressure lowers. a Quantity of adjustment per turn of adjustment screw: 4.70 MPa {47.9 kg/cm2} 3) Fixing adjustment screw (15), tighten locknut (16). 3 Locknut: 147 – 196 Nm {15 – 20 kgm}
4) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.
20-127 (1)
TESTING AND ADJUSTING
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT a Measuring instruments for basic pressure in control circuit Symbol 1 L 2
Part No.
Part Name
799-101-1502
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
3. Run the engine and raise the hydraulic oil temperature to the operating range. 4. Run the engine at high idling and set all the control levers in neutral and measure the oil pressure.
k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1. Remove the control valve top cover and remove control circuit basic pressure pick-up plug (1). a The figure shows the control valve seen from inside of the pump room.
5. After finishing measurement, remove the measuring instruments and return the removed parts. a The relief valve for the control circuit basic pressure is not adjustable.
2. Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.
20-128 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT a Testing and adjusting instruments for oil pressure in pump PC control circuit Symbol 1 M 2
Part No.
Part Name
799-101-1502
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
2) Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}. • The figure shows the pump discharge pressure side.
Measuring a Before measuring the oil pressure in the pump PC control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure in the control circuit are normal. k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure.
1. Measuring PC valve output pressure (servo piston inlet pressure) a Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and compare them. 1) Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (3), and (4). • (1): Front pump discharge pressure pickup plug • (2): Rear pump discharge pressure pickup plug • (3): Front PC valve output pressure pickup plug • (4): Rear PC valve output pressure pickup plug
PC400/450(LC)-7
•
The figure shows the PC valve output pressure side.
3) Run the engine and raise the hydraulic oil temperature to the operating range.
20-129 (1)
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TESTING AND ADJUSTING
4) Run the engine at high idling and measure the pump discharge pressure and PC valve output pressure (servo piston inlet pressure) at the same time under the following condition. • Working mode: A • Swing lock switch: ON (2-stage relief solenoid valve is turned ON and oil is relieved at high pressure) • Work equipment, swing, and travel circuits: Relieve by moving arm IN. a Judging method: If the pump discharge pressure and PC valve output pressure (servo piston output pressure) are as follows, they are normal. Measured pressure Pump discharge pressure PC valve output pressure
2. Measuring PC-EPC valve output pressure 1) Open the pump room cover and remove PC-EPC valve output pressure pick-up plug (5).
Pressure ratio 1 Approx. 0.6 (Approx. 3/5)
2) Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.
a If the PC valve or servo piston is abnormal, the PC valve output pressure (servo piston output pressure) becomes “the same as the pump discharge pressure” or “almost 0”. 5) After finishing measurement, remove the measuring instruments and return the removed parts.
3) Run the engine and raise the hydraulic oil temperature to the operating range.
20-130 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TESTING AND ADJUSTING
4) Set all the control levers in neutral and measure the oil pressure while running the engine at low idling and high idling. a If the PC-EPC valve output pressure changes as shown below, it is normal. Engine
Control lever
Low idling Neutral High idling
Oil pressure 2.94 MPa {30 kg/cm2} 0 MPa {0 kg/cm2}
5) After finishing measurement, remove the measuring instruments and return the removed parts. Adjusting a If any of the following phenomena occurs and the PC valve seems to be defective, adjust PC valves (6) and (7) according to the procedure shown below. • When the working load is increased, the engine speed is drastically reduced. • The engine speed is normal but the work equipment speed is low. • (6): Front pump PC valve • (7): Rear pump PC valve a The width across flats of the PC valve locknut is 13 mm, and the adjustment screw (inside width) is 4 mm. Do not turn any other locknuts or adjustment screws since they effect the hydraulic pumps.
2. Turn adjustment screw (9) to the right or left to adjust. a Turn the adjustment screw in the following directions. • If the work equipment speed is low, turn the adjustment screw to the right (to increase the pump absorption torque). • If the engine speed lowers, turn the adjustment screw to the left (to decrease the pump absorption torque). a The adjustable range of the adjustment screw is as follows. • Counterclockwise: Max. 1 turn • Clockwise: Max. 1 turn 3. Tighten locknut (8). 3 Locknut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
4. After finishing adjustment, check that the PC valve output pressure (servo piston inlet pressure) is normal according to the procedure for measurement described above.
1. Loosen locknut (8). a Before loosening the locknut, make match marks at the adjustment screw end so that you can see the position of the locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse).
PC400/450(LC)-7
20-131 (1)
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT a Testing and adjusting instruments for oil pressure in pump LS control circuit Symbol 1 N
2 3
Part No.
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
799-401-2701
Differential pressure gauge
2) Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}. • The figure shows the pump discharge pressure side.
Measuring a Before measuring the oil pressure in the pump LS control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure in the control circuit are normal.
k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1. Measuring LS valve output pressure (servo piston inlet pressure) a Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and compare them. 1) Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (3), and (4). • (1): Front pump discharge pressure pickup plug • (2): Rear pump discharge pressure pickup plug • (3): Front LS valve output pressure pickup plug • (4): Rear LS valve output pressure pickup plug
•
The figure shows the LS valve output pressure side.
3) Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. • When measuring front circuit: Left track shoe • When measuring rear circuit: Right track shoe
k Since the track shoe pushed up will be driven idle for measurement, secure sufficient work area.
20-132 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TESTING AND ADJUSTING
2. Measuring LS differential pressure a Measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time and calculate the difference between them. 1) Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (5), and (6). • (1): Front pump discharge pressure pickup plug • (2): Rear pump discharge pressure pickup plug
4) Run the engine at high idling and measure the pump discharge pressure and LS valve output pressure (servo piston inlet pressure) at the same time under the following condition. • Working mode: A • Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only the travel lever operated halfway (with the track shoe on one side driven idle). a Check the safety around the machine, drive the track shoe pushed up idle. a Judging method: If the pump discharge pressure and LS valve output pressure (servo piston output pressure) are as follows, they are normal. Measured pressure Pump discharge pressure LS valve output pressure
•
(5): Front LS valve output pressure pickup plug (6): Rear LS valve output pressure pickup plug
Pressure ratio Travel lever All levers operated in neutral halfway Almost same
1 Approx. 0.6 (Approx. 3/5)
5) After finishing measurement, remove the measuring instruments and return the removed parts.
PC400/450(LC)-7
•
2) Install nipple N2 and connect it to differential pressure gauge N3 or the oil pressure gauge of hydraulic tester N1. a When using differential pressure gauge: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12-V power source, connect it to a battery.
20-133 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
a When using oil pressure gauge: Use the oil pressure gauge of 58.8 MPa {600 kg/cm2}. Since the differential pressure is about 2.9 MPa {30 kg/cm2} at maximum, measure it by installing the same gauge to the pick-up plugs alternately. • The figure shows the pump discharge pressure side.
•
The figure shows the LS valve output pressure side.
4) Run the engine at high idling and measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time under the following condition. • Working mode: A • Travel speed: Hi • Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only the travel lever operated halfway (with the track shoe on one side driven idle). a Check the safety around the machine, drive the track shoe pushed up idle. a Calculation of LS differential pressure (When oil pressure gauge is used): LS differential pressure = Pump discharge pressure – LS pressure a If the LS differential pressure is as follows, it is normal. LS differential pressure Unload pressure Set all levers in (See standard values neutral table) Specified LS differenOperate travel lever tial pressure halfway (See standard values (Run track shoe idle) table) Operation of lever
3) Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. • When measuring front circuit: Left track shoe • When measuring rear circuit: Right track shoe k Since the track shoe pushed up will be driven idle for measurement, secure sufficient work area.
20-134 (1)
5) After finishing measurement, remove the measuring instruments and return the removed parts.
PC400/450(LC)-7
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
3. Measuring LS-EPC valve output pressure 1) Open the pump room cover and remove LSEPC valve output pressure pick-up plug (7).
4) Operate the travel speed switch and travel lever and measure the oil pressure while running the engine at high idling. a If the LS-EPC valve output pressure changes as shown below, it is normal. Travel speed
Travel lever
Lo
Netral
Hi
Fine operation (Note)
Oil pressure 2.94 MPa {30 kg/cm2} 0 MPa {0 kg/cm2}
Note: Operate the travel lever to a degree that the PPC oil pressure switch is turned ON (Stop before the machine starts traveling). 2) Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.
5) After finishing measurement, remove the measuring instruments and return the removed parts. Adjusting a If the LS differential pressure is abnormal, adjust LS valves (8) and (9) according to the following procedure. • (8): Front pump LS valve • (9): Rear pump LS valve
3) Run the engine and raise the hydraulic oil temperature to the operating range.
1. Fixing adjustment screw (10), loosen locknut (11). 2. Turn adjustment screw (10) to adjust the differential pressure. a If the adjustment screw is • Turned to the right, differential pressure rises. • Turned to the left, differential pressure lowers. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. 1.3 MPa {Approx. 13.3 kg/cm2}
PC400/450(LC)-7
20-135 (1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
3. After finishing adjustment, check that the LS pressure is normal according to the procedure for measurement described above.
20-136 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE a Measuring instruments for solenoid valve output pressure Symbol 1 P 2
Part No.
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
799-401-3100
Adapter (Size 02)
799-401-3200
Adapter (Size 03)
2. Install adapter P2 and reconnect the hose. 3. Install nipple [1] of hydraulic tester P1 and connect it to hydraulic gauge [2]. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}. a The figure shows the measuring instruments connected to the outlet hose of the 2-stage relief solenoid valve.
a Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal. k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure.
1. Remove the control valve top cover and disconnect outlet hoses (1) – (7) of the solenoid valve to be removed. a Since the outlet hoses of the PPC lock solenoid valves have quick couplers on the solenoid valve side, measure the pressure on the PPC valve side (on the back side of the operator’s cab). No.
4. Run the engine and raise the engine oil temperature to the operating range.
Solenoid valve to be measured
1
2-stage relief solenoid valve
2
Machine push-up solenoid valve
3
Swing holding brake solenoid valve
4
Travel speed selector solenoid valve
5
Merge-divider solenoid valve
6
Travel junction solenoid valve
7
PPC lock solenoid valve
PC400/450(LC)-7
5. Run the engine at high idling, operate the control levers and switches to turn the solenoid valve ON or OFF, and measure the oil pressure. a For the conditions for turning the solenoid valve ON and OFF, see the operations table of each solenoid valve. a The operating condition of the solenoid valve can be checked with the monitoring function of the monitor panel (For the operating method, see “Special functions of machine monitor”).
20-137 (1)
TESTING AND ADJUSTING
MEASURING SOLENOID VALVE OUTPUT PRESSURE
a If the output pressure is as follows, the solenoid valve is normal. Solenoid valve
Output pressure
OFF (Deenergized)
0 MPa {0 kg/cm2}
ON (Energized)
Almost same as control basic pressure (See standard values table)
6. After finishing measurement, remove the measuring instruments and return the removed parts. Operation table of 2nd-stage relief solenoid valve Operating condition When overheating No. 1 setting is turned ON When all of work equipment, swing, and travel signals are turned OFF When swing lock switch is turned ON
Operation OFF
When travel signal is turned ON When in L-mode ON
When boom LOWER signal is turned ON When signal other than swing sinWhen left knob switch gle operation signal is turned ON is turned ON When swing single operation signal is turned ON
When in A/E-mode
OFF
When not under above condition
Operation table of machine push-up solenoid valve Operating condition OFF Machine push-up switch ON
Operation ON OFF
Operation table of swing holding brake solenoid valve Operating condition When all are turned OFF
Work equipment, swing, travel signal When one of them is turned ON
Operation OFF ON
Operation table of travel speed shifting solenoid valve Operating condition When overheating No. 2 setting is turned ON When fuel control dial is below 1,200 rpm When travel speed switch is set to Lo
When travel speed switch is set to Mi or Hi
When travel signal is turned OFF When F or R pump pressure is 2 When travel signal is above 32.3 MPa {330 kg/cm } turned ON When F or R pump pressure is below 18.6 MPa {190 kg/cm2}
Operation
OFF
ON
When not under above condition
20-138 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING SOLENOID VALVE OUTPUT PRESSURE
Operation table of merge-divider solenoid valve When in B-mode
Operating condition When service signal is turned ON
Operation
When travel operation is performed singly When not in L-mode When travel signal is When work equipment, turned ON switch, and service signals are turned ON
When travel signal is When swing signal is turned OFF turned OFF
When F or R pump pressure is above 19.6 MPa {200 kg/cm2} When F or R pump pressure is below 14.7 MPa {150 kg/cm2}
When F or R pump pressure is above 16.7 MPa {170 kg/cm2} When in L-mode When F or R pump pressure is below 11.8 MPa {120 kg/cm2} When F or R pump pressure is When arm IN and above 24.5 MPa {250 kg/cm2} bucket CURL PPC pressures are above When F or R pump pressure is 1.9 MPa {19.5 kg/cm2} below 19.6 MPa {200 kg/cm2}
ON
OFF ON OFF ON OFF
When not under above condition
Operation table of travel junction solenoid valve Operating condition
Operation
When travel steering signal is turned ON When travel steering signal is turned OFF
When travel system is When F or R pump pressure is operated singly above 34.3 MPa {350 kg/cm2} When not under above condition
ON OFF
Operation table of PPC lock solenoid valve Operating condition Lock Safety lock lever Free
PC400/450(LC)-7
OFF ON
20-139 (1)
TESTING AND ADJUSTING
MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE a Measuring instruments for PPC valve output pressure Symbol 1
Q
2
Part No.
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
790-301-1740
Joint (PF 1/4 + PT 1/8)
k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release residual pressure in the piping, then slowly loosen the hydraulic tank oil filler cap to release the internal pressure. 1. Remove the control valve top cover and operator’s cab undercover. 2. Disconnect PPC oil pressure switch or PPC pressure sensors (1) – (10) of the solenoid valve to be removed. a If the starting switch is turned ON while the arm IN or bucket CURL PPC pressure sensor is disconnected, an electrical equipment system error is detected. Accordingly, if the pressure sensor is removed, reconnect it to the connector and clamp it to the nearest bracket. No.
Circuit to be measured
No.
1
Boom RAISE (S06)
7
Swing LEFT (S07)
2
Boom LOWER (S02)
8
Swing RIGHT (S03)
3
Arm IN (S04)
9
Travel (S30)
4
Arm OUT (S08)
10 Steering (S31)
5
Bucket CURL (S01)
6
Bucket DUMP (S05)
20-140 (1)
3. Install joint Q2 and nipple [1] of hydraulic tester Q1 and connect them to oil pressure gauge [2]. a Use joint Q2 only when measuring the pressure at the pressure sensor mounting part. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}. a The figure shows the measuring instruments installed to the mounting part of the arm IN PPC pressure sensor.
Circuit to be measured
4. Run the engine and raise the engine oil temperature to the operating range.
PC400/450(LC)-7
TESTING AND ADJUSTING
MEASURING PPC VALVE OUTPUT PRESSURE
5. Run the engine at high idling and measure the oil pressure while the control lever of the measured circuit is in neutral and while it is operated to the stroke end. a If the PPC valve output pressure is as follows, the solenoid valve is normal. Operation of lever
Output pressure
In neutral
0 MPa {0 kg/cm2}
Operated to stroke end
Almost same as control basic pressure (See standard values table)
6. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400/450(LC)-7
20-141 (1)
TESTING AND ADJUSTING
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES a If the work equipment and swing levers have excessive play, adjust them according to the following procedure. 1. Remove the work equipment and swing PPC valve assembly. 2. Remove bellows (1). 3. Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4). a Do not move the piston at this time. 4. Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 98 – 127 Nm {10 – 13 kgm} 5. Install bellows (1). 6. Install the work equipment and swing PPC valve assembly.
20-142 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT a If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylinder packing side or control valve side according to the following procedure.
2. Testing arm cylinder 1) Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine.
1. Testing boom cylinder and bucket cylinder 1) Set the machine in the position of measuring hydraulic drift and stop the engine. a Fill the bucket with a rated load or with dirt and sand.
2) When testing the boom cylinder, set the boom control lever in the RAISE position. When testing the bucket cylinder, set the bucket control lever in the CURL position. • If the lowering speed is increased at this time, the cylinder packing is defective. • If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator.
PC400/450(LC)-7
2) Operate the arm control lever in the IN position. • If the lowering speed is increased at this time, the cylinder packing is defective. • If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. [Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2) As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then the lowering speed is lowered. 3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.
20-143 (1)
TESTING AND ADJUSTING
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
3. Testing PPC valve While the pressure in the accumulator is high, set the safety lock lever in the LOCK/FREE position and measure the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. a If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).
20-144 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT 1. Releasing residual pressure in hydraulic tank
k Since the hydraulic tank is enclosed and pressurized, release the residual pressure in it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable position and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank.
3. Releasing residual pressure in swing motor circuit a The residual pressure in the swing motor circuit can be released by performing the operation for RELEASING RESIDUAL PRESSURE IN HYDRAULIC CYLINDER CIRCUIT. (Operate the control lever in the swing direction only.) 4. Releasing residual pressure in travel motor circuit a Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by performing RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK.
2. Releasing residual pressure in hydraulic cylinder circuit
k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the residual pressure in the piping according to the following procedure. 1) Release the residual pressure in the hydraulic tank. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK. a Keep the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch ON and set the safety lock lever in the FREE position, then operate the work equipment control levers on both sides forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. However, the accumulator pressure is released after the control valve is operated 2 – 3 times. 3) Run the engine at low idling for 5 seconds to heighten the pressure in the accumulator. a When starting engine, set the safety lock lever in the LOCK position. 4) Repeat steps 2) and 3) above 2 – 3 times, and the residual pressure in the piping is released.
PC400/450(LC)-7
20-145 (1)
TESTING AND ADJUSTING
MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE a Measuring device for oil leakage Symbol
Part No.
R
Commercially available
Part Name Measuring cylinder
1. Measuring oil leakage from boom cylinder 1) Run the engine and raise the engine oil temperature to the operating range. 2) Move the boom cylinder to the RAISE stroke end and stop the engine.
k Release the residual pressure in the piping on the boom cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT. (Operate the control lever in the boom RAISE direction only.) 3) Disconnect hose (1) on the cylinder head side and block the hose side with a plate.
2. Measuring oil leakage from arm cylinder 1) Run the engine and raise the engine oil temperature to the operating range. 2) Move the arm cylinder to the IN stroke end and stop the engine.
k Release the residual pressure in the piping on the arm cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT. (Operate the control lever in the arm IN direction only.) 3) Disconnect hose (2) on the cylinder head side and block the hose side with a plate. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-01044 (Flange #10)
k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-01044 (Flange #10)
4) Run the engine at high idling and relieve the arm circuit by moving the arm IN.
k Take care not to “move the arm OUT”. 5) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 4) Run the engine at high idling and relieve the boom circuit by raising the boom.
k Take care not to “lower the boom”. 5) Measure the oil leakage for 1 minute after 30 seconds since relieving is started.
6) After finishing measurement, return the removed parts.
6) After finishing measurement, return the removed parts.
20-146 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
3. Measuring oil leakage from bucket cylinder 1) Run the engine and raise the engine oil temperature to the operating range. 2) Move the bucket cylinder to the CURL stroke end and stop the engine.
k Release the residual pressure in the piping on the bucket cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT. (Operate the control lever in the arm CURL direction only.) 3) Disconnect hose (3) on the cylinder head side and block the hose side with a plate.
MEASURING OIL LEAKAGE
4. Measuring oil leakage from swing motor 1) Run the engine and raise the engine oil temperature to the operating range. 2) Disconnect drain hose (4) and block the hose side with a plug. a Use the following part to block the hose side. 07376-70522 (Plug #05)
k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07379-01044 (Flange #10)
3) Turn the swing lock switch ON. 4) Run the engine at high idling and relieve the swing circuit by swinging. a Measure the oil leakage for 1 minute after 30 seconds since relieving is started. a After measuring 1 time, swing 180°, and then measure again. 5) After finishing measurement, return the removed parts. 4) Run the engine at high idling and relieve the bucket circuit by curling the bucket.
k Take care not to “dump the bucket”. 5) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 6) After finishing measurement, return the removed parts.
PC400/450(LC)-7
20-147 (1)
TESTING AND ADJUSTING
MEASURING OIL LEAKAGE
5. Measuring oil leakage from travel motor 1) Remove the travel motor cover. 2) Run the engine and raise the engine oil temperature to the operating range, and then lock the travel system and stop the engine.
k Put pin [1] between the sprocket and track frame to lock the travel system securely.
3) Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Use the following part to block the hose side. 07376-70522 (Plug #05)
4) Run the engine at high idling and relieve the travel circuit.
k Wrong operation of the lever can cause an accident. Accordingly, make signs and checks securely. a Measure the oil leakage for 1 minute after 30 seconds since relieving is started. a Measure several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time. 5) After finishing measurement, return the removed parts.
20-148 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART
Air bleeding item Work • •
Replacing hydraulic oil Cleaning strainer
•
Replacing return filter element
•
Replacing and repairing hydraulic pump Removing suction piping Replacing and repairing control valve Removing control valve piping Replacing and repairing cylinder Removing cylinder piping Replacing and repairing swing motor Removing swing motor piping Replacing and repairing travel motor Removing travel motor piping Replacing and repairing swivel joint Removing swivel joint piping
• • • • • • • • • • •
Note:
1 Bleeding air from hydraulic pump q
2 Starting engine q
Air bleeding procedure 3 4 5 Bleeding Bleeding Bleeding air from air from air from swing travel cylinder motor motor q q q (See note) (See note)
6 Check oil level and starting work q
q q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump 1) Loosen bleeder (1) and check that oil flows out. 2) If the oil does not flow out, disconnect drain hose (2) and fill the pump case with oil through the drain port. a Fix the drain hose adapter to a place higher than the oil level in the hydraulic tank. a Fill the pump case with oil until oil containing no bubbles flows out of the bleeder. 3) After oil containing no bubbles flows out of bleeder (1), tighten air bleeder (1). 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} a If the drain hose has been disconnected, connect it after tightening the air bleeder.
PC400/450(LC)-7
2. Starting engine When running the engine after performing step 1, keep its speed at low idling for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation has started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial. (Set the starting switch to the ON position and hold the fuel control dial in the MAX position for 3 seconds, the automatic warm-up operation is reset.)
20-149 (1)
TESTING AND ADJUSTING
3. Bleeding air from cylinder a If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idling for about 5 minutes. 2) Running the engine at low idling, raise and lower the boom 4 – 5 times. a Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil. 3) Running the engine at high idling, perform step 2). 4) Running the engine at low idling, move the piston rod to the stroke end and relieve the oil. 5) Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4). 4. Bleeding air from swing motor 1) Run the engine at low idling. 2) Loosen hose (3) of port S slowly and check that oil flows out.
k At this time, do not perform the swinging operation. 3) If the oil does not flow out, stop the engine and disconnect the hose of port S and fill the pump case with oil. a After filling the pump case with oil, connect the hose of port S, and then repeat steps 1) and 2). 4) After oil containing no bubbles flows out, tighten the hose of port S. 5) Slowly swing 2 turns or more in each direction.
20-150 (1)
BLEEDING AIR FROM EACH PART
5. Bleeding air from travel motor 1) Remove the travel motor cover. 2) Run the engine at low idling. 3) Loosen bleeder (4) and check that oil flows out. 4) After oil containing no bubbles flows out, tighten bleeder (4). 3 Bleeder: 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
5) Using the work equipment, raise the track shoe on either side. 6) Drive the raised track shoe idle slowly for about 2 minutes. a Drive the track shoe on the opposite side idle similarly.
PC400/450(LC)-7
TESTING AND ADJUSTING
BLEEDING AIR FROM EACH PART
6. Check oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.
2) Check the oil level by sight gauge (5) of the hydraulic tank. a If the oil level is between lines H and L, it is normal. a If the oil level is below line L, add new oil.
PC400/450(LC)-7
20-151 (1)
TESTING AND ADJUSTING
TESTING PROCEDURE OF DIODE
TESTING PROCEDURE OF DIODE a Test an assembled-type diode or a diode unit according to the following procedure. a The conductive direction of an assembled-type diode is marked as shown in the figure. a The conductive direction of each diode is marked on its surface.
1. When using a digital tester 1) Set the tester in the diode range and check the indicated value. a If an ordinary tester is used, the voltage of the battery in itself is indicated. 2) Apply the red (+) test pin to the anode (P) side of the diode and the black (–) test pin to the cathode (N) side and read the indicated value. 3) Judge the condition of the diode from the indicated value. • The indicated value does not change: There is no continuity (Defective). • The indicated value changes: There is continuity (Normal) (Note). Note: In the case of a silicon diode, the tester indicates a value of 460 – 600.
20-152 (1)
2. When using an analog tester 1) Set the tester in the resistance range. 2) Apply the test pins as shown and check movement of the pointer. i) Apply the red (+) test pin to the anode (P) side of the diode and the black (–) test pin to the cathode (N) side. ii) Apply the red (+) test pin to the cathode (N) side of the diode and the black (–) test pin to the anode (P) side. 3) Judge the condition of the diode from movement of the pointer. • The pointer does not move in step i) above but moves in step ii): Normal (Moving angle (resistance) depends on the type and measurement range of the tester) • The pointer moves in both step i) and step ii): Defective (Internal short circuit) • The pointer does not move in either step i) or step ii): Defective (Internal disconnection)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
SPECIAL FUNCTIONS OF MONITOR PANEL
[1] Numeral input switch 1
[6] Numeral input switch 6
[
] Return switch
[2] Numeral input switch 2
[7] Numeral input switch 7
[
] Move-up switch
[3] Numeral input switch 3
[8] Numeral input switch 8
[
] Move-down switch
[4] Numeral input switch 4
[9] Numeral input switch 9
[
] Input check switch
[5] Numeral input switch 5
[0] Numeral input switch 0
PC400/450(LC)-7
20-153 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
Ordinary functions and special functions of monitor panel The monitor panel has the ordinary functions and special functions and displays various pieces of information on the multi-display unit. Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by operating switches. 1. Ordinary functions: Operator menu The items in this menu are displayed normally. The operator can display and set them by operating switches. 2. Special functions: Service menu The items in this menu are not displayed normally. Each serviceman can display them by operating special switches. Operator’s Menu 1
Function of inputting and setting password
2
Screen to display KOMATSU logo
Service Menu 16
Function of monitoring [01]
17
Function of abnormality record [02]
Electrical system
3
Function of check before starting
4
Function of displaying maintenance items
18
Function of maintenance record [03]
5
Function of displaying caution items
19
Function of maintenance mode change [04]
6
Function of checking working mode and travel speed
20
Function of phone No. entry [05]
7
Function of displaying ordinary screen
8
Function of adjusting brightness and contrast of display
9
Function of adjusting flow rate for breaker and attachments
10
Function of checking maintenance information
With/Without service circuit
11
Function of displaying service meter
Pump absorption torque
12
Function of checking display LCD
13
Function of displaying cautions
14
Function of displaying user code
15
Function of displaying error code and failure code
20-154 (1)
Mechanical system
Mode in which key is ON
21
Function of initial setting and default [06]
Language Unit
22
Function of adjustment [07]
23
Function of cylinder cut out mode operation [09]
Adjustment of flow for attachment during compound operation
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
Operation and display of Operator ’s Menu (Outline) a Only outline of the operating method is described in this section. For details of contents and operation of each menu, see OPERATION MANUAL or the volume of STRUCTURE AND FUNCTION. 1. Function of inputting and setting password When the starting switch is turned ON, the screen to input a password is displayed. a This screen is displayed only when the password function is set. 2. Screen to display KOMATSU logo When a password is input (if it is set) or when the starting switch is turned ON, the KOMATSU logo is displayed for 2 seconds.
3. Function of check before starting After the KOMATSU logo is displayed, the screen for check before starting is displayed for 2 seconds.
4. Function of displaying maintenance items After the screen for check before starting is displayed, if any oil or filter is near or has passed the set maintenance time, the maintenance mark is displayed for 30 seconds. a This screen is displayed only when the maintenance function is set.
PC400/450(LC)-7
20-155 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
5. Function of displaying caution items After the screen for check before starting is displayed, if any check item is abnormal, the corresponding symbol mark is displayed.
6. Function of checking working mode and travel speed After the screen for check before starting is displayed, the symbol marks of the working mode and travel speed are displayed in large size for 2 seconds to urge the operator to check the setting.
7. Function of displaying ordinary screen After the screen for checking the working mode and travel speed is displayed, the ordinary screen is displayed. a When the ordinary screen is displayed, if the working mode or travel speed is changed or if the auto deceleration or windshield wiper is set effective, the corresponding symbol mark is displayed in large size for 2 seconds. a The preheating monitor is displayed only when the preheater is turned ON.
8. Function of adjusting brightness and contrast of display The operator can adjust the brightness and contrast of the display with the screen adjustment switches.
20-156 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
9. Function of adjusting flow rate for breaker and attachments (for machine with breaker or attachment) The operator can adjust the pump flow rate for the breaker or an attachment with the selector switch. a The symbol marks and description of the breaker and attachment shown on the screen are partly different.
10. Function of checking maintenance information The operator can check the detailed information about the maintenance items (set time and elapsed time) and reset them after checking with the maintenance switches. a The maintenance function is set and reset and the maintenance time is set with the service menu.
11. Function of displaying service meter When the starting switch is turned OFF, the operator can display only the service meter by operating the following switches. • Operation of switches: [ ] + [ ] (Operate these switches simultaneously)
12. Function of checking display LCD On the password inputting screen or ordinary screen, the operator can check the display LCD. • Operation of switches: [ ] + [A] (Operate these switches simultaneously) a The whole LCD unit is turned ON and all the surface becomes white. If there is not any black part, the LCD unit is normal. a If any switch is operated while the LCD unit is being checked, the screen before the check is displayed again.
PC400/450(LC)-7
20-157 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
13. Function of displaying cautions If there is any abnormal item in the calculation items, the corresponding symbol mark is displayed in large size for 2 seconds, then it is displayed in small size until the abnormal item is repaired.
14. Function of displaying user code If the machine has any failure, the corresponding user code is displayed to urge the operator to take a proper remedy, depending on the degree of the failure. a If any switch is operated while the user code is displayed, the service code and failure code screen appears (See 15).
a User codes and instructions given to operator User code
Failure mode
Instructions given to operator
Error in pump control system
If the emergency pump drive switch is set in the upper (emergency) position, the machine can operate normally. Have the machine inspected immediately, however.
E03
Error in swing brake system
Set the swing holding brake release switch in the upper (release) position to release the brake. Apply the swing brake manually with the swing lock switch, if necessary. The brake may not be released, depending on the cause of the failure. In any case, have the machine inspected immediately.
E10
Error in engine controller power supply or abnormality in engine controller drive system circuit (Engine stops)
Have the machine inspected immediately.
E11
Error in engine controller system Set the machine in a safe position and have the machine inspected immedi(Engine protection output is down) ately.
E14
Error in throttle system
Set the machine in a safe position and have the machine inspected immediately.
E15
Error in engine sensor (coolant temperature, fuel temperature, or oil pressure)
Although the machine can operate normally, have the machine inspected immediately.
E0E
Error in network
Set the machine in a safe position and have the machine inspected immediately.
E02
20-158 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
15. Function of displaying error code and failure code While a user code is displayed, if the following switches are operated, the phone mark (if registered), phone No. (if registered), error code, and failure code are displayed in order. • Operation of switch: [ ] a The following are displayed in order repeatedly as the switch is operated. (1) Phone mark (2) Phone No. (3) Error code and failure code a The phone mark and phone No. are displayed only when the phone No. is registered in the monitor panel. The phone No. is registered, changed, or deleted with the service menu. a For details of the displayed error code and failure code, see the error codes and failure codes table.
PC400/450(LC)-7
20-159 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
Code
Contents
Failure code Code
Component
Trouble
—
E112 Wiper Drive (For) S/C
DY2DKB Wiper motor (Forward)
Short Circuit
—
E113 Wiper Drive (Rev) S/C
DYDEKB Wiper Motor (Reverse)
Short Circuit
—
E114 Washer Drive S/C
Windshield Washer DY2CKB Motor
Short Circuit
—
E115 Wiper Working Abnormality
DY20KA Wiper Motor
Disconnection
—
E116 Wiper Parking Abnormality
DY20MA Wiper Motor
Malfunction
—
E117 Eng. Controller S-NET Comm Err.
DAC0KR Engine Controller
Defective communication (Abnormality in related component)
—
E118 Pump Controller S-NET Comm Err.
DAB0KR Pump Controller
Defective communication (Abnormality in related component)
E0E E128 Monitor Comm. Abnormality —
E201 Travel Junction Sol. S/C
E03 E203 Swing Brake Sol. S/C
DAFRMC
Monitor CAN CommuniDefective Operation cation
DW91KB
Travel Neutral Solenoid Valve
Short Circuit
DW45KB
Swing Holding Brake Solenoid Valve
Short Circuit
—
E204 Merge-divider Sol. S/C
DWJ0KB
Pump Merge-divider Solenoid Valve
Short Circuit
—
E205 2-stage Relief Sol. S/C
DWK0KB
2-stage Relief Solenoid Valve
Short Circuit
—
E206 Travel Speed Sol. S/C
DW43KB
Travel Speed Hi/Lo Short Circuit Selector Solenoid Valve
—
E211 Travel Junction Sol. Disc.
DW91KA
Travel Neutral Solenoid Valve
Disconnection
DW45KA
Swing Holding Brake Solenoid Valve
Disconnection
E03 E213 Swing Brake Sol. Disc. —
E214 Merge-divider Sol. Disc.
DWJ0KA
Pump Merge-divider Solenoid Valve
Disconnection
—
E215 2-stage Relief Sol. Disc.
DWK0KA
2-stage Relief Solenoid Valve
Disconnection
—
E216 Travel Speed Sol. Disc.
DW43KA
Travel Speed Hi/Lo Disconnection Selector Solenoid Valve
—
E217 Model Selection Abnormality
Pump Controller Model DA2SKQ Selection Wiring Harness
E0E E218 S-Net Comm. Disc.
DA2SKA
Pump Controller S-NET Communication
Disagreement of Model Selection Signals Disconnection
—
E222 LS-EPC Sol. S/C
DXE0KB LS-EPC Solenoid Valve
Short Circuit
—
E223 LS-EPC Sol. Disc.
DXE0KA LS-EPC Solenoid Valve
Disconnection
—
E224 F Pump P. Sensor Abnormality
F Pump Pressure SenDHPAMA sor
Malfunction
—
E225 R Pump P. Sensor Abnormality
DHPBMA
R Pump Pressure Sensor
Malfunction
—
E226 Press. Sensor Power Abnormality
DA25KP
Pump Controller Power Supply Output
Lowering of Output Voltage
—
E227 Engine Speed Sensor Abnormality
DLE2MA Engine Speed Sensor
Malfunction
—
E228 Service Return Relay S/C
D196KB
ATT Selector Relay
Short Circuit
DXA0KB TVC Solenoid Valve
Short Circuit
E02 E232 PC-EPC Sol. S/C
20-160 (1)
History division
Error code
Electrical system
User code
Table for Error and Failure Code Nos.
PC400/450(LC)-7
SPECIAL FUNCTIONS OF MONITOR PANEL
Code
Contents
E02 E233 PC-EPC Sol. Disc.
Failure code Code
Component
History division
Error code
Trouble
DXA0KA TVC Solenoid Valve
Disconnection
—
E238 Service Return Relay Disc.
D196KA
ATT Selector Relay
Disconnection
—
E245 Service Current EPC S/C
DXE4KB
ATT Flow Throttle EPC Valve
Short Circuit
—
E246 Service Current EPC Disc.
DXE4KA
ATT Flow Throttle EPC Valve
Disconnection
—
E247 Arm Curl PPC Sen. Abnormality
DHS3MA
Arm IN PPC Pressure Sensor
Malfunction
—
E248 Bucket Curl PPC Sen. Abnormality
DHS4MA
Bucket CURL PPC Pressure Sensor
Malfunction
—
E251 Overload Sensor Abnormality
DHX1MA
Malfunction
Pump Controller CAN DA2RMC Communication
Defective Operation
D110KB
Battery Relay
Short Circuit
E11 E91B Engine Ne Sensor Problem
DLE3LC
NE Speed Sensor
Disagreement of Speed Signal
E11 E91C Engine G Sensor Problem
DLH1LC G Speed Sensor
E11 E920 Engine Type Selection Error
Engine Controller Model Disagreement of Model DB29KQ Selection Wiring HarSelection Signals ness
E11 E921 Engine Type Mismatch
DB20KQ Engine Controller
Disagreement of Model Selection Signals
E14 E931 Fuel Dial sys. error
DK10KX Throttle Angle Sensor
Out of input signal range
E15 E934 Engine Coolant Sensor Hi Error
Engine Coolant TemperDGE2KX Out of input signal range ature Sensor
E15 E936 Engine Oil Press. Sw. Error
DDE2L6
E11 E93C Engine Boost Sensor Error
DH30KX Boost Pressure Sensor
Out of input signal range
E15 E93D Engine Fuel Temp. Sensor Error
Fuel Temperature SenDGE4KX sor
Out of input signal range
E0E E953 Engine Comm. Abnormality
DB2RMC
E0E E257 Pump Comm. Abnormality —
—
E315 Battery Relay Drive S/C
E954 Short Engine Starter SW.
Engine Oil Pressure Switch
Engine Controller CAN Communication
Disagreement of Speed Signal
Disagreement of signal with operation of engine
Defective Operation
DD11KB Starter SW
Short Circuit
E0E E955 Engine S-NET error
Engine Controller SDB2SMC NET Communication
Defective Operation
E10 E956 Engine Power Failure (1)
DB22KK
Engine Controller Load Power Supply Line
Lowering of source voltage (Input)
E15 E957 Engine Power Failure (2)
D1D0KB
Engine Controller Load Power Supply Relay
Short Circuit
DB2AMA
Rotary Switch in Engine Malfunction Controller
E15 E96A Engine Coolant Sensor Lo Error
DGE3L6
Engine Coolant Temper- Disagreement of signal ature Sensor with operation of engine
E11 E970 PCV1 Over Current
AD11KB
Supply Pump (1) Solenoid Valve
Short Circuit
E11 E971 PCV2 Over Current
AD51KB
Supply Pump (2) Solenoid Valve
Short Circuit
E11 E974 PCV1 Line Cut
AD11KA
Supply Pump (1) Solenoid Valve
Disconnection
E11 E975 PCV2 Line Cut
AD51KA
Supply Pump (2) Solenoid Valve
Disconnection
E11 E977 Rail Press. Sensor Error
DH40KX
Common Rail Pressure Sensor
Out of input signal range
—
E95A Engine Q-adj. Sw. Signal Error
PC400/450(LC)-7
Electrical system
User code
TESTING AND ADJUSTING
20-161 (1)
Code
Contents
Failure code Code
Component
E11 E979 Rail Press. High 1
AD00L2
Common Rail
E11 E97A Rail Press. High 2
AD00MA Common Rail Supply Pump
Trouble Abnormally High Fuel Pressure Malfunction
E15 E97B Rail press. low
AD10L3
E11 E97C Rail press. too low
AD10MB Supply Pump
Lowering of Function
E11 E97D Rail Press. Out of Control
AD10MA Supply Pump
Malfunction
E11 E980 Eng. Controller Abnormality
DB20KT
Abnormality in Controller
E11 E981 Fuel Injector 1 Disc.
ADA1KA Injector 1 Solenoid Valve Disconnection
E11 E982 Fuel Injector 2 Disc.
ADB1KA Injector 2 Solenoid Valve Disconnection
E11 E983 Fuel Injector 3 Disc.
ADC1KA Injector 3 Solenoid Valve Disconnection
E11 E984 Fuel Injector 4 Disc.
ADD1KA Injector 4 Solenoid Valve Disconnection
E11 E985 Fuel Injector 5 Disc.
ADE1KA Injector 5 Solenoid Valve Disconnection
E11 E986 Fuel Injector 6 Disc.
ADF1KA Injector 6 Solenoid Valve Disconnection
E11 E98A Fuel Injector 1 – 3 S/C
ADAZKB
Injector 1, 2, 3 Solenoid Valve
Short Circuit
E11 E98B Fuel Injector 4 – 6 S/C
ADDZKB
Injector 4, 5, 6 Solenoid Valve
Short Circuit
E22 E922 Eng. Hi Out of Std
A000N1
Engine
Overrun
Engine
Engine Controller
Out of control
—
Eng. Lo Out of Std
A000N2
—
Aircleaner Clogging
AA10NX Air Cleaner Element
Out of input signal range
—
Charge Voltage Low
AB00KE Alternator
—
Eng. Oil Press. Low
B@BAZG Engine Oil
—
Eng. Oil LvI. Low
B@BAZK Engine Oil
Lowering of level
—
Eng. Coolant Overheat
B@BCNS Coolant
Overheating
—
Eng. Coolant Lvl Low
B@BCZK Coolant
Lowering of level
—
Hydr. Oil Overheat
B@HANS Hydraulic Oil
Overheating
Clogging Defective Charge Lowering of Oil Pressure
Electrical system
Error code
History division
SPECIAL FUNCTIONS OF MONITOR PANEL
Mechanical system
User code
TESTING AND ADJUSTING
a The items in this table are arranged in the order of the error codes. a The error codes having no numbers in the user code column and the failure codes having no numbers in the user code column and error code column are not displayed on the normal screen, even if abnormality related to them occurs. They are simply recorded in the failure history of the service menu (Electrical equipment system or mechanical equipment system). a The history division column shows in which division each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the failure history. a Letter “E” at the head of each error code indicates the following condition. • With E: The failure has not been repaired yet. • Without E: The failure has been repaired.
20-162 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
Operation and display of Service Menu How to select service menu a When using the service menu, perform the following special operation to change the screen. 1) Checking display Check that the ordinary screen is displayed. a The service menu can be selected only while the ordinary screen is displayed.
2) Operating switches Operate the following switches. • Operation of switches: [ ] o [1] o [2] o [3] (While pressing [ ], press the numeral keys) 3) Displaying menu screen The initial screen of the service menu is displayed. Select a menu which you will use. No.
Service menu
00 01
Return (Finish service menu) Monitoring
02 03
Abnormality record Maintenance record
04 05
Maintenance mode change Phone number entry
06 07
Initial setting/Default Adjust
09
Cylinder cut out mode operation
4) Finishing menu and function To finish the service menu screen or each menu screen, perform one of the following operations. (1) Press the [ ] switch (This operation is effective on all screens). (2) When the “Return” switch is displayed, press it. (3) When the “Return” menu is displayed, select it and press the [ ] switch.
PC400/450(LC)-7
20-163 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
16. Function of monitoring [01] The monitor panel monitors the signals from various switches, sensors, and actuators installed to various parts of the machine. The operator can display and check the monitoring information in real time by the following operation. 1) Selecting menu On the initial screen of the service menu, select “01 Monitoring” and press the [ ] switch.
2) Setting monitoring items Select and register monitoring items with the following switches. • [ ] switch: Select • [ ] switch: Select • [ ] switch: Register a You can set up to 4 monitoring items (You cannot set up to 4 monitoring items, however, depending on the selected items). a When monitoring up to 3 items, go to the monitoring information screen by either of the following operations after registering those items. • Hold the [ ] switch (for about 3 seconds). • Select menu “99999” and press the [ ] switch. a If all of the settable items are registered, the monitoring information screen appears automatically after registering those items. a For the detail, display units, etc. of the monitoring items, see the monitoring items table.
3) Operating for monitoring After the monitoring infomation screen appears, operate the machine to check the monitoring information.
20-164 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
4) Function of holding monitoring information If the [ ] switch is pressed during the monitoring operation, all the monitoring information is held. If the [ ] switch is pressed while the monitoring information is held, the monitoring information is released.
5) Function of selecting machine setting mode To change settings of the working mode, travel speed, or auto deceleration during the monitoring operation, press the switches for those items, and the mode checking screen appears. a After checking the settings, press the [ ] switch, and the monitoring screen appears again. a If the settings are changed during the monitoring operation, the new settings are held even after monitoring is finished and the service menu disappears and the operator menu appears again.
PC400/450(LC)-7
20-165 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
Monitoring items list Code No.
Monitoring item
Unit (Default: ISO) SI
meter
inch
Remarks
00000 Return
(Not displayed)
Finish Menu
99999 To Display Screen
(Not displayed)
Display and Execution Menu
00200 Controller Model Select
Numerals
00201 Controller Model Select
Numerals
01002 Engine Speed
r/min
rpm
rpm
01601 2nd Eng. Speed Command
r/min
rpm
rpm
01100 F Pump Pressure
MPa
kg/cm2
psi
01101 R Pump Pressure
MPa
kg/cm
psi
07200 Arm Curl PPC Pressure
MPa
2
kg/cm
psi
07300 Bucket Curl PPC Pressure
MPa
kg/cm2
psi
04102 Engine Coolant Temp. Hi
°C
°C
°F
14200 Fuel Temperature
°C
°C
°F
04401 Hydr. Oil Temperature
°C
°C
°F
01300 PC-EPC Sol. Curr.
mA
mA
mA
01500 LS-EPC Sol. Curr.
mA
mA
mA
01700 Service Sol. Curr.
mA
mA
mA
03200 Battery Voltage
V
V
V
03500 Battery Relay O/P Vol.
V
V
V
04300 Battery Charge Vol.
V
V
V
r/min
rpm
rpm
°C
°C
°F
36400 Rail Pressure
MPa
kg/cm2
psi
36500 Boost Pressure
kPa
kg/cm2
psi
36700 Torque Ratio
%
%
%
03000 Fuel Dial Vol.
V
V
V
04200 Fuel Level Sensor Vol.
V
V
V
04106 Engine Coolant Temp. Vol. Hi
V
V
V
04105 Engine Coolant Temp. Vol. Lo
V
V
V
14201 Fuel Temp. Sensor Vol.
V
V
V
36501 Boost Press. Sensor Vol.
V
V
V
36401 Rail Press. Sensor Vol.
V
V
V
CA
CA
CA
01006 Engine Speed 04107 Engine Coolant Temp. Low
17200 PCV Close Angle 17300 Eng. Control Mode 31701 Throttle Level
2
Numeral %
%
%
36100 Fuel Delivery Command
mm3/st
mm3/st
mm3/st
36200 Rail Pressure Command
MPa
kg/cm2
psi
CA
CA
CA
36300 Injection Timing Angle
20-166 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
Code No.
Monitoring item
01900 Pressure Switch 1
01901 Pressure Switch 2
02300 Solenoid 1
02301 Solenoid 2
02200 Switch Input 1
02201 Switch Input 2
02202 Switch Input 3
04501 Monitor Input 2
04502 Monitor Input 3
PC400/450(LC)-7
Unit (Default: ISO) SI
meter
Swing
ON/OFF
Travel
ON/OFF
Boom Lower
ON/OFF
Boom Raise
ON/OFF
Arm Curl
ON/OFF
Arm Dump
ON/OFF
Bucket Curl
ON/OFF
Bucket Dump
ON/OFF
Service
ON/OFF
Travel Steering
ON/OFF
Travel Junction
ON/OFF
Swing Brake
ON/OFF
Merge-divider
ON/OFF
2-stage Relief
ON/OFF
Travel Speed
ON/OFF
Service Return
ON/OFF
Lever Sw.
ON/OFF
Swing Release Sw.
ON/OFF
Swing Brake Sw.
ON/OFF
Model Select 1
ON/OFF
Model Select 2
ON/OFF
Model Select 3
ON/OFF
Model Select 4
ON/OFF
Model Select 5
ON/OFF
Key Switch (ACC)
ON/OFF
03700 Controller Output 1 Batt. Relay Dr.
04500 Monitor Input 1
SPECIAL FUNCTIONS OF MONITOR PANEL
inch
Remarks
ON/OFF
Key Switch
ON/OFF
Start
ON/OFF
Preheat
ON/OFF
Light
ON/OFF
Rad. Level
ON/OFF
Aircleaner
ON/OFF
Eng. Oil Level
ON/OFF
Battery Charge
ON/OFF
Swing Brake Sw.
ON/OFF
Bzzr Cancel Sw.
ON/OFF
Window Limit Sw.
ON/OFF
W Limit Sw.
ON/OFF
P Limit Sw.
ON/OFF
20-167 (1)
TESTING AND ADJUSTING
Code No.
17400
Monitoring item
Eng. Controller Input
SPECIAL FUNCTIONS OF MONITOR PANEL
Unit (Default: ISO) SI
meter
Key SW (C)
ON/OFF
Eng. Oil Press. Lo
ON/OFF
Eng. Oil Press. Hi
ON/OFF
Machine Sel. 1
ON/OFF
Machine Sel. 2
ON/OFF
Machine Sel. 3
ON/OFF
36800 Q Adjust Switch R (ROT-SW1)
Alphanumerals
36801 Q Adjust Switch L (ROT-SW2)
Alphanumerals
05100 S-NET Connection
Pump Controller
ON/OFF
Eng. Controller
ON/OFF
20200 Monitor Prog. Version
Numerals
20212 Pump Con. Prog. Version
Numerals
20209 Eng. Con. Prog. Version
Numerals
inch
Remarks
a As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be selected. The unit of display can be changed with “Selecting unit” in the “Setting initial values” function of the service menu. a “CA” of the unit of display denotes the crankshaft angle.
20-168 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
17. Function of abnormality record [02] The monitor panel classifies and records the past failures into the electrical system group and mechanical system group. The operator can display and check those failures by the following operation. 1) Selecting menu On the initial screen of the service menu, select “02 Abnormality Record” and press the [ ] switch.
2) Selecting sub-menu On the abnormality record menu screen, select a sub-menu and press the [ } switch. No.
Sub-menu of abnormality record
00 01
Return (Finish sub-menu) Electrical systems
02
Mechanical systems
3) Contents of electrical system abnormality record screen [1]: Reverse sequential order/Total number of records [2]: Error code [3]: Failure code (Component: 4 characters, Trouble: 2 characters) [4]: Advance of service meter after 1st occurrence [5]: Contents of failure a See “Error codes and failure codes table” in the operator menu.
4) Contents of mechanical system abnormality record screen [1]: Record No. [2]: Contents of failure [3]: Failure code (Component: 4 characters, Trouble: 2 characters) [4]: Total number of occurrences [5]: Service meter reading at 1st occurrence a See “Error codes and failure codes table” in the operator menu.
PC400/450(LC)-7
20-169 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
5) Resetting electrical system abnormality record a Only the abnormality record of the electrical system can be reset (deleted). The abnormality record of the mechanical system cannot be reset. a If necessary, reset each item or all items of the abnormality record of the electrical system according to the following procedure. i) While the electrical system abnormality record screen is displayed, operate the following switches to display the reset screen. • Operation of switches: [ ] + [1] [2] [3] a This operation is the same as that for selecting the service menu. ii) Operate the switches according to the direction shown on the reset screen. a When resetting only 1 item, be sure display it with the [ ] switch or [ ] switch, and then perform the reset procedure. a When resetting all the items, you can perform the reset procedure, regardless of the item displayed on the screen.
20-170 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
18. Function of maintenance record [03] The monitor panel records the maintenance information about the filters and oils. The operator can display and check that information by the following operation. 1) Selecting menu On the initial screen of the service menu, select “03 Maintenance Record” and press the [ ] switch.
2) Displayed information (1) Names of oils and filters (2) Number of replacement times up to now (3) Service meter reading at previous replacement
PC400/450(LC)-7
20-171 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
19. Function of maintenance mode change [04] The condition for setting the operation of the maintenance display function can be changed according to the following procedure. • Set the function effective or ineffective. • Change the set replacement interval. 1) Selecting menu On the initial screen of the service menu, select “04 Maintenance Mode Change” and press the [ ] switch.
2) Selecting item to be changed On the screen of maintenance mode changing menu, select an item to be changed. No.
Item of maintenance mode change
00 01
Return Use/Disuse maintenance mode
02 03
Replacement interval of engine oil Replacement interval of engine oil filter
04 05
Replacement interval of fuel filter Replacement interval of hydraulic oil filter
06
Replacement interval of hydraulic tank breather
07
Replacement interval of corrosion resistor (if equipped)
08 09
Check and refill interval of damper case oil Replacement interval of final drive case oil
10 11
Replacement interval of machinery case oil Replacement interval of hydraulic oil
12
Return all items to initial values
a Menus “01” and “12” are used to set the whole maintenance mode and menus “02” – “11” are used to set the items one by one. 3) Contents of setting of “maintenance mode On/Off” • On: The function of displaying all the oil and filter items becomes effective (This setting is applied, even if On/Off is set for each item). • Off: The function of displaying all the oil and filter items becomes ineffective (This setting is applied, even if On/Off is set for each item).
20-172 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
4) Contents of setting of each item (1) Default: Maintenance time set in monitor. (Value recommended by manufacturer. Constant value.) (2) Set value: Maintenance time which operation can set freely. Monitor panel operates according to this value in maintenance mode. (This value can be changed by 50 hours with [ ] and [ ] switches.) (3) Off: Function of displaying this maintenance item becomes ineffective. (4) On: Function of displaying this maintenance item becomes effective. a The lower limit of the set time is 50 h. 5) Contents of setting “Return all items to initial values” If this menu is selected and the [ ] switch is pressed, all the information items are changed to the initial values.
PC400/450(LC)-7
20-173 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
20. Function of phone number entry [05] The operator can input a phone No. and change it according to the following procedure. Once the phone No. is input, it and service code are displayed alternately when the user code is displayed. a If a phone No. is not input, the phone No. screen is not displayed. 1) Selecting menu On the initial screen of the service menu, select “05 Phone Number Entry” and press the [ ] switch. 2) Selecting input screen Select “Entry” to display the phone No. input screen. a Even if a phone No. has been registered, if the phone No. input screen is displayed, the registered phone No. is cleared.
3) Inputting and setting phone No. On the phone No. input screen, input a phone No. according to the following procedure (The phone No. is input from the cursor at the left end automatically). i) Input a No. with the numeral keys from the cursor at the left end. ii) After finishing inputting the No., press the [ ] switch. a Up to 12 digits can be input. You do not need to input a digit to an unnecessary place, however. a If you input a wrong No., press the [B] switch, and the cursor returns 1 place by 1. a If the phone No. is input, the “Entry” screen above is displayed again. If the phone No. is displayed on this screen, it is input normally.
20-174 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
21. Function of initial setting and default [06] The operator can change the following items related to the monitor panel and machine, if necessary. • Working mode when starting switch is turned ON • Language displayed on service menu • Unit displayed in monitoring function mode • With/Without attachment 1) Selecting menu On the initial screen of the service menu, select “06 Function of initial setting and default” and press the [ ] switch. 2) Selecting sub-menu Select a sub-menu to change its setting and press the [ ] switch. No. 00 01 02 03 04
Sub-menu of initial value/default Return (Finish initial value/default) Key-on mode Language Unit With/Without service circuit
3) Function of selecting mode when key is ON When the starting switch is turned ON, a working mode is displayed on the monitor panel. The operator can change this working mode. • A-mode, E-mode, L-mode, B-mode: If any of these modes are set, the machine is started in the selected mode when the starting switch is turned ON. • Mode when key was turned off last: If this mode is set, the machine is started in the mode used last when the starting switch is turned ON. • Initial value: If this mode is set, the machine is started in the default mode set in the factory when the starting switch is turned ON. a If the machine having an attachment is stopped in the B-mode, it is started in the B-mode when the starting switch is turned ON next time, regardless of this setting.
PC400/450(LC)-7
20-175 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
4) Function of setting language The operator can select Japanese or English as the language displayed on the service menu. a The default language of the monitor panel is English. a When using a spare monitor panel in the Japanese language area, select Japanese with this function.
5) Function of selecting unit The operator can select 1 of the 3 unit systems as the unit system used for the data displayed by the monitoring function of the service menu. a The default unit system of the monitor panel is the SI unit system.
6) Function of selecting “with/without service circuit” The operator can set “with/without service circuit”. • With service circuit: When attachment is installed • Without service circuit: When attachment is not installed. a When an service circuit is installed, if “With service circuit” is not set on this screen, the operator cannot use the select function (adjustment of oil flow for the attachment) in the operator mode.
20-176 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
22. Function of adjustment [07] The operator can adjust various items of the machine on the monitor panel. 1) Selecting menu On the initial screen of the service menu, select “07 Adjustment” and press the [ ] switch. 2) Selecting sub-menu Select a sub-menu to change its setting and press the [ ] switch. No. 00
Sub-menu of adjustment Return (Finish adjustment)
01
Pump absorption torque Adjustment of oil flow for attachment in compound operation
02
3) Function of pump absorption torque The operator can adjust the pump absorption torque within the ranges shown in the following table. Adjustment Adjustment Adjustment Adjustment value torque value torque 220
+8.0 kgm
225
–2.0 kgm
221 222
+6.0 kgm +4.0 kgm
226 227
–4.0 kgm –6.0 kgm
223 224
+2.0 kgm 0.0 kgm
228
–8.0 kgm
4) Function of adjustment of oil flow for attachment in compound operation The operator can adjust the oil flow for the attachment in compound operation within the ranges shown in the following table. Adjustment value 370
Oil flow for attachment 0.5 times
371 372
0.7 times 1.0 times
373
0.4 times
PC400/450(LC)-7
20-177 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
23. Function of cylinder cut out mode operation [09] The operator can operate the machine in the cylinder cut out mode with the monitor panel. Cylinder cut out mode operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). 1) Selecting menu On the initial screen of the service menu, select “09 Cylinder cut out mode operation” and press the [ ] switch. 2) Setting cylinders to be disabled Press switches [1] – [6] on the monitor panel corresponding to the cylinder Nos. to be disabled. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed white in a white frame, the cylinder is disabled (If setting is wrong, press the same switch again). a Only one or more cylinders can be disabled for the reduced cylinder mode operation. 3) Cancellation of disabled cylinders Press switches [1] – [6] on the monitor panel corresponding to the disabled cylinder Nos. to cancel disabling of those cylinders. a After a switch is pressed, if the cylinder No. corresponding to it on the monitor panel is displayed black in a black frame, disabling of the cylinder is cancelled.
20-178 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL
4) Function of holding engine speed If the [ ] switch is pressed while the reduced cylinder mode operation screen is used, the engine speed is held and displayed on the lower line. If the [ ] switch is pressed while the engine speed is held, holding of the engine speed is cancelled and the engine speed displayed on the lower line goes off. a If the holding function is used, the held engine speed is displayed in ( ) on the lower line and the current engine speed is displayed on the upper line. a The holding function can be used both in and out of the cylinder cut out mode.
[Reference]: How to use holding function effectively The engine speed displayed by the holding function is held on the screen until the holding function is cancelled, regardless of setting and cancellation of the cylinder cut out mode. Accordingly, a defective cylinder can be found out effectively according to the following procedure. (1) Run the engine normally (without disabling any cylinder) and hold the engine speed. (2) Disable a cylinder to be checked. (3) Run the engine under the same condition as the normal operation in step (1) and compare the engine speed at this time with the held engine speed. (4) Cancel the cylinder cut out mode, regardless of the change of the engine speed. (5) Repeat steps (2) – (4) to check the other cylinders. a If the engine speed does not lower at all or lowers less when a cylinder is selected for the cylinder cut out mode operation, combustion in that cylinder must be abnormal.
PC400/450(LC)-7
20-179 (1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Section to display special functions
Section to operate special function 1 (Basic operation)
Section to operate special function 2 (Selecting operation and special operation)
1. Display section
3. Caution buzzer stop switch
7. Working mode selector (UP) switch
2. Service meter section
4. Auto-decelerator switch
8. Working mode selector (DOWN) switch
5. Setting switch (Black switch) 6. Travel speed shifting switch
PC400/450(LC)-7
20-179-2 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Ordinary functions and special functions of monitor panel The monitor panel has the ordinary functions and special functions and displays various pieces of information on display section (1) and service meter section (2). Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by operating switches. 1. Ordinary functions: Operator menu The items in this menu are displayed normally or displayed automatically when a trouble occurs. 2. Special functions: Service menu The items in this menu are not displayed normally. Each serviceman can display them by operating special switches. These functions are used for special setting, testing, adjusting, or troubleshooting. Flow of each function
1 Function of displaying service meter O
2 Function of displaying user code
Special functions (Service menu) O
Ordinary functions (Operator menu)
3 Function of displaying service code [01] 4 Monitoring function [02] 5 Function of selecting maintenance period [04] 6 Function of selecting default working mode [05] 7 Function of setting installation of attachment [16] 8
Special function of monitoring replacement of engine oil
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
Display of operator menu a Only outline of the operator menu is described in this section. For details of each menu, see OPERATION MANUAL or the volume of STRUCTURE AND FUNCTION. 1. Function of displaying service meter While the machine is used normally, the monitor panel displays the following information. • Display section (1): Nothing is displayed • Service meter section (2): Service meter
20-179-3 (7)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
2. Function of displaying user code If the machine has any trouble, the corresponding user code is displayed automatically in display section (1) and the caution buzzer is turned ON to urge the operator to take a proper remedy, depending on the degree of the trouble. a Service meter section (2) continues displaying the service meter. a For displayed user codes and the remedies shown to the operator, see "User codes and remedies shown to operator". a Each user code simply shows occurrence of a trouble to the operator. To find out the cause of the trouble, a serviceman must check the service code with the "Function of displaying service code [01]" in the service menu. A user code is displayed only when a serious trouble occurs. Even if a user code is not displayed, a trouble may have occurred. If you feel any abnormality, be sure to check for a service code with the "Function of displaying service code [01]" in the service menu. a User codes and remedies shown to operator User code E02
E03
Remedy (shown to operator)
Caution buzzer
Error in pump control system
If the emergency pump drive switch is set in the upper position, the machine can operate normally. Have the machine inspected immediately, however.
q
Error in swing brake system
Set the swing holding brake release switch in the upper position to release the brake. When applying the swing brake, operate the swing lock switch manually. The brake may not be released, depending on the cause of the failure. In this case, have the machine inspected immediately.
q
Error mode
Error in engine controller power supply E10 Abnormality in engine con- Have the machine inspected immediately. troller drive system circuit (Engine is stopped) Error in engine controller system (Engine output is reduced for protection)
q
Move the machine to safe place and have it inspected immediately.
q
E14 Error in throttle system
Move the machine to safe place and have it inspected immediately.
q
Error in engine sensor E15 (coolant temperature, fuel temperature, oil pressure)
Have the machine inspected, although it can be operated normally.
q
E0E Error in network
Move the machine to safe place and have it inspected immediately.
q
E11
PC400/450(LC)-7
20-179-4 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Operation and display of service menu How to select service menu a When using the general functions in the service menu, perform the following switch operation to change the screen of the monitor panel. 3. Function of displaying service code [01] 4. Monitoring function [02] 5. Function of selecting maintenance period [04] 6. Function of selecting default working mode [05] 7. Function of setting installation of attachment [16] 1) Operating switches While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds. 2) Displaying display section and service meter section If the switches are operated as shown above, the first menu No. [01] (Monitoring function) is displayed in service meter section (2). a Nothing is displayed in display section (1). 3) Selecting menu While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a menu you will use. • UP switch (7): Increase Menu No. • DOWN switch (8): Decrease Menu No. Menu No. 01 02 04 05 16
Service menu (Excluding special functions) Function of displaying error code Monitoring function Function of selecting maintenance period Function of selecting default working mode Function of setting installation of attachment
4) Executing menu Select a menu you will use and press set switch (5), and the menu is executed. 5) Finishing service menu While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds (similarly to the selecting operation). a The service menu is finished and the ordinary screen appears. a The service menu can be also finished by turning the starting switch OFF while the service menu is selected. (In this case, the ordinary screen appears when the starting switch is turned ON again.)
20-179-5 (7)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
a To use the following special function, you must operate the switches differently from the above. See details of this function "8. Special function of monitoring replacement of engine oil". 3. Function of displaying service code [01] With this function, you can check the service code of a trouble which is occurring at present or has occurred in the past. 1) Selecting and executing function i) Select menu No. [01] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Information displayed in display section and service meter section 1 (When service code is recorded) If a service code is recorded, the following information is displayed in display section (1) and service meter section (2). (a): Service code (b): Service meter reading increased after trouble occurred (c): Mark [E] to indicate that trouble is occurring at present a Mark [E] to indicate that a trouble is occurring at present indicates that the service code is being detected now. It is not displayed if the trouble has been repaired or the service code is not detected. a For the service codes which the monitor panel and engine throttle and pump controller can detect, see the "Service codes table". 3) Information displayed in display section and service meter section 2 (When service code is not recorded) If a service code is not recorded, display section (1) and service meter section (2) display as shown in the figure. 4) Number of recorded service codes and display order of them This function can record up to 20 service codes, which are displayed in order from the latest one. a If a new trouble occurs while 20 service codes are recorded, the oldest service code is deleted and the service code of the new trouble is recorded.
PC400/450(LC)-7
20-179-6 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
5) Change of displayed service codes While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to change the displayed service codes. • UP switch (7): Next service code appears. • DOWN switch (8): Previous service code appears. 6) How to delete service code i) While holding caution buzzer stop switch (3), turn the starting switch OFF and keep holding caution buzzer stop switch (3). ii) Under the above condition, turn the starting switch ON again and hold caution buzzer stop switch (3) for 5 seconds. a A service code having the mark [E] is not deleted.
20-179-7 (7)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Service codes table User code
Service code
Trouble
—
E112
Short circuit in wiper motor drive forward system
—
E113
Short circuit in wiper motor drive reverse system
—
E114
Short circuit in windshield washer drive system
—
E115
Trouble in operation of windshield wiper
—
E116
Trouble in storage of windshield wiper
—
E117
Abnormality in engine controller S-NET
—
E118
Abnormality in pump controller S-NET
E0E
E128
Abnormality in communication (monitor)
—
E201
Short circuit in travel junction solenoid
E03
E203
Short circuit in swing holding brake solenoid
—
E204
Short circuit in merge-divider solenoid
—
E205
Short circuit in 2-stage relief solenoid
—
E206
Short circuit in travel speed shifting solenoid
—
E211
Disconnection in travel junction solenoid
E03
E213
Disconnection in swing holding brake solenoid
—
E214
Disconnection in merge-divider solenoid
—
E215
Disconnection in 2-stage relief solenoid
—
E216
Disconnection in travel speed shifting solenoid
—
E217
Abnormality in input model code
—
E218
Disconnection in S-NET signal line
—
E222
Short circuit in LS-EPC solenoid
—
E223
Disconnection in LS-EPC solenoid
—
E224
Abnormality in F pump pressure sensor
—
E225
Abnormality in R pump pressure sensor
—
E226
Abnormality in pressure sensor power supply
—
E227
Abnormality in engine speed sensor
—
E228
Short circuit in ATT return selector relay
E02
E232
Short circuit in PC-EPC solenoid
E02
E233
Disconnection in PC-EPC solenoid
—
E238
Disconnection in ATT return selector relay
—
E245
Short circuit in ATT flow adjustment EPC
—
E246
Disconnection in ATT flow adjustment EPC
—
E247
Abnormality in arm IN PPC pressure sensor
—
E248
Abnormality in bucket CURL PPC pressure sensor
—
E251
Abnormality in overload sensor
E0E
E257
Abnormality in communication (pump)
—
E315
Short circuit in battery relay output line
E11
E91B
Abnormality in engine Ne speed sensor system
E11
E91C
Abnormality in engine G speed sensor system
E11
E920
Abnormality in model selection system
E11
E921
Abnormality in model checking
E14
E931
Abnormality in fuel control dial system
E15
E934
Abnormality in coolant high temperature sensor
E15
E936
Abnormality in engine oil pressure switch system
PC400/450(LC)-7
20-179-8 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
User code
Service code
Trouble
E11
E93C
Abnormality in boost pressure sensor system
E15
E93D
Abnormality in fuel temperature sensor system
E0E
E953
Abnormality in communication (engine)
—
E954
Short circuit in starting switch C terminal system
E0E
E955
Abnormality in network system
E10
E956
Abnormality in power supply system 1
E15
E957
Abnormality in power supply system 2
—
E95A
Abnormality in Q-adjustment switch signal
E15
E96A
Abnormality in coolant low temperature sensor system
E11
E970
Overcurrent in fuel supply pump PCV1 system
E11
E971
Overcurrent in fuel supply pump PCV2 system
E11
E974
Disconnection in fuel supply pump PCV1 system
E11
E975
Disconnection in fuel supply pump PCV2 system
E11
E977
Abnormality in common rail fuel pressure sensor system
E11
E979
Abnormality in common rail fuel high pressure 1
E11
E97A
Abnormality in common rail fuel high pressure 2
E15
E97B
No-pressure feed by supply pump 1
E11
E97C
No-pressure feed by supply pump 2
E11
E97D
Abnormality in common rail fuel pressure
E11
E980
Abnormality in controller
E11
E981
Disconnection in fuel injector 1 system
E11
E982
Disconnection in fuel injector 2 system
E11
E983
Disconnection in fuel injector 3 system
E11
E984
Disconnection in fuel injector 4 system
E11
E985
Disconnection in fuel injector 5 system
E11
E986
Disconnection in fuel injector 6 system
E11
E98A
Short circuit in fuel injector 1 – 3 systems
E11
E98B
Short circuit in fuel injector 4 – 6 systems
E22
E922
Out of engine high idle standard
a "E" at the head of each service code indicates the following condition. • With E: The trouble has not been repaired. • Without E: The trouble has been repaired.
20-179-9 (7)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
4. Monitoring function [02] With this function, you can monitor the revolution speed, oil pressure, current, voltage, input condition, output condition, etc. in real time by the signals from the sensors, switches, and solenoids installed to various parts of the machine. 1) Selecting and executing function i) Select menu No. [02] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Selecting and executing monitoring code While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a monitoring code displayed in service meter section (1). • UP switch (7): Increase code No. • DOWN switch (8): Decrease code No. a This function displays monitoring code [00200] and its information first. a For the items and code Nos. which you can monitor, see the "Monitoring codes table".
3) Information displayed in display section and service meter section 1 (When numeral code is displayed) If a numeral monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (Value is displayed)
4) Information displayed in display section and service meter section 2 (When 6-bit code is displayed) If a 6-bit monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (6 pieces of information are displayed in bits) a In the 6-bit display mode, only the top and bottom of the 7-segments mark are used to display. "Solid black" indicates the ON state, and "white on black background" indicates the OFF state. a For the No. of each bit, see the "Monitoring codes table" and the drawing attached to it. PC400/450(LC)-7
20-179-10 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Monitoring codes table Code
Monitoring item
Unit
Remarks
00200
Controller model code
Numeral
00201
Controller model code
Numeral
01002
Engine speed
rpm
01601
2nd throttle command
rpm
01100
F pump pressure
kg/cm2
01101
R pump pressure
kg/cm2
07200
Arm IN PPC pressure
kg/cm2
07300
Bucket curl PPC pressure
kg/cm2
04102
Engine coolant temperature (high)
°C
14200
Fuel temperature
°C
04401
Hydraulic oil temperature
°C
01300
PC-EPC solenoid current
mA
01500
LS-EPC solenoid current
mA
01700
Service solenoid current
mA
03200
Power supply voltage
V
03500
Battery relay output voltage
V
04300
Charge voltage
V
01006
Engine speed
rpm
04107
Engine coolant temperature (low)
°C
36400
Common rail fuel pressure
kg/cm2
36500
Boost pressure
kg/cm2
36700
Converted torque
%
03000
Fuel control dial voltage
V
04200
Fuel sensor voltage
V
04106
Engine coolant temperature sensor voltage high
V
04105
Engine coolant temperature sensor voltage low
V
14201
Fuel temperature sensor voltage
V
36501
Boost pressure sensor voltage
V
36401
Common rail pressure sensor voltage
V
17200
PCV valve closing timing
17300
Engine control mode
31701
Throttle angle
36100
Fuel injection rate command
mm3/st
36200
Common rail pressure command
kg/cm2
36300
Fuel injection timing command
20-179-11 (7)
CA Numeral %
CA
PC400/450(LC)-7
TESTING AND ADJUSTING
Code
01900
01901
02300
02301 02200
02201
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Monitoring item
Pressure switch 1
Pressure switch 2
Solenoid 1
a
Swing
(6 bit)
b
Travel
(6 bit)
c
Boom LOWER
(6 bit)
d
Boom RAISE
(6 bit)
e
Arm IN
(6 bit)
f
Arm OUT
(6 bit)
a
Bucket CURL
(6 bit)
b
Bucket DUMP
(6 bit)
c
Service
(6 bit)
d
Travel differential pressure
(6 bit)
a
Travel junction
(6 bit)
b
Swing holding brake
(6 bit)
c
Pump merge-divider
(6 bit)
d
2-stage relief
(6 bit)
e
Travel speed shifting
(6 bit)
ATT return selection
(6 bit)
a
Knob switch
(6 bit)
b
Swing brake release switch
(6 bit)
c
Swing holding brake switch
(6 bit)
a
Model selection 1
(6 bit)
b
Model selection 2
(6 bit)
c
Model selection 3
(6 bit)
d
Model selection 4
(6 bit)
e
Model selection 5
(6 bit)
Solenoid 2 Switch input 1
Switch input 2
Unit
02202
Switch input 3
Key switch (ACC)
(6 bit)
03700
Controller output 1
Battery relay drive
(6 bit)
a
Key switch
(6 bit)
b
Start
(6 bit)
c
Preheating
(6 bit)
d
Light
(6 bit)
e
Radiator coolant level
(6 bit)
a
Air cleaner
(6 bit)
b
Engine oil level
(6 bit)
c
Charge voltage
(6 bit)
04500
04501
Monitor input 1
Monitor input 2
PC400/450(LC)-7
Remarks
20-179-12 (7)
TESTING AND ADJUSTING
Code
04502
17400
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Monitoring item
Monitor input 3
Engine controller input state
Unit
a
Swing holding brake switch
(6 bit)
b
Buzzer cancel switch
(6 bit)
c
Window limit switch
(6 bit)
d
W limit switch
(6 bit)
e
P limit switch
(6 bit)
a
Key switch (C)
(6 bit)
b
Engine oil pressure low
(6 bit)
c
Engine oil pressure high
(6 bit)
d
Model selection 1
(6 bit)
e
Model selection 2
(6 bit)
f
Model selection 3
(6 bit)
Remarks
36800
Right Q-adjustment switch (ROT-SW1)
Numeral and alphabet
36801
Left Q-adjustment switch (ROT-SW2)
Numeral and alphabet
05100
S-NET connection state
20200
Program version (monitor)
Numeral
20212
Program version (pump controller)
Numeral
20209
Program version (engine controller)
Numeral
a
Pump controller
(6 bit)
b
Engine controller
(6 bit)
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or (d) and (e) light up. Display of numeral code
20-179-13 (7)
Display of 6-bit code
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
5. Function of selecting maintenance period [04] With this function, you can adjust the maintenance period of the engine oil for the function of the engine oil replacement monitor. 1) Selecting and executing function i) Select menu No. [04] in the menu selection mode. ii) Press set switch (5) to execute this function.
2) Selecting maintenance period The current display mode or maintenance period is displayed in service meter section (2). Press set switch (5) to select a maintenance period. a Nothing is displayed in display section (1). a Each time the set switch is pressed, the display mode or maintenance period changes in the following order. Display
Display mode/ Maintenance period
0
Maintenance function is reset.
125
125-hour interval
250
250-hour interval
500
500-hour interval
d
Demonstration mode
3) Settling maintenance period The display or maintenance period becomes effective when it is selected. Accordingly, perform the ordinary finishing operation. a For the method of displaying the engine oil replacement monitor, method of checking the elapsed time after replacement of engine oil, method of clearing the elapsed time, and method of displaying demonstration mode, see "8. Special functions of engine oil replacement monitor".
PC400/450(LC)-7
20-179-14 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
6. Function of selecting default working mode [05] With this function, you can freely select the working mode which is set automatically when the starting switch is turned ON (When the machine is delivered, mode A is set). 1) Selecting and executing function i) Select menu No. [05] in the menu selection mode. ii) Press set switch (5) to execute this function.
2) Selecting default working mode The currently set working mode is displayed in service meter section (2). Press working mode selector switches (7) and (8) to select a working mode. • UP switch (7): Next mode is displayed. • DOWN switch (8): Previous mode is displayed. a Nothing is displayed in display section (1). a The working mode changes in the following order: A o E o B 3) Settling default working mode Press set switch (5) to settle the selected working mode.
20-179-15 (7)
PC400/450(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
7. Function of setting installation of attachment [16] With this function, you can set installation of attachment. a When an attachment is installed, if INSTALLED is not set with this function, the Bmode function (automatic single/double operation selecting function) cannot be used. 1) Selecting and executing function i) Select menu No. [16] in the menu selection mode. ii) Press set switch (5) to execute this function. a While this function is executed, [16SET] is displayed in the service meter section (2) and [0] or [1] is displayed in display section (1). 2) Selecting installation of attachment i) The current setting is displayed in service meter section (1). Check the actual installation of attachment and setting. • [0]: Attachment is not installed. • [1]: Attachment is installed. ii) While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select [0] or [1]. • UP switch (7): [1] is selected. • DOWN switch (8): [0] is selected. 3) Settling installation of attachment Press set switch (5) to settle the selected setting of installation of attachment.
PC400/450(LC)-7
20-179-16 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
8. Special functions of engine oil replacement monitor 1) Ordinary display of engine oil replacement monitor If the rest of time before the set engine oil replacement time is 10 hours or shorter, engine oil replacement monitor (10) lights up and display the elapsed time in service meter section (2) for 20 seconds each time the starting switch is turned ON. 2) Checking elapsed time To check the elapsed time while engine oil replacement monitor (10) is OFF, turn the starting switch OFF and press set switch (5) and then turn the starting switch ON and keep holding set switch (5). 3) Clearing elapsed time To clear the elapsed time after replacing the engine oil, hold set switch (5) for 3 seconds while the elapsed time is displayed in service meter section (2). a If the above operation is performed, the elapsed time in the monitor panel is set to 0 hours. 4) Function of demonstration mode If the demonstration mode is selected, you can perform demonstration of the oil maintenance function when teaching the operation to a customer. The functions and display of the demonstration mode are as follows. i) The internally set interval is recognized as 250 hours and the elapsed time is recognized as 240 hours. ii) When the starting switch is turned ON after the demonstration mode is set, the ordinary display is repeated up to 3 times (number of the times of turning the starting switch ON). iii) After the demonstration is finished, resetting of maintenance setting [0] is recognized. a When the demonstration is repeated 3 times, resetting of maintenance setting is recognized. If setting is necessary at this time, see "Function of selecting maintenance period".
20-179-17 (7)
PC400/450(LC)-7
TESTING AND ADJUSTING
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
k The engine controller has a high-voltage circuit (110 – 130 V) to drive the fuel injector. This circuit is connected to the wiring harness and connectors between the engine controller and fuel injector. a Normally, the engine controller outputs the high voltage to the fuel injector only while the engine is running and stops outputting if the engine stops.
k If you touch the high-voltage circuit directly, you may get an electric shock. To avoid this, observe the following precautions. 1. The following connectors are used in the highvoltage circuit. • Engine controller connector: CB3 • Junction connector: ER03 • Injector connectors: CN1, CN2, CN3, CN4, CN5, CN6 • Injector head terminal (in head cover) 2. When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF. 3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position, but must not turn it to the START position.
20-180 (1)
PC400/450(LC)-7
TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM a When carrying out troubleshooting for an electric circuit related to the monitor panel, engine controller, or pump controller, expose the related connectors according to the following procedure.
2. Engine controller 1) Open the right side cover and remove radiator sub tank (3) and bracket together.
1. Monitor panel 1) Remove cover (1). a The cover is fixed with the upper and lower 2 clips. You can remove the cover by pulling it up. a If the sunlight sensor for the air conditioner is installed, disconnect connector P15 on the back side of the cover.
2) Remove the 3 mounting screws and disconnect monitor panel (2) from the mount. a Take care not to drop the mounting screws in the console. 3) Insert or connect T-adapters in or to connectors P01, P02, P70 of the monitor panel.
PC400/450(LC)-7
2) Remove the 4 mounting bolts and pull out engine controller (4). 3) Insert or connect T-adapters in or to connectors CB1, CB2, and CB3 of the engine controller. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
20-181 (1)
TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM
3. Pump controller a The pump controller is installed inside the cover at the rear of the operator’s seat. 1) Remove the 3 mounting bolts and cover (5).
2) Insert or connect T-adapters in or to connectors C01, C02, and C03 of the pump controller. a Since the connectors are secured with screws, loosen those screws before disconnecting. a When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}
20-182 (1)
PC400/450(LC)-7
PM-CLINIC SERVICE
PC400/450(LC)-7
20-183 (1)
MEASURING PROCEDURES
Positions to install measuring devices (Related to engine)
20-184 (1)
PC400/450(LC)-7
MEASURING PROCEDURES
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
PC400/450(LC)-7
20-185 (1)
20-186 (1)
PC400/450(LC)-7
PC400/450(LC)-7
20-187 (1)
Pm-CLINIC SERVICE PC400 (LC), 450 (LC)-7 Visual check of welded structures a If any crack is found, draw its shape below.
Arm 1. Arm cylinder bracket T Left T Right 2. Arm foot T Left T Right T End plate 3. Arm top boss T Left T Right
20-188 (1)
Boom 4. Boom top bracket T Left T Right 5. Boom cylinder bracket T Left T Right 6. Arm cylinder bracket T Left T Right 7. Boom lower plate T Left T Right 8. Boom foot T Left T Right
Revolving frame 9. Boom bracket T Left T Right Track frame 10. Circle bracket T Front T Rear T Left T Right
PC400/450(LC)-7
UNDERCARRIAGE INSPECTION Komatsu Undercarriage Inspection
Y
T20606
(Program form No.: SELA195001)
Customer name: Address:
PC400/450-7
Model
Serial#
Location Soil condition Working condition
Equip#
Work Order No
SMR
Wet,AR,HD or Dry
Dealer
Shoe width (mm)
nspector
LH
Insp.Date(yyyy/mm/dd) New 100% Measured Wear mm 915.6 927.6
Shoe type (yyyy/m/d)
Wear %
New
SMR Hours on Rebuilt Parts:
DRY
TRIPLE
NORMAL Wear type Comments/Observation
R RH
915.6
LH
228.90 231.90
927.6
RH
228.90 231.90
LH
129.0
119.0
RH
129.0
119.0
LH
71.5
66.5
RH
71.5
66.5
LH
37.0
22.0
M
RH
37.0
22.0
LH
148.0
134.0
RH
148.0
134.0
LH
148.0
134.0
RH
148.0
134.0
LH
22.0
28.0
RH
22.0
28.0
LH
22.0
28.0
New
Turned
New
Turned
Front
Rear
Front
Rear
1.3
RH
22.0
28.0
1
LH
200.0
188.0
2
LH
200.0
188.0
3
LH
200.0
188.0
4
LH
200.0
188.0
5
LH
200.0
188.0
6
LH
200.0
188.0
7
LH
200.0
188.0
8
LH
200.0
188.0
9
LH
200.0
188.0
10
LH
200.0
188.0
1
RH
200.0
188.0
2
RH
200.0
188.0
3
RH
200.0
188.0
4
RH
200.0
188.0
5
RH
200.0
188.0
6
RH
200.0
188.0
7
RH
200.0
188.0
8
RH
200.0
188.0
9
RH
200.0
188.0
10
RH
200.0
188.0
LH
0.0
6.0
RH
0.0
6.0
Remarks:
PC400/450(LC)-7
20-189 (1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204 CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM.................................................................................................................................... 20-217 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-234 T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-256 TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED .................................................. 20-301 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................................................................. 20-501 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) ................................. 20-601 TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................... 20-701
PC400/450(LC)-7
20-201 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. 4) Check the stroke of the control valve spool.
20-202 (1)
5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting • Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure • Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
PC400/450(LC)-7
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC400/450(LC)-7
20-203 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment“ and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). 1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
20-204 (1)
PC400/450(LC)-7
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
PC400/450(LC)-7
20-205 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors and wiring harnesses •
Disconnecting connectors 1) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2) When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. a If the connector is twisted up and down or to the left or right, the housing may break.
3) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-206 (1)
PC400/450(LC)-7
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors 1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. 4) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
•
Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c
PC400/450(LC)-7
20-207 (1)
TROUBLESHOOTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1) Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with contact restorer and reassemble.
20-208 (1)
PC400/450(LC)-7
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Handling control box 1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2) Do not open the cover of the control box unless necessary.
3) Do not place objects on top of the control box. 4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5) During rainy weather, do not leave the control box in a place where it is exposed to rain.
6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
PC400/450(LC)-7
20-209 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
20-210 (1)
PC400/450(LC)-7
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7) Cleaning operations After repairing the hydraulic equipment (pump, c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
PC400/450(LC)-7
20-211 (1)
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Electrics, electrical equipment
Hydraulic, Electrical mechanical equipment equipment
Lubricating oil, coolant
Item
20-212 (1)
Check fuel level, type of fuel Check for impurities in fuel Check hydraulic oil level Check hydraulic oil strainer Check swing machinery oil level Check engine oil level (oil pan oil level) Check coolant level Check dust indicator for clogging Check hydraulic filter Check final drive oil level
Judgement value — — — — — — — — — —
Action Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Replace Add oil
1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring
— — —
Tighten or replace Tighten or replace Tighten or replace
1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding
— — —
Repair Repair Bleed air
1. 2. 3. 4. 5.
Check battery voltage (engine stopped) Check battery electrolyte level Check for discolored, burnt, exposed wiring Check for missing wiring clamps, hanging wiring Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) 6. Check for blown, corroded fuses 7. Check alternator voltage (engine running at 1/2 throttle or above)
8. Check operating sound of battery relay (when switch is turned ON/OFF)
20 – 30V — — — —
Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace
— After running for several minutes : 27.5 – 29.5V — Replace
PC400/450(LC)-7
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING Classification of troubleshooting Mode Code display
Content Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are displayed.
E mode
Troubleshooting of electrical system
H mode
Troubleshooting of hydraulic and mechanical systems
S mode
Troubleshooting of engine
Steps for troubleshooting If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. 1. Troubleshooting steps when calling User Code display in the monitor panel In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error Code for the electrical system, carry out the troubleshooting along the corresponding code display. 2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is recorded in the failure history: If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system Failure Code, using the failure history function of the monitor panel. a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to check if the same abnormality still persists. a Failure Code in the mechanical system cannot be deleted. 3. Troubleshooting steps without User Code display and no failure history is available If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from among “Failure like Phenomena and Troubleshooting No.” and carry out E mode or H mode troubleshooting related to the phenomenon in question.
PC400/450(LC)-7
20-213 (1)
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Phenomena considered to be failures and troubleshooting Nos. Troubleshooting No.
Phenomena considered to be failures
Display of code
E-mode
H-mode
S-mode
Possible faults related to user code, error code, or failure code 1
User code is displayed on monitor panel
2
When failure history is checked, error code is displayed in electrical system
3
When failure history is checked, error code is displayed in mechanical system
According to displayed code
Possible faults related to engine 4
Engine does not start easily (It always takes time to start)
5
Engine does not crank
S-1 E-1
S-2 a)
Engine cranks but exhaust smoke does not come out
S-2 b)
7
Exhaust smoke comes out but engine does not start
S-2 c)
8
Engine speed does not rise sharply (Follow-up performance is low)
S-3
9
Engine stops during operation
S-4
10
Engine rotation is abnormal (Engine hunts)
S-5
11
Output is insufficient (Power is low)
S-6
12
Exhaust gas color is bad (Incomplete combustion)
S-7
13
Oil is consumed much or exhaust gas color is bad
S-8
14
Oil becomes dirty quickly
S-9
15
Fuel is consumed much
S-10
16
Coolant contains oil (or it blows back or reduces)
S-11
17
Engine oil pressure caution lamp lights up (Oil pressure lowers)
S-12
18
Oil level rises (Water or fuel is mixed in oil)
S-13
19
Water temperature rises too high (Overheating)
S-14
20
Abnormal sound comes out
S-15
21
Vibration is excessive
S-16
22
Engine is not preheated normally
E-2
23
Automatic warm-up function does not work
E-3
24
Automatic decelerator does not work
E-4
6
Engine does not start
H-5
Possible faults related to work equipment, swing, and travel 25
Speed or power of whole work equipment, travel, and swing is low
H-1
S-6
26
Engine speed lowers extremely or engine stalls
H-2
S-4
27
Work equipment, travel, and swing systems do not work
28
Abnormal sound comes out from around hydraulic pump
H-4
29
Fine control performance or response is low
H-6
20-214 (1)
E-5
H-3
PC400/450(LC)-7
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting No.
Phenomena considered to be failures
Display of code
E-mode
H-mode
S-mode
Possible faults related to work equipment 30
Speed or power of boom is low
H-7
31
Speed or power of arm is low
H-8
32
Speed or power of bucket is low
H-9
33
Work equipment does not move singly
H-10
34
Hydraulic drift of work equipment is large
H-11
35
Time lag of work equipment is large
H-12
36
When a work equipment device is relieved singly, other work equipment device moves
H-13
37
One-touch power maximizing function does not work
E-6
H-14
38
Machine push-up function does not work normally
E-7
H-15
39
Attachment circuit is not selected (when attachment is installed)
E-8
H-30
40
Oil flow in attachment circuit cannot be adjusted (when attachment is installed)
H-31
Possible faults related to compound operation 41
In compound operation of work equipment, speed of part loaded more is low
H-16
42
When machine swings and raises boom simultaneously, boom rising speed is low
H-17
43
When machine swings and travels simultaneously, travel speed lowers largely
H-18
Possible faults related to travel 44
Machine deviates during travel
H-19
45
Travel speed is low
H-20
46
Machine is not steered well or steering power is low
H-21
47
Travel speed does not change or it is lower or higher than set speed
H-22
48
Travel motor does not work (only 1 side)
H-23
49
Travel alarm does not sound or does not stop sounding
E-31
Possible faults related to swing 47
Machine does not swing
H-24
48
Swing acceleration or swing speed is low
H-25
50
Upper structure overruns remarkably when it stops swinging
H-26
51
Large shock is made when upper structure stops swinging
H-27
52
Large sound is made when upper structure stops swinging
H-28
53
Hydraulic drift of swing is large
H-29
Possible faults related to monitor panel (Operator menu: Ordinary screen) 54
No items are displayed on monitor panel
E-9
55
Some items are not displayed on monitor panel
E-10
56
Items displayed on monitor panel are not matched to machine model
E-11
57
Fuel level monitor lights red while engine is running
E-12
PC400/450(LC)-7
20-215 (1)
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting No.
Phenomena considered to be failures
Display of code
E-mode
58
Engine coolant temperature gauge does not indicate normally
E-13
59
Hydraulic oil temperature gauge does not indicate normally
E-14
60
Fuel level gauge does not indicate normally
E-15
61
Swing lock monitor does not indicate normally
E-16
62
When monitor switches are operated, no items are displayed
E-17
63
Windshield wiper or windshield washer does not operate
E-18
64
Alarm buzzer cannot be cancelled
E-19
H-mode
S-mode
Possible faults related to monitor panel (Service menu: Special function screen) 65
Monitoring function does not indicate “Boom RAISE” normally.
E-20
66
Monitoring function does not indicate “Boom LOWER” normally.
E-21
67
Monitoring function does not indicate “Arm IN” normally.
E-22
68
Monitoring function does not indicate “Arm OUT” normally.
E-23
69
Monitoring function does not indicate “Bucket CURL” normally.
E-24
70
Monitoring function does not indicate “Bucket DUMP” normally.
E-25
71
Monitoring function does not indicate “Swing” normally.
E-26
72
Monitoring function does not indicate “Travel” normally.
E-27
73
Monitoring function does not indicate “Travel differential pressure” normally.
E-28
74
Monitoring function does not indicate “Service” normally.
E-29
Other failure 75
Air conditioner does not operate (Troubleshooting for air conditioner system)
20-216 (1)
E-31
PC400/450(LC)-7
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM Connectors list a The address of each connector roughly shows the place of the connector in the connectors stereogram and the circuit diagram of each system. Connector No.
Type
No. of pins
A01 A02 A03 A04 A05 A06 A07 A09 A10 A11 A12 A13 A14 A15 A16 A20 A21 A22 A23 A31 A33 A34 A35 A40 A41 A42 A43 A44 A50 A51 A52 A60 A61
X X DT SWP SWP SWP SWP SWP Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal D X L M Terminal Terminal M D M KES0 D D X D
4 4 12 6 14 14 16 8 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 2 1 2 3 3 1 2
A70
D
3
A73 A80 AL/B AL/E AL/R C01 C02 C03 C09 CB1
D DT Terminal Terminal Terminal DRC DRC DRC S DRC
2 8 1 1 1 24 40 40 8 24
PC400/450(LC)-7
Name of device Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Revolving frame grounding Battery relay (Terminal E) Battery relay (Terminal BR) Battery relay (Terminal N) Battery relay (Terminal B) Air cleaner clogging sensor Radiator water level sensor Fusible link (65 A) Fusible link (30 A) Horn (Low tone) Horn (High tone) Intermediate connector Travel alarm Right headlamp Windshield washer motor (Tank) F pump oil pressure sensor R pump oil pressure sensor Fuel level sensor Hydraulic oil temperature sensor Boom cylinder bottom pressure sensor for overload alarm Fuel priming pump Intermediate connector Alternator B terminal Alternator E terminal Alternator R terminal Pump controller Pump controller Pump controller Model selection connector (Pump controller) Pump controller
Stereogram T-1 T-1 N-2 O-1 T-1 O-1 S-1 N-2 H-2 I-2 I-2 I-2 F-1 J-3 J-3 D-1 D-2 F-2 F-2 H-9 H-9 D-2 G-9 G-9 G-9 H-9 J-3 D-5 L-5 L-8 L-7 G-9 L-5
Address M E circuit circuit H-6 D-7 H-6 H-6 D-7 H-5 H-5 A-4 I-1 I-1 I-1 I-1 I-1 I-1 L-5 J-6 J-5 J-6 K-4 K-5 K-6 K-6
D-7 F-1 F-1
D-8
D-9
J-8 J-8 J-8 K-8 K-9 K-9 K-9 K-9
K-9 K-9
J-7 K-5 K-7 K-5 L-5 L-5 K-4 K-5
H-1 G-9 S-1 AE-6 AE-6 AE-6 U-9 U-9 W-9 W-9 I-9
P circuit G-7 G-7 G-7 G-6 G-6 G-5 G-5 G-5 J-8
K-3 H-3
D-6
G-4
A-3 A-3 A-2
A-8 A-8
K-1
A-6
A-8 A-7 A-6 B-1 L-8
20-217 (4)
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
TROUBLESHOOTING
Connector No.
Type
No. of pins
CB2 CB3 CB5 CN1 CN2 CN3 CN4 CN5 CN6 D01 D02 E06 ENE ER02 ER03 F02 FB1 G GND GND2 GND3 H08 H09 H10 H11 H12 H15 HT/B HT/S J01 J02 J03 J04 J05 J06 J07 J08 K19 K30 K31 M07 M09 M13 M19 M21 M22 M23 M26 M27 M29 M30
DRC DRC DT DT DT DT DT DT DT SWP SWP M DT HD30 HD30 M — YAZAKI DT Terminal Terminal M S S S S S090 Terminal Terminal J J J J J J J J M DT DT M M M YAZAKI PA Y090 Y090 S YAZAKI 040 040
40 40 8 2 2 2 2 2 2 8 8 3 2 31 31 2 — 2 2 1 1 8 8 16 16 12 20 1 1 20 20 20 20 20 20 20 20 2 3 3 3 1 2 2 9 2 2 12 18 20 16
20-218 (4)
Name of device Pump controller Pump controller Model selection connector (Engine controller) No. 1 fuel injector No. 2 fuel injector No. 3 fuel injector No. 4 fuel injector No. 5 fuel injector No. 6 fuel injector Concentrated diode Concentrated diode Fuel control dial Engine speed sensor Intermediate connector Intermediate connector Rotary lamp Fuse box Engine G sensor Joint connector (with diode) Engine grounding Engine grounding Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Heater relay B terminal Heater relay S terminal Junction connector (Black) Junction connector (Black) Junction connector (Green) Junction connector (Green) Junction connector (Pink) Junction connector (Orange) Junction connector (Orange) Junction connector (Pink) Pump resistor (For driving pump in emergency) CAN terminal resistance CAN terminal resistance Light switch Working lamp (Right front) Speaker (Right) Cigarette lighter Radio Horn switch One-touch power maximizing switch Intermediate connector Air conditioner unit Air conditioner control panel Air conditioner control panel
Stereogram I-9 J-9 J-9 AI-2 AI-3 AJ-3 AJ-5 AJ-6 AJ-6 W-7 W-5 P-7 AJ-5 AF-8 AF-8 AA-9 V-2 AH-2 AJ-6 AJ-5 AE-7 W-6 W-6 T-9 S-9 S-9 O-7 AH-9 AJ-7 T-9 T-9 U-9 V-3 V-3 W-3 W-5 W-5 W-5 K-9 N-4 P-8 E-9 AC-9 N-3 U-2 O-7 T-1 W-4 W-4 U-2 U-2
Address M E circuit circuit K-1 A-5 A-3 A-7 K-3 K-2 K-2 K-2 K-3 K-2 A-9 A-8 K-7
P circuit L-8
A-4 A-4
J-3
I-5 I-3
K-6
I-9
E-7 K-3
G-8
I-7
E-2 E-2 E-2 A-2
J-8 J-8 D-6 D-6 D-5 C-2
I-6 I-7
C-9 D-9 D-9 E-9 E-9 F-9 F-9
H-9
A-2 A-4 C-1 K-7
A-9 K-6
H-9 H-9 I-9 I-9 I-9
B-9 C-1 C-9 C-9 D-9 D-9 D-9 E-9 B-1 A-9 E-1
F-9
PC400/450(LC)-7
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
TROUBLESHOOTING
Connector No. M31 M32 M33 M33 M34 M37 M38 M38 M40 M41 M42 M43 M45 M46 M71 M72 M73 M79 NE OL P01 P02 P03 P05 P15 P70 PCV1 PCV2 PSH PSL PFUEL PIM R10 R11 R13 R20 R22 R30 R31 S01 S02 S03 S04 S05 S06 S07 S08 S09 S10 S11 S14
Type M M M SUMITOMO
X Terminal Terminal M M M M M D X M M M M YAZAKI DT 070 040 M M Y050 040 SUMITOMO SUMITOMO
Terminal Terminal AMP SUMITOMO
R R R R R R R D X X D X X X X X X X M
PC400/450(LC)-7
No. of pins 2 2 2 4 1 1 1 2 2 2 1 1 12 4 2 4 2 2 2 2 12 20 2 2 2 16 2 2 1 1 3 3 5 5 5 5 5 5 5 4 2 2 3 2 2 2 2 2 2 2 3
Address StereoM E gram circuit circuit Optional power supply (2) W-7 Optional power supply (1) W-6 Optional power supply (3) V-9 Air conditioner unit W-4 Air conditioner compressor electromagnetic clutch I-9 Horn switch (High tone) H-1 Horn switch (Low tone) G-1 Machine push-up switch Q-8 Working lamp Z-8 K-8 Working lamp (Additional) Y-7 K-8 J-7, K-7 Intermediate connector H-9 Working lamp (Rear) J-9 K-7 Intermediate connector W-7 RS232C junction connector V-9 Room lamp AA-8 DC/DC converter U-2 Speaker (Left) AD-8 12-V accessory outlet V-9 Engine Ne sensor AJ-5 K-4 Engine oil level sensor AJ-3 K-2 Monitor panel N-6 A-7 K-7 Monitor panel N-5 A-6 K-6 Buzzer cancel switch Q-8 D-1 Rotary lamp switch U-2 Air conditioner daylight sensor N-5 Monitor panel N-5 A-5 K-6 Fuel supply pump PCV1 AH-2 K-1 Fuel supply pump PCV2 AI-2 K-1 Engine oil pressure switch (High pressure) AH-2 L-5 Engine oil pressure switch (Low pressure) AG-1 L-5 Common rail pressure sensor AJ-4 K-5 Boost pressure sensor AJ-8 K-5 Light relay P-7 E-1 Starting motor cutout relay (PPC lock) P-8 E-1 Starting motor cutout relay (Personal code) Q-8 F-1 ATT circuit selector relay W-7 Power supply relay for engine controller W-6 G-9 Air conditioner blower relay W-4 Air conditioner compressor relay W-3 Bucket CURL pressure sensor K-3 Boom LOWER oil pressure switch L-2 Swing RIGHT oil pressure switch L-2 Arm IN pressure switch K-3 Bucket DUMP oil pressure switch L-2 Boom RAISE oil pressure switch L-2 Swing LEFT oil pressure switch L-2 Arm DUMP oil pressure switch L-1 Service oil pressure switch (Intermediate connector) L-1 Service front oil pressure switch K-1 Service rear oil pressure switch L-1 Safety lock lever switch S-1 K-9 Name of device
P circuit
A-1
A-4
E-1 E-1
E-1
E-9
K-3 K-2 K-2 K-3 K-2 K-2 K-2 K-2 K-1 K-1 K-1 E-9
20-219 (4)
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
TROUBLESHOOTING
Connector No.
Type
No. of pins
S21 S22 S25 S30 S31 ST ST/B T05 T06 T06A T11 THL
Terminal Terminal S090 X X DT Terminal Terminal Terminal M Terminal DT
6 6 16 2 2 2 1 1 1 1 1 3
TWH
DT
2
TWL
DT
3
V01 V02 V03 V04 V05 V06 V08 V12 V21 V22 V30 W03 W04 X05
DT DT D D D D D D D D X M M M
2 2 2 2 2 2 2 2 2 2 2 2 6 4
20-220 (4)
Name of device Emergency pump drive switch Swing holding brake release switch Intermediate connector Travel oil pressure switch Travel steering oil pressure switch Starting motor Starting motor B terminal Floor frame grounding Radio body grounding Intermediate connector Cab grounding Spill fuel temperature sensor Engine water temperature sensor (High temperature) Engine water temperature sensor (Low temperature) PPC oil pressure lock solenoid valve Travel junction solenoid valve Merge-divider solenoid valve Travel speed solenoid valve Swing holding brake solenoid valve Machine push-up solenoid valve 2nd-stage relief solenoid valve ATT return selector solenoid valve PC-EPC solenoid valve LS-EPC solenoid valve ATT flow adjustment EPC solenoid valve Rear limit switch (Window) Wiper motor Swing lock switch
Stereogram R-9 R-8 R-9 P-1 P-1 AF-7 AF-7 V-3 S-9 T-2
Address M E circuit circuit
K-3
P circuit C-1 D-1 C-2 A-9 A-9 K-6
J-8
K-8 AJ-4
K-3
AE-7
K-5
AG-8
K-5
J-3 J-2 J-2 J-2 J-2 J-2 J-1 J-1 L-6 L-6 P-1 AB-9 Y-5 Q-8
K-5 K-5 K-4 K-4 K-4 K-4 K-4 K-4 L-7 L-7 F-1 K-8 B-9 D-2
A-1
PC400/450(LC)-7
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
TROUBLESHOOTING
Connector type D or DT
Detailed information Japanese and German makes DT type connector (08192-XXXXX)
L
Product of Yazaki Corporation L type connector (08056-2XXXX)
J
Product of Sumitomo Wiring Systems 090 type splice
M
Product of Yazaki M type connector (08056-0XXXX)
R
Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S
Product of Yazaki S type connector (08056-1XXXX)
X
Product of Yazaki X type connector (08055-0XXXX)
PA
Product of Yazaki PA type connector
SWP
Product of Yazaki SWP type connector (08055-1XXXX)
DRC
Japanese and German makes DRC type connector
040
Product of Japan AMP 040 type connector
070
Product of Japan AMP 070 type connector
Y050
Product of Yazaki 050 type connector
S090
Product of Sumitomo 090 type connector
Y090
Product of Yazaki 090 type connector
YAZAKI SUMITOMO KES0
Yazaki-made connector Product of Sumitomo Wiring Systems 6098 type connector KESO type connector (08027-0XXXX)
Terminal
Round pin type single terminal connector
Terminal
Round terminal
PC400/450(LC)-7
20-221 (1)
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
Connector Location Stereogram
20-222 (1)
PC400/450(LC)-7
TROUBLESHOOTING
PC400/450(LC)-7
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
20-223 (4)
TROUBLESHOOTING
20-224 (1)
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
PC400/450(LC)-7
TROUBLESHOOTING
PC400/450(LC)-7
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
20-225 (1)
TROUBLESHOOTING
20-226 (1)
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
PC400/450(LC)-7
TROUBLESHOOTING
PC400/450(LC)-7
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
20-227 (1)
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
Monitor Panel System Circuit Diagram (M Circuit)
20-228 (1)
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
a This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging system, light system, and communication network system from the general electric circuit diagram.
PC400/450(LC)-7
20-229 (1)
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
Engine Control System Circuit Diagram (E Ciruit)
20-230 (1)
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
a This circuit diagram is made by extracting the engine controller system from the general electric circuit diagram.
PC400/450(LC)-7
20-231 (1)
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
Pump Controller System Circuit Diagram (P Circuit)
20-232 (4)
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM
a This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram.
PC400/450(LC)-7
20-233 (4)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS a The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.
X type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
1
Part No.: 08055-00181
Part No.: 08055-00191
799-601-7010
2
799-601-7020
Part No.: 08055-00282
Part No.: 08055-00292
3
799-601-7030
Part No.: 08055-00381
Part No.: 08055-00391
4
799-601-7040
Part No.: 08055-00481
Part No.: 08055-00491
—
Terminal part No.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
Terminal part No.: 79A-222-3390 • 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
Terminal part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20
—
20-234 (1)
PC400/450(LC)-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector Male (female housing)
Female (male housing)
6
T-adapter Part No.
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
PC400/450(LC)-7
Part No.: 08055-11491
20-235 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector
No. of pins
Male (female housing)
Female (male housing)
16
T-adapter Part No.
799-601-7320
Part No.: 08055-11681
Part No.: 08055-11691
—
Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
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
Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20
—
20-236 (1)
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
1
Part No.: 08056-00171
Part No.: 08056-00181
799-601-7080
2
799-601-7090
Part No.: 08056-00271
Part No.: 08056-00281
3
799-601-7110
Part No.: 08056-00371
Part No.: 08056-00381
4
799-601-7120
Part No.: 08056-00471
Part No.: 08056-00481
6
799-601-7130
Part No.: 08056-00671
Part No.: 08056-00681
8
799-601-7340
Part No.: 08056-00871
PC400/450(LC)-7
Part No.: 08056-00881
20-237 (1)
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector Male (female housing)
Female (male housing)
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
20-238 (1)
T-adapter Part No.
Part No.: 08056-11681
PC400/450(LC)-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector Male (female housing)
Female (male housing)
10 (Blue)
—
—
—
12 (Blue)
799-601-7160
Part No.: 08056-11272
Part No.: 08056-11282
16 (Blue)
799-601-7170
Part No.: 08056-11672
PC400/450(LC)-7
T-adapter Part No.
Part No.: 08056-11682
20-239 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
7
Body part No.: 79A-222-2640 (Q’ty: 5)
Body part No.: 79A-222-2630 (Q’ty: 5)
—
11
Body part No.: 79A-222-2680 (Q’ty: 5)
Body part No.: 79A-222-2670 (Q’ty: 5)
—
5
799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5)
Body part No.: 79A-222-2610 (Q’ty: 5)
9
799-601-2950
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)
20-240 (1)
Body part No.: 79A-222-2690 (Q’ty: 2)
PC400/450(LC)-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector Male (female housing)
Female (male housing)
17
T-adapter Part No.
799-601-2730
Body part No.: 79A-222-2730 (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)
Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 (Q’ty: 50)
Terminal part No.: 79A-222-2760 (Q’ty: 50)
PC400/450(LC)-7
—
20-241 (1)
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP040 type connector Male (female housing)
Female (male housing)
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)
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-242 (1)
PC400/450(LC)-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP070 type connector Male (female housing)
Female (male housing)
10
799-601-7510
—
Part No.: 08195-10210
12
799-601-7520
—
Part No.: 08195-12210
14
799-601-7530
—
Part No.: 08195-14210
18
799-601-7540
—
Part No.: 08195-18210
20
799-601-7550
—
PC400/450(LC)-7
T-adapter Part No.
Part No.: 08195-20210
20-243 (1)
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector Male (female housing)
Female (male housing)
2
—
—
No.of pins
—
Connector for PA Male (female housing)
Female (male housing)
9
—
Bendix MS connector Male (female housing)
Female (male housing)
10
(1)
T-adapter Part No.
799-601-3460
—
20-244
T-adapter Part No.
—
—
No.of pins
T-adapter Part No.
—
PC400/450(LC)-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector Male (female housing)
Female (male housing)
2
T-adapter Part No.
—
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)
PC400/450(LC)-7
Part No.: 08027-10660 (Natural color) 08027-10670 (Black)
20-245 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector
No.of pins
Male (female housing)
Female (male housing)
8
—
Part No.: 08027-10810 (Natural color) 08027-10820 (Black)
No.of pins
Part No.: 08027-10860 (Natural color) 08027-10870 (Black)
Connector for relay (Socket type) Male (female housing)
Female (male housing)
5
—
6
799-601-7370
—
20-246
T-adapter Part No.
799-601-7360
—
(1)
T-adapter Part No.
—
PC400/450(LC)-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector Male (female housing)
Female (male housing)
4
—
—
PC400/450(LC)-7
T-adapter Part No.
—
20-247 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9210
18-8 (1)
Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)
Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)
Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female termial)
799-601-9220
Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206 18-14 (2) Pin (female terminal)
Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106 Pin (male termial)
799-601-9220
Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206
20-248 (1)
Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9230
18-20 (3)
Part No.:08191-31201, 08191-31202
Part No.:08191-34101, 08191-34102
Pin (female terminal)
Pin (male termial)
799-601-9230
Part No.:08191-32201, 08191-32202
Part No.:08191-33101, 08191-33102
Pin (male terminal)
Pin (female termial)
799-601-9240
18-21 (4)
Part No.:08191-41201, 08191-42202
Part No.:08191-44101, 08191-44102
Pin (female terminal)
Pin (male termial)
799-601-9240
Part No.:08191-42201, 08191-42202
PC400/450(LC)-7
Part No.:08191-43101, 08191-43102
20-249 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9250
24-9 (5)
Part No.:08191-51201, 08191-51202
Part No.:08191-54101, 08191-54102
Pin (female terminal)
Pin (male termial)
799-601-9250
Part No.:08191-52201, 08191-52202
Part No.:08191-53101, 08191-53102
Pin (male terminal)
Pin (female termial)
799-601-9260
Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206 24-16 (6) Pin (female terminal)
Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106 Pin (male termial)
799-601-9260
Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206
20-250 (1)
Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9270
24-21 (7)
Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206 Pin (female terminal)
Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 Pin (male termial)
799-601-9270
Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)
Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female termial)
799-601-9280
Part No.: 08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 24-22 (8) Pin (female terminal)
Part No.: 08191-84101, 08191-84103, 08191-84105,
08191-84102 08191-84104 08191-84106
Pin (male termial)
799-601-9280
Part No.: 08191-82201, 08191-82203, 08191-82205,
PC400/450(LC)-7
08191-82202 08191-82204 08191-82206
Part No.: 08191-83101, 08191-83103, 08191-83105,
08191-83102 08191-83104 08191-83106
20-251 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male termial)
Pin (female terminal)
T-adapter Part No.
799-601-9290
24-31 (9)
Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206 Pin (female terminal)
Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 Pin (male termial)
799-601-9290
Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206
20-252 (1)
Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector
No.of pins
Body (plug)
Body (receptacle)
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)
PC400/450(LC)-7
Part No.: 08192-16100 (normal type) 08192-26100 (fine wire type)
20-253 (1)
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector
No.of pins
Body (plug)
Body (receptacle)
8GR: 8B: 8G: 8BR:
8
Part No.: 08192-1820 08192-2820
(normal type) Part No.: 08192-1810 (fine wire type) 08192-2810
799-601-9060 799-601-9070 799-601-9080 799-601-9090
(normal type) (fine wire type)
12GR: 12B: 12G: 12BR:
12
Part No.: 08192-1920 08192-2920
20-254 (1)
T-adapter Part No.
(normal type) Part No.: 08192-1910 (fine wire type) 08192-2910
799-601-9110 799-601-9120 799-601-9130 799-601-9140
(normal type) (fine wire type)
PC400/450(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DTM Series connector
No.of pins
Body (plug)
Body (receptacle)
T-adapter Part No.
799-601-9010
2
Part No.: 08192-02200
Part No.: 08192-02100
[The pin No. is also marked on the connector (electric wire insertion end)] DTHD Series connector
No.of pins
Body (plug)
Body (receptacle)
2
T-adapter Part No.
—
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12) 08192-41200 (Contact size #8) 08192-41100 (Contact size #8) 08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC400/450(LC)-7
20-255 (1)
TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE
799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340
20-256 (1)
Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP SWP SWP SWP M M M M M M
—
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
799-601-2800
Connector type or No. of pins part name
799-601-2700
Part No.
799-601-2500
a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker Ass'y.
Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P 1P 2P 3P 4P 6P 8P 12P 14P 16P 1P 2P 3P 4P 6P 8P
PC400/450(LC)-7
799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410
S S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 HD30 HD30 HD24 HD30 HD30 HD30 HD30 Plate Measurement box Case Case DEUTSCH DEUTSCH For NE, G sensor For fuel, boost 799-601-9420 press. 799-601-9430 PVC socket
PC400/450(LC)-7
—
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
799-601-2800
Connector type or No. of pins part name
799-601-2700
Part No.
T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
TROUBLESHOOTING
8P 10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2 10P 12P 14P 18P 20P 5P 6P 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Brown 12P-Gray 12P-Black 12P-Green 12P-Brown 18-8 18-14 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD 40P 24P 2P 3P 2P
20-257 (1)
TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH TABLE
Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if the power is supplied normally. Type of power supply
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Constant power supply (Fusible link: A35)
20-258 (1)
Fuse No.
Fuse capacity
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)
PC400/450(LC)-7
TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304 Error Code in Electrical System [E112] (Short-circuiting in normal rotation system of windshield wiper motor drive)........................................ 20-306 Error Code in Electrical System [E113] (Short-circuiting in reverse rotation system of windshield wiper motor drive)....................................... 20-308 Error Code in Electrical System [E114] (Short-circuiting in window washer drive system) ......................... 20-310 Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion) ........................................... 20-312 Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper) ................................. 20-314 Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)............................................. 20-316 Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)........................................... 20-318 Error Code in Electrical System [E128] (Monitor Comm. Abnormality)....................................................... 20-320 Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid) ............................ 20-322 Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid) ........................ 20-324 Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid).................................... 20-326 Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid) ................................... 20-327 Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid) ........................ 20-328 Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid).............................. 20-329 Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid).......................... 20-330 Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)..................................... 20-332 Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)..................................... 20-333 Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid).......................... 20-334 Error Code in Electrical System [E217] (Abnormal input model code)........................................................ 20-336 Error Code in Electrical System [E218] (S-Net Comm. Disc.)..................................................................... 20-338 Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid) ........................................... 20-340 Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system) ................................ 20-341 Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality) .................................................. 20-342 Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality) .................................................. 20-344 Error Code in Electrical System [E226] (Press. Sensor Power Abnormality).............................................. 20-346 Error Code in Electrical System [E227] (Abnormality in engine rotation sensor) ........................................ 20-348 Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay).................. 20-349 Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid) .......................................... 20-350 Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)................................ 20-352 Error Code in Electrical System [E238] (Disconnection in attachment return switching relay) ................... 20-354 Error Code in Electrical System [E245] (Short-circuiting in attachment oil flow rate adjusting EPC).......... 20-356 Error Code in Electrical System [E246] (Disconnection in attachment oil flow rate adjusting EPC) ........... 20-357 Error Code in Electrical System [E247] (Arm IN PPC pressure sensor abnormality) ................................. 20-358 Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)....................... 20-360 Error Code in Electrical System [E257] (Pump Abnormality) ...................................................................... 20-362 Error Code in Electrical System [E315] (Battery Relay Drive S/C) ............................................................. 20-364 Error Code in Electrical System [E91B] (Engine Ne sensor problem) ........................................................ 20-366 Error Code in Electrical System [E91C] (Engine G sensor problem) .......................................................... 20-367 Error Code in Electrical System [E920] (Engine type selection error)......................................................... 20-368 Error Code in Electrical System [E921] (Engine type mismatch) ................................................................ 20-370 Error Code in Electrical System [E931] (Fuel dial sys. error)...................................................................... 20-372 Error Code in Electrical System [E934] (Engine coolant sensor Hi error)................................................... 20-374
PC400/450(LC)-7
20-301 (1)
TROUBLESHOOTING
Error Code in Electrical System [E936] (Engine oil press. sw. error) .......................................................... 20-376 Error Code in Electrical System [E93C] (Engine boost sensor error) ......................................................... 20-378 Error Code in Electrical System [E93D] (Engine fuel temp. sensor error) .................................................. 20-380 Error Code in Electrical System [E953] (Engine Comm. Abnormality)........................................................ 20-382 Error Code in Electrical System [E954] (Short engine starter sw.).............................................................. 20-384 Error Code in Electrical System [E955] (Engine S-NET error) .................................................................... 20-386 Error Code in Electrical System [E956] (Engine power failure (1)) ............................................................. 20-388 Error Code in Electrical System [E957] (Engine power failure (2)) ............................................................. 20-390 Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error).................................................... 20-392 Error Code in Electrical System [E96A] (Engine coolant sensor Lo error) .................................................. 20-394 Error Code in Electrical System [E970] (PCV1 over current) ...................................................................... 20-396 Error Code in Electrical System [E971] (PCV2 over current) ...................................................................... 20-397 Error Code in Electrical System [E974] (PCV1 line cut).............................................................................. 20-398 Error Code in Electrical System [E975] (PCV2 line cut).............................................................................. 20-399 Error Code in Electrical System [E977] (Rail press. sensor error) .............................................................. 20-400 Error Code in Electrical System [E979] (Rail press. high)........................................................................... 20-402 Error Code in Electrical System [E97A] (Rail press. abnormal) .................................................................. 20-402 Error Code in Electrical System [E97B] (Rail press. low)............................................................................ 20-403 Error Code in Electrical System [E97C] (Rail press. too low) ..................................................................... 20-405 Error Code in Electrical System [E97D] (Rail press. out of control) ............................................................ 20-405 Error Code in Electrical System [E980] (Eng. Controller Abnormality) ....................................................... 20-406 Error Code in Electrical System [E981] (Fuel Injector 1 Disc.).................................................................... 20-408 Error Code in Electrical System [E982] (Fuel Injector 2 Disc.).................................................................... 20-409 Error Code in Electrical System [E983] (Fuel Injector 3 Disc.).................................................................... 20-410 Error Code in Electrical System [E984] (Fuel Injector 4 Disc.).................................................................... 20- 411 Error Code in Electrical System [E985] (Fuel Injector 5 Disc.).................................................................... 20-412 Error Code in Electrical System [E986] (Fuel Injector 6 Disc.).................................................................... 20-413 Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C) ............................................................... 20-414 Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C) ............................................................... 20-416 Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)........................... 20-418 Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard) ............................ 20-418 Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging) ........................................................ 20-420 Failure Code in Mechanical System [AB00KE] (Charge Voltage Low) ....................................................... 20-422 Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)...................................................... 20-424 Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)........................................................ 20-426 Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat).................................................... 20-427 Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)....................................................... 20-428 Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)........................................................ 20-429
20-302 (1)
PC400/450(LC)-7
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work. User Code
Error Code
Failure Code
Display in monitor panel
Display in monitor panel
Display in monitor panel
Failure phenomenon
Title of failure phenomenon shown in failure history
Failure content
Failure status as detected by monitor panel or controller
Response from monitor panel or controller
Action taken by the monitor panel or controller to protect an affected system or equipment, when they detect some failure.
Phenomenon occurring on machine
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or controller
Relative information
Information on the failure occurred as well as the troubleshooting Cause
1
Presumed cause and standard value in normalcy
2
Cause that presumably triggered failure in 3 question (The assigned No. is for filing purpose only. It does not stand for any priority) 4
5
20-304 (1)
Standard value in normalcy and references for troubleshooting • Standard value in normalcy by which to pass “Good” or “No Good” judgement over the presumed cause • Reference for passing the above “Good” or “No Good” judgement • Disconnection There is a faulty contact at the connector or disconnection of wiring harness occurred. • Defective grounding A wiring harness that is not connected with a grounding circuit has a contact with the grounding circuit. • Short-circuiting A wiring harness that is not connected with a 24 V electric circuit has a contact with the electric circuit. 1) Connector No. display method and handling of T-adapter Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed. • If there is no indication of “male” or “female” in a specific connector No., disconnect the connector and insert the T-adapter into both male and female sides. • If there is an indication of “male” or “female” in a specific connector No., disconnect the connector and connect the T-adepter with only one side of either “male” or “female”. 2) Entry sequence of pin No. and handling of circuit tester lead Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the following manner unless otherwise instructed. • Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness. • Connect the negative (–) lead with the pin No. indicated at the front or the wiring harness.
PC400/450(LC)-7
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.
PC400/450(LC)-7
20-305 (1)
TROUBLESHOOTING
E112
Error Code in Electrical System [E112] (Short-circuiting in normal rotation system of windshield wiper motor drive) User Code
Error Code
Failure Code
—
E112
DY2DKB
Failure phenomenon
Short-circuiting in normal rotation system of windshield wiper motor drive (in monitor panel system)
Failure content
• Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from Monitor Panel
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Phenomenon occurring on machine
• The windshield wiper stops moving.
Relative information
Presumed cause and standard value in normalcy
Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female)
Continuity and resistance value
Between (3) and (1)
Continued
Between (3) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) (9) and W04 (male) (3) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective
P01 Between (9) and grounding
20-306 (1)
Resistance value
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V 20 – 30 V (at constant cycle)
PC400/450(LC)-7
TROUBLESHOOTING
E112
Electric Circuit Diagram for Windshield Wiper Motor
PC400/450(LC)-7
20-307 (1)
TROUBLESHOOTING
E113
Error Code in Electrical System [E113] (Short-circuiting in reverse rotation system of windshield wiper motor drive) User Code
Error Code
Failure Code
—
E113
DY2EKB
Failure content
Failure phenomenon
Short-circuiting in reverse rotation system of windshield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the windshield wiper was set in motion.
Response from • Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF. Monitor Panel Phenomenon occurring on machine
• The windshield wiper stopped moving.
Relative information
Presumed cause and standard value in normalcy
Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between (1) and (3)
Continued
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) (10) and W04 (male) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective
P01 Between (10) and grounding
20-308 (1)
Continuity and resistance value
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V 20 – 30 V (at constant cycle)
PC400/450(LC)-7
TROUBLESHOOTING
E113
Electric Circuit Diagram for Windshield Wiper Motor
PC400/450(LC)-7
20-309 (1)
TROUBLESHOOTING
E114
Error Code in Electrical System [E114] (Short-circuiting in window washer drive system) User Code
Error Code
Failure Code
—
E114
DY2CKB
Failure content
Failure phenomenon
Short-circuiting in window washer drive system (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was switched ON.
Response from • Power supply to the grounding in the window washer motor circuit was switched OFF. Monitor Panel Phenomenon occurring on machine
• The window washer stopped moving.
Relative information
Presumed cause and standard value in normalcy
Cause Window washer drive 1 motor defective (Internal short-circuiting)
Short-circuiting of wiring harness 2 (Contact with 24 V circuit)
A50 (male)
Resistance value
Between (1) and (2)
5 – 20 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. Between wiring harness from P01 (female) (3) to J04 to A50 (female) (2) and grounding, or between wiring harness between P01 (female) (3) and D02 (female) (8) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective
20-310 (1)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting.
P01
Window washer switch
Voltage
Between (3) and grounding
OFF
20 – 30 V
ON
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E114
Electrical Circuit Diagram for Window Washer Motor
PC400/450(LC)-7
20-311 (1)
TROUBLESHOOTING
E115
Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion) User Code
Error Code
Failure Code
—
E115
DY20KA
Failure content
Failure phenomenon
Abnormal operation of windshield wiper (in Monitor Panel system)
• A W signal is not inputted at both ends of movement, when it is in motion.
Response from • Power to the windshield wiper motor is turned OFF. Monitor Panel Phenomenon occurring on machine
• The windshield wiper motor does not work.
Relative information
• Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting.
Presumed cause and standard value in normalcy
Windshield wiper motor 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or faulty contact with connector)
W04 (female)
Between (6) and (5)
Resistance value Below 1 z
Outside upper end of operation range
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Wiring harness between P01 (female) (5) and W04 (male) (6)
Resistance value
Below 1 z
Wiring harness between W04 (male) (5) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. P01 3 Monitor panel defective Between (5) and grounding
20-312 (1)
Windshield wiper blade At upper end of operation range
Windshield wiper blade
Voltage
At upper end of operation range
Below 1 V
Outside upper end of operation range
20 – 30 V
PC400/450(LC)-7
TROUBLESHOOTING
E115
Windshield Wiper Motor Electrical Circuit Diagram
PC400/450(LC)-7
20-313 (1)
TROUBLESHOOTING
E116
Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper) User Code
Error Code
Failure Code
—
E116
DY20MA
Failure content
Failure phenomenon
Abnormal in retracting windshield wiper (in Monitor Panel system)
• P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is Monitor Panel retracted. Phenomenon occurring on machine
• The windshield wiper cannot be retracted completely.
Relative information
• It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No.: 04502 Monitor Input 3)
Presumed cause and standard value in normalcy
Cause Windshield wiper motor 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between (4) and (5)
Windshield wiper blade
Resistance value
Retraction range
Below 1 z
Operation range
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (12) and W04 (male) (4)
Resistance value
Below 1 z
Between wiring harness W04 (male) (5) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective
20-314 (1)
Standard value in normalcy and references for troubleshooting
P01
Windshield wiper blade
Voltage
Between (12) and grounding
Retraction range
Below 1V
Operation range
20 – 30 V
PC400/450(LC)-7
TROUBLESHOOTING
E116
Windshield Wiper Motor Electrical Circuit Diagram
PC400/450(LC)-7
20-315 (1)
TROUBLESHOOTING
E117
Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.) User Code
Error Code
Failure Code
—
E117
DAC0KR
Failure content
Failure phenomenon
Eng. Controller S-NET Comm. Err. (Monitor panel system)
• The monitor panel detected communication failure in the S-NET communication circuit to the engine controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause
Standard value in normalcy and references for troubleshooting
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
4
Engine controller defective
5 Monitor panel defective
20-316 (1)
Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CB2
Voltage
Between (21), (31) and (11)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
PC400/450(LC)-7
TROUBLESHOOTING
E117
Electrical circuit diagram related to S-NET communication
PC400/450(LC)-7
20-317 (1)
TROUBLESHOOTING
E118
Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.) User Code
Error Code
Failure Code
—
E118
DAB0KR
Failure content
Failure phenomenon
Pump Controller S-NET Comm. Err. (Monitor panel system)
• The monitor panel detected communication failure in the S-NET communication circuit to the pump controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. • The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause
Standard value in normalcy and references for troubleshooting
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) and related circuits and grounding
4
Pump controller defective
5 Monitor panel defective
20-318 (1)
Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02
Voltage
Between (21) and (31)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
PC400/450(LC)-7
TROUBLESHOOTING
E118
Electrical circuit diagram related to S-NET communication
PC400/450(LC)-7
20-319 (1)
TROUBLESHOOTING
E128
Error Code in Electrical System [E128] (Monitor Comm. Abnormality) User Code
Error Code
Failure Code
E0E
E128
DAF0MC
Failure content
Failure phenomenon
Monitor Comm. Abnormality (Monitor panel system)
• The monitor panel detected communication failure in the CAN communication circuit to the engine controller or pump controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22)
Resistance value
Below 1 z
Wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32)
Resistance value
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value
Above 1 Mz
Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit)
4
CAN terminal resistor defective
Monitor panel, engine 5 controller, or pump controller defective
20-320 (1)
Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Voltage
Below 1 V
Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male)
Voltage
Between (1) and (2)
40 – 80 z
If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller may be defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
PC400/450(LC)-7
TROUBLESHOOTING
E128
Electrical circuit diagram related to CAN communication
PC400/450(LC)-7
20-321 (1)
TROUBLESHOOTING
E201
Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid) User Code
Error Code
Failure Code
—
E201
DW91KB
Failure content
Failure phenomenon
Short-circuiting in travel interlocking solenoid (Pump controller system)
• Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF. Response from • Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the controller engine starting switch is once turned OFF. Phenomenon occurring on machine
• It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits connot be disconnected)
Relative information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Presumed cause and standard value in normalcy
Cause Travel interlocking solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (7) to V02 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Pump controller defective
C03 Between (7) and grounding
R.H. & L.H. travel control lever
Voltage
Neutral
Below 1 V
Steering
20 – 30 V
Electrical Circuit for Travel Interlocking Solenoid
20-322 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E203
Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid) User Code
Error Code
Failure Code
E03
E203
DW45KB
Failure content
Failure phenomenon
Short-circuiting in swing holding brake solenoid (Pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the circuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the swing and steering brake does not return to controller normalcy, unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The upper structure cannot swing. (The swing holding brake cannot be released.)
Relative information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing holding brake releasing switch to the RELEASE position. (In this case, however, the holding brake does not work, when stopping the machine)
Presumed cause and standard value in normalcy
Cause Swing holding brake solenoid defective 1 (Internal short-circuiting or grounding fault)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male) Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (37) to D01 to J02 to X05 to V05 (female) (2), or C03 (female) (37) and S25 (female) (8) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Pump controller defective
C03 Between (37) and grounding
20-324 (1)
Resistance value
L.H. work equipment control lever
Voltage
NEUTRAL
Below 1 V
Swing operated
20 – 30 V
PC400/450(LC)-7
TROUBLESHOOTING
E203
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400/450(LC)-7
20-325 (1)
TROUBLESHOOTING
E204
Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid) User Code
Error Code
Failure Code
—
E204
DWJ0KB
Failure content
Failure phenomenon
Short-circuiting in merge/divide solenoid (Pump controller system)
• Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation. (F•R pumps cannot be disconnected.)
Relative information
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Presumed cause and standard value in normalcy
Cause Merge/divide solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Pump controller defective
C03 Between (17) and grounding
L.H. and R.H. travel control levers
Voltage
NEUTRAL
Below 1 V
When operating one side only
20 – 30 V
Electrical Circuit Diagram for Merge/Divide Solenoid
20-326 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E205
Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid) User Code
Error Code
Failure Code
—
E205
DWK0KB
Failure content
Failure phenomenon
Short-circuiting in 2-stage relief solenoid (Pump controller system)
• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.)
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Presumed cause and standard value in normalcy
Cause 2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to V08 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3
Pump controller defective
C03
Working mode
Voltage
Between (28) and grounding
Other than L mode
Below 1 V
L mode
20 – 30 V
Electric Circuit Diagram for 2-stage Relief Solenoid
PC400/450(LC)-7
20-327 (1)
TROUBLESHOOTING
E206
Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid) User Code
Error Code
Failure Code
—
E206
DW43KB
Failure content
Failure phenomenon
Short-circuiting in travel speed shifting solenoid (Pump controller system)
• Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The travel speed does not turn to Hi. (The travel motor swash plate angle does not turn to minimum.)
Relative information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1)
Presumed cause and standard value in normalcy
Cause Travel speed shifting solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Pump controller defective
C03
Travel speed + travel lever
Voltage
Between (27) and grounding
Lo + Neutral
Below 1 V
Hi + Travel operation
20 – 30 V
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
20-328 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E211
Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid) User Code
Error Code
Failure Code
—
E211
DW91KA
Failure content
Failure phenomenon
Disconnection in travel interlocking solenoid (Pump controller system)
• No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• It is difficult to steer the machine while traveling. (L.H. and R.H. travel circuits cannot be disconnected.)
Relative information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E201].) Cause
Presumed cause and standard value in normalcy
Travel interlocking 1 solenoid defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (7) to V02 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3), (13), (23) and V02 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (7) to V02 (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (7) and (3), (13), (23)
20 – 60 z
Electrical Circuit Diagram for Travel Interlocking Solenoid
PC400/450(LC)-7
20-329 (1)
TROUBLESHOOTING
E213
Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid) User Code
Error Code
Failure Code
E03
E213
DW45KA
Failure content
Failure phenomenon
Disconnection in swing holding brake solenoid (Pump controller system)
• No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The machine's upper structure does not swing. (The swing holding brake cannot be released.)
Relative information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing by moving the swing holding brake release switch to the RELEASE position. (In this case, however, the holding brake does not work, when stopping the machine) • While in troubleshooting, hold both the swing lock switch and the swing holding brake release switch in the OFF position. • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E203].) Cause
Swing holding brake 1 solenoid defective (Internal disconnection)
Presumed cause and standard value in normalcy
Swing lock switch 2 defective (Internal disconnection)
Assembled-type diode 3 D01 defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (3) and (4)
Swing lock switch
Resistance value
OFF
Below 1 z
ON
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)
Digital type circuit tester
Continuity
Between (7) and (3)
Diode mode
Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector)
Wiring harness between C03 (female) (37) and D01 (female) (7)
Resistance value
Below 1 z
Wiring harness from D01 (female) (3) to J02 to X05 (male) (3)
Resistance value
Below 1 z
Wiring harness from X05 (male) (4) to V05 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3), (13), (23) and V05 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of position during the troubleshooting. 5 Wiring harness (Contact with 24V circuit) Between wiring harness between C03 (female) (37) and Voltage Below 1 V D01 (female) (7) and grounding
6
20-330 (1)
Pump controller defective
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (37) and (3), (13), (23)
Disconnect D01 and connect pins (3) and (7) of the female side.
Resistance value 20 – 60 z
PC400/450(LC)-7
TROUBLESHOOTING
E213
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400/450(LC)-7
20-331 (1)
TROUBLESHOOTING
E214
Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid) User Code
Error Code
Failure Code
—
E214
DWJ0KA
Failure content
Failure phenomenon
Disconnection in merge/divide solenoid (Pump controller system)
• No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• In L mode, speeds of the work equipment and swing in its single operation are too fast. (F•R pumps cannot be disconnected.)
Relative information
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E204].) Cause
Presumed cause and standard value in normalcy
Merge/divide solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3), (13), (23) and V03 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (17) and (3), (13), (23)
20 – 60 z
Electrical Circuit Diagram for Merge/Divide Solenoid
20-332 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E215
Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid) User Code
Error Code
Failure Code
—
E215
DWK0KA
Failure content
Failure phenomenon
Disconnection in 2-stage relief solenoid (Pump controller system)
• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.)
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E205].) Cause
Presumed cause and standard value in normalcy
2-stage relief solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to V08 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3), (13), (23) and V08 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (28) to V08 (female) (1) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (28) and (3), (13), (23)
20 – 60 z
Electrical Circuit Diagram for 2-stage Relief Solenoid
PC400/450(LC)-7
20-333 (1)
TROUBLESHOOTING
E216
Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid) User Code
Error Code
Failure Code
—
E216
DW43KA
Failure content
Failure phenomenon
Disconnection in travel speed shifting solenoid (Pump controller system)
• No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The travel speed does not shift to Hi. (The travel motor swash plate angle does not turn to minimum.)
Relative information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No.: 02300 Solenoid 1) • The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E206].) Cause
Presumed cause and standard value in normalcy
Travel speed shifting 1 solenoid defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)
Resistance value
Between (1) and (2)
20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3), (13), (23) and V04 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (27) and grounding (3), (13), (23)
20 – 60 z
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
20-334 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E217
Error Code in Electrical System [E217] (Abnormal input model code) User Code
Error Code
Failure Code
—
E217
DA2SKQ
Failure content
Failure phenomenon
Abnormality in inputting model code (Pump controller system)
• A model code signal for a model which is not registered in the controller is inputted.
• The controller controls the machine as a default model (PC750). Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• Since the controller controls the machine as PC750/800, the working speed changes and operation becomes difficult.
Relative information
• The model name (number) recognized by the controller can be checked in the monitoring function. (Code No. 00200: Controller model code) • Input of the model selection signal (ON or OFF) can be checked in the monitoring function. (Code No. 02201: Switch input 2) Cause
Model selection connector defective 1 (Internal disconnection or short-circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C09 (female)
Resistance value
Between (4), (5), (6) and (8)
Min. 1 Mz
Between (1), (2), (3), (7) and (8)
Max. 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between C02 (female) (37) and C09 (male) (1)
Resistance value
Max, 1 z
Wiring harness between C02 (female) (27) and C09 (male) (2)
Resistance value
Max, 1 z
Wiring harness between C02 (female) (17) and C09 (male) (3)
Resistance value
Max, 1 z
Wiring harness between C02 (female) (13) and C09 (male) (7)
Resistance value
Max, 1 z
Wiring harness between C09 (male) (8), J05, and grounding
Resistance value
Max, 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (7) and C09 (male) (4) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Pump controller defective
20-336 (1)
C02
Voltage
Between (7) and grounding
5 – 30 V
Between (37), (27), (17), (13) and grounding
Max. 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E217
Electrical circuit diagram related to model selection connector (for pump controller)
PC400/450(LC)-7
20-337 (1)
TROUBLESHOOTING
E218
Error Code in Electrical System [E218] (S-Net Comm. Disc.) User Code
Error Code
Failure Code
E0E
E218
DA2SKA
Failure content
Failure phenomenon
S-Net Comm. Disc. (Pump controller system)
• The pump controller detected communication failure in the S-NET communication circuit to the monitor panel or engine controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Presumed cause and standard value in normalcy
Grounding fault of wiring harness 2 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
4 Monitor panel defective
5
Engine controller defective
6 Pump controller defective
20-338 (1)
Standard value in normalcy and references for troubleshooting
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CB2
Voltage
Between (21), (31) and (11)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02
Voltage
Between (21) and (31)
6–9V
PC400/450(LC)-7
TROUBLESHOOTING
E218
Electrical Circuit Diagram for S-NET Communication
PC400/450(LC)-7
20-339 (1)
TROUBLESHOOTING
E222
Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid) User Code
Error Code
Failure Code
—
E222
DXE0KB
Failure content
Failure phenomenon
Disconnection in LS-EPC solenoid (Pump controller system)
• Abnormal current flew to the LS-EPC solenoid circuit.
• The controller reduces the output to the LS-EPC solenoid circuit to 0. Response from • Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting controller switch is once turned OFF. Phenomenon occurring on machine
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too fast. (The LS valve set pressure cannot be controlled.)
Relative information
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01500 LS-EPC solenoid current)
Presumed cause and standard value in normalcy
Cause LS-EPC solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V22 (male)
Resistance value
Between (1) and (2)
7 – 14 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (6) and V22 (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3
Pump controller defective
C03 (female)
Resistance value
Between (6) and (3) (13) (23)
7 – 14 z
Between (6) and grounding
Above 1 Mz
Electrical Circuit Diagram for LS-EPC Solenoid
20-340 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E223
Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system) User Code
Error Code
Failure Code
—
E223
DXE0KA
Failure content
Failure phenomenon
Disconnection in LS-EPC solenoid (Pump controller system)
• No current flows to the LS-EPC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too fast. (The LS valve set pressure cannot be controlled.)
Relative information
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01500 LS-EPC solenoid current) Cause
Presumed cause and standard value in normalcy
LS-EPC solenoid 1 defective (Internal short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4 Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V22 (male)
Resistance value
Between (1) and (2)
7 – 14 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (6) and V22 (female) (1) and grounding
Resistance value
Below 1 z
Wiring harness between C03 (female) (3) (13) (23) and V22 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (6) and V22 (female) (1) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (6) and (3) (13) (23)
7 – 14 z
Electrical Circuit Diagram for LS-EPC Solenoid
PC400/450(LC)-7
20-341 (1)
TROUBLESHOOTING
E224
Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality) User Code
Error Code
Failure Code
—
E224
DHPAMA
Failure content
Failure phenomenon
F Pump P. Sensor Abnormality (Pump controller system)
• Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the F pump pressure to 0 MP {0 kg/cm2} for control. • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine
• The travel speed does not shift automatically (The travel load pressure cannot be detected).
Relative information
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the front pump pressure sensor (pressure) can be checked in the monitoring function. (Code No. 01100: Front pump pressure) Cause
1
Sensor power supply system defective
Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Front pump pressure 2 sensor defective (Internal defect)
A51
Voltage
Between (B) and (A)
Power supply
4.5 – 5.5 V
Between (C) and (A)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C01 (female) (22) and A51 (female) (B)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10) and A51 (female) (A)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (8) and P30 (female) (C)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (8) and A51 (female) (C) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness A51 (female) (B) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (8) and A51 (female) (C) and grounding
Voltage
Max. 1 V
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective
20-342 (1)
C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
Between (8) and (10)
0.5 – 4.5 V
PC400/450(LC)-7
TROUBLESHOOTING
E224
Electrical circuit diagram related to front pump pressure sensor
PC400/450(LC)-7
20-343 (1)
TROUBLESHOOTING
E225
Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality) User Code
Error Code
Failure Code
—
E225
DHPBMA
Failure content
Failure phenomenon
R Pump P. Sensor Abnormality (Pump controller system)
• Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the R pump pressure to 0 MP {0 kg/cm2} for control. • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine
• The travel speed does not shift automatically (The travel load pressure cannot be detected).
Relative information
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function. (Code No. 01101: Rear pump pressure) Cause
1
Sensor power supply system defective
Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Rear pump pressure 2 sensor defective (Internal defect)
A52
Voltage
Between (B) and (A)
Power supply
4.5 – 5.5 V
Between (C) and (A)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C01 (female) (22) and A52 (female) (B)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10) and A52 (female) (A)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (2) and A52 (female) (C)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness A52 (female) (B) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding
Voltage
Max. 1 V
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective
20-344 (1)
C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
Between (2) and (10)
0.5 – 4.5 V
PC400/450(LC)-7
TROUBLESHOOTING
E225
Electrical circuit diagram related to rear pump pressure sensor
PC400/450(LC)-7
20-345 (1)
TROUBLESHOOTING
E226
Error Code in Electrical System [E226] (Press. Sensor Power Abnormality) User Code
Error Code
Failure Code
—
E226
DA25KP
Failure content
Failure phenomenon
Press. Sensor Power Abnormality (Pump controller system)
• Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
• Power to the power supply (5 V) circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The pressure sensor signal is not input normally. • The error code of abnormality in the pressure sensor is displayed, too.
Relative information Cause
Standard value in normalcy and references for troubleshooting a Disconnect the connector when the engine starting switch is in OFF, and hold it in the ON position during the troubleshooting.
Presumed cause and standard value in normalcy
Pressure sensor 1 defective (Internal short-circuiting)
Connector A51
Rear pump pressure sensor
Connector A52
Arm IN PPC pressure sensor
Connector S04
Bucket CURL PPC pressure sensor
Connector S01
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 2 (Contact with grounding circuit)
3 Pump controller defective
20-346 (1)
Disconnect the parts shown at right in order. If the error code goes off when one of those parts is disconnected, that part is defective.
Front pump pressure sensor
Between wiring harness between C01 (female) (22), A51 (female) (B) and grounding [Front pump pressure sensor system]
Resistance value
Min. 1 Mz
Between wiring harness between C01 (female) (22), A51 (female) (B) and grounding [Rear pump pressure sensor system]
Resistance value
Min. 1 Mz
Between wiring harness between C01 (female) (22), S04 (female) (A) and grounding [Arm IN PPC pressure sensor system]
Resistance value
Min. 1 Mz
Between wiring harness between C01 (female) (22), S01 (female) (A) and grounding [Bucket CURL PPC pressure sensor system]
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
PC400/450(LC)-7
TROUBLESHOOTING
E226
Electrical circuit diagram related to pressure sensor power supply
PC400/450(LC)-7
20-347 (1)
TROUBLESHOOTING
E227
Error Code in Electrical System [E227] (Abnormality in engine rotation sensor) User Code
Error Code
Failure Code
—
E227
DLE2MA
Failure content
Failure phenomenon
Abnormality in engine rotation sensor (Pump controller system)
• A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from • The controller exercises a control equivalent to E mode. controller • If the failure cause disappears of itself, the signal input returns to normalcy. Phenomenon occurring on machine
• The machine lacks power a bit. (The engine rotation sensing does not work.) • The engine speed (in the pump controller system) is not monitored on the monitor panel.
Relative information
• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No.: 01006 Engine RPM) Cause
Presumed cause and standard value in normalcy
Engine rotation sensor fault 1 (Internal short-circuiting or disconnection) 2
Engine rotation sensor adjustment improper
Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. ENE (male)
Resistance value
Between (1) and (2)
500 – 1,000 z
Between (1) and grounding
Above 1 Mz
For the inspection and adjustment, refer to the section of “Adjusting Engine Rotation Sensor” in this manual. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (40) and ENE (female) (1)
Resistance value
Below 1 z
Wiring harness between C02 (female) (29) (39) and ENE (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (40) and ENE (female) (1) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
Pump controller defective
C02 (female)
Resistance value
Between (40) and (29) (39)
500 – 1,000 z
Between (40) and grounding
Above 1 Mz
Electrical Circuit Diagram for Engine Rotation Sensor
20-348 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E228
Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay) User Code
Error Code
Failure Code
—
E228
D196KB
Failure content
Failure phenomenon
Short-circuiting in attachment return switching relay (Pump controller system)
• Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit. controller • Even when the failure cause disappears of itself, the current does not return to normalcy. Phenomenon occurring on machine
• The hydraulic circuit for attachments is not switched to the single operation circuit. (The switching valve is not switched to the tank circuit.)
Relative information
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No.: 02301 Solenoid 2) • This error code detects abnormality on the primary side (coil side) of the attachment return selector relay and cannot detect abnormality on the secondary side (contact side).
Presumed cause and standard value in normalcy
Cause Attachment return 1 switching relay defective (Internal short-circuiting) Short-circuiting of wiring harness 2 (Contact with 24 V circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male)
Resistance value
Between (1) and (2)
100 – 500 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (8) and R20 (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3
Pump controller defective
C02
Working mode
Voltage
Between (8) and grounding
Other than B mode
20 – 30 V
B mode
Below 1 V
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400/450(LC)-7
20-349 (1)
TROUBLESHOOTING
E232
Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid) User Code
Error Code
Failure Code
E02
E232
DXA0KB
Failure content
Failure phenomenon
Disconnection in PC-EPC solenoid (Pump controller system)
• Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to OFF. Response from • Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting controller switch is once turned OFF. Phenomenon occurring on machine
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled.)
Relative information
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01300 PC-EPC solenoid current) • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated in a working mode equivalent to E mode by turning the emergency pump drive switch to the emergency position. (At that time the monitor panel continues to display Error Code No. [E233], but this is not abnormal) • Turn the emergency driving switch normal position during the troubleshooting. Cause
PC-EPC solenoid defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male)
Resistance value
Between (1) and (2)
7 – 14 z
Between (1) and grounding
Above 1 Mz
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Emergency pump driving switch defective 2 (Internal short-circuiting or grounding fault)
S25 (male)
Emergency pump drive switch
Between (3) and (4) Between (3) and grounding
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Resistance value Above 1 Mz
Normal
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (16) to S25 (female) (3) and grounding
Resistance value
Above 1 Mz
Between wiring harness from S25 (female) (2) to V21 (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-350 (1)
Pump controller defective
C03 (female)
Resistance value
Between (16) and (3) (13) (23)
7 – 14 z
Between (16) and grounding
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
E232
Electrical Circuit Diagram for PC-EPC Solenoid
PC400/450(LC)-7
20-351 (1)
TROUBLESHOOTING
E233
Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system) User Code
Error Code
Failure Code
E02
E233
DXA0KA
Failure content
Failure phenomenon
Disconnection in PC-EPC solenoid (Pump controller system)
• No current flows to the PC-EPC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it) controller • When the failure cause disappears of itself, the current returns to normalcy. Phenomenon occurring on machine
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled.)
Relative information
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No.: 01300 PC-EPC solenoid current) • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated in a working mode equivalent to E mode by turning the emergency pump driving switch to the emergency position. Cause
PC-EPC solenoid 1 defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male)
Resistance value
Between (1) and (2)
7 – 14 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Emergency pump driving 2 switch defective (Internal disconnection)
Emergency pump driving switch
Resistance value
Normal
Below 1 z
Emergency
Above 1 Mz
Normal
Below 1 z
Emergency
Above 1 Mz
Between (2) and (3) Between (5) and (6)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
5
20-352 (1)
S25 (male)
Pump controller defective
Wiring harness between C03 (female) (16) and S25 (female) (3)
Resistance value
Below 1 z
Wiring harness between S25 (female) (2) and V21 (female) (1)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3) (13) (23) and S25 (female) (6)
Resistance value
Below 1 z
Wiring harness between S25 (female) (5) and V21 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (16) and S25 (female) (3) and grounding
Voltage
Below 1 V
Between wiring harness between S25 (female) (2) and V21 (female) (1) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (16) and (3) (13) (23)
7 – 14 z
PC400/450(LC)-7
TROUBLESHOOTING
E233
Electrical Circuit Diagram for PC-EPC Solenoid
PC400/450(LC)-7
20-353 (1)
TROUBLESHOOTING
E238
Error Code in Electrical System [E238] (Disconnection in attachment return switching relay) User Code
Error Code
Failure Code
—
E238
D196KA
Failure content
Failure phenomenon
Disconnection in attachment return switching relay (Pump controller system)
• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V voltage is not generated.
Response from • None in particular controller • If the failure cause disappears, the governor returns to normalcy. Phenomenon occurring on machine
• The hydraulic circuit for attachments cannot be switched to the single operation. (The switching valve cannot be switched to the tank circuit.)
Relative information
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No.: 02301 Solenoid 2) • This error code detects abnormality on the primary side (coil side) of the attachment return selector relay and cannot detect abnormality on the secondary side (contact side). Cause
1 Fuse No. 2 fault
Presumed cause and standard value in normalcy
Attachment return 2 switching relay defective (Internal disconnection)
Disconnection in wiring harness (Disconnection 3 in wiring or defective contact in connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting If fuse No.2 has been blown, there is a big possibility that grounding fault occurred in the relay circuit. (See Cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male)
Resistance value
Between (1) and (2)
100 – 500 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (8) and R20 (female) (2)
Resistance value
Below 1 z
Wiring harness from R20 (female) (1) to J03 to FB1-2 outlet
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (8) and R20 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness from R20 (female) (1) to J03 to FB1-2 outlet and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
20-354 (1)
Pump controller defective
C02
Working mode
Voltage
Between (8) and grounding
Other than B mode
20 – 30 V
B mode
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E238
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400/450(LC)-7
20-355 (1)
TROUBLESHOOTING
E245
Error Code in Electrical System [E245] (Short-circuiting in attachment oil flow rate adjusting EPC) User Code
Error Code
Failure Code
—
E245
DXE4KB
Failure content
Failure phenomenon
Short-circuiting in attachment oil flow rate adjusting EPC (Pump controller system)
• Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF. Response from • Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless controller the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
Relative information
• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)
Presumed cause and standard value in normalcy
Cause Attachment oil flow rate adjusting EPC defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V30 (male)
Resistance value
Between (1) and (2)
7 – 14 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3
Pump controller defective
C03 (female)
Resistance value
Between (26) and (3) (13) (23)
7 – 14 z
Between (26) and grounding
Above 1 Mz
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
20-356 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E246
Error Code in Electrical System [E246] (Disconnection in attachment oil flow rate adjusting EPC) User Code
Error Code
Failure Code
—
E246
DXE4KA
Failure content
Failure phenomenon
Disconnection in attachment oil flow rate adjusting EPC (Pump controller system)
• No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it) controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself. Phenomenon occurring on machine
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
Relative information
• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current) Cause
Presumed cause and standard value in normalcy
Attachment oil flow rate adjusting EPC defective 1 (Internal short-circuiting or grounding fault) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V30 (male)
Resistance value
Between (1) and (2)
7 – 14 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (male) (1) and grounding
Resistance value
Below 1 z
Between wiring harness between C03 (female) (3) (13) (23) and V30 (male) (2) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (female) (1) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (26) and (3) (13) (23)
7 – 14 z
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400/450(LC)-7
20-357 (1)
TROUBLESHOOTING
E247
Error Code in Electrical System [E247] (Arm IN PPC pressure sensor abnormality) User Code
Error Code
Failure Code
—
E247
DHS3MA
Failure content
Failure phenomenon
Arm IN PPC pressure sensor abnormality (Pump controller system)
• Signal voltage from the arm IN PPC pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the arm IN PPC pressure to 0 MP {0 kg/cm2} for control. • When the failure cause disappears of itself, the machine operation returns to normalcy. controller Phenomenon occurring on machine
• If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The arm IN PPC circuit pressure cannot be detected).
Relative information
a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function. (Code No. 07200: Arm IN PPC pressure) Cause
Sensor power supply 1 system defective
Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Arm IN PPC pressure 2 sensor defective (Internal defect)
S04
Voltage
Between (A) and (C)
Power supply
4.5 – 5.5 V
Between (B) and (C)
Signal
0.5 – 4.5 V
The pressure voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C01 (female) (22) and S04 (female) (A)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10) and S04 (female) (C)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (19) and S04 (female) (E)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (19) and S04 (female) (E) and grounding
Resistance value
Min. 1 M z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness S04 (female) (A) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (19) and S04 (female) (B) and grounding
Voltage
Max. 1 V
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective
20-358 (1)
C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
Between (19) and (10)
0.5 – 4.5 V
PC400/450(LC)-7
TROUBLESHOOTING
E247
Circuit diagram related to arm IN PPC pressure sensor
PC400/450(LC)-7
20-359 (1)
TROUBLESHOOTING
E248
Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality) User Code
Error Code
Failure Code
—
E248
DHS4MA
Failure content
Failure phenomenon
Bucket CURL PPC pressure sensor abnormality (Pump controller system)
• Signal voltage from the bucket CURL PPC pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the bucket CURL PPC pressure to 0 MP {0 kg/cm2} for control. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• If auto deceleration is operated, when auto deceleration cannot be released when moving the bucket CURL (The bucket CURL PPC circuit pressure cannot be detected).
Relative information
a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function. (Code No. 07300: Bucket CURL PPC pressure) Cause
1
Sensor power supply system defective
Standard value in normalcy and references for troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Bucket CURL PPC pres2 sure sensor defective (Internal defect)
S04
Voltage
Between (1) and (3)
Power supply
4.5 – 5.5 V
Between (2) and (3)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C01 (female) (22) and S04 (female) (1)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10) and S04 (female) (3)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (13) and S04 (female) (2)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (13) and S04 (female) (2) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between C01 (female) (22) and 5 harness S04 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between C01 (female) (13) and S04 (female) (2) and grounding
Voltage
Max. 1 V
Voltage
Max. 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 6 Pump controller defective
20-360 (1)
C01
Voltage
Between (22) and (10)
4.5 – 5.5 V
Between (13) and (10)
0.5 – 4.5 V
PC400/450(LC)-7
TROUBLESHOOTING
E248
Circuit diagram related to bucket CURL PPC pressure sensor
PC400/450(LC)-7
20-361 (1)
TROUBLESHOOTING
E257
Error Code in Electrical System [E257] (Pump Abnormality) User Code
Error Code
Failure Code
E0E
E257
DA2RMC
Failure content
Failure phenomenon
Pump Abnormality (Pump controller system)
• The pump controller detected communication failure in the CAN communication circuit to the monitor panel or engine controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22)
Resistance value
Below 1 z
Wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32)
Resistance value
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit)
4
CAN terminal resistor defective
Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Voltage
Below 1 V
Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male)
Resistance value
Between (1) and (2)
40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller 5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be carpump controller defective ried out.)
20-362 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E257
Electrical circuit diagram related to CAN communication
PC400/450(LC)-7
20-363 (1)
TROUBLESHOOTING
E315
Error Code in Electrical System [E315] (Battery Relay Drive S/C) User Code
Error Code
Failure Code
—
E315
D110KB
Failure content
Failure phenomenon
Battery Relay Drive S/C (Pump controller system)
• When a signal is output to the battery relay drive circuit, abnormal current flowed.
Response from • The controller turns OFF the output to the battery relay drive circuit. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
Relative information
• Operation of the battery relay (ON or OFF) can be checked in the monitoring function. (Code No. 03700: Controller output 1)
Presumed cause and standard value in normalcy
Cause Battery relay defective 1 (Internal short-circuiting or grounding fault)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
3
20-364 (1)
Pump controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Battery relay (Unit)
Resistance value
Between BR and E
Approx. 100 z
Between BR and grounding
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (4), D01, J01, battery relay terminal BR or between C03 (female) (4) and starting switch terminal B or between C03 (female) (4) and D01 (female) (2) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C03 (female)
Starting switch
Voltage
Between (4) and grounding
ON o OFF
20 – 30 V (For 0.5 sec)
PC400/450(LC)-7
TROUBLESHOOTING
E315
Electrical circuit diagram related to battery relay drive
PC400/450(LC)-7
20-365 (1)
TROUBLESHOOTING
E91B
Error Code in Electrical System [E91B] (Engine Ne sensor problem) User Code
Error Code
Failure Code
E11
E91B
DLE3LC
Failure content
Failure phenomenon
Engine Ne sensor problem (Engine controller system)
• Cranking angle cannot be judged from the engine Ne speed sensor signal.
Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function. (Code No. 01002: Engine speed) • Special adapter (799-601-9410) is necessary for troubleshooting for the engine Ne speed sensor. Cause
Presumed cause and standard value in normalcy
Engine Ne speed sensor defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. NE (male)
Resistance value
Between (1) and (2)
85 – 210 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (36) and NE (female) (2)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (26) and NE (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (36) and NE (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB2 (female) (26) and NE (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
CB2 (female)
Resistance value
Between (36) and (26)
85 – 210 z
Between (36), (26) and grounding
Above 1 Mz
Electrical circuit diagram related to engine Ne speed sensor
20-366 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E91C
Error Code in Electrical System [E91C] (Engine G sensor problem) User Code
Error Code
Failure Code
E11
E91C
DLH1LC
Failure content
Failure phenomenon
Engine G sensor problem (Engine controller system)
• Cylinder cannot be judged from the engine G speed sensor signal.
• The machine is driven with limited output. Response from • Control is carried out with the Ne speed sensor signal. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor. Cause
Presumed cause and standard value in normalcy
Engine G speed sensor defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. G (male)
Resistance value
Between (1) and (2)
1.4 k – 3.5 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (35) and G (female) (2)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (25) and G (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (35) and G (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB2 (female) (25) and G (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
E12 (female)
Resistance value
Between (35) and (25)
1.4 k – 3.5 kz
Between (35), (25) and grounding
Above 1 Mz
Electrical circuit diagram related to engine G speed sensor
PC400/450(LC)-7
20-367 (1)
TROUBLESHOOTING
E920
Error Code in Electrical System [E920] (Engine type selection error) User Code
Error Code
Failure Code
E11
E920
DB29KQ
Failure content
Failure phenomenon
Engine type selection error (Engine controller system)
• The model selection signal directly taken by the engine controller does not conform to the model in the controller or it is not confirmed.
• Control is carried out with the default model (PC400). Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• The model name (figure) recognized by the controller can be checked in the monitoring function. (Code No. 00201: Controller model code) • Input of the model selection signal (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input state) Cause
Presumed cause and standard value in normalcy
Model selection connector defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB5 (female)
Resistance value
Between (2), (3) (4), (5), (6), (7), and (8)
Above 1 Mz
Between (1) and (8)
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB1 (female) (3) and CB5 (male) (1)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (1) and CB5 (male) (8)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB1 (female) (23) and CB5 (male) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB1 (female) (17) and CB5 (male) (3) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
20-368 (1)
Engine controller defective
CB1, CB2
Voltage
Between CB1 (23), (17) and CB2 (1)
20 – 30 V
Between CB1 (3) and CB2 (1)
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E920
Electrical circuit diagram related to model selection connector (for engine controller)
PC400/450(LC)-7
20-369 (1)
TROUBLESHOOTING
E921
Error Code in Electrical System [E921] (Engine type mismatch) User Code
Error Code
Failure Code
E11
E921
DB20KQ
Failure content
Failure phenomenon
Engine type mismatch (Engine controller system)
• The model information taken by the engine controller through the model selection connector does not conform to the model information taken from the pump controller by communication.
• The normal operation is continued. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• The model name (figure) recognized by the engine controller can be checked in the monitoring function. (Code No. 00201: Controller model code) • The model name (figure) recognized by the pump controller can be checked in the monitoring function. (Code No. 00200: Controller model code)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause 1
Model selection connector system defective
If error code [E920] is displayed, carry out troubleshooting for it.
2
Engine controller defective
Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)
3 Pump controller defective
20-370 (1)
Standard value in normalcy and references for troubleshooting
Pump controller may be defective. (Since trouble is in the controller, troubleshooting cannot be carried out.)
PC400/450(LC)-7
TROUBLESHOOTING
E931
Error Code in Electrical System [E931] (Fuel dial sys. error) User Code
Error Code
Failure Code
E14
E931
DK10KX
Failure content
Failure phenomenon
Fuel dial sys. error (Engine controller system)
• The signal voltage from the fuel control dial is below 0.3 V or above 4.5 V.
• If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or 100% after the engine is started. Response from • If the abnormality is detected while the engine is running, the fuel control dial signal just before the controller abnormality is detected is kept. • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine speed cannot be controlled.
Relative information
• Input from the fuel control dial (voltage) can be checked in the monitoring function. (Code No. 03000: Fuel control dial voltage) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Fuel control dial defective 1 (Internal disconnection or short-circuiting)
E06 (male)
Resistance value
Between (1) and (3)
4.0 – 6.0 kz
Between (1) and (2)
0.25 – 7.0 kz
Between (3) and (2)
0.25 – 7.0 kz
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between CB2 (female) (19) and E06 (female) (1)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (10) and E06 (female) (2)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (29), (39), and E06 (female) (3)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (19) and E06 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB2 (female) (10) and E06 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between CB2 (female) (19) and 4 harness E06 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between CB2 (female) (10) and E06 (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5
20-372 (1)
Engine controller defective
CB2
Voltage
Between (19) and (29), (39)
4.6 – 5.4 V
Between (10) and (29), (39)
0.3 – 4.5 V
PC400/450(LC)-7
TROUBLESHOOTING
E931
Electrical circuit diagram related to fuel control dial
PC400/450(LC)-7
20-373 (1)
TROUBLESHOOTING
E934
Error Code in Electrical System [E934] (Engine coolant sensor Hi error) User Code
Error Code
Failure Code
E15
E934
DGE2KX
Failure content
Failure phenomenon
Engine coolant sensor Hi error (Engine controller system)
• The signal voltage from the engine water high temperature sensor is below 0.5 V or above 4.5 V.
Response from • The signal of the engine water high temperature sensor is kept at 90°C. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the engine water high temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No. 04106: Engine water temperature sensor Hi, 04102: Engine water temperature (High temperature)) Cause
Presumed cause and standard value in normalcy
Engine water high temperature sensor 1 defective (Internal disconnection or short circuit) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. TWH (male)
Resistance value
Between (1) and (2)
3.5 k – 90 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (27) and TWH (female) (1)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (29), (39), and TWH (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (27) and TWH (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-374 (1)
Engine controller defective
CB2
Resistance value
Between (27), (29) and (39)
3.5 k – 90 kz
Between (27), (29), (39) and grounding
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
E934
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC400/450(LC)-7
20-375 (1)
TROUBLESHOOTING
E936
Error Code in Electrical System [E936] (Engine oil press. sw. error) User Code
Error Code
Failure Code
E15
E936
DDE2L6
Failure content
Failure phenomenon
Engine oil press. sw. error (Engine controller system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the high-pressure switch is opened (disconnected from grounding) while the engine is running. • The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine is stopped (the starting signal is OFF). • The signal circuit of the high-pressure switch is opened (disconnected from grounding) while the engine is stopped (the starting signal is OFF).
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input) Cause
Engine low-oil pressure switch defective 1 (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Engine high-oil pressure switch defective 2 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position and start the engine during the troubleshooting. PSL
Engine
Resistance value
Between terminal and grounding
Stopped
Below 1 z
Low idling
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position and start the engine during the troubleshooting. PSH Between terminal and grounding
Engine
Resistance value
Stopped
Below 1 z
Running at 1,300 rpm or higher
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB1 (female) (21) and PSL
Resistance value
Below 1 z
Wiring harness between CB1 (female) (15) and PSH
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB1 (female) (21) and PSL and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB1 (female) (15) and PSH and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position and start the engine during the troubleshooting.
5
Engine controller defective
CB1
Engine
Voltage
Between (21) and grounding (Low-pressure switch signal)
Stopped
Below 1 V
Low idling
20 – 30 V
Stopped
Below 1 V
Running at 1,300 rpm or higher
20 – 30 V
Between (15) and grounding (High-pressure switch signal)
Carry out troubleshooting while the engine is running 15 seconds after the engine is started.
20-376 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E936
Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)
PC400/450(LC)-7
20-377 (1)
TROUBLESHOOTING
E93C
Error Code in Electrical System [E93C] (Engine boost sensor error) User Code
Error Code
Failure Code
E11
E93C
DH30KX
Failure content
Failure phenomenon
Engine boost sensor error (Engine controller system)
• The signal voltage from the boost pressure sensor is below 0.3 V or above 4.7 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36501: Boost pressure sensor voltage, 36500: Boost pressure) • Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor. Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Boost pressure sensor 1 defective (Internal defect)
PIM
Voltage
Between (3) and (1)
Power supply
4.6 – 5.4 V
Between (2) and (1)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between CB2 (female) (9) and PIM (female) (3)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (29), (39), and PIM (female) (1)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (20) and PIM (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (9) and PIM (female) (3), or between CB2 (female) (9) and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB2 (female) (20) and PIM (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring Between wiring harness between CB2 (female) (9), and PIM (female) (3), or between CB2 (female) (9) and 4 harness (Contact with 24 V circuit) related circuits and grounding
Voltage
Below 1 V
Between wiring harness between CB2 (female) (20) and PIM (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5
20-378 (1)
Engine controller defective
CB2
Voltage
Between (9) and (29), (39)
4.6 – 5.4 V
Between (20) and (29), (39)
0.3 – 4.7 V
PC400/450(LC)-7
TROUBLESHOOTING
E93C
Electrical circuit diagram related to boost pressure sensor
PC400/450(LC)-7
20-379 (1)
TROUBLESHOOTING
E93D
Error Code in Electrical System [E93D] (Engine fuel temp. sensor error) User Code
Error Code
Failure Code
E15
E93D
DGE4KX
Failure content
Failure phenomenon
Engine fuel temp. sensor error (Engine controller system)
• The signal voltage from the fuel temperature sensor is above 4.5 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the fuel temperature sensor (voltage) can be checked in the monitoring function. (Code No. 14201: Fuel temperature sensor voltage) Cause
Presumed cause and standard value in normalcy
Fuel temperature sensor defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. THL (male)
Resistance value
Between (1) and (2)
0.3 k – 9 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between E12 (female) (17) and THL (female) (1)
Resistance value
Below 1 z
Wiring harness between E12 (female) (29), (39) and THL (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (17) and THL (female) (A) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-380 (1)
Engine controller defective
CB2
Resistance value
Between (17), (29) and (39)
0.3 k – 9 kz
Between (17) and (29), (39) and grounding
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
E93D
Electrical circuit diagram related to fuel temperature sensor
PC400/450(LC)-7
20-381 (1)
TROUBLESHOOTING
E953
Error Code in Electrical System [E953] (Engine Comm. Abnormality) User Code
Error Code
Failure Code
E0E
E953
DB2RMC
Failure content
Failure phenomenon
Engine Comm. Abnormality (Engine controller system)
• The engine controller detected communication failure in the CAN communication circuit to the monitor panel or pump controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22)
Resistance value
Below 1 z
Wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32)
Resistance value
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring 3 harness (Contact with 24 V circuit)
4
CAN terminal resistor defective
Between wiring harness between P70 (female) (16) and CB2 (female) (22) or between P70 (female) (16) and C02 (female) (22) or between P70 (female) (16) and related circuits and grounding
Voltage
Below 1 V
Between wiring harness between P70 (female) (15) and CB2 (female) (32) or between P70 (female) (15) and C02 (female) (32) or between P70 (female) (15) and related circuits and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. K30 (male), K31 (male)
Resistance value
Between (1) and (2)
40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller 5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be carpump controller defective ried out.)
20-382 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E953
Electrical circuit diagram related to CAN communication
PC400/450(LC)-7
20-383 (1)
TROUBLESHOOTING
E954
Error Code in Electrical System [E954] (Short engine starter sw.) User Code
Error Code
Failure Code
—
E954
DD11KB
Failure content
Failure phenomenon
Short engine starter sw. (Engine controller system)
• Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Response from • Starting switch signal is recognized to be OFF. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The machine operates normally.
Relative information
• Input of starting switch signal C (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting.
Presumed cause and standard value in normalcy
1
Starting switch Between terminal B and terminal C
Resistance value OFF
Above 1 Mz
START
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between starting switch termiShort-circuiting of wiring nal C, J01, and CB1 (female) (20) or between starting 2 harness switch terminal C and C01 (female) (17) or between (Contact with 24 V circuit) starting switch terminal C and P01 (female) (4) or between starting switch terminal C and R11 (female) (5), or between starting switch terminal C or related circuits and grounding
4
20-384 (1)
Starting switch defective (Internal short-circuiting)
Engine controller defective
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. CB1
Starting switch
Voltage
Between (20) and grounding
ON (Engine is running)
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E954
Electrical circuit diagram related to engine preheating, starting, charging
PC400/450(LC)-7
20-385 (1)
TROUBLESHOOTING
E955
Error Code in Electrical System [E955] (Engine S-NET error) User Code
Error Code
Failure Code
E0E
E955
DB2SMC
Failure content
Failure phenomenon
Engine S-NET error (Engine controller system)
• The engine controller detected communication failure in the S-NET communication circuit to the monitor panel or pump controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The pump absorption torque is reduced). • If the working load increases, the engine may stall.
Relative information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function. (Code No. 05100: Connection of S-NET) Cause
Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Presumed cause and standard value in normalcy
Grounding fault of wiring harness 2 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (9), (10) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between P02 (female) (9), (10) 3 harness (Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) (9), (10) and C02 (female) (21) or between P02 (female) (9), (10) and related circuits and grounding
4 Monitor panel defective
5
Engine controller defective
6 Pump controller defective
20-386 (1)
Standard value in normalcy and references for troubleshooting
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Voltage
Between (9), (10) and (20)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. CB2
Voltage
Between (21), (31) and (11)
6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02
Voltage
Between (21) and (31)
6–9V
PC400/450(LC)-7
TROUBLESHOOTING
E955
Electrical circuit diagram related to S-NET communication
PC400/450(LC)-7
20-387 (1)
TROUBLESHOOTING
E956
Error Code in Electrical System [E956] (Engine power failure (1)) User Code
Error Code
Failure Code
E10
E956
DB22KK
Failure content
Failure phenomenon
Engine power failure (1) (Engine controller system)
• When the starting switch is turned ON, the source voltage of the controller is below 10 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine stalls. • The engine cannot be started.
Relative information Cause Circuit breaker 7 1 defective
Standard value in normalcy and references for troubleshooting If circuit breaker is turned OFF, the circuit probably has grounding fault, etc. (See cause 4.)
Engine controller power a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. supply relay defective 2 (Internal disconnection or Replace the power supply relay with another one. If the condition R22 short-circuiting) becomes normal, the relay is defective.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Wiring harness between CB3 (female) (1), (2), (21) and R22 (female) (5)
Resistance value
Below 1 z
Wiring harness between R22 (female) (3) and B27
Resistance value
Below 1 z
Wiring harness between B17 and battery relay B terminal
Resistance value
Below 1 z
Wiring harness between R22 (female) (1) and J02 (male) (1)
Resistance value
Below 1 z
Wiring harness between R22 (female) (2) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit)
Between wiring harness between CB3 (female) (1), (2), (21) and R22 (female) (5) and grounding
Resistance value
Above 1 Mz
Between wiring harness between R22 (female) (3) and B27
Resistance value
Above 1 Mz
Between wiring harness between R22 (female) (1) and J02 (male) (1) or between R22 (female) (1) and related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting. 5
20-388 (1)
Engine controller defective
E13
Starting switch
Voltage
Between (1), (2), (21) and (11), (31), (32)
OFF
Below 1 V
ON
20 – 30 V
PC400/450(LC)-7
TROUBLESHOOTING
E956
Electrical circuit diagram related to engine controller power supply
PC400/450(LC)-7
20-389 (1)
TROUBLESHOOTING
E957
Error Code in Electrical System [E957] (Engine power failure (2)) User Code
Error Code
Failure Code
E15
E957
D1D0KB
Failure content
Failure phenomenon
Engine power failure (2) (Engine controller system)
• When the starting switch is turned OFF, the source voltage of the controller is above 10 V.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
Presumed cause and standard value in normalcy
Cause Engine controller power 1 supply relay defective (Internal short-circuiting)
Replace the power supply relay with another one. If the condition becomes normal, the relay is defective.
R22
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between E13 (female) (1), (2), 2 harness (21) and R22 (female) (3) and grounding (Contact with 24 V circuit) Between wiring harness between R22 (female) (1) and J03, J06 (male) (2), or related circuits and grounding
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and ON positions during the troubleshooting. 3
20-390 (1)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Engine controller defective
CB3
Starting switch
Voltage
Between (1), (2), (21) and (11), (31), (32)
OFF
Below 1 V
ON
20 – 30 V
PC400/450(LC)-7
TROUBLESHOOTING
E957
Electrical circuit diagram related to engine controller power supply
PC400/450(LC)-7
20-391 (1)
TROUBLESHOOTING
E95A
Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error) User Code
Error Code
Failure Code
—
E95A
DB2AMA
Failure content
Failure phenomenon
Engine Q-adj. sw. signal error (Engine controller system)
• The fuel injection amount adjustment switch of the controller is not set to the correct position.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. • Setting of the fuel injection amount adjustment switch cannot be changed.
Relative information
• Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring function. (Code No. 36800: Right fuel injection amount adjustment switch, 36801: Left fuel injection amount adjustment switch)
Presumed cause and standard value in normalcy
Phenomenon occurring on machine
Cause Setting of fuel injection amount adjustment 1 switch of engine controller defective
2
20-392 (1)
Engine controller defective
Standard value in normalcy and references for troubleshooting If the fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting is wrong.
If the cause is not detected, engine controller may be defective.
PC400/450(LC)-7
TROUBLESHOOTING
E96A
Error Code in Electrical System [E96A] (Engine coolant sensor Lo error) User Code
Error Code
Failure Code
E15
E96A
DGE3L6
Failure phenomenon
Engine coolant sensor Lo error (Engine controller system)
Failure content
• The signal voltage from the engine water low temperature sensor is above 4.5 V.
Response from controller
• The signal of the engine water low temperature sensor is kept at 20°C (If the signal of the high temperature sensor is effective, it is used as a substitute). • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the engine water low temperature sensor (voltage and water temperature) can be checked in the monitoring function. (Code No. 04105: Engine water temperature sensor voltage Lo, 04107: Engine water temperature (Low temperature)) Cause
Presumed cause and standard value in normalcy
Engine water low temperature sensor 1 defective (Internal disconnection or short circuiting) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. TWL (male)
Resistance value
Between (1) and (2)
0.3 k – 9 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (37) and TWL (female) (1)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (29), (39), and TWL (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between E12 (female) (37) and TWL (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
20-394 (1)
Engine controller defective
E12
Resistance value
Between (29), (37) and (39)
0.3 k – 9 kz
Between (29), (37), (39) and grounding
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
E96A
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC400/450(LC)-7
20-395 (1)
TROUBLESHOOTING
E970
Error Code in Electrical System [E970] (PCV1 over current) User Code
Error Code
Failure Code
E11
E970
AD11KB
Failure content
Failure phenomenon
PCV1 over current (Engine controller system)
• Abnormal current flowed in the fuel supply pump PCV1 circuit.
• Power to the fuel supply pump PCV1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV1 defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV1 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (12) and PCV1 (female) (1)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between CB3 (female) (12) and 3 harness PCV1 (female) (1) (Contact with 24 V circuit) Between wiring harness between CB3 (female) (22) and PCV1 (female) (2)
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
CB3 (female)
Resistance value
Between (12) and (22)
2.3 – 5.3 z
Between (12), (22) and grounding
Above 1 Mz
Electrical circuit diagram related to fuel supply pump PCV1
20-396 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E971
Error Code in Electrical System [E971] (PCV2 over current) User Code
Error Code
Failure Code
E11
E971
AD51KB
Failure content
Failure phenomenon
PCV2 over current (Engine controller system)
• Abnormal current flowed in the fuel supply pump PCV2 circuit.
• Power to the fuel supply pump PCV2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV2 defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV2 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (13) and PCV2 (female) (1)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring Between wiring harness between CB3 (female) (13) and 3 harness PCV2 (female) (1) (Contact with 24 V circuit) Between wiring harness between CB3 (female) (23) and PCV2 (female) (2)
Voltage
Below 1 V
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
CB3 (female)
Resistance value
Between (13) and (23)
2.3 – 5.3 z
Between (13), (23) and grounding
Above 1 Mz
Electrical circuit diagram related to fuel supply pump PCV2
PC400/450(LC)-7
20-397 (1)
TROUBLESHOOTING
E974
Error Code in Electrical System [E974] (PCV1 line cut) User Code
Error Code
Failure Code
E11
E974
AD11KA
Failure content
Failure phenomenon
PCV1 line cut (Engine controller system)
• Fuel supply pump PCV1 circuit is disconnected.
• Power to the fuel supply pump PCV1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV1 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV1 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (12) and PCV1 (female) (1)
Resistance value
Below 1 z
Between wiring harness between CB3 (female) (22) and PCV1 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (22) and PCV1 (female) (2)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
CB3 (female)
Resistance value
Between (12) and (22)
2.3 – 5.3 z
Between (12), (22) and grounding
Above 1 Mz
Electrical circuit diagram related to fuel supply pump PCV1
20-398 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E975
Error Code in Electrical System [E975] (PCV2 line cut) User Code
Error Code
Failure Code
E11
E975
AD51KA
Failure content
Failure phenomenon
PCV2 line cut (Engine controller system)
• Fuel supply pump PCV2 circuit is disconnected.
• Power to the fuel supply pump PCV2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2. Cause
Presumed cause and standard value in normalcy
Fuel supply pump PCV2 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. PCV2 (male)
Resistance value
Between (1) and (2)
2.3 – 5.3 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (13) and PCV2 (female) (1)
Resistance value
Below 1 z
Between wiring harness between CB3 (female) (23) and PCV2 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB3 (female) (23) and PCV2 (female) (2)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Engine controller defective
CB3 (female)
Resistance value
Between (13) and (23)
2.3 – 5.3 z
Between (13), (23) and grounding
Above 1 Mz
Electrical circuit diagram related to fuel supply pump PCV2
PC400/450(LC)-7
20-399 (1)
TROUBLESHOOTING
E977
Error Code in Electrical System [E977] (Rail press. sensor error) User Code
Error Code
Failure Code
E11
E977
DH40KX
Failure content
Failure phenomenon
Rail press. sensor error (Engine controller system)
• The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.
Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) • Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor. Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting.
Common rail fuel pressure sensor 1 defective (Internal defect)
PFUEL
Voltage
Between (3) and (1)
Power supply
4.6 – 5.4 V
Between (2) and (1)
Signal
0.7 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge.
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Wiring harness between CB2 (female) (9) and PFUEL (female) (3)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (39) and PFUEL (female) (1)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (40) and PFUEL (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (9) and PFUEL (female) (3), or between CB2 (female) (9) and related ciricuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB2 (female) (40) and PFUEL (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Short-circuiting of wiring Between wiring harness between CB2 (female) (9) and 4 harness PFUEL (female) (3), or between CB2 (female) (9) and (Contact with 24 V circuit) related ciricuits and grounding
Voltage
Below 1 V
Between wiring harness between CB2 (female) (40) and PFUEL (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. 5
20-400 (1)
Engine controller defective
CB2
Voltage
Between (9) and (39)
4.6 – 5.4 V
Between (40) and (39)
0.7 – 4.5 V
PC400/450(LC)-7
TROUBLESHOOTING
E977
Electrical circuit diagram related to common rail fuel pressure sensor
PC400/450(LC)-7
20-401 (1)
TROUBLESHOOTING
E979, E97A
Error Code in Electrical System [E979] (Rail press. high) User Code
Error Code
Failure Code
E11
E979
AD00L2
Failure content
Failure phenomenon
Rail press. high (Engine controller system)
• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).
Response from • The machine is driven with limited output. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Related systems 1 defective
If any other error code or failure code is displayed, carry out troubleshooting for it first.
2 Fuel used improper
Fuel used may be improper. Check it directly.
Electric system of 3 common rail fuel Carry out troubleshooting for error code [E977]. pressure sensor defective Mechanical system of The common rail fuel pressure sensor may have a mechanical defect. Check it 4 common rail fuel directly. pressure sensor defective 5 Overflow valve defective
The overflow valve may have trouble of breakage of spring, wear of seat, or fixing of ball. Check it directly.
6 Overflow piping clogged
The overflow piping may be clogged. Check it directly.
7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
Error Code in Electrical System [E97A] (Rail press. abnormal) User Code E11 Failure content
Error Code
Failure Code
E97A
AD00MA
Failure phenomenon
Rail press. abnormal (Engine controller system)
• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).
• The machine is driven with limited output. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
20-402 (1)
Cause 1
Common rail related device defective
Standard value in normalcy and references for troubleshooting Carry out troubleshooting for error code [E979].
PC400/450(LC)-7
TROUBLESHOOTING
E97B
Error Code in Electrical System [E97B] (Rail press. low) User Code
Error Code
Failure Code
E15
E97B
AD10L3
Failure content
Failure phenomenon
Rail press. low (Engine controller system)
• No-pressure feed by fuel supply pump (level 1) occurred.
• The machine is driven with limited output. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The engine does not start easily when temperature is low. • The overheat protection function does not operate. • If the controller is also defective, the engine does not stop.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure) Cause
Presumed cause and standard value in normalcy
1
Related systems defective
Standard value in normalcy and references for troubleshooting If any other error code or failure code is displayed, carry out troubleshooting for it first.
2 Fuel used improper
Fuel used may be improper. Check it directly.
Fuel low-pressure circuit 3 device defective
A low-pressure circuit device may be defective. Referring to Note 1, carry out troubleshooting.
4
Fuel filter/strainer clogged
Electrical system of fuel 5 supply pump PCV1 defective 6
Fuel supply pump defective
Common rail fuel 7 pressure sensor defective
The fuel filter/strainer may be clogged. Referring to Note 2, carry out troubleshooting. Carry out troubleshooting for error codes [E970], [E971], [E974], and [E975]. The fuel supply pump may be defective. Check it directly. The common rail fuel pressure sensor may be defective. Check it directly.
8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly. 9 Fuel injector defective
Note 1: 1) 2) 3) 4) 5) 6)
The fuel injector may be defective. Referring to Note 3, check it directly.
Check the low-pressure circuit devices for the following points. Insufficiency of fuel Fixing and wear of feed pump and clogging of filter Leakage from and clogging of low-pressure fuel piping Malfunction of bypass valve and installation of wrong part (See Fig. 1) Clogging of fuel filter Entry of fuel in oil pan (Fuel leakage in head cover) • Fuel low-pressure circuit pressure: 0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}
PC400/450(LC)-7
20-403 (1)
TROUBLESHOOTING
E97B
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) • Overflow valve (1): Spring is seen through both holes. • Bypass valve (2): Spring is seen through hole on nut side. • Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure. 1) Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it. 2) Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too. 3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter. Note 3:
Judge the condition of the fuel injector by measuring the fuel spill rate. k When performing the follow work, take care not to scald yourself with the fuel which becomes hot (up to 90°C). 1) Disconnect the hose connected to the centralized return spill tube adapters (at the rear of the engine). 2) Connect another hose to the spill tube end so that spill fuel can be received in a container.
20-404 (1)
3) Run the engine and stall at each speed (relieve the arm circuit by moving the arm in). Measure the quantity of the fuel spilling in 1 minute under this condition. a Limit of spill of fuel (Total of spill from 6 cylinders) Stall speed (rpm)
Limit of spill (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
PC400/450(LC)-7
TROUBLESHOOTING
E97C, E97D
Error Code in Electrical System [E97C] (Rail press. too low) User Code
Error Code
Failure Code
E11
E97C
AD10MB
Failure content
Failure phenomenon
Rail press. too low (Engine controller system)
• No-pressure feed by fuel supply pump (level 2) occurred.
• The machine is driven with limited output and speed. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
Cause 1
Standard value in normalcy and references for troubleshooting
Common rail-related device defective
Carry out troubleshooting for error code [E97B].
Error Code in Electrical System [E97D] (Rail press. out of control) User Code
Error Code
Failure Code
E11
E97D
AD10MA
Failure content
Failure phenomenon
Rail press. out of control (Engine controller system)
• Abnormal fuel pressure was generated in the common rail.
• The machine is driven under the normal control. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). • The output lowers (Only the pump absorption torque is reduced). • The engine speed does not rise above low idling.
Relative information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed cause and standard value in normalcy
Cause 1
PC400/450(LC)-7
Common rail-related device defective
Standard value in normalcy and references for troubleshooting Carry out troubleshooting for error code [E97B].
20-405 (1)
TROUBLESHOOTING
E980
Error Code in Electrical System [E980] (Eng. Controller Abnormality) User Code
Error Code
Failure Code
E10 or E11
E980
DB20KT
Failure content
Failure phenomenon
Eng. Controller Abnormality (Engine controller system)
• The controller has abnormality in it.
• The machine is driven with limited output or all output is turned OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stop and it cannot be started (when user code [E10] is displayed).
Presumed cause and standard value in normalcy
Relative information Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector) 2
20-406 (1)
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (11), (31), (32) and grounding
Resistance value
Below 1 z
If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
PC400/450(LC)-7
TROUBLESHOOTING
E980
Electrical circuit diagram related to engine controller power supply
PC400/450(LC)-7
20-407 (1)
TROUBLESHOOTING
E981
Error Code in Electrical System [E981] (Fuel Injector 1 Disc.) User Code
Error Code
Failure Code
E11
E981
ADA1KA
Failure content
Failure phenomenon
Fuel Injector 1 Disc. (Engine controller system)
• Fuel injector 1 circuit is disconnected.
• Power to the fuel injector 1 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN1 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (14) and CN1 (female) (1)
Resistance value
Below 1 z
Wiring harness between CB3 (female) (24) and CN1 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female)
Resistance value
Between (14) and (24)
0.4 – 1.1 z
Electrical circuit diagram related to fuel injector 1
20-408 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E982
Error Code in Electrical System [E982] (Fuel Injector 2 Disc.) User Code
Error Code
Failure Code
E11
E982
ADB1KA
Failure content
Failure phenomenon
Fuel Injector 2 Disc. (Engine controller system)
• Fuel injector 2 circuit is disconnected.
• Power to the fuel injector 2 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 2 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN2 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (6) and CN2 (female) (1)
Resistance value
Below 1 z
Wiring harness between CB3 (female) (16) and CN2 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female)
Resistance value
Between (6) and (16)
0.4 – 1.1 z
Electrical circuit diagram related to fuel injector 2
PC400/450(LC)-7
20-409 (1)
TROUBLESHOOTING
E983
Error Code in Electrical System [E983] (Fuel Injector 3 Disc.) User Code
Error Code
Failure Code
E11
E983
ADC1KA
Failure content
Failure phenomenon
Fuel Injector 3 Disc. (Engine controller system)
• Fuel injector 3 circuit is disconnected.
• Power to the fuel injector 3 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 3 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN3 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (5) and CN3 (female) (1)
Resistance value
Below 1 z
Wiring harness between CB3 (female) (15) and CN3 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female)
Resistance value
Between (5) and (15)
0.4 – 1.1 z
Electrical circuit diagram related to fuel injector 3
20-410 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E984
Error Code in Electrical System [E984] (Fuel Injector 4 Disc.) User Code
Error Code
Failure Code
E11
E984
ADD1KA
Failure content
Failure phenomenon
Fuel Injector 4 Disc. (Engine controller system)
• Fuel injector 4 circuit is disconnected.
• Power to the fuel injector 4 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 4 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN4 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (26) and CN4 (female) (1)
Resistance value
Below 1 z
Wiring harness between CB3 (female) (36) and CN4 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female)
Resistance value
Between (26) and (36)
0.4 – 1.1 z
Electrical circuit diagram related to fuel injector 4
PC400/450(LC)-7
20-411 (1)
TROUBLESHOOTING
E985
Error Code in Electrical System [E985] (Fuel Injector 5 Disc.) User Code
Error Code
Failure Code
E11
E985
ADF1KA
Failure content
Failure phenomenon
Fuel Injector 5 Disc. (Engine controller system)
• Fuel injector 5 circuit is disconnected.
• Power to the fuel injector 5 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 5 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN5 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (33) and CN5 (female) (1)
Resistance value
Below 1 z
Wiring harness between CB3 (female) (34) and CN5 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female)
Resistance value
Between (34) and (33)
0.4 – 1.1 z
Electrical circuit diagram related to fuel injector 5
20-412 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E986
Error Code in Electrical System [E986] (Fuel Injector 6 Disc.) User Code
Error Code
Failure Code
E11
E986
ADF1KA
Failure content
Failure phenomenon
Fuel Injector 6 Disc. (Engine controller system)
• Fuel injector 6 circuit is disconnected.
• Power to the fuel injector 6 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause
Presumed cause and standard value in normalcy
1
Fuel injector 6 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
3
Engine controller defective
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN6 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB3 (female) (25) and CN6 (female) (1)
Resistance value
Below 1 z
Wiring harness between CB3 (female) (35) and CN6 (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female)
Resistance value
Between (25) and (35)
0.4 – 1.1 z
Electrical circuit diagram related to fuel injector 6
PC400/450(LC)-7
20-413 (1)
TROUBLESHOOTING
E98A
Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C) User Code
Error Code
Failure Code
E11
E98A
ADAZKB
Failure content
Failure phenomenon
Fuel Injector 1 – 3 S/C (Engine controller system)
• Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.
• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause Fuel injector 1 defective 1 (Internal short-circuiting or grounding fault)
Presumed cause and standard value in normalcy
Fuel injector 2 defective 2 (Internal short-circuiting or grounding fault)
Fuel injector 3 defective 3 (Internal short-circuiting or grounding fault)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN1 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN2 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN3 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 4 (Contact with grounding circuit)
20-414 (1)
Standard value in normalcy and references for troubleshooting
Between wiring harness between CB3 (female) (14) and CN1 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (24) and CN1 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (6) and CN2 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (16) and CN2 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (5) and CN3 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (15) and CN3 (female) (2) and grounding
Resistance value
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
Cause
E98A
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between CB3 (female) (14) and CN1 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between CB3 (female) (24) and CN1 (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
Voltage
Below 1 V
Between wiring harness between CB3 (female) (5) and CN3 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between CB3 (female) (15) and CN3 (female) (2) and grounding
Voltage
Below 1 V
Short-circuiting of wiring Between wiring harness between CB3 (female) (6) and 5 harness CN2 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between CB3 (female) (16) and CN2 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) 6
Engine controller defective
Resistance value
Between (14) and (24)
0.4 – 1.1 z
Between (6) and (16)
0.4 – 1.1 z
Between (5) and (15)
0.4 – 1.1 z
Between (5), (6), (14), (15), (16), (24) and grounding
Above 1 Mz
Electrical circuit diagram related to fuel injectors 1, 2, and 3
PC400/450(LC)-7
20-415 (1)
TROUBLESHOOTING
E98B
Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C) User Code
Error Code
Failure Code
E11
E98B
ADDZKB
Failure content
Failure phenomenon
Fuel Injector 4 – 6 S/C (Engine controller system)
• Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.
• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF. Response from • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, controller unless the engine starting switch is once turned OFF. Phenomenon occurring on machine
• • • •
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced). The output lowers (Only the pump absorption torque is reduced). The engine speed does not rise above low idling. The engine stops and it cannot be started (when user code [E10] is displayed).
Relative information Cause Fuel injector 4 defective 1 (Internal short-circuiting or grounding fault)
Presumed cause and standard value in normalcy
Fuel injector 5 defective 2 (Internal short-circuiting or grounding fault)
Fuel injector 6 defective 3 (Internal short-circuiting or grounding fault)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN4 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN5 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CN6 (male)
Resistance value
Between (1) and (2)
0.4 – 1.1 z
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 4 (Contact with grounding circuit)
20-416 (1)
Standard value in normalcy and references for troubleshooting
Between wiring harness between CB3 (female) (26) and CN4 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (36) and CN4 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (34) and CN5 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (33) and CN5 (female) (2) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (25) and CN6 (female) (1) and grounding
Resistance value
Above 1 Mz
Between wiring harness between CB3 (female) (35) and CN6 (female) (2) and grounding
Resistance value
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
Cause
E98B
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between CB3 (female) (26) and CN4 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between CB3 (female) (36) and CN4 (female) (2) and grounding
Voltage
Below 1 V
Voltage
Below 1 V
Voltage
Below 1 V
Between wiring harness between CB3 (female) (25) and CN6 (female) (1) and grounding
Voltage
Below 1 V
Between wiring harness between CB3 (female) (35) and CN6 (female) (2) and grounding
Voltage
Below 1 V
Short-circuiting of wiring Between wiring harness between CB3 (female) (34) and 5 harness CN5 (female) (1) and grounding (Contact with 24 V circuit) Between wiring harness between CB3 (female) (33) and CN5 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB3 (female) 6
Engine controller defective
Resistance value
Between (26) and (36)
0.4 – 1.1 z
Between (34) and (33)
0.4 – 1.1 z
Between (25) and (35)
0.4 – 1.1 z
Between (25), (26), (33), (34), (35), (36) and grounding
Above 1 Mz
Electrical circuit diagram related to fuel injectors 4, 5, and 6
PC400/450(LC)-7
20-417 (1)
TROUBLESHOOTING
A000N1, A000N2
Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard) User Code
Error Code
Failure Code
E22
E922
A000N1
Failure content
Failure phenomenon
Engine high-idling speed out of standard (Mechanical system)
• While the engine is running, its speed above 2,350 rpm is detected.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01006: Engine speed)
Presumed cause and standard value in normalcy
Cause Overrun of engine 1 (While system is normal) 2
3
Engine speed sensor system abnormal
Engine controller defective
Standard value in normalcy and references for troubleshooting Check for an external or an internal factor which heightens the engine high-idling speed, and then check the mechanical system of the engine. If error code [E227] is displayed, carry out troubleshooting for it first. a Turn the engine starting switch ON for the preparations, and keep the engine running during the troubleshooting. Monitoring
Engine
Engine speed
01006 Engine speed
High idling
1,880 – 1,980 rpm
Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard) User Code — Failure content
Error Code
Failure Code
—
A000N2
Failure phenomenon
Engine low-idling speed out of standard (Mechanical system)
• While the engine is running, its speed below 500 rpm is detected.
Response from • None in particular. controller • When the failure cause disappears of itself, the machine operation returns to normalcy. Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• Input from the engine speed sensor (rpm) can be checked in the monitoring function. (Code No. 01006: Engine speed)
Presumed cause and standard value in normalcy
Cause 1
Engine mechanical system defective
Check for an external or an internal factor which lowers the engine low-idling speed, and then check the mechanical system of the engine.
2
Engine speed sensor system abnormal
If error code [E227] is displayed, carry out troubleshooting for it first.
3
20-418 (1)
Standard value in normalcy and references for troubleshooting
Engine controller defective
a Turn the engine starting switch ON for the preparations, and keep the engine running during the troubleshooting. Monitoring
Engine
Engine speed
01006 Engine speed
Low idling
975 – 1,025 rpm
PC400/450(LC)-7
TROUBLESHOOTING
AA10NX
Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging) User Code
Error Code
Failure Code
—
—
AA10NX
Failure content
Failure phenomenon
Aircleaner Clogging (Mechanical system)
• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 1) Cause
Presumed cause and standard value in normalcy
1
Air cleaner clogged (While system is normal)
Air cleaner clogging 2 switch defective (Internal disconnection)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting Check the air cleaner. If it is clogged, clean or replace it. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position or keep the engine running during the troubleshooting. A31 (male) Between (1) and (2)
Air cleaner
Resistance value
Normal
Below 1 z
Clogged
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (5) and A31 (female) (1)
Resistance value
Below 1 z
Wiring harness between A31 (female) (2) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or keep the engine running during the troubleshooting. 4 Monitor panel defective
P02 Between (5) and grounding
20-420 (1)
Air cleaner
Voltage
Normal
Below 1 V
Clogged
20 – 30 V
PC400/450(LC)-7
TROUBLESHOOTING
AA10NX
Electrical circuit diagram related to air cleaner clogging switch
PC400/450(LC)-7
20-421 (1)
TROUBLESHOOTING
AB00KE
Failure Code in Mechanical System [AB00KE] (Charge Voltage Low) User Code
Error Code
Failure Code
—
—
AB00KE
Failure content
Failure phenomenon
Charge Voltage Low (Mechanical system)
• Signal voltage from alternator is below 20 V while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the battery may not be charged.
Relative information
• If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function. (Code No. 04300: Charge voltage, 04501: Monitor input 2) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
1
Alternator defective (Internal defect)
Alternator
Engine
Voltage
Between terminal R and grounding
Above low idling
Above 20 V
Presumed cause and standard value in normalcy
If the voltage is abnormal, check the belt tension too. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (11), J02, and alternator terminal R
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (11), J02, and alternator terminal R, or between P02 (female) (11), D01, J01, and starting switch terminal BR, or between P02 (female) (11), battery relay terminal BR and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Monitor panel defective
20-422 (1)
P02
Engine
Voltage
Between (11) and grounding
Above low idling
Above 20 V
PC400/450(LC)-7
TROUBLESHOOTING
AB00KE
Electrical circuit diagram related to engine preheating, starting, charging
PC400/450(LC)-7
20-423 (1)
TROUBLESHOOTING
B@BAZG
Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low) User Code
Error Code
Failure Code
E11
E924
B@BAZG
Failure content
Failure phenomenon
Eng. Oil Press. Low (Mechanical system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above 600 rpm. • The signal circuit of the low-pressure switch is opened (disconnected from grounding) and the signal circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above 1,300 rpm.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• When this failure occurs, the error code is displayed only when the user code is turned ON and the failure code is recorded in only the mechanical system of the failure history. • If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function. (Code No. 17400: Engine controller input)
Presumed cause and standard value in normalcy
Cause Engine oil pressure 1 lowered (While system is normal) 2
Engine oil pressure switch system defective
Standard value in normalcy and references for troubleshooting Check the engine oil pressure. If it is abnormal, find out the cause and check the engine for damage, then repair. Carry out troubleshooting for error code [E936]. a Turn the engine starting switch OFF for the preparations, and hold it in the ON position or start the engine during the troubleshooting.
3
Engine controller defective
CB1
Engine
Voltage
Between (21) and grounding (Low-pressure switch signal)
Stopped
Below 1 V
Low idling
20 – 30 V
Stopped
Below 1 V
Above 1,300 rpm
20 – 30 V
Between (15) and grounding (High-pressure switch signal)
When carrying out troubleshooting while the engine is running, wait for 15 seconds after the engine is started.
20-424 (1)
PC400/450(LC)-7
TROUBLESHOOTING
B@BAZG
Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
PC400/450(LC)-7
20-425 (1)
TROUBLESHOOTING
B@BAZK
Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low) User Code
Error Code
Failure Code
—
—
B@BAZK
Failure content
Failure phenomenon
Eng. Oil Level Low (Mechanical system)
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the engine is stopped.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04501: Monitor input 2) Cause
Presumed cause and standard value in normalcy
1
Engine oil level low (While system is normal)
Engine oil level switch 2 defective (Internal disconnection) Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently, find out the cause.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. OL (male) Between (1) and grounding
Engine oil level
Resistance value
Normal level
Below 1 z
Below normal level
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (8) and OL (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective
P02 Between (8) and grounding
Engine oil level
Voltage
Normal level
Below 1 V
Below normal level
20 – 30 V
Electrical circuit diagram related to engine oil level switch
20-426 (1)
PC400/450(LC)-7
TROUBLESHOOTING
B@BCNS
Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat) User Code
Error Code
Failure Code
—
—
B@BCNS
Failure content
Failure phenomenon
Eng. Water Overheat (Mechanical system)
• The signal circuit of the engine water high temperature sensor detected temperature above 105°C.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine may be damaged.
Relative information
• If the engine water temperature monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine water high temperature sensor (water temperature and voltage) can be checked in the monitoring function. (Code No. 04102: Engine water temperature (High), 04106: Engine water temperature sensor voltage Hi)
Presumed cause and standard value in normalcy
Cause 1
Engine overheated (While system is normal)
Engine water high 2 temperature sensor system defective
3
Engine controller defective
Standard value in normalcy and references for troubleshooting Check the engine for overheating. If it has been overheated, find out the cause and check the engine for damage, then repair. Carry out troubleshooting for “Display of engine water temperature gauge on monitor panel is abnormal” in E mode. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. CB2 (female)
Engine water temperature
Resistance value
Between (27) and (29), (39)
105°C
3.28 kz
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high temperature)
PC400/450(LC)-7
20-427 (1)
TROUBLESHOOTING
B@BCZK
Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low) User Code
Error Code
Failure Code
—
—
B@BCZK
Failure content
Failure phenomenon
Eng. Water Lvl Low (Mechanical system)
• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the engine will overheat.
Relative information
• If the radiator water level monitor on the monitor panel lights up in red while the engine is stopped (the starting switch is at the ON position), this failure code is recorded. • Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1) Cause
Presumed cause and standard value in normalcy
1
Sub-tank water level low (While system is normal)
Radiator water level 2 switch defective (Internal disconnection)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting Check the radiator sub-tank water level. If it is low, add water. (If it is reduced frequently, find out the cause.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A33 (male) Between (1) and (2)
Sub-tank water level
Resistance value
Within normal level
Below 1 z
Below LOW level
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (3) and A33 (female) (1)
Resistance value
Below 1 z
Wiring harness between A33 (female) (2), J08, J12 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective
P02 Between (3) and grounding
Sub-tank water level
Voltage
Within normal level
Below 1 V
Below LOW level
20 – 30 V
Electrical circuit diagram related to radiator water level switch
20-428 (1)
PC400/450(LC)-7
TROUBLESHOOTING
B@HANS
Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat) User Code
Error Code
Failure Code
—
—
B@HANS
Failure content
Failure phenomenon
Hydr. Oil Overheat (Mechanical system)
• The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
Response from • None in particular. controller Phenomenon occurring on machine
• If the machine is used as it is, the hydraulic equipment may be damaged.
Relative information
• If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring function. (Code No. 04401: Hydraulic oil temperature) Cause
Presumed cause and standard value in normalcy
1
Hydraulic oil overheated (While system is normal)
Hydraulic oil temperature 2 sensor defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the hydraulic equipment for damage, then repair. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A61 (male) Between (1) and (2) Between (2) and grounding
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Hydraulic oil temperature 10 – 100°C
Resistance value 90 – 3.5 kz Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective
P02
Hydraulic oil temperature
Between (12) and (13) Between (12) and grounding
Resistance value 90 – 3.5 kz
10 – 100°C
Above 1 Mz
Electrical circuit diagram related to hydraulic oil temperature sensor
PC400/450(LC)-7
20-429 (1)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-503 E-1 The engine does not start (The engine does not rotate) ...................................................................... 20-504 E-2 Preheater does not operate.................................................................................................................. 20-508 E-3 Auto engine warm-up device does not work ........................................................................................ 20-510 E-4 Auto-decelerator does not operate ....................................................................................................... 20- 511 E-5 All work equipment, swing and travel do not move .............................................................................. 20-512 E-6 One-touch power max. function does not operate ............................................................................... 20-514 E-7 Machine push-up function does not operate normally.......................................................................... 20-515 E-8 Attachment circuit does not change ..................................................................................................... 20-517 E-9 No display in monitor panel at all ......................................................................................................... 20-519 E-10 Part of display on monitor panel is missing ........................................................................................ 20-520 E-11 Monitor panel displays contents irrelevant to the model..................................................................... 20-520 E-12 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-521 E-13 Engine water temperature gauge does not display correctly ............................................................. 20-522 E-14 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-524 E-15 Fuel gauge does not display correctly ................................................................................................ 20-525 E-16 Swing lock monitor does not display correctly.................................................................................... 20-526 E-17 When monitor switch is operated, nothing is displayed...................................................................... 20-528 E-18 Windshield wiper and window washer do not work ............................................................................ 20-530 E-19 Alarm buzzer cannot be cancelled ..................................................................................................... 20-534 E-20 “Boom RAISE” is not correctly displayed in monitor function ............................................................. 20-535 E-21 “Boom LOWER” is not correctly displayed in monitor function........................................................... 20-536 E-22 “Arm IN” is not displayed normally in monitoring function .................................................................. 20-537 E-23 “Arm DUMPING” is not correctly displayed in monitor function.......................................................... 20-538 E-24 “Bucket CURL” is not displayed normally in monitoring function........................................................ 20-539 E-25 “Bucket DUMPING” is not correctly displayed in monitor function ..................................................... 20-540 E-26 “Swing” is not displayed normally in monitoring function.................................................................... 20-542 E-27 “TRAVEL” is not correctly displayed in monitor function..................................................................... 20-544 E-28 “Travel Differential Pressure” is not correctly displayed in monitor function ....................................... 20-546 E-29 “Service” is not correctly displayed in monitor function ...................................................................... 20-548 E-30 Travel alarm does not sound or does not stop sounding.................................................................... 20-550 E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.............................................................. 20-552
PC400/450(LC)-7
20-501 (1)
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
Before carrying out troubleshooting for electrical system (E-mode) Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if the power is supplied normally. Type of power supply
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Constant power supply (Fusible link: A35)
20-502 (1)
Fuse No.
Fuse capacity
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 power Pump controller (Controller power supply) Swing holding brake solenoid (When emergency brake is released) PC-EPC solenoid (When emergency pump is driven) Pump controller (Solenoid power supply) Machine push-up solenoid ATT return selector relay & solenoid Starting motor cutout relay (For PPC lock) PPC lock solenoid Cigarette lighter Windshield washer motor Horn (Spare) Rotary lamp Right front working lamp & boom working lamp One-touch power maximizing switch (Input to pump controller input) Radio (Spare) Air conditioner unit Monitor panel Starting motor cutout relay (For personal code) Light relay (For right front working lamp & boom working lamp) Headlamp & additional headlamp Service power supply 1 (M32 connector) Travel alarm Service power supply 2 (DC/DC converter) Radio (For backing up) Monitor panel (For backing up) Starting switch Room lamp (Spare)
PC400/450(LC)-7
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE a The following information are edited and contained in the “Information Contained in Troubleshooting Table”. You are required to proceed with troubleshooting after fully grasping the contents. Failure information
Phenomena occurring on machine
Relative information
Information on occurred failures and troubleshooting Cause
• The standard values in normalcy by which to judge “good” or “no good” about presumed causes. • References for making judgement of “good” or “no good”
1
Presumed cause and standard value in normalcy
Standard value in normalcy and references for troubleshooting
2
Cause for presumed failure (The attached No. for 3 filing and reference purpose only. It does not stand for any priority)
4
5
• Failure due to disconnection Defective contact with connector or disconnection of wiring harness has occurred. • Grounding fault A wiring harness that is not originally connected with a grounding circuit is in contact with it. • Failure due to short-circuiting A wiring harness that is not originally connected with a power source circuit (24 V) is in contact with it. 1) Connector denotation method and handling of T-adapters Insert or connect T-adapters in the following manner, unless specifically otherwise instructed. • If there is no indication of (male) or (female) in the connector No., pull off a connector and insert a T-adapter into both sides of male and female. • If there is an indication of (male9 and (female) in the connection No., pull off a connector and insert a T-adapter into only one side of (male) or (female). 2) Description sequence of pin No. and handling of circuit tester leads Connect the positive lead (+) and negative lead (–) for troubleshooting in the following manner unless specifically otherwise instructed. • Connect the positive lead (+) to a pin No. marked at the front or wiring harness. • Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.
PC400/450(LC)-7
20-503 (1)
TROUBLESHOOTING
E-1
E-1 The engine does not start (The engine does not rotate) Failure information
• The engine does not start.
Relative information
• The engine starting circuit has the start lock mechanism of the safety lock lever type Cause
1
2
Insufficient battery capacity Defective fusible link A35 or fuse No. 3 or 17
Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Battery voltage
Electrolyte specific gravity
Min. 24 V
Min. 1.26
If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has a grounding fault (See cause 9). a Prepare with starting switch OFF, then keep starting switch OFF or turn it START and carry out troubleshooting.
3
Defective starting switch (Internal disconnection)
H15 (male)
Starting switch
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
Between (1) and (4)
Presumed cause and standard value in normalcy
4
Defective safety lock switch (Internal short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S14 (female)
Safety lock lever
Resistance
FREE
Min. 1 Mz
LOCK
Max. 1 z
Between (1) and (3)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Defective starting motor cut-out relay (Internal defect)
R11 (female), R13 (female)
Resistance
Between (1) and (2)
100 – 500 z
Between (3) and (5)
Min. 1 Mz
Between (3) and (6)
Max. 1 z
a Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to START and carry out troubleshooting. Starting motor
6
Defective starting motor (Internal defect)
Voltage
Between terminal B and chassis ground
B (Power supply)
20 – 30 V
Between ST (1) and chassis ground
S (Start)
20 – 30 V
Between ST (2) and chassis ground
R (Charge)
Max. 1 V
If the above voltage is normal and the starting motor does not rotate, starting motor has a defect in it or the engine is defective.
7
20-504 (1)
Defective alternator (Internal short circuit)
a Prepare with starting switch OFF (with only wiring harness R disconnected), then turn starting switch ON and carry out troubleshooting. Alternator
Voltage
Between terminal R and chassis ground
Max. 1 V
PC400/450(LC)-7
TROUBLESHOOTING
Cause
E-1
Standard value in normalcy and references for troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Presumed cause and standard value in normalcy
8
Disconnection in wiring harness (Disconnection in wiring harness or defective contact in connector)
Wiring harness between battery relay B terminal and A35 (male) (1)
Resistance
Max. 1 z
Wiring harness between A35 (male) (2) and H15 (female) (1)
Resistance
Max. 1 z
Wiring harness between H15 (female) (4), J01, and R11 (female) (5)
Resistance
Max. 1 z
Wiring harness between R11 (female) (3) and ST (female) (1)
Resistance
Max. 1 z
Wiring harness between FB1-3 and S14 (male) (1)
Resistance
Max. 1 z
Wiring harness between S14 (male) (3) and R11 (female) (1)
Resistance
Max. 1 z
Wiring harness between R11 (female) (2) and R13 (female) (6)
Resistance
Max. 1 z
Wiring harness between R13 (female) (3), J04, and chassis ground
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
9
Short circuit with chassis ground in wiring harness (Contact with ground circuit)
Short circuit with power source in wiring harness 10 (Contact with 24-V circuit)
PC400/450(LC)-7
Between wiring harness between A35 (male) (2) and H15 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between H15 (female) (4), J01, and R11 (female) (5), and other related circuits and chassis ground
Resistance
Min. 1 Mz
Wiring harness between R11 (female) (3) and ST (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between FB1-3 and S14 (male) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between A14 (male) (3) and R11 (female) (1) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between R11 (female) (2) and R13 (female) (6) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between R13 (female) (2), J05, P02 (female) (14), and other related circuits and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between wiring harness between ST (female) (2), alternator terminal R, J02, D01 (female) (6), and P02 (female) (11) and chassis ground
Voltage
Max. 1 V
20-505 (1)
TROUBLESHOOTING
E-1
Electrical circuit diagram for engine preheating, starting, charging
20-506 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-1
E-2 Preheater does not operate Failure information
• The preheater does not operate.
Relative information
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds). • Input of the preheating signal (ON or OFF) can be checked in the monitoring function. (Code No. 04500: Monitor input 1)
Presumed cause and standard value in normalcy
Cause
(1) When the starting switch is turned to the HEAT position, the preheating monitor does not light up.
Standard value in normalcy and references for troubleshooting
Starting switch system 1 defective
If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting (2).
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (18) and J02 (male) (7)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or HEAT position during troubleshooting. 3 Monitor panel defective
P02
Starting switch
Voltage
Between (18) and grounding
OFF
Below 1 V
HEAT
20 – 30 V
Failure information
• The preheater does not operate.
Relative information
• Check that the starting motor rotates normally. • (If the starting motor does not rotate, carry out troubleshooting in “Engine does not start”.) Cause
(2) When the starting switch is turned to the HEAT position, the heater unit is not warmed.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or HEAT position during troubleshooting.
1
Starting switch defective (Internal disconnection)
H15 (male) Between (1) and (3)
Starting switch
Resistance value
OFF
Above 1 Mz
HEAT
Below 1 z
Presumed cause and standard value in normalcy
a Turn the engine starting switch OFF for the preparations (with the wiring harness connected), and hold it in the OFF or HEAT position during troubleshooting. 2
Heater relay defective (Internal disconnection)
Intake air heater 3 defective (Internal disconnection)
Disconnection of wiring harness 4 (Disconnection or defective contact with connector)
20-508 (1)
Heater relay
Starting switch
Continuity and resistance value
Between coil terminal and grounding
OFF
Continued
Between contact terminals
HEAT
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Intake air heater Between terminals
Continuity Continued
Wiring harness between H15 (female) (3), J02, and heater relay terminal
Resistance value
Below 1 z
Wiring harness between starting motor terminal B and heater relay
Resistance value
Below 1 z
Wiring harness between heater relay and intake air heater
Resistance value
Below 1 z
Wiring harness between intake air heater and engine
Resistance value
Below 1 z
PC400/450(LC)-7
TROUBLESHOOTING
E-2
Electrical circuit diagram for engine preheating, starting, charging
PC400/450(LC)-7
20-509 (1)
TROUBLESHOOTING
E-3
E-3 Auto engine warm-up device does not work Failure information
• The auto engine warm-up device does not work.
Relative information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 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.
Presumed cause and standard value in normalcy
Cause
a Turn the starting switch ON for the troubleshooting (monitoring). Monitoring code 1
Engine cooling water temperature signal fault
04107
Item
Normal display
Engine cooling water temperature (low temperature)
Compare the monitor indication with the actual engine cooling water temperature.
If the display on the monitor panel is abnormal, carry out troubleshooting in “Engine water thermometer does not display normally”. 2
20-510 (1)
Standard value in normalcy and references for troubleshooting
Engine controller defective
If cause 1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
PC400/450(LC)-7
TROUBLESHOOTING
E-4
E-4 Auto-decelerator does not operate Failure information
• The auto-decelerator does not operate.
Relative information
• Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above this level. • Check the display on the monitor panel while the engine is running. • If the display on the monitor panel is abnormal, carry out troubleshooting in “ is not displayed normally in monitoring function”. Cause
1
Boom RAISE signal defective
Boom LOWER signal 2 defective
3 Arm IN signal defective
Presumed cause and standard value in normalcy
4 Arm OUT signal defective
5
Bucket CURL signal defective
Bucket DUMP signal 6 defective
7 Swing signal defective
8 Travel signal defective
9 Service signal defective
10 Pump controller defective 11
Engine controller defective
PC400/450(LC)-7
Standard value in normalcy and references for troubleshooting Monitoring code
Item
Normal display
01900 Pressure switch 1
Boom RAISE
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Boom LOWER
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Arm IN
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Arm OUT
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01901 Pressure switch 2
Bucket CURL
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01901 Pressure switch 2
Bucket DUMP
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Swing
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01900 Pressure switch 1
Travel
Lever operated: ON Lever in neutral: OFF
Monitoring code
Item
Normal display
01901 Pressure switch 2
Service
Lever operated: ON Lever in neutral: OFF
If causes 1 – 9 are not detected, the pump controller may be defective. (Since trouble is in the pump controller, troubleshooting cannot be carried out.) If causes 1 – 9 are not detected, the engine controller may be defective. (Since trouble is in the pump controller, troubleshooting cannot be carried out.)
20-511 (1)
TROUBLESHOOTING
E-5
E-5 All work equipment, swing and travel do not move Failure information
• All the work equipment, swing and travel do not move.
Relative information
— Cause
1 Fuse No. 3 fault
Presumed cause and standard value in normalcy
Safety lock switch 2 defective (Internal disconnection)
PPC lock solenoid defective 3 (Internal disconnection, short-circuiting, or grounding fault) Assembled-type diode 4 D01 defective (Internal short-circuiting)
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See cause 6.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female)
Safety lock lever
Between (1) and (2)
Resistance value
Free
Below 1 z
Lock
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)
Resistance value (Continuitiy)
Between (4) and (8)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 6 (Contact with grounding circuit)
20-512 (1)
Standard value in normalcy and references for troubleshooting
Wiring harness between FB1-3 outlet and S14 (male) (1)
Resistance value
Below 1 z
Wiring harness from S14 (male) (2) and J02 – V01 (female) (2)
Resistance value
Below 1 z
Wiring harness between V08 (female) (1) to J13 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-3 outlet and S14 (male) (1) and grounding
Resistance value
Above 1 Mz
Wiring harness from S14 (male) (2) to J02 – V01 (female) (2), or between wiring harness between S14 (male) (2) and D01 (female) (4) and grounding
Resistance value
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
E-5
Electrical circuit diagram for PPC lock solenoid
PC400/450(LC)-7
20-513 (1)
TROUBLESHOOTING
E-6
E-6 One-touch power max. function does not operate Failure information
• One-touch power max. function does not operate
Relative information
• If the one-touch power max. switch is pressed while the engine is running, the one-touch power max. monitor is displayed on the monitor panel. • Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in the monitoring function. (Code No. 02200: Switch input 1) Cause
1 Fuse No. 9 defective
Standard value in normalcy and references for troubleshooting If the fuse is broken, there is a big possibility that grounding fault occurred in the circuit. (See cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
One-touch power max. 2 switch defective (Internal disconnection)
M23 (male)
Presumed cause and standard value in normalcy
Between (1) and (2) Disconnection of wiring harness (Disconnection 3 or defective contact with connector)
One-touch power max. switch
Resistance value
Released
Min. 1 Mz
Pressed
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between FB1-9 outlet and M23 (female) (1)
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring 4 harness (Contact with grounding circuit)
Between wiring harness between FB1-9 outlet and M23 (female) (1), or between wiring harness between FB1-9 outlet and other related circuit and grounding
Resistance value
Min. 1 Mz
Between wiring harness between M23 (female) (2) and C01 (female) (11) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Pump controller defective
C01 Between (11) and grounding
One-touch power max. switch
Voltage
Released
Max. 1 V
Pressed
20 – 30 V
Electrical circuit diagram related to one-touch power max. switch
20-514 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-7
E-7 Machine push-up function does not operate normally Failure information
• Machine push-up function does not operate normally.
Relative information
• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
Presumed cause and standard value in normalcy
Cause Machine push-up switch 1 defective (Internal short-circuiting)
(1) The machine push-up function does not operate.
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M38 (female) Between (1) and (2)
Machine push-up switch
Resistance value
Low pressure position
Below 1 z
High pressure position
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during troubleshooting. Short-circuiting of wiring 2 harness Between wiring harness between M38 (female) (2), J07 (Contact with 24 V circuit) and V06 (female) (2) or between M38 (female) (2) and Voltage Below 1 V D02 (female) (3) and grounding
Electrical circuit diagram related to machine push-up solenoid
PC400/450(LC)-7
20-515 (1)
TROUBLESHOOTING
E-7
Failure information
• Machine push-up function does not operate normally.
Relative information
• When the machine push-up function is set in the low pressure position, the solenoid is turned ON. Cause
1 Fuse No. 2 defective
Presumed cause and standard value in normalcy
Machine push-up switch 2 defective (Internal disconnection)
Machine push-up solenoid defective 3 (Internal disconnection, short-circuiting or grounding fault) Assembled-type diode 4 D04 defective (Internal short-circuiting)
(2) The machine push-up function is not turned OFF.
Standard value in normalcy and references for troubleshooting If the fuse is broken, the circuit probably has grounding fault (See cause 6). a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M38 (female)
Machine push-up switch
Resistance value
Low pressure position
Below 1 z
High pressure position
Above 1 Mz
Between (1) and (2)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during troubleshooting. D02 (male)
Resistance value (Continuitiy)
Between (3) and (7)
Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 5 (Disconnection or defective contact with connector)
Wiring harness between FB1-2 outlet and M38 (male) (1)
Resistance value
Below 1 z
Wiring harness between M38 (male) (2), J07 and V06 (female) (2)
Resistance value
Below 1 z
Wiring harness between V06 (female) (1) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 6 (Contact with grounding circuit)
20-516 (1)
Between wiring harness between FB1-2 outlet and M38 (male) (1) or between FB1-2 outlet and related circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness between M38 (male) (2), J07 and V06 (female) (2) or between M38 (male) (2) and D02 (female) (3) and grounding
Resistance value
Above 1 Mz
PC400/450(LC)-7
TROUBLESHOOTING
E-8
E-8 Attachment circuit does not change When attachment is installed (1) When working mode A or E is selected, attachment circuit is not switched to crusher circuit (reciprocation circuit). (2) When working mode B is selected, attachment circuit is not switched to breaker circuit (one-way circuit).
Failure information
• Attachment circuit does not change.
Relative information
• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or disconnection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected, however. Cause
Presumed cause and standard value in normalcy
Attachment return selector solenoid defective 1 (Internal disconnection or short-circuit)
Attachment return selector relay defective 2 (Internal disconnection or short-circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V12 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male)
Resistance value
Between (3) and (5)
Below 1 z
Between (3) and (6)
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Short-circuit of wiring harness 4 (Contact with 24 V circuit)
PC400/450(LC)-7
Wiring harness between J03 (male) (8) and R20 (female) (3)
Resistance value
Below 1 z
Wiring harness between R20 (female) (5) and V12 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3), (13), (23) and V12 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness and R20 (female) (5) and V12 (female) (2) and grounding
Voltage
Below 1 V
20-517 (1)
TROUBLESHOOTING
E-8
Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid
20-518 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-9
E-9 No display in monitor panel at all Failure information
• No display in monitor panel at all. When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
1 Fuse No. 12 fault
Disconnection of wiring harness 2 (Disconnection or defect contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting If the fuse No. 12 is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 3.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from P01 (female) (1) (2) to J07 to FB112
Resistance value
Below 1 z
Wiring harness from P01 (female) (6) (7) to J04 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P01 (female) (1) (2) to J07 to FB1-12 outlet or related circuits and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Monitor panel 4 controller defective
P01
Starting switch
Voltage and resistance value
Between (1) (2) and grounding
ON
Voltage: 20 – 30 V
Between (6) (7) and grounding
OFF
Resistance value: Below 1z
Electrical Circuit Diagram for Power Source in Monitor Panel
PC400/450(LC)-7
20-519 (1)
TROUBLESHOOTING
E-10, E-11
E-10 Part of display on monitor panel is missing • Part of display on monitor panel is missing
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
Part of the display in the monitor panel is missing during starting switch in ON.
Standard value in normalcy and references for troubleshooting a Turn the starting switch ON during the troubleshooting.
1 Monitor panel LCD fault
2
Monitor panel defective
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen becomes totally white) by the following switching operation, then the monitor panel is normal. • Switching operation: [ ] + [ A ] (push swiches simultaneously.) If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
E-11 Monitor panel displays contents irrelevant to the model • The monitor panels displays contents that have nothing to do with the model on which it is installed.
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
a Turn the starting switch in ON during the troubleshooting (monitoring). 1
Model code signal fault (Internal failure)
Monitoring code
Item
Normal display
00200
Controller model code
PC400-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217]. 2
20-520 (1)
Standard value in normalcy and references for troubleshooting
Monitor panel defective
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
PC400/450(LC)-7
TROUBLESHOOTING
E-10, E-11
E-12 Fuel level monitor red lamp lights up while engine is running Failure information
• The fuel level monitor red lamp lights up while the engine was running.
Relative information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red. • (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No.: 04200 Fuel level sensor) Cause
Presumed cause and standard value in normalcy
Fuel level lowered (sys1 tem in normal condition) Fuel level sensor fault 2 (Internal disconnection) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting a Check fuel level in fuel tank. If insufficient, refill fuel. a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A60 (male)
Fuel level
Resistance value
Between (1) and grounding
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (2) and A60 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Monitor panal defective
P02 (female)
Fuel level
Resistance value
Between (2) and grounding
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
Electrical Circuit Diagram for Fuel Level Sensor
PC400/450(LC)-7
20-521 (1)
TROUBLESHOOTING
E-13
E-13 Engine water temperature gauge does not display correctly (1) While the engine water temperature rises normally, the temperature gauge does not rise above the white range (C). (2) While the engine water temperature is stabilized normally, the temperature gauge rises up to the red range (H).
Failure information
• Engine water temperature gauge does not display correctly
Relative information
• The signal of the engine water high temperature sensor for the water temperature gauge is received from the engine controller through the communication line. • If the engine water high temperature sensor system becomes defective, error code [E934] may be displayed. • Input from the engine water high temperature sensor (voltage and temperature) can be checked in the monitoring function. (Code No. 04106: Engine water sensor voltage Hi, 04102: Engine water temperature (High temperature)) Cause
Presumed cause and standard value in normalcy
Engine water high temperature sensor defective 1 (Internal disconnection, short-circuiting or grounding fault) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and turn to ON or keep the engine running during the troubleshooting. TWH (male)
Resistance value
Between (1) and (2)
3.5 k – 90 kz
Between (1), (2) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between CB2 (female) (27) and TWH (female) (1)
Resistance value
Below 1 z
Wiring harness between CB2 (female) (29), (39) and TWH (female) (2)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between CB2 (female) (27) and TWH (female) (1) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 4 harness Between wiring harness between CB2 (female) (27) and (Contact with 24 V circuit) Voltage Below 1 V TWH (female) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Engine controller defective
6 Monitor panel defective
20-522 (1)
CB2 (female)
Resistance value
Between (27), (29) and (39)
3.5 k – 90 kz
Between (27), (29), (39) and grounding
Above 1 Mz
If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot be carried out.)
PC400/450(LC)-7
TROUBLESHOOTING
E-13
Electrical circuit diagram related to engine water high temperature sensor
PC400/450(LC)-7
20-523 (1)
TROUBLESHOOTING
E-14
E-14 Hydraulic oil temperature gauge does not display correctly Failure information
• Hydraulic oil temperature gauge does not display correctly (1) Hydraulic oil temperature rises normally, but the display does not rise from the white range (C). (2) Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative information
• Input from the hydraulic oil temperature sensor can be confirmed in the monitor function. (Code No.: 04401 Hydraulic oil temperature) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Hydraulic oil temperature sensor fault 1 (Internal disconnection or short-circuiting)
A61 Between (1) and (2)
Presumed cause and standard value in normalcy
Between (2) and grounding Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Engine cooling water temperature
Resistance value 90 – 3.5 kz
10 – 100 °C
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (12) and A61 (female) (2)
Resistance value
Below 1 z
Wiring harness between P02 (female) (13) and A61 (female) (1)
Resistance value
Below 1 z
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding
Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding
Resistance value
Voltage
Above 1 Mz
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Monitor panal defective
P02
Engine cooling water temperature
Between (12) and (13) Between (12) and grounding
Resistance value 90 – 3.5 kz
10 – 100 °C
90 – 3.5 kz
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
20-524 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-15
E-15 Fuel gauge does not display correctly Failure information
• Fuel gauge does not display correctly (1) Though fuel was refilled, the display does not exceed the red range (E). (2) Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative information
• Input from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No.: 04200 Fuel sensor voltage) Cause
Presumed cause and standard value in normalcy
Fuel level sensor fault 1 (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A60 (male)
Fuel level
Resistance value
Between (1) and grounding
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Wiring harness between P02 (female) (2) and A60 (female) (1)
Between wiring harness between P02 (female) (2) and A60 (female) (1) and grounding
Between wiring harness between P02 (female) (2) and A60 (female) (1) and grounding
Resistance value
Resistance value
Voltage
Below 1 z
Above 1 Mz
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Monitor panal defective
P01
Fuel level
Resistance value
Between (2) and grounding
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 – 110 z
Electrical Circuit Diagram for Fuel Level Sensor
PC400/450(LC)-7
20-525 (1)
TROUBLESHOOTING
E-16
E-16 Swing lock monitor does not display correctly Failure information
(1) Though the swing lock switch was turned ON, the swing lock monitor does not light up. • Swing lock monitor does not display correctly (2) Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative information
• Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause
Presumed cause and standard value in normalcy
Swing lock switch defective 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (1) and (2)
Swing lock switch
Resistance value
OFF
Above 1 Mz
ON
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from P02 (female) (17) to J02 and X05 (male) (1)
Resistance value
Below 1 z
Wiring harness from X05 (male) (2) to J05 and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P02 (female) (17) to J02 and X05 (male) (1), or between P02 (female) (17) to C02 (female) (38) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Short-circuiting of wiring 4 harness Between wiring harness from P02 (female) (17) to J02 (Contact with 24 V circuit) and X05 (male) (1), or between P02 (female) (17) to C02 (female) (38) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5 Monitor panel defective
20-526 (1)
P02
Swing lock switch
Voltage
Between (17) and grounding
OFF
20 – 30 V
ON
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E-16
Electrical circuit diagram related to swing holding brake solenoid
PC400/450(LC)-7
20-527 (1)
TROUBLESHOOTING
E-17
E-17 When monitor switch is operated, nothing is displayed Failure information
• When monitor switch is operated, nothing is dis- (1) When mode selector switch is operated, working played. mode monitor is not displayed.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information
• When monitor switch is operated, nothing is displayed.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information
• When monitor switch is operated, nothing is displayed.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted.
• When monitor switch is operated, nothing is displayed.
Relative information
— Cause 1
Monitor panel defective
(3) When selector switch is operated, flow rate adjustment screen or flow rate selection screen is not displayed.
Standard value in normalcy and references for troubleshooting
Failure information
Presumed cause and standard value in normalcy
(2) When LCD monitor adjustment switch is operated, mode selection screen is not displayed.
(4) When maintenance switch is operated, item selection screen is not displayed.
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information
• When monitor switch is operated, nothing is displayed.
Relative information
• When the automatic decelerator does not operate either, conduct the troubleshooting for E-4.
Presumed cause and standard value in normalcy
20-528 (1)
Cause 1
Monitor panel defective
(5) When automatic deceleration switch is operated, automatic deceleration monitor is not displayed.
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
PC400/450(LC)-7
TROUBLESHOOTING
E-17
Failure information
• When monitor switch is operated, nothing is displayed.
Relative information
• When the travel speed does not change either, conduct the troubleshooting for H-22.
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
(6) When travel speed selector switch is operated, travel speed monitor is not displayed.
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information
• When monitor switch is operated, nothing is displayed.
Relative information
• When the wiper does not operate either, conduct the troubleshooting for E-18.
Presumed cause and standard value in normalcy
Cause 1
PC400/450(LC)-7
Monitor panel defective
(7) When wiper switch is operated, wiper monitor is not displayed.
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
20-529 (1)
TROUBLESHOOTING
E-18
E-18 Windshield wiper and window washer do not work Failure information
• Windshield wiper and window washer do not work.
Relative information
• Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause
Window rear limit switch fault 1 (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Windshield wiper motor 2 fault (Internal disconnection)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit)
Monitor panel fault (Window rear limit switch system)
Monitor panel fault (Windshield wiper motor system)
(1)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W03 (female) Between (1) and (2)
Front window
Resistance value
When installed at front
Above 1 Mz
When retracted at rear
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (male)
Continuity and resistance value
Between (3) and (1)
Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (9) and W04 (female) (3)
Resistance value
Below 1 z
Wiring harness between P01 (female) (10) and W04 (female) (1)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (15) and W03 (2)
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
Front window
Voltage
Between (15) and grounding
When installed at front
20 – 30 V
When retracted at rear
Below 1 V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5
20-530
(1) The windshield wiper does not work.
P01
Windshield wiper switch
Resistance value
Between (9) and grounding Between (10) and grounding
OFF
Below 3 V
ON
Below 3 V 20 – 30 V (Constant cycle)
PC400/450(LC)-7
TROUBLESHOOTING
E-18
Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch
PC400/450(LC)-7
20-531 (1)
TROUBLESHOOTING
E-18
Failure information
• Windshield wiper and window washer do not work.
Relative information
— Cause
1 Fuse No. 4 defective
Presumed cause and standard value in normalcy
Washer motor defective 2 (Internal disconnection or grounding fault)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
(2) Windshield washer does not operate.
Standard value in normalcy and references for troubleshooting If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 4.) a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A50 (male)
Resistance value
Between (1) and (2)
5 – 20 z
Between (1) and grounding
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1)
Resistance value
Below 1 z
Wiring harness from A50 (female) (2) to J04 and P01 (female) (3)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit)
Between wiring harness from FB1-4 to J03 to J06 and A50 (female) (1), or FB1-4 to D02 (female) (4), and to other relative circuits and grounding
Resistance value
Above 1 Mz
Between wiring harness from A50 (female) (2) to J04 and P01 (female) (3), or A50 (female) (2) to D02 (female) (8) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
20-532 (1)
Monitor panel defective
P01
Windshield washer switch
Voltage
Between (3) and grounding
OFF
20 – 30 V
ON
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E-18
Electrical Circuit Diagram for Window Washer Motor
PC400/450(LC)-7
20-533 (1)
TROUBLESHOOTING
E-19
E-19 Alarm buzzer cannot be cancelled Failure information
• The alarm buzzer cannot be cancelled.
Relative information
• Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function. (Code No.: 04502 Monitor input 3) Cause
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Alarm buzzer stop switch 1 defective (Internal disconnection)
P03 (female)
Presumed cause and standard value in normalcy
Between (1) and (2) Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Alarm buzzer stop switch
Resistance value
Release
Above 1 Mz
Depress
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (16) and P03 (male) (1)
Resistance value
Below 1 z
Wiring harness from P03 (male) (2) to J05 to grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 3 harness Between wiring harness between P02 (female) (16) and (Contact with 24 V circuit) Voltage Below 1 V P03 (male) (1) and grounding a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective
P02
Alarm buzzer stop switch
Voltage
Between (16) and grounding
Release
20 – 30 V
Depress
Below 1 V
Electrical circuit diagram related to alarm buzzer stop switch
20-534 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-20
E-20 “Boom RAISE” is not correctly displayed in monitor function Failure information
• “Boom RAISE” is not correctly displayed in monitor function “Boom RAISE” is not correctly displayed in the monitor function on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Boom RAISE PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S06 (male) Between (1) and (2)
R.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Boom RAISE
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (10) and S06 (female) (2)
Resistance value
Below 1 z
Wiring harness between S06 (female) (1) and grounding
Resistance value
Below 1 z
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female) (10) and S06 (female) (2) and grounding
Between wiring harness between C03 (female) (10) and S06 (female) (2) and grounding
Resistance value
Voltage
Above 1 Mz
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Pump controller defective
C03 Between (10) and grounding
R.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Boom RAISE
Below 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC400/450(LC)-7
20-535 (1)
TROUBLESHOOTING
E-21
E-21 “Boom LOWER” is not correctly displayed in monitor function Failure information
• “Boom LOWER” is not correctly displayed in monitor function “Boom LOWER” is not correctly displayed in the monitor function on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Boom LOWER PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S02 (male) Between (1) and (2)
R.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Boom LOWER
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (20) and S02 (female) (2)
Resistance value
Below 1 z
Wiring harness between S02 (female) (1) and grounding
Resistance value
Below 1 z
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female) (20) and S02 (female) (2) and grounding
Between wiring harness between C03 (female) (20) and S02 (female) (2) and grounding
Resistance value
Voltage
Above 1 Mz
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Pump controller defective
C03 Between (20) and grounding
R.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Boom LOWER
Below 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-536 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-22
E-22 “Arm IN” is not displayed normally in monitoring function Failure information
• “Arm IN” is not displayed normally in monitoring “Arm IN” is not displayed normally in monitoring function. function (special function) of monitor panel.
Presumed cause and standard value in normalcy
Relative information Cause
Standard value in normalcy and references for troubleshooting
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).
PC400/450(LC)-7
20-537 (1)
TROUBLESHOOTING
E-23
E-23 “Arm DUMPING” is not correctly displayed in monitor function Failure information
• “Arm DUMPING” is not correctly displayed in monitor function “Arm DUMPING” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Arm DUMPING PPC hydraulic switch defect 1 (Internal disconnection and short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S08 (male) Between (1) and (2)
L.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Arm DUMPING
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (40) and S08 (female) (2)
Resistance value
Below 1 z
Wiring harness between S08 (female) (1) and grounding
Resistance value
Below 1 z
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female) (40) and S08 (female) (2) and grounding
Between wiring harness between C03 (female) (40) and S08 (female) (2) and grounding
Resistance value
Voltage
Above 1 Mz
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Pump controller defective
C03 Between (40) and grounding
L.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Arm DUMPING
Below 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-538 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-24
E-24 “Bucket CURL” is not displayed normally in monitoring function Failure information
• “Bucket CURL” is not displayed normally in monitoring function.
“Bucket CURL” is not displayed normally in monitoring function (special function) of monitor panel.
Presumed cause and standard value in normalcy
Relative information Cause
Standard value in normalcy and references for troubleshooting
1
Bucket CURL PPC pressure sensor defective
The bucket CURL PPC pressure sensor may be defective. Carry out troubleshooting for error code [E248].
2
Pump controller defective
If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot be carried out since the defect is in the pump controller).
PC400/450(LC)-7
20-539 (1)
TROUBLESHOOTING
E-25
E-25 “Bucket DUMPING” is not correctly displayed in monitor function Failure information
• “Bucket DUMPING” is not correctly displayed in monitor function “Bucket DUMPING” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Bucket DUMPING PPC hydraulic switch fault 1 (Internal disconnection and short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S05 (male) Between (1) and (2)
R.H. work equipment control lever
Resistance value
NEUTRAL
Above 1 Mz
Bucket DUMPING
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (19) and S05 (female) (2)
Resistance value
Below 1 z
Wiring harness between S05 (female) (1) and grounding
Resistance value
Below 1 z
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C03 (female) (19) and S05 (female) (2) and grounding
Between wiring harness between C03 (female) (19) and S05 (female) (2) and grounding
Resistance value
Voltage
Above 1 Mz
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Pump controller defective
C03 Between (19) and grounding
R.H. work equipment control lever
Voltage
NEUTRAL
20 – 30 V
Bucket DUMPING
Below 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-540 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-26
E-26 “Swing” is not displayed normally in monitoring function Failure information
• “Swing” is not displayed normally in monitoring function.
“Swing” is not displayed normally in monitoring function (special function) of monitor panel.
Relative information Cause Swing left PPC pressure switch defective 1 (Internal disconnection or short-circuit)
Presumed cause and standard value in normalcy
Swing right PPC pressure switch defective 2 (Internal disconnection or short-circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S07 (male) Between (1) and (2)
Left work equipment control lever
Resistance value
Neutral
Min. 1 Mz
Left swing position
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S03 (male) Between (1) and (2)
Left work equipment control lever
Resistance value
Neutral
Min. 1 Mz
Right swing position
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Wiring harness between C03 (female) (29) and S07 (female) (2) or S03 (female) (2)
Resistance value
Max. 1 z
Wiring harness between S07 (female) (1) and grounding
Resistance value
Max. 1 z
Wiring harness between S03 (female) (1) and grounding
Resistance value
Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (29) and S07 (female) (2) or S03 (female) (2) and grounding
Resistance value
Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON Short-circuiting of wiring position during the troubleshooting. 5 harness (Contact with 24 V circuit) Between wiring harness between C03 (female) (29) and Voltage Max. 1 V S07 (female) (2) or S03 (female) (2) and grounding a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6 Pump controller defective
C03 Between (29) and grounding
20-542 (1)
Left work equipment control lever
Voltage
Neutral
20 – 30 V
Left or right swing position
Max. 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E-26
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC400/450(LC)-7
20-543 (1)
TROUBLESHOOTING
E-27
E-27 “TRAVEL” is not correctly displayed in monitor function Failure information
• “TRAVEL” is not correctly displayed in monitor function “TRAVEL” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
Travel PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S30 (male) Between (1) and (2)
Travel control lever
Resistance value
NEUTRAL
Above 1 Mz
Forward or reverse
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (39) to J01 to S30 (female) (2)
Resistance value
Below 1 z
Wiring harness from S30 (female) (1) to J05 to grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (39) to J01 to S30 (female) (2), or between wiring harness between C03 (female) (39) and A43 (female) (2) and grounding
Resistance value
Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (39) to J01 to S30 (female) (2), or between wiring harness between C03 (female) (39) and A43 (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
20-544 (1)
Pump controller defective
C03
Travel control lever
Voltage
Between (39) and grounding
NEUTRAL
20 – 30 V
Forward or backward
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E-27
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC400/450(LC)-7
20-545 (1)
TROUBLESHOOTING
E-28
E-28 “Travel Differential Pressure” is not correctly displayed in monitor function Failure information
• “Travel Differential Pressure” is not correctly displayed in monitor function “Travel Differential Pressure” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
• When pressure difference is created between the right and left travel PPC circuits (in steering), the travel differential mechanism is turned ON. Cause
Presumed cause and standard value in normalcy
Travel steering PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S31 (male)
Travel control lever
Resistance value
NEUTRAL
Above 1 Mz
Between (1) and (2)
One side of right or left only
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (16) and S31 (female) (2)
Resistance value
Below 1 z
Wiring harness from S31 (female) (1) to J05 to grounding
Resistance value
Below 1 z
Grounding fault of wiring harness 3 (Contact with grounding (GND) circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
Between wiring harness between C02 (female) (16) and S31 (female) (2) and grounding
Between wiring harness between C02 (female) (16) and S31 (female) (2) and grounding
Resistance value
Voltage
Above 1 Mz
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
20-546 (1)
Pump controller defective
C02 Between (16) and grounding
Travel control lever
Voltage
NEUTRAL
20 – 30 V
One side of right or left only
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E-28
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC400/450(LC)-7
20-547 (1)
TROUBLESHOOTING
E-29
E-29 “Service” is not correctly displayed in monitor function Failure information
• “Service” is not correctly displayed in monitor function “Service” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
Service (front) PPC hydraulic switch fault 1 (Internal disconnection or short-circuiting)
Presumed cause and standard value in normalcy
Service (rear) PPC hydraulic switch fault 2 (Internal disconnection or short-circuiting)
Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit) Short-circuiting of wiring harness 5 (Contact with 24 V circuit)
Standard value in normalcy and references for troubleshooting a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S10 (male) Between (1) and (2)
Service pedal
Resistance value
NEUTRAL
Above 1 Mz
Operated to front
Below 1 z
a Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S11 (male) Between (1) and (2)
Service pedal
Resistance value
NEUTRAL
Above 1 Mz
Operated to rear
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (2), or wiring harness between C02 (female) (35) and S11 (female) (2)
Resistance value
Below 1 z
Wiring harness between S10 (female) (1) and grounding
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (2), or between wiring harness between C02 (female) (35) and S11 (female) (2) and grounding
Above 1 Mz
Resistance value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (2), or between wiring harness between C02 (female) (35) and S11 (female) (2) and grounding
Voltage
Below 1 V
a Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 6 Pump controller defective
20-548 (1)
C02
Service pedal
Voltage
Between (35) and grounding
NEUTRAL
20 – 30 V
Operated to front or rear
Below 1 V
PC400/450(LC)-7
TROUBLESHOOTING
E-29
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC400/450(LC)-7
20-549 (1)
TROUBLESHOOTING
E-30
E-30 Travel alarm does not sound or does not stop sounding Failure information
• Travel alarm does not sound or does not stop sounding. (1) The travel alarm does not sound while the machine is traveling. (2) The alarm begins to sound when the machine is at a standstill.
Relative information
— Cause
1 Fuse No. 15 fault
Standard value in normalcy and references for troubleshooting When fuse No.15 is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 4.) a Start the engine during the troubleshooting (monitoring). Monitoring code
Presumed cause and standard value in normalcy
2 Travel signal fault
Normal display
Travel
Control lever operated: ON Control lever NEUTRAL: OFF
If the monitor display is not correct, proceed to No. E-29 Troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding (GND) circuit)
5 Travel alarm fault
20-550 (1)
01900
Item
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between FB1-15 outlet to J03 and A43 (female) (1)
Resistance value
Below 1 z
Wiring harness between A43 (female) (2) and J01 (19)
Resistance value
Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-15 outlet to J03 and A43 (female) (1), or between wiring harness between FB1-15 outlet and other related circuit and grounding
Resistance value
Above 1 Mz
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
PC400/450(LC)-7
TROUBLESHOOTING
E-30
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
PC400/450(LC)-7
20-551 (1)
TROUBLESHOOTING
E-31
E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM Troubleshooting procedure for air conditioner system a The control panel of the air conditioner constantly monitors the sensors and other devices in the system . When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially. a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to the procedure for “Troubleshooting by self-diagnosis notice”, and then; • If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”. • If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
Troubleshooting by self-diagnosis notice a Check the “Self-diagnosis notice” on the control panel according to the following procedure. •
How to display “Self-diagnosis notice” 1) Turn the starting switch ON. 2) Press OFF switch (1) and check that anything is not displayed on display monitor (2). 3) Hold the UP switch ( ) and DOWN switch ( ) of temperature setting switch (3) simultaneously for 3 seconds or more. 4) Check the “Self-diagnosis notice” displayed on display monitor (2).
•
How to select “Self-diagnosis notice” If multiple “Self-diagnosis notices” are recorded, press the UP switch ( ) or DOWN switch ( ) of temperature setting switch (3) to select another notice.
•
How to delete “Self-diagnosis notice” When reproducing the “Self-diagnosis notices” or after removing the cause of a failure, press the switches on both sides of recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the “Self-diagnosis notices” are deleted.
•
Finishing display of “Self-diagnosis notice” To finish display of the “Self-diagnosis notice”, press OFF switch (1) or turn the starting switch OFF.
20-552 (1)
Self-diagnosis Failure mode notice E-No failures Disconnection in recirculated air E11 sensor E12 Short-circuit in recirculated air sensor Disconnection in water temperature E15 sensor Short-circuit in water temperature E16 sensor E18 Short-circuit in daylight sensor E43 Abnormality in air outlet damper E44 Abnormality in air mix damper Abnormality in recirculated and fresh E45 air damper
PC400/450(LC)-7
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Disconnection in recirculated air sensor
E11 Contents of trouble Action of control panel
• Disconnection in the recirculated air sensor system is detected. • Fixes the recirculated air temperature for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective recirculated 1 air sensor (Internal disconnection)
Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
Self-diagnosis notice
Trouble
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)
Resistance
Between (1) and (2)
300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and TH I (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Short circuit in recirculated air sensor
E12 Contents of trouble Action of control panel
• Short circuit in the recirculated air sensor system is detected. • Fixes the recirculated air temperature for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause Defective recirculated air 1 sensor (Internal short circuit)
Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
PC400/450(LC)-7
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)
Resistance
Between (1) and (2)
300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and TH I (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-553 (1)
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Disconnection in water temperature sensor
E15 Contents of trouble Action of control panel
• Disconnection in the water temperature sensor system is detected. • Ignores the warm-up control and fixes the engine water temperature at 60°C for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning Defective water temperastarting switch ON. 1 ture sensor (Internal disTHW (male) Resistance connection) Between (1) and (2) 95 z – 455 kz Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
Self-diagnosis notice
Trouble
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and THW (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Short circuit in water temperature sensor
E16 Contents of trouble Action of control panel
• Short circuit in the water temperature sensor system is detected. • Ignores the warm-up control and fixes the engine water temperature at 60°C for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause Defective water tempera1 ture sensor (Internal short circuit)
Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
20-554 (1)
Defective air conditioner system
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male)
Resistance
Between (1) and (2)
95 z – 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and THW (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC400/450(LC)-7
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Short circuit in daylight sensor
E18 Contents of trouble Action of control panel
• 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. + + +
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective daylight sen1 The daylight sensor may be defective. Check it directly. sor (Internal short circuit) Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
Self-diagnosis notice
Trouble
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (16) and P15 (female) (2)
Resistance
Max. 1 z
Wiring harness between M30 (female) (3) and P15 (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Abnormality in air outlet damper
E43 Contents of trouble
• Abnormality in air outlet servomotor system is detected.
Action of control panel
• Stops the air outlet servomotor. • When the following condition is satisfied, the operation returns to normalcy. • + + +
Related information
a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause
Standard value in normalcy and references for troubleshooting
Possible causes and standard value in normal state
Defective air outlet servo1 The air outlet servomotor may be defective. Check it directly. motor (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)
3
Defective air conditioner system
PC400/450(LC)-7
Wiring harness between MV1 (female) (1) and M30 (female) (3)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (3) and M29 (female) (11)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (5) and M30 (female) (9)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (6) and M29 (female) (8)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (7) and M29 (female) (9)
Resistance
Max. 1 z
If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-555 (1)
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Abnormality in air mix damper
E44 Contents of trouble
• Abnormality in air mix servomotor system is detected.
Action of control panel
• Stops the air mix servomotor. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause
Possible causes and standard value in normal state
Defective air mix servo1 motor (Internal defect)
The air mix servomotor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)
3
20-556 (1)
Standard value in normal state/Remarks on troubleshooting
Defective air conditioner system
Wiring harness between MAM (female) (1) and M29 (female) (11)
Resistance
Max. 1 z
Wiring harness between MAM (female) (3) and M30 (female) (3)
Resistance
Max. 1 z
Wiring harness between MAM (female) (5) and M30 (female) (2)
Resistance
Max. 1 z
Wiring harness between MAM (female) (6) and M29 (female) (4)
Resistance
Max. 1 z
Wiring harness between MAM (female) (7) and M29 (female) (5)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC400/450(LC)-7
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Abnormality in recirculated and fresh air damper
E45 Contents of trouble
• Abnormality in recirculated and fresh air servomotor system is detected.
Action of control panel
• Stops the recirculated and fresh air servomotor. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective recirculated 1 and fresh air servomotor (Internal defect)
The recirculated and fresh air servomotor may be defective. Check it directly.
2 Defective fuse (in unit)
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector)
4
Defective air conditioner system
PC400/450(LC)-7
Wiring harness between MRF (female) (1) and M29 (female) (6)
Resistance
Max. 1 z
Wiring harness between MRF (female) (3) and M29 (female) (7)
Resistance
Max. 1 z
Wiring harness between MRF (female) (7), fuse in unit, and M33 (female) (3)
Resistance
Max. 1 z
If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-557 (1)
TROUBLESHOOTING
E-31
Electrical Circuit Diagram for Air Conditioner
20-558 (1)
PC400/450(LC)-7
TROUBLESHOOTING
E-31
Troubleshooting by failure phenomenon Trouble
• The air conditioner does not operate.
(1) The air conditioner does not operate at all.
Related information Cause 1 Defective fuse No. 11
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Wiring harness between fuse 11 outlet and M33 (male) (3)
Resistance
Max. 1z
Wiring harness between M27 (female) (14) and M30 (female) (6)
Resistance
Max. 1z
Wiring harness between M33 (male) (2) and chassis ground
Resistance
Max. 1z
Wiring harness between M29 (female) (12) and chassis ground
Resistance
Max. 1z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between circuit breaker fuse 11 outlet and M33 (male) (3) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between M27 (female) (14) and M30 (female) (6) and chassis ground
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Defective air conditioner unit
M33
Voltage
Between (2) and (3)
20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective control panel
M30, M29
Voltage
Between M30 (6) and M29 (12)
20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control panel is defective.
PC400/450(LC)-7
20-559 (1)
TROUBLESHOOTING
Trouble
E-31
• The air conditioner does not operate.
(2) Air does not come out (Air flow is insufficient).
Related information Cause 1 Defective fuse (in unit)
2
3
Defective blower relay (on coil side)
Defective blower relay (on contact side)
Possible causes and standard value in normal state
Defective power transis4 tor (Internal defect)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R30 (male)
Resistance
Between (1) and (3)
140 – 340 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. R30
Fan switch
Voltage
Between (4) and chassis ground
ON (Operated)
20 – 30 V
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch
If air flow can be changed with fan switch, Operate in range of Low, Medium, and High power transistor is normal. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5
Defective blower motor (Internal defect)
MB (female)
Fan switch
Voltage
Between (1) and (2)
ON (Operated)
20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 6 in wiring harness or defective contact in connector)
7
20-560 (1)
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
Defective air conditioner system
Wiring harness between fuse 11 outlet, fuse in unit, R30 (3), R31 (female) (1), and M30 (female) (6)
Resistance
Max. 1 z
Wiring harness between M29 (female) (3) and R30 (female) (1)
Resistance
Max. 1 z
Wiring harness between M29 (female) (12) and chassis ground
Resistance
Max. 1 z
Wiring harness between MB (female) (1) and R30 (female) (4)
Resistance
Max. 1 z
Wiring harness between MB (female) (2) and PTR (female) (3)
Resistance
Max. 1 z
Wiring harness between PTR (female) (1) and chassis ground
Resistance
Max. 1 z
Wiring harness between PTR (female) (2) and M30 (female) (7)
Resistance
Max. 1 z
Wiring harness between PTR (female) (4) and M30 (female) (8)
Resistance
Max. 1 z
If none of causes 1 – 6 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC400/450(LC)-7
TROUBLESHOOTING
Trouble
E-31
• The air conditioner does not operate.
(3) Air is not cooled (Cooling capacity is low).
Related information Cause 1 Defective fuse (in unit)
2
3
Possible causes and standard value in normal state
4
Defective compressor relay (on coil side)
Defective compressor relay (on contact side)
Defective thermostat (Internal defect)
Defective high/low pres5 sure switch (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R31 (male)
Resistance
Between (1) and (2)
140 – 340 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position). R31
Fan switch
Voltage
Between (4) and chassis ground
ON (Operated)
20 – 30 V
The thermostat may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P17 (male)
Resistance
Between (1) and (2)
Max. 1 z
6
Defective compressor clutch (Internal defect)
The compressor clutch may be defective. Check it directly.
7
Defective compressor (Internal defect)
The compressor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 8 in wiring harness or defective contact in connector)
9
Defective air conditioner system
PC400/450(LC)-7
Wiring harness between M30 (female) (4) and P17 (female) (1)
Resistance
Max. 1 z
Wiring harness between P17 (female) (2) and chassis ground
Resistance
Max. 1 z
Wiring harness between fuse 11 outlet, R31 (female) (2), fuse in unit, R31 (female) (1), and M30 (female) (6)
Resistance
Max. 1 z
Wiring harness between ST1 (female) (1) and R31 (female) (3)
Resistance
Max. 1 z
Wiring harness between M29 (female) (2) and ST1 (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (12) and chassis ground
Resistance
Max. 1 z
Wiring harness between R31 (female) (4) and M34 (female) (1)
Resistance
Max. 1 z
If none of causes 1 – 8 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-561 (1)
TROUBLESHOOTING
E-31
Electrical Circuit Diagram for Air Conditioner
20-562 (1)
PC400/450(LC)-7
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) System chart for hydraulic and mechanical system .................................................................................... 20-602 H-1 All work equipment lack power, or travel and swing speeds are slow.................................................. 20-605 H-2 Engine speed sharply drops or engine stalls ....................................................................................... 20-606 H-3 No work equipment, travel or swing move ........................................................................................... 20-607 H-4 Abnormal noise is heard from around hydraulic pump......................................................................... 20-607 H-5 Auto-decelerator does not work ........................................................................................................... 20-608 H-6 Fine control mode does not function .................................................................................................... 20-608 H-7 Boom moves slowly or lacks power ..................................................................................................... 20-609 H-8 Arm moves slowly or lacks power ........................................................................................................ 20-610 H-9 Bucket moves slowly or lacks power.................................................................................................... 20- 611 H-10 Work equipment does not move in its single operation...................................................................... 20- 611 H-11 Work equipment has a bit too fast hydraulic drift................................................................................ 20-612 H-12 Work equipment has big time lag ....................................................................................................... 20-613 H-13 Other work equipment moves when relieving single circuit................................................................ 20-613 H-14 One-touch power max. function does not work .................................................................................. 20-613 H-15 Machine push-up function does not work........................................................................................... 20-614 H-16 In compound operation, work equipment with larger load moves slowly ........................................... 20-615 H-17 In swing + boom RAISE operation, boom moves slowly.................................................................... 20-615 H-18 In swing + travel, travel speed drops sharply ..................................................................................... 20-615 H-19 Machine swerves in travel .................................................................................................................. 20-616 H-20 Machine travels slowly ....................................................................................................................... 20-617 H-21 Machine cannot be easily steered or lacks power ............................................................................. 20-618 H-22 Travel speed does not shift, or it is slower or faster than preset speed. ............................................ 20-619 H-23 Track shoe does not turn (on one side only) ...................................................................................... 20-620 H-24 Machine does not swing..................................................................................................................... 20-621 H-25 Swing acceleration is poor, or swing speed is slow ........................................................................... 20-622 H-26 Excessive overrun when stopping swing ........................................................................................... 20-623 H-27 There is big shock when stopping swing............................................................................................ 20-624 H-28 There is big abnormal noise caused when stopping swing ................................................................ 20-624 H-29 Swing natural drift is too big ............................................................................................................... 20-625 H-30 Attachment circuit does not change ................................................................................................... 20-626 H-31 Flow rate in attachment circuit cannot be adjusted ............................................................................ 20-626
PC400/450(LC)-7
20-601 (1)
TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM
20-602 (1)
PC400/450(LC)-7
TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.
PC400/450(LC)-7
20-603 (1)
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Failure information
Phenomena occurring on machine
Relative information
Information on occurred failures and troubleshooting
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
1
2 Cause for presumed failure (The attached No. for 3 filing and reference purpose only. It does not stand for any priority) 4
• The standard values in normalcy by which to judge “good” or “no good” about presumed causes. • References for making judgement of “good” or “no good”
5
20-604 (1)
PC400/450(LC)-7
TROUBLESHOOTING
H-1
H-1 All work equipment lack power, or travel and swing speeds are slow Failure information
• 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 a 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 ± 10kg/cm2}
a Stop engine for preparations. Start troubleshooting at engine high idling. Improper adjustment or 2 malfunctioning of main relief valve
Malfunctioning of 3 self pressure decompression valve
Control lever
Main relief pressure
Arm, DIGGING
33.34 – 36.77 MPa {340 – 375kg/cm2}
If the pressure does not return to normalcy even after the adjustment, malfunctioning of main relief valve or its internal failure is suspected. In that case, check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.84 – 3.43 MPa {29 – 35kg/cm2}
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure to be measured Improper adjustment or 4 malfunctioning of PC valve
Pump delivery pressure PC valve output pressure
Measurement condition Swing lock: ON Arm: Digging relief
Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of PC valve or its internal failure is suspected. In that case, check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. 5
Malfunctioning of LS-EPC valve
Travel speed
Travel control lever
LS-EPC output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {Approx. 14 kg/cm2}
Hi
OPERATED
0 MPa {0 kg/cm2}
a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured Improper adjustment or 6 malfunctioning of LS valve
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)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of LS valve or its internal failure is suspected. In that case, check the valve itself. 7
Malfunctioning of servo piston
8 Piston pump defective
PC400/450(LC)-7
Malfunctioning of servo piston is suspected. Check the piston itself. If none of the above listed causes is detected, the piston pump is suspected of deteriorated performance, malfunctioning or internal failure.
20-605 (1)
TROUBLESHOOTING
H-2
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 a Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or 1 malfunctioning of main relief valve
Control lever
Main relief pressure
Arm, DIGGING
33.34 – 36.77 MPa {340 – 375kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the main relief valve or its internal failure is suspected. In that case, check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Oil pressure to be measured Improper adjustment or 2 malfunctioning of PC valve
Pump delivery pressure PC valve output pressure
Measurement condition Swing lock: ON Arm: Digging relief
Oil pressure ratio 1 Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the PC valve or its internal failure is suspected. In that case, check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured Improper adjustment or 3 malfunctioning of LS valve
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)
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.
20-606 (1)
PC400/450(LC)-7
TROUBLESHOOTING
H-3, H-4
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.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling. 1
Malfunctioning of PPC lock solenoid valve
Malfunctioning of 2 self pressure decompression valve
Safety lock lever
Solenoid output pressure
Locked
0 MPa {0 kg/cm2}
Released
2.84 – 3.43 MPa {29 – 35kg/cm2}
a Stop engine for preparations. Start troubleshooting at engine high idling. Control lever
Control circuit source pressure
All control levers in NEUTRAL position
2.84 – 3.43 MPa {29 – 35kg/cm2}
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 Failure information
• An abnormal noise is heard from around the hydraulic pump.
Relative information
—
Presumed cause and standard value in normalcy
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
PC400/450(LC)-7
The piston pump is suspected of an internal failure. Check the pump itself.
20-607 (1)
TROUBLESHOOTING
H-5, H-6
H-5 Auto-decelerator does not work • 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
Failure information
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Operation
Above 2.75 MPa {Above 28 kg/cm2}
Malfunctioning of travel 1 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 a Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of LS1 EPC valve
2
Orifice in LS circuit clogged
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {Approx. 14 kg/cm2}
Hi
OPERATED
0 MPa {0 kg/cm2}
The orifice in the LS circuit is presumed to be clogged. Check the orifice itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured
Improper adjustment or 3 malfunctioning of LS valve
All control levers in NEUTRAL
Pump delivery pressure PC valve output pressure
Travel without load (control lever held at half stroke) 1
Nearly equal oil pressure
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
20-608 (1)
Malfunctioning of servo piston
Malfunctioning of the servo piston is suspected. Check the piston itself.
PC400/450(LC)-7
TROUBLESHOOTING
H-7
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 a Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of right PPC valve (in boom circuit)
R.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Boom RAISE Boom LOWER
Above 2.75 MPa {Above 28 kg/cm2}
a 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 kg/cm2}
Operated (Note)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
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 • Hi) 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 con- The check valve in the boom control valve (Hi) is presumed to malfunction. Check trol valve (check valve) 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.
Malfunctioning of boom 10 control valve (suction valve) or seal defective
The suction valve (bottom side) in the boom control valve (Lo) is presumed to malfunction, or the seal is suspected to be defective.
Malfunctioning of boom control valve (safety and 11 suction valves) or seal defective
The safety and suction valves (head side) in the boom control valve (Lo) are presumed to malfunction, or the seal is suspected to be defective. Check those valves themselves.
Malfunctioning of LS shuttle valve (left travel, 12 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. a Stop engine for preparations. Start troubleshooting at engine high idling.
13 Boom cylinder defective
Note:
Boom cylinder
Amount oil leakage from cylinder
Raise relief
20 cc/min
Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
PC400/450(LC)-7
20-609 (1)
TROUBLESHOOTING
H-8
H-8 Arm moves slowly or lacks power Failure information
• 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 a Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of left PPC valve (arm circuit)
1
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Arm DIGGING Arm DUMPING
Above 2.75 MPa {Above 28 kg/cm2}
a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of merge/ divide solenoid valve
Presumed cause and standard value in normalcy
2
Travel lever
Solenoid output pressure
Neutral
0 MPa {0 kg/cm2}
Operated (Note)
2.84 – 3.43 MPa {29 – 35 kg/cm2}
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 arm control valve (spool)
The spool in the arm control valve (Lo • Hi) is presumed to malfunction. Check the valve itself.
5
Malfunctioning of arm control valve (pressure compensation valve)
The pressure compensation valve in the arm control valve (Lo • Hi) is presumed to malfunction. Check the valve itself.
6
Malfunctioning of arm control valve (regeneration valve)
The generation valve in the arm control valve (Lo) is presumed to malfunction, or the seal is suspected to be defective. Check the valve itself.
7
Malfunctioning of arm control valve (safety and suction valves) or seal defective
The safety and suction valves in the arm control valve (Lo • Hi) are presumed to malfunction, or the seal is suspected of defect. Check those valves themselves.
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. a Stop engine for preparations. Start troubleshooting at engine high idling.
10 Arm cylinder defective
Note:
Amount oil leakage from cylinder
Digging relief
20 cc/min
Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
20-610 (1)
Arm cylinder
PC400/450(LC)-7
TROUBLESHOOTING
H-9, H-10
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 a Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of right 1 PPC valve (bucket circuit)
2
Malfunctioning of bucket control valve (spool)
R.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Bucket DIGGING Bucket DUMPING
Above 2.75 MPa {Above 28 kg/cm2}
The spool in the bucket control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of bucket 3 control valve (pressure compensation valve)
The pressure compensation valve in the bucket control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of bucket control valve (safety and 4 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. a 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
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
• 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.
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of PPC valve
Malfunctioning of work 2 equipment control valve (spool)
PC400/450(LC)-7
Work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Operated
Above 2.75 MPa {Above 28 kg/cm2}
The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
20-611 (1)
TROUBLESHOOTING
H-11
H-11 Work equipment has a bit too fast hydraulic drift • 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
Failure information
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
1 Boom cylinder defective
Boom cylinder
Amount oil leakage from cylinder
Raise relief
20 cc/min
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.
Failure information
• 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.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Arm cylinder defective
Arm control valve (safety 2 and suction valves) seal defective
Arm cylinder
Amount oil leakage from cylinder
Digging relief
20 cc/min
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.)
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.
Arm control valve 4 (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.
3
Failure information
• 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.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling. 1 Bucket cylinder defective
Amount oil leakage from cylinder
Digging relief
20 cc/min
Bucket control valve 2 (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.)
Bucket control valve (spool) seal defective
The seal for spool in the bucket control valve is suspected to be defective. Check the seal itself.
Bucket control valve 4 (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.
3
20-612 (1)
Bucket cylinder
PC400/450(LC)-7
TROUBLESHOOTING
H-12, H-13, H-14
H-12 Work equipment has big time lag Failure information
• The work equipment has a big time lag.
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
Malfunctioning of 1 LS-EPC valve
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {approx. 14 kg/cm2}
Hi
Operation
0 MPa {0 kg/cm2}
Malfunctioning of control valve (regeneration 2 valve) - with boom and arm only
The regeneration valve in the control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of control 3 valves (safety & suction valve)
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.)
Malfunctioning of control 4 valve (pressure compensation valve)
The pressure compensation valve of the control valve is presumed to malfunction. Check the valve itself directly.
H-13 Other work equipment moves when relieving single circuit • 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
Control valve (pressure 1 compensation valve) seal defective
Standard value in normalcy and references for troubleshooting
The seal for pressure compression valve in the control valve is suspected to be defective. Check the seal itself.
H-14 One-touch power max. function does not work • 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 a Stop engine for preparations. Start troubleshooting at engine high idling.
1
2
Malfunctioning of 2-stage solenoid valve
Malfunctioning of main relief valve
PC400/450(LC)-7
Swing lock switch
Solenoid valve output pressure
OFF
0 MPa {0 kg/cm2}
ON
2.84 – 3.43 MPa {29 – 35kg/cm2}
The main relief valve of control valve is presumed to malfunction. Check the valve itself.
20-613 (1)
TROUBLESHOOTING
H-15
H-15 Machine push-up function does not work • 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
Failure information
Cause
a Prepare with starting switch OFF, then run engine at high idling and carry out troubleshooting. 1
Malfunction of machine push-up solenoid valve
Malfunction of boom 2 control valve (safety-suction valve)
20-614 (1)
Standard value in normalcy and references for troubleshooting
Machine push-up switch
Solenoid outlet pressure
OFF
Min. 2.75 MPa {Min. 28 kg/cm3}
ON
0 MPa {0 kg/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.
PC400/450(LC)-7
TROUBLESHOOTING
H-16, H-17, H-18
H-16 In compound operation, work equipment with larger load moves slowly Failure information
• In a compound operation, work equipment with larger load tends to move slowly.
Relative information
—
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
The pressure compensation valve for the work equipment with larger load is presumed to malfunction. Check the valve itself.
Malfunctioning of pressure compensation 1 valve for work equipment with larger load
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
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
Malfunctioning of LS 1 select valve or seal defective
Standard value in normalcy and references for troubleshooting
The LS select valve of control valve is presumed to malfunction, or the seal is suspected to be defective. Check the valve and seal themselves.
H-18 In swing + travel, travel speed drops sharply • 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
Malfunctioning of LS 1 shuttle valve (left travel and swing)
PC400/450(LC)-7
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.
20-615 (1)
TROUBLESHOOTING
H-19
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 a Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of travel 1 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 kg/cm2}
Differential output between right and left sides
0.4 MPa {4 kg/cm2}
a 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 kg/cm2}
a Stop engine for preparations. Start troubleshooting at engine high idling. Presumed cause and standard value in normalcy
Oil Pressure ratio Improper adjustment or 3 malfunctioning of LS valve
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)
a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of travel 4 interlocking solenoid valve
Travel control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Operating one side only
2.84 – 3.43 MPa {29 – 35 kg/cm2}
5
Malfunctioning of travel interlocking valve
The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
6
Malfunctioning of travel control valve (spool)
The spool in the travel interlocking valve is presumed to malfunction. Check the spool itself.
Malfunction of travel 7 motor
8 Final drive defective
20-616 (1)
Oil pressure to be measured
a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever
Amount of oil leakage from travel motor
Travel relief
40 l/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.)
PC400/450(LC)-7
TROUBLESHOOTING
H-20
H-20 Machine travels slowly Failure information
a The machine's travel speed is slow.
Relative information
a Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of travel 1 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 kg/cm2}
Output differential between right and left or front and rear
Below 0.4 MPa {Below 4 kg/cm2}
a 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 – 35kg/cm2}
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling.
3
4
Malfunctioning of LS-EPC valve
Malfunction of travel control valve (spool)
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.37 MPa {approx. 14 kg/cm2}
Hi
Operated
0 MPa {0 kg/cm2}
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.
Malfunctioning of travel 6 control valve (suction valve)
The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
7
Malfunctioning of LS shuttle valve (bucket)
7
Malfunction of travel motor
8 Final drive defective
PC400/450(LC)-7
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. Travel control lever
Amount of oil leakage from travel motor
Travel relief
40 l/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-21
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 a 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 kg/cm2}
Operating one side only
Above 2.75 MPa {Above 28 kg/cm2}
a Stop engine for preparations. Start troubleshooting at engine high idling. 2
3
Malfunctioning of travel interlocking solenoid valve Malfunctioning of travel interlocking valve
Travel control lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Operating one side only
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling. 4
Travel control lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
OPERATED
2.84 – 3.43 MPa {29 – 35 kg/cm2}
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.
Check valve seal 10 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.
Malfunctioning of travel 11 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.)
Malfunctioning of travel 12 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.)
20-618 (1)
Malfunctioning of merge/ divide solenoid valve
PC400/450(LC)-7
TROUBLESHOOTING
H-22
H-22 Travel speed does not shift, or it is slower or faster than preset speed. Failure information
• 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 a Stop engine for preparations. Start troubleshooting at engine high idling. Travel speed
Travel control lever
Monitoring [01500]
Lo
Fine control (to the extent that the decelerator is released)
740 mA
Presumed cause and standard value in normalcy
Mi 1
Malfunctioning of LS-EPC valve
Hi
690 mA 0 mA
a 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 {approx. 14 kg/cm2}
Hi
Operation
0 MPa {0 kg/cm2}
a Stop engine for preparations. Start troubleshooting at engine high idling. Malfunctioning of travel 2 speed solenoid valve
3
Malfunctioning of travel motor (speed shifting)
PC400/450(LC)-7
Travel speed
Travel control lever
Solenoid output pressure
Lo
NEUTRAL
0 MPa {0 kg/cm2}
Hi
Operation
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The travel motor is presumed to malfunction when shifting speed. Check the speed shifting portion directly.
20-619 (1)
TROUBLESHOOTING
H-23
H-23 Track shoe does not turn (on one side only) Failure information
• 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
Cause 1
Travel control valve (suc- The suction valve seat in the travel control valve is suspected of defect. Check the tion valve) seat defective seat itself.
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. a Stop engine for preparations. Start troubleshooting at engine high idling.
4 Travel Motor speed
5 Final drive defective
20-620 (1)
Standard value in normalcy and references for troubleshooting
Travel control lever
Amount of oil leakage from travel motor
Travel relief
40 l/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.)
PC400/450(LC)-7
TROUBLESHOOTING
H-24
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 a Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of swing 1 holding brake solenoid valve
Presumed cause and standard value in normalcy
2
Malfunctioning of swing motor (holding brake)
R.H. work equipment control lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Swing operated
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The parking brake portion of the swing motor is presumed to malfunction. Check it directly. a Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or 3 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 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. 4 Swing motor defective
5
Swing machinery defective
L.H. work equipment control lever
Amount of oil leakage from swing motor
Swing relief
Below 11 l/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.)
Failure information
• 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.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling. 1
2
Malfunctioning of swing PPC valve Malfunctioning of swing control valve (spool)
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Swing operated
Above 2.75 MPa {Above 28 kg/cm2}
The spool in the swing control valve is presumed to malfunction. Check the spool itself.
Swing motor (suction 3 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.)
Swing motor (check 4 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.)
PC400/450(LC)-7
20-621 (1)
TROUBLESHOOTING
H-25
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.
Cause Malfunctioning of LS 1 shuttle valve (all LS shuttles)
Presumed cause and standard value in normalcy
2
Malfunctioning of swing motor (holding brake)
Standard value in normalcy and references for troubleshooting The LS shuttle valves for all the control valves are presumed to malfunction. Check them directly. The swing holding brake portion of the swing motor is presumed to malfunction. Check it directly. a Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or 3 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 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. 4 Swing motor defective
5
Swing machinery defective
L.H. work equipment control lever
Amount of oil leakage from swing motor
Swing relief
Below 11 l/min
Inside of the swing machinery is presumed to malfunction. Check itself. (Whether it is defective or not may well be determined by abnormal noise, abnormal generation of heat and the mixture of the metal particles in drain oil.)
Failure information
• 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.
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Swing operated
Above 2.75 MPa {Above 28 kg/cm2}
Malfunctioning of swing control valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of swing 3 control valve (pressure compensation valve)
The pressure compensation valve in the swing motor is presumed to malfunction. Check the valve itself.
Swing motor (suction 4 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.)
Swing motor (check 5 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.)
2
20-622 (1)
Malfunctioning of swing PPC valve
PC400/450(LC)-7
TROUBLESHOOTING
H-26
H-26 Excessive overrun when stopping swing Failure information
• 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.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
a Stop engine for preparations. Start troubleshooting at engine high idling.
Improper adjustment or 1 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 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. a Stop engine for preparations. Start troubleshooting at engine high idling. 2 Swing motor defective
L.H. work equipment control lever
Amount of oil leakage from swing motor
Swing relief
Below 11 l/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.
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Malfunctioning of swing PPC valve
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Swing operated
Above 2.75 MPa {Above 28 kg/cm2}
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.
Swing motor (suction 4 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.)
Swing motor (check 5 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.)
PC400/450(LC)-7
20-623 (1)
TROUBLESHOOTING
H-27, H-28
H-27 There is big shock when stopping swing Failure information
• 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
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of swing PPC valve
L.H. work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Swing operated
Above 2.75 MPa {Above 28 kg/cm2}
2
Malfunctioning of swing PPC slow return valve
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.)
3
Malfunctioning of swing motor (shockless valve)
The swing motor shockless valve is presumed to malfunction. Check the valve itself.
H-28 There is big abnormal noise caused when stopping swing Failure information
• 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
Cause Malfunctioning of 1 backpressure valve 2
Malfunction of swing 3 motor (suction valve)
4
20-624 (1)
Malfunction of swing motor (safety valve)
Swing machinery defective
Standard value in normalcy and references for troubleshooting The backpressure valve is presumed to malfunction. Check the valve itself. The safety valve in the swing motor is presumed to malfunction. Check the valve itself. The seal in suction valve of the swing motor is suspected of defect. Check the seal itself. (Whether the seal is defective or not may well be determined by swapping the right and left valves and watching the result.) The swing machinery is suspected of an internal failure. Check the inside of the machinery itself. (A failure inside the swing machinery may well be determined by monitoring abnormal noise, abnormal heat generated or metal dust or chips contained in the drained oil.)
PC400/450(LC)-7
TROUBLESHOOTING
H-29
H-29 Swing natural drift is too big • Swing natural drift is too big. (1) When the swing holding brake is activated.
Relative 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.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting a Stop engine for preparations. Start troubleshooting at engine high idling.
Swing and holding brake 1 solenoid valve malfunctioned Swing motor (parking 2 brake portion) malfunctioned
R.H. work equipment control lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Swing operated
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that portion directly.
Failure information
• Swing natural drift is too big. (2) When the swing holding brake is released.
Relative information
• 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.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Swing control valve 1 (spool) malfunctioned
The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly.
Swing control valve 2 (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.
Swing motor (shockless 6 valve) malfunctioned or seal defective
PC400/450(LC)-7
The shockless valve in the swing motor is suspected of malfunction or the seal is suspected of defect. Check the valve or seal itself directly.
20-625 (1)
TROUBLESHOOTING
H-30, H-31
H-30 Attachment circuit does not change When attachment is installed Failure information
• The return circuit of the attachment circuit does not change.
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 a Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.
Malfunction of 1 attachment return selector solenoid valve
Working mode
Solenoid valve output pressure
Mode E or A
0 MPa {0 kg/cm2}
Mode B
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunction of 2 attachment return selector valve
The attachment return selector valve may have a malfunction. Check it directly.
Malfunction of service 3 control valve (safety valve)
The safety valve of the service control valve (on port B side) may have a malfunction. Check it directly.
H-31 Flow rate in attachment circuit cannot be adjusted When attachment is installed Failure information
• 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 Malfunction of 1 attachment flow rate adjustment EPC valve
The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly. a Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.
2
20-626 (1)
Standard value in normalcy and references for troubleshooting
Malfunction of service PPC valve
Wiring harness connector
Service pedal
PPC valve output pressure
Disconnect connector V30 of attachment flow rate adjustment EPC valve.
In NEUTRAL
0 MPa {0 kg/cm2}
Operated
Above 2.75 MPa {Above 28 kg/cm2}
PC400/450(LC)-7
TROUBLESHOOTING OF ENGINE (S MODE) POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-702 METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-703 S-1 Starting performance is poor (starting always takes time).................................................................... 20-706 S-2 Engine does not start ........................................................................................................................... 20-707 S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................................... 20-710 S-4 Engine stops during operations ............................................................................................................ 20- 711 S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-712 S-6 Engine lacks output (or lacks power) ................................................................................................... 20-713 S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 20-714 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-715 S-9 Oil becomes contaminated quickly ....................................................................................................... 20-716 S-10 Fuel consumption is excessive........................................................................................................... 20-717 S-11 Oil is in cooling water (or water spurts back, or water level goes down) ............................................ 20-718 S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-719 S-13 Oil level rises (water, fuel in oil) .......................................................................................................... 20-720 S-14 Water temperature becomes too high (overheating) .......................................................................... 20-721 S-15 Abnormal noise is made..................................................................................................................... 20-722 S-16 Vibration is excessive ......................................................................................................................... 20-723
PC400/450(LC)-7
20-701 (1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the water temperature to go down before removing the radiator cap. k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?
3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 5) Check for any error display on the controller. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Us e th e r e s u l ts o f t he i nv e s ti g a ti o n a n d inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-702 (1)
PC400/450(LC)-7
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation.
[Questions] Sections + in the chart on the right corresponds to the items where answers can be obtained from the user. The items in are items that can be obtained from the user, depending on the user's level.
[Check items] The serviceman carries out simple inspection to narrow down the causes. The items under in the chart on the right correspond to this. The serviceman narrows down the causes from information that he has obtained from the user and the results of that he has obtained from his own inspection.
[Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with , and of these, causes that have a high probability are marked with . Check each of the [Questions] and [Check items] in turn, and marked the or in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting. Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference.
PC400/450(LC)-7
20-703 (1)
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
Exhaust smoke is black S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
20-704 (1)
PC400/450(LC)-7
TROUBLESHOOTING
PC400/450(LC)-7
METHOD OF USING TROUBLESHOOTING CHARTS
20-705 (1)
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (starting always takes time) General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel a With the common rail fuel injection system, the fuel injection timing is recognized electrically, so even when the starting operation is carried out, the engine may not start until the crankshaft has completed two rotations. However, this does not indicate any abnormality.
20-706 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-2
S-2 Engine does not start a) Engine does not turn General causes why engine does not turn • Internal parts of engine seized a See “Engine stops during operations”. • Defective electrical system • Failure on chassis side
PC400/450(LC)-7
20-707 (1)
TROUBLESHOOTING
S-2
b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter)
20-708 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-2
c) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel
PC400/450(LC)-7
20-709 (1)
TROUBLESHOOTING
S-3
S-3 Engine does not pick up smoothly (follow-up is poor) General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
20-710 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-4
S-4 Engine stops during operations General causes why engine stops • Internal part of engine seized • Insufficient supply of fuel • Engine overheating a See troubleshooting for [Overheat]. • Failure on chassis side
PC400/450(LC)-7
20-711 (1)
TROUBLESHOOTING
S-5
S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly • Air in fuel system • Speed sensor is not normal (abnormality not big enough to generate error display)
20-712 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-6
S-6 Engine lacks output (or lacks power) General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
PC400/450(LC)-7
20-713 (1)
TROUBLESHOOTING
S-7
S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)
20-714 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive • Abnormal combustion of oil • The engine has been run at low or high idling for a long time continuously (more than 20 minutes continuous operation is not allowed). • External leakage of oil • Wear of lubrication system
PC400/450(LC)-7
20-715 (1)
TROUBLESHOOTING
S-9
S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Improper fuel used • Improper oil used • Operation under excessive load
20-716 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection (injection pressure, injection timing) • Excessive injection of fuel
PC400/450(LC)-7
20-717 (1)
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water (or water spurts back, or water level goes down) General causes why oil is in cooling water • Internal leakage in lubrication system • Internal leakage in cooling system
20-718 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure) General causes why oil pressure drops • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper oil used (improper viscosity) • Deterioration of oil due to overheating
PC400/450(LC)-7
20-719 (1)
TROUBLESHOOTING
S-13
S-13 Oil level rises (water, fuel in oil) General causes why oil level rises • Water in oil (cloudy white) • Fuel in oil (diluted, smells of diesel fuel) a If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”.
20-720 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (overheating) General causes why water temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Defective cooling circulation system • Rise of hydraulic oil temperature on chassis side
PC400/450(LC)-7
20-721 (1)
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system a Judge if the noise is an internal noise or an external noise. a If the engine is not thoroughly warmed up, the engine sound becomes slightly louder because it is operated in the low temperature mode, but this is not an abnormality. a When the engine is accelerated, it enters the acceleration mode and the engine noise is higher for 3 seconds, but this is not an abnormality.
20-722 (1)
PC400/450(LC)-7
TROUBLESHOOTING
S-16
S-16 Vibration is excessive General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment with machine • Abnormal combustion a If there is abnormal noise together with the vibration, carry out troubleshooting also for “Abnormal noise is made”.
PC400/450(LC)-7
20-723 (1)
30 DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL.................... 30PRECAUTIONS WHEN PERFORMING OPERATION ............................................30SPECIAL TOOL LIST .................................... 30REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY ................ 30REMOVAL AND INSTALLATION OF ENGINE REAR SEAL ............................................. 30REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...........................................30REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY.................... 30REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY ...........................30REMOVAL AND INSTALLATION OF NOZZLE TIP ............................................30REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY ............. 30REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...........................30REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY .30REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY .... 30REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY................................ 30REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY .............................................. 30DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY .............................................. 30REMOVAL AND INSTALLATION OF SPROCKET ............................................. 30REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .............................................. 30DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY ..................................30DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY ............. 30DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...............................30DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY .............................................. 30PC400/450(LC)-7
2 4 6 13 20 24 27 30 33 35 36 38 40 45 46 47 54 55 56 63 65 66
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY................. 30- 69 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY................................... 30- 71 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY .......... 30- 73 REMOVAL AND INSTALLATION OF OPERATOR’S CAB ................................. 30- 75 REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY............................ 30- 78 REMOVAL AND INSTALLATION OF PUMP CONTROLLER ........................................ 30- 79 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ........................................ 30- 80 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY .......... 30- 81 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY............. 30- 84 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.............. 30- 85 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY............. 30- 87 REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT ... 30- 90 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY ............... 30- 91 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY ............... 30- 94 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY .... 30- 98 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY .... 30-100 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY... 30-101 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY........... 30-102 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..... 30-103 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY ....................... 30-108 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) ..................................... 30- 111 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY ............................. 30-121
30-1 (2)
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
HOW TO READ THIS MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES SPECIAL TOOLS • Special tools that are deemed necessary for removal or installation of parts are listed. • List of the special tools contains the following kind of information. 1) Necessity t: Special tools which cannot be substituted, should always be used. q:Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. a Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
INSTALLATION OF PARTS • Except where otherwise instructed, install parts is the reverse order of removal. • Instructions and precautions for installing parts are shown with [*1] mark in the INSTALLATION Section, identifying which step the instructions are intended for. • Marks shown in the INSTALLATION Section stand for the following. k
This mark indicates safety-related precautions which must be followed when doing the work. a This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5 This mark indicates an amount of oil or water to be added. SKETCHES OF SPECIAL TOOLS • Various special tools are illustrated for the convenience of local manufacture.
REMOVAL OF PARTS • The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the REMOVAL Section are explained and listed below. k
This mark indicates safety-related precautions which must be followed when doing the work.
a
This mark gives guidance or precautions when doing the procedure.
[*1]
This mark shows that there are instructions or precautions for installing parts.
6 This mark shows oil or water to be drained.
30-2 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES SPECIAL TOOLS • Special tools which are deemed necessary for disassembly and assembly are listed in this section. • List of the special tools contains the following kind of information. 1) Necessity t: Special tools which cannot be substituted, should always be used. q: Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
ASSEMBLY • Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil or water to be added. • Various symbols used in the ASSEMBLY Section are explained and listed below. k
This mark indicates safety-related precautions which must be followed when doing the work. a This mark gives guidance or precautions when doing the procedure. 2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5 This mark indicates an amount of oil or water to be added. SKETCHES OF SPECIAL TOOLS • Various special tools are illustrated for the convenience of local manufacture.
4) Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx. DISASSEMBLY • The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. • Various symbols used in the DISASSEMBLY Section are explained and listed below. k
This mark indicates safety-related precautions which must be followed when doing the work.
a
This mark gives guidance or precautions when doing the procedure.
[*1]
This mark shows that there are instructions or precautions for installing parts.
6 This mark shows oil or water to be drained.
PC400/450(LC)-7
30-3 (2)
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN PERFORMING OPERATION
PRECAUTIONS WHEN PERFORMING OPERATION Be sure to follow the general precautions given below when performing removal or installation (disassembly or assembly) of units. 1. Precautions when performing removal work • If the engine coolant water contains antifreeze, dispose of it properly. • After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake during assembly. • To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wiring, hold onto the connectors when disconnecting them. • Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any mistakes when re-installing. • Count and check the number and thickness of the shims, and keep them in a safe place. • When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembly Install the following blind plugs into the piping after disconnecting it during disassembly operations. A. Face seal type hoses and tubes Nominal number
Plug (nut end)
Nut (elbow end)
02
07376-70210
02789-00210
03
07376-70315
02789-00315
04
07376-70422
02789-00422
05
07376-70522
02789-00522
06
07376-70628
02789-00628
B. 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
C. If the part is not under hydraulic pressure, the following corks can be used.
06
30-4 (2)
Dimensions 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
27
07049-02734
27 22.5 34
20
Taper 1/8
ød
Part Number
øD
Nominal number
L
DEW00401
30
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
2. • • • • • • • • • • • • •
PRECAUTIONS WHEN PERFORMING OPERATION
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press-fitting parts, coat the surface with anti-friction compound (LM-P). After installing snap rings, check that the snap ring is installed securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect it securely. When using eye bolts, check that there is no deformation or deterioration. Screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other hydraulic equipment removed for repair, bleed the air as follows: 1) Start the engine and run it at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the cylinders 100 mm from the end of their stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this run the engine at normal speed. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operations • If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified level. Run the engine to circulate the coolant water through the system. Then check the coolant water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed for repair, bleed the air from the system after reassembling the parts. a For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
PC400/450(LC)-7
30-5 (2)
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST a Tools with part number 79 Ttured).
-
cannot be supplied (they are items to be locally manufac-
a Necessity:
t............Cannot be substituted, must always be installed (used) q............Extremely useful if available or can be substituted with commercially available part a New/Remodel: N............Tools with new part numbers, newly developed for this model R: ...........Tools with upgraded part numbers, remodeled from items already available for other models Blank: ....Tools already available for other models, can be used without any modification
Q'ty
Puller
t
1
Removal, installation of nozzle holder assembly
2 790-331-1110
Wrench
q
1
Tightening of cylinder head bolt
3 795-931-1100
Seal puller
t
1
Removal of engine seal
Push tool
t
1
4 • 01050-31625 • Bolt
t
3
• 01050-31645 • Bolt
t
3
795-931-1220
t
1
• 01050-31645 • Bolt
t
3
795T-521-1140 Push tool
t
1
• 790-101-5221 • Grip
t
1
• 01010-81225 • Bolt
t
1
• 01050-31640 • Bolt
t
3
795-471-1800
t
1
• 795-471-1810 • Plate
t
1
• 795-471-1820 • Bolt
t
1
• 795-471-1830 • Bracket
t
1
• 01435-01035 • Bolt
t
3
• 01435-01025 • Bolt
t
1
8 795T-471-1550 Wrench
t
1
Q
796T-601-1110 Stopper
t
1
N Q
796-460-1210
Oil stopper
q
1
796-770-1320
Adapter
q
1
Part No.
795-931-1210
5 Engine assembly
A 6
7
Engine and hydraulic pump assembly
30-6 (5)
B C
Part Name
Push tool
Remover
Sketch
Necessity
1 795-799-1170
Symbol
Component
New/remodel
a Tools marked Q 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
Q Press fitting of engine front seal N
Removal of fuel supply pump
Removal, installation of nozzle tip Removal, installation of engine mounting bolt Stopping of oil
PC400/450(LC)-7
Q'ty
q
1
2 790-201-2350
Push tool
t
1
Removal of bearing
3 790-201-2510
Push tool
t
1
Press fitting of bearing
Push tool kit
t
1
Part No.
790-101-5401 Swing motor and swing machinery assembly
4 D
• 790-101-5531 • Plate
1
• 790-101-5421 • Grip
1
• 01010-51240 • Bolt
1 1
Press fitting of bearing inner race
6 790-201-2770
Push tool
t
1
Press fitting of bearing inner race
7 796T-626-1110 Push tool
t
1
t
1
Idler assembly
H
1
• 796-427-1140 • Pin
3
• 01314-20612 • Screw
3
796T-627-1230 Push tool
t
1
790-101-2510
Block
q
1
791-122-1130
Plate
q
1
790-101-2550
Leg
q
2
Adapter
q
2
790-101-2570
Plate
q
4
790-101-2560
Nut
q
2
790-101-2102
Puller (294 kN {30 t}) t
1
790-101-1102
Pump
t
1
3 796-627-1020
Installer
t
1
791-430-3230
Installer
t
1
791-601-1000
Oil pump
t
1
791-630-1780
Installer
t
1
791-601-1000
Oil pump
t
1
791-575-1520
Installer
t
1
791-601-1000
Oil pump
t
1
791-685-8006
Compressor
t
1
791-635-3160
Extension
t
1
790-101-1600
Cylinder (686 kN {70 t})
t
1
790-101-1102
Pump
t
1
790-201-1500
Push tool kit
t
1
1 Recoil spring assembly
J
2
PC400/450(LC)-7
Wrench assembly
• 796-627-1220 • Wrench
2 790-101-2740
G
Press fitting of oil seal
t
Final drive assemE bly
Track roller assembly
Q Removal of shaft
Push tool
1
F
Nature of work, remarks
5 790-201-2870
796-627-1210
Carrier roller assembly
Part Name
Sketch
Necessity
1 796T-627-1630 Push tool
Symbol
Component
SPECIAL TOOL LIST
New/remodel
DISASSEMBLY AND ASSEMBLY
• 790-201-1660 • Plate
1
• 790-101-5021 • Grip
1
• 01010-50816 • Bolt
1
Q Press fitting of bearing Removal, installation of round nut Q
Pressing of bearing inner race
Installation of floating seal
Supply of oil
Disassembly, assembly of recoil spring assembly
Installation of dust seal
30-7 (5)
K
Remover and installer
t
1
790-101-1300
Cylinder (980 kN {100 t})
t
1
790-101-1102
Pump
t
1
796-946-1310
Guide
Part Name
21.8
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 Control valve assembly
2 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 3
Sleeve
1
(For 723-46-42800) 796-946-2130
Sleeve
1
(For 723-46-44100) 796-946-2230
Sleeve
1
(For 723-46-45100, 723-46-45500) 790-101-2501
Center swivel joint assembly
30-8 (2)
M
Push puller
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
791-650-3000
Part No.
New/remodel
Q'ty
Track shoe assembly
SPECIAL TOOL LIST
Necessity
Component
Symbol
DISASSEMBLY AND ASSEMBLY
t
1
• 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
Disassembly, assembly of center swivel joint assembly
PC400/450(LC)-7
t
1
790-102-4310
Pin
t
2
Expander
q
1
Ring (For boom and bucket)
q
1
Clamp (For boom and bucket)
q
1
796-720-1690
Ring (For arm)
q
1
07281-01919
Clamp (For arm)
q
1
790-201-1702
Push tool kit
t
1
• 790-201-1851
• Push tool (For bucket)
1
• 790-201-1861
• Push tool (For boom)
1
4 07281-01589
• Push tool (For arm) • 790-201-1871 120
1
• 790-101-5021 • Grip
1
• 01010-50816 • Bolt
1
790-201-1500
6
PC400/450(LC)-7
P
Push tool kit
t
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
Remover
q
Sketch
New/remodel
Nature of work, remarks
Disassembly, assembly of hydraulic cylinder assembly Removal, installation of piston assembly
Installation of piston ring
Press fitting of bushing
1
• 790-101-5021 • Grip
796-670-1100
Work equipment assembly
Q'ty
Wrench assembly
796-720-1680
5
1
Part Name
790-102-4300
3 790-720-1000
Hydraulic cylinder N assembly
Cylinder repair stand t
Part No.
1 790-502-1003 2
SPECIAL TOOL LIST
Necessity
Component
Symbol
DISASSEMBLY AND ASSEMBLY
Press fitting of dust seal
1
• 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}, q long)
1
790-101-1102
Pump (294 kN {30t}) q
1
Removal of foot pin
30-9 (2)
30-10 (5)
t
1
799-703-1100
Vacuum pump (100V)
t
1
Q
799-703-1110
Vacuum pump (220V)
t
1
799-703-1120
Vacuum pump (240V)
t
1
799-703-1401
Gas leak detector
t
1
1 793-498-1210
Lifter (Suction cup)
Y
t
2
2 20Y-54-13180
Adapter
t
2
Part Name
Sketch
Service tool kit
Part No.
New/remodel
Q'ty
Air conditioner unit assembly
Operator’s cab glass
799-703-1200
Symbol
Component
SPECIAL TOOL LIST
Necessity
DISASSEMBLY AND ASSEMBLY
Nature of work, remarks
Filling with air conditioner refrigerant (gas)
Removal and Installation of operator’s cab glass
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. A6. Push tool
A8. Wrench
PC400/450(LC)-7
30-11 (2)
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
B. Stopper
D1. Push tool
30-11-1 (5)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
D7. Push tool
E2. Push tool
30-12 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
A
Part No.
7. Remove fuel filter (8) and bracket (9).
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1 795-799-1170 Puller
t 1
2 790-331-1110 Wrench
q 1
REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
8. Remove clamp (10), 2 tubes (11), and filter (12). 9. Remove cap (13) and disconnect wire (15).
1. Remove 2 engine undercovers (1).
10. Disconnect heater switch (14). 11. Remove the 2 clips on the back side and remove bracket (16).
2. Drain the coolant. 6
Coolant: Approx. 35 l
3. Open the engine hood. 4. Remove tube (2). [*1] a Remove the tube and bracket together. 5. Remove clamp (4) and disconnect the bracket and pipe (5) together. [*2] a Fix hose (3) and pipe (5) with cords, etc. apart from the engine. 6. Remove 2 clamps (6) and 2 tubes (7).
PC400/450(LC)-7
12. Disconnect fuel supply pump wiring connectors PCV1 (17) and PCV2 (18) and remove 2 clips (19). 13. Disconnect bracket (20) and connector PIM (21) and remove spacer (22). [*4]
[*3]
30-13 (2)
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
14. Disconnect clip (23) and bracket (24), and then disconnect 6 fuel injector connectors (25). a Place disconnected wiring harness assembly (26) so that it will not be an obstacle. [*4]
17. Remove 3 high-pressure pipe clamps (31) and 3 brackets (32). [*6]
a To disconnect fuel injector connector "c", insert flat-head screwdriver [1] in stepped part "a" and move it in direction "X", pressing stopper "b".
19. Sling air intake manifold assembly (34) temporarily and remove the air intake manifold mounting bolts. [*7] a Do not remove XX.
18. Remove lubrication tube clamp (33).
20. Lift off air intake manifold assembly (34). 4
Air intake manifold assembly: 45 kg
15. Remove common rail-side high-pressure pipe clamp (28), cover (27), and gate-type bracket (29). [*5] 16. Remove each high-pressure pipe cover (30). [*5]
21. Remove mounting bolts (35) and disconnect lower lubrication tube (36). 22. Remove heat insulation cover (37) and cover (38).
30-14 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
23. Remove clip (39) and lubrication tubes (40) and (36). [*8] a Take care of the spacer. 24. Remove clamp (41).
29. Remove coolant tube (48).
[*13]
30. Remove each high-pressure pipe cover (49). [*14]
[*9]
25. Remove cover (44). 26. Remove clamp (42) and disconnect hose (43). [*10]
31. Remove 6 high-pressure pipe sleeve nuts (50) on the common rail side. [*15] 32. Loosen 6 high-pressure pipe sleeve nuts (51) on the head side and remove 6 high-pressure pipes (52). [*16] 27. Sling turbocharger assembly (45) temporarily and remove the mounting bolts of exhaust manifold (46). [*11]
33. Remove spill tube (55).
[*17]
34. Remove return tube (53).
[*18]
35. Remove 6 head covers (54).
[*19]
28. Lift off turbocharger and exhaust manifold assembly (47). 4
Turbocharger and exhaust manifold assembly: 75 kg a When lifting up, remove part A. Note that the center of gravity is off to the left. [*12]
PC400/450(LC)-7
30-15 (2)
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
36. Remove capture nut (56) and disconnect the wiring harness from the injector. [*20]
INSTALLATION •
Carry out installation of all the parts, except the high-pressure pipe, in the reverse order to removal.
[*1]
3 Hose clamp: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*2]
3 Air aftercooler pipe clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
3 Fuel tube (7): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
37. Remove rocker shaft mounting bolts (57) and rocker arm and rocker shaft assembly (58). [*21] 38. Remove injector mounting bolts (59) and injector assembly (60). [*22] a If the injector assembly is not removed easily, use tool A1. a Do not hold the solenoid valve on the top of the injector with pliers, etc.
[*4] Install wiring harness assembly (26) and other wiring harnesses at least 10 mm apart from the high-pressure pipe. [*7]
39. Remove cross head (61).
[*23]
40. Remove 2 push rods (62).
41. Remove 6 mounting bolts (63) and rocker housing (64). [*24] 42. Remove 7 cylinder head mounting bolts (65) and cylinder head assembly (66). [*25]
30-16 (2)
The tightening torque and tightening order of the air intake manifold assembly mounting bolts are not specified. [*8]
3 Joint bolt on engine block side of lubrication tube: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*9]
3 Clamp (41): 68.6 – 98 Nm {7 – 10 kgm}
[*10] 3 Hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} [*11] Tighten the following 3 exhaust manifold assembly mounting bolts first in the given order, and then tighten the other bolts. 3 Exhaust manifold assembly mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
[*12] 2 All periphery of inserting part of exhaust pipe: Thermosetting sealant (FIREGUM manufactured by HOLTS or equivalent) [*13] 3 Coolant tube (48): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} [*14] a For the installation procedure for high-pressure pipe cover (49), see REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY. [*5] [*6] [*15] [*16] Installation procedure for high-pressure pipe a Do not correct the high-pressure pipe by bending before installing it. 1) Tighten high-pressure pipe (52) permanently. 3 Sleeve nuts (50) and (51): 39.2 – 49.0 Nm {4.0 – 5.0 kgm} 2) Tighten high-pressure pipe clamps (28) and (31) and bracket (32) with your fingers. 3) Tighten high-pressure pipe clamps (28) and (31) permanently. 3 Clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 4) Tighten bracket (32) permanently. 5) Install cover (30). a Set the slit on the cylinder head side. 6) Install gate-type bracket (29) and cover (which is used as the clamp, too) (27) temporarily. 7) Tighten cover (27) permanently. 3 Cover mounting bolt: 11.8 – 14.7 kgm {1.2 – 1.5 kgm} 8) Tighten the gate-type bracket permanently.
PC400/450(LC)-7
[*17] 3 Spill tube (55): 24.5 – 34.3 Nm {2.5 – 3.5 kgm} [*18] 3 Return tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} [*19] 3 Head cover mounting bolt: 9.8 ± 1 Nm {1.0 ± 0.1 kgm} [*20] 3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm} [*21] 1) Loosen the locknut and install the rocker arm and rocker shaft assembly. 3 Rocker shaft mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm} 2) Remove covers (70) and (71) and adjust the valve clearance. The pointer is under cover (70). • Valve clearance Intake: 0.33 mm Exhaust: 0.71 mm a For the adjustment procedure for the valve clearance, see TESTING AND ADJUSTING, Adjusting valve clearance. 3 Rocker arm locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm}
30-17 (2)
DISASSEMBLY AND ASSEMBLY
[*22] a For the installation procedure for the injector and holder, see REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY. [*23] a Apply engine oil (EO30-CD) to the cross head guide and cross head top sufficiently. a Adjust the cross head according to the following procedure. 1) Loosen locknut (73) and return the adjustment screw. 2) Press the cross head top lightly to put it to valve stem (74) and tighten the adjustment screw. 3) After the adjustment screw touches the valve stem, tighten it further by 20°. 4) Tighten the locknut at this position. 3 Locknut: 58.8 – 73.5 Nm {6 – 7.5 kgm}
CYLINDER HEAD
[*25] a Clean the underside of the head, top of the block, and liner with dry cloths or cloths soaked with solvent. a If a bolt has 5 punch marks on its head, replace it. a Tighten the bolts with your fingers into the block at least 2 turns. 2 Bolt threads and underside of bolt head: LM-P or engine oil (EO30-CD) a Tighten the cylinder head mounting bolts in the following order. 3 Cylinder head mounting bolts 1 – 6: 1st time: 88.3 – 108 Nm {9 – 11 kgm} 2nd time: 157 – 167 Nm {16 – 17 kgm} 3rd time: 1) When using tool A2
Using tool A2, retighten the bolts in the order of 1 – 6 by 90° +30° . 0 [*24] 3 Rocker housing mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
30-18 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
2) When not using tool A2 Make marks on the bolt heads with a marker pen and retighten the bolts in the order of 1 – 6 by 90° +30° . 0 a After tightening bolts 1 – 6, tighten auxiliary bolt 7. 3 Cylinder head auxiliary mounting bolt 7: 66.2 ± 7.4 Nm {6.8 ± 0.8 kgm} a After tightening the bolts, make a punch mark on each bolt head to show the number of tightening time.
•
Refilling with coolant Add coolant through the coolant filler of the radiator to the specified level. Run the engine to circulate the coolant through the piping. Then, check the coolant level again. 5
Coolant: Approx. 35 l
PC400/450(LC)-7
30-19 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
Part No.
Part Name
3 795-931-1100 Seal puller 795-931-1210 Push tool A
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1 t 1
4 • 01050-31625 • Bolt
t 3
• 01050-31645 • Bolt
t 3
5
795-931-1220 Push tool • 01050-31645 • Bolt
4. Leave 1 mounting bolt (5) and sling flywheel (4) temporarily. [*3] a Sling [2] becomes diagonal because of the muffler. 5. Lift off flywheel assembly (4).
[*3]
4 Flywheel assembly: 50 kg When the flywheel is hung temporarily, sling [2] becomes diagonal. Accordingly, when flywheel assembly (4) (which has been fitted firmly) is removed, it swings. Take care.
k
t 1 t 3
REMOVAL 1. Remove they hydraulic pump assembly. For details, see REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY. 2. Using guide bolt [1], remove damper assembly (1). [*1]
6. Rear seal Remove rear seal (6) according to the following procedure. [*4]
3. Disconnect engine speed sensor connector EREV (2), loosen speed sensor locknut (3), and separate the speed sensor from flywheel (4).[*2]
30-20 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
•
Removal of original rear seal Set the drill-type tip to tool A3, make a hole on the seal, and pull out the seal with the impact force of the slide hammer (SH). a Remove all the chips.
• Removal of spare rear seal 1) Set the hook-type tip to tool A3, hook it to the metallic ring of seal (6), and pull out the seal with the impact force of the slide hammer (SH). a Drive in the seal a little before pulling it out to separate it from the housing, and you can put it out easily. 2) If sleeve (9) is installed, cut and remove it with a chisel and a hammer. a When cutting sleeve (9), take care extremely not to damage crankshaft (8). a If chips are made, remove all of them.
PC400/450(LC)-7
ENGINE REAR SEAL
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
2 Mounting bolt: Adhesive (LT-2)
[*2] Installation procedure for sensor 1) 2 Threads of sensor: Hydraulic sealant manufactured by LOCTITE 2) Screw the sensor into the flywheel housing to touch it to the ring gear. 3) Return the sensor by 1/2 – 2/3 turns. (Clearance between the sensor and ring gear: 0.75 – 1 mm) 4) 3 Sensor locknut: 69 – 74 Nm {7 – 7.5 kgm} [*3]
a Apply sufficient amount of clean lubricating oil (EO30-CD) to the threads of the bolt, seat, and washer. a Tighten the 6 flywheel assembly mounting bolts in the order of 1 – 6 shown in the following figure. a Tighten the flywheel assembly mounting bolts 2 times. 3 Mounting bolt: 1st tightening torque: 147 ± 19.6 Nm {15 ± 2.0 kgm} 2nd tightening torque: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
30-21 (2)
DISASSEMBLY AND ASSEMBLY
[*4] • Installation procedure for engine rear seal (6) a Rear seal 6151-21-4161: Check the shaft for wear and install "standard seal A" or "sleeved seal B" according to the check result. The part No. of the spare rear seal is 615129-4160 (same as one installed to PC400-6) and its shape is different from that of the seal installed when shipped. a If the shaft is still glossy (If the wear depth felt with a finger cushion is 10 m or less) and it does not have a flaw, install "standard seal A". In other cases, install "sleeved seal B". a Part (7) is the internal plastic cylinder which is also used as a installation guide. a Part (9) is the sleeve. a Wipe off oil from the crankshaft and install the seal while the crankshaft is dry (Do no apply lubricating oil to the lip).
•
Installation procedure for standard seal A a Before installing the seal, check the rims of the crankshaft end, sliding surfaces of the lip, and housing for flaw, burr, rust, etc. a When installing the seal, do not apply oil, grease, etc. to the shaft. Wipe oil thoroughly from the shaft. a Never remove internal plastic cylinder (7) of the spare seal before installing the seal.
30-22 (2)
ENGINE REAR SEAL
1) Put large inside diameter side "b" of internal plastic cylinder (7) to the end of crankshaft (8). a Take care not to mistake the direction of the plastic internal cylinder.
2) Evenly push in the metallic ring of seal (6) with both hands, getting over the large diameter side of the internal plastic cylinder. 3) After pushing in seal (6), remove internal plastic cylinder (7). a When removing, take care not to damage the seal lip.
4) Tighten the bolt of tool A4 evenly until the end of tool A4 touches the end of crankshaft (8) to press fit seal (6). a When press fitting the seal, take care not to damage the lip on the damper side with the tool, etc. a After press fitting the seal, remove the red sealant layer on its periphery.
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
•
Installation procedure for sleeved seal B a Before installing the seal, check the rims of the crankshaft end, sliding faces of the lip, and housing for flaw, burr, sharp fin, rust, etc. a When installing the seal, do not apply oil, grease, etc. to the shaft. Wipe oil thoroughly from the shaft. a Handle the seal and sleeve as an assembly. Never separate them from each other. 1) Set sleeved seal (6) to tool A5. a Take care not to mistake the direction of the seal. 2 Internal cylinder (C) of sleeve: Gasket sealant (LG-7)
ENGINE REAR SEAL
3) Remove tool A5 and install tool A4. 4) Tighten the bolt of tool A4 evenly until the end of tool A4 touches the end of crankshaft (8) to press fit sleeved seal (6). a After press fitting the seal, remove the red sealant layer on its periphery.
2) Put the sleeve of the seal to the end of the crankshaft and tighten the bolt of tool A5 evenly until the end of tool A5 touches the end of crankshaft (8) to press fit sleeved seal (6).
PC400/450(LC)-7
30-23 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
Part No.
A3
795-931-1100
A6
5. Remove covers (5) and (6).
Part Name
Seal puller assembly
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1
795T-521-1140 Push tool
t 1
• 790-101-5221 • Grip
t 1
• 01010-81225 • Bolt
t 1
• 01050-31640 • Bolt
t 3
Q
REMOVAL 1. Remove the radiator and hydraulic oil cooler. For details, see REMOVAL AND INSTALLATION OF RADIATOR and REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER.
6. Loosen the air conditioner compressor assembly mounting bolt and adjustment screw (7). [*2] 7. Loosen alternator assembly mounting bolt (11), adjustment bolt nuts (8) and (9), and adjustment bolt guide bolt (10). [*3]
2. Open the right side cover. 3. Remove reservoir tank bracket (1) and disconnect air aftercooler hoses (2) and (3). [*1] 4. Remove the 4 mounting bolts and air aftercooler (4).
8. Remove fan (12).
30-24 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
9. Remove alternator belt (13) and air conditioner compressor belt (14). 10. Remove 6 pulley mounting bolts (15) and (16) in total, and then remove pulley and damper assembly (17). a One mounting bolt (16) is small in diameter. [*4]
ENGINE FRONT SEAL
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Air aftercooler hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*2]
a Belt tension: 14 – 16 mm (When pressed with finger to about 58.8 N {6 kg}) 3 Mounting bolt: 24.5 – 29.4 Nm {2.5 – 3.0 kgm}
[*3] •
Tense the belt according to the following procedure. 1) Loosen mounting bolt (11), nut (9), and bolt (10). 2) Tense the belt with nut (8). 3) Tighten mounting bolt (11), nut (9), and bolt (10). a Tension of belt: 13 mm (When pressed with finger to about 58.8 N {6 kg}) 3 Bolt: 107.8 – 147 Nm {11 – 15 kgm}
11. Using the seal pulley assembly and tool A3, remove the front seal. [*5] a Remove all the chips.
[*4]
PC400/450(LC)-7
3 Pulley mounting bolt: (M14): 156.8 – 196 Nm {16 – 20 kgm} (M16): 245 – 308.7 Nm {25 – 31 kgm}
30-25 (2)
DISASSEMBLY AND ASSEMBLY
[*5]
ENGINE FRONT SEAL
ii) 4) Installation procedure for front seal (18) a Before installing the seal, check the rims of the crankshaft end, sliding surfaces of the lip, and housing for flaw, burr, rust, etc. a When installing the seal, do not apply oil, grease, etc. to the shaft. Wipe oil thoroughly from the shaft. a Never remove internal plastic cylinder of the spare seal before installing the seal.
i)
Put large inside diameter side "b" of internal plastic cylinder (19) to the end of crankshaft (20). a Take care not to mistake the direction of the plastic internal cylinder. 2 Lip: Lithium grease (G2-LI)
30-26 (2)
Evenly push in the metallic ring of seal (18) with both hands, getting over the large diameter side of the internal plastic cylinder. iii) After pushing in seal (18), remove internal plastic cylinder (19). a When removing, take care not to damage the seal lip.
iv) Tighten the bolt of tool A5 evenly until the end of tool A6 touches the end of crankshaft (20) to press fit seal (18). a When press fitting the seal, take care not to damage the lip on the pulley side with the tool, etc. a After press fitting the seal, remove the red sealant layer on its periphery. a Seal driving dimension "a": 16 +10 mm
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
FUEL SUPPLY PUMP
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY
Part No.
4. Open the engine hood.
Part Name
795-471-1800 Remover
A7
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1 N
• 795-471-1810 • Plate
1
• 795-471-1820 • Bolt
1
• 795-471-1830 • Bracket
1
• 01435-01035 • Bolt
3
• 01435-01025 • Bolt
1
5. Remove air cleaner tube (2) and bracket together. [*1] 6. Fix hose (3) with cords apart from the engine. 7. Remove cover (4).
REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
1. Release the residual pressure from the fuel system. For details, see TESTING AND ADJUSTING, Releasing residual pressure from fuel system. 2. Close the fuel supply valve of the fuel tank.
8. Remove clamp (5). 9. Disconnect fuel supply pump wiring connectors PCV1 (6), PCV2 (7), and G (8). 10. Remove fuel hoses (9) and (10).
[*2]
11. Remove cover (11).
[*3]
3. Remove two engine undercovers (1).
PC400/450(LC)-7
30-27 (2)
DISASSEMBLY AND ASSEMBLY
FUEL SUPPLY PUMP
12. Remove 4 high-pressure pipe clamps (12). [*4] 13. Remove 2 clamps (13) and fuel tubes (14) and (15). [*5] 14. Remove 2 covers (16).
[*3]
15. Remove 2 high-pressure pipes (17).
[*6]
16. Remove lubrication tube (18).
[*7]
17. Setting tool to remove fuel supply pump drive gear 1) Remove 2 mounting bolts (19) and cover (20). [*8]
4) Install plate (23) of tool A7 to installation hole B and install bracket (24) of tool A7 to C. 5) Set bolt (25) of tool A7. a Keep tool A7 installed until the pump is installed so that meshing point of the fuel supply pump drive gear and camshaft will change.
18. Remove bracket (26) and mounting bolts of fuel supply pump assembly (27) and install guide bolt [1]. [*10] a The proper length of the guide bolt is a half of the length shown in the photo. 19. Remove the remaining 3 mounting bolts.
2) Remove mounting nut (22) and the washer of fuel supply pump drive gear (21). [*9] 3) Rotate the crankshaft so that key way A of the shaft will be in the 11 o'clock direction.
30-28 (2)
20. Tighten bolt (25) of tool A7 to remove fuel supply pump assembly (27).
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
FUEL SUPPLY PUMP
INSTALLATION •
3) Tighten the fuel supply pump mounting bolts.
Carry out installation in the reverse order to removal.
[*1]
3 Air cleaner hose clamp: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*2]
3 Fuel hoses (9) and (10): 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
4) Tighten the mounting bolts of bracket (26). 5) Tighten 4 high-pressure pipe clamps (12) temporarily with your fingers. 6) Tighten 4 high-pressure pipe clamps (12) to the following torque. 3 High-pressure pipe clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}
[*3] a Install cover (11) with the slit on the cylinder block side and install cover (16) with the slit directed down. [*4], [*6], [*10] k Do not correct the high-pressure pipe by bending before installing it. k Be sure to use the genuine high-pressure pipe clamps and tighten them to the specified torque. k Install the wiring harnesses at least 10 mm apart from the high-pressure pipe. a When installing each high-pressure pipe, check the taper seal of its joint (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and spot "c" and check part "d" (End of taper seal: Part of 2 mm from the end) for stepped-type wear caused by fatigue which your nail can feel. If there is any of those defects, it can cause fuel leakage. In this case, replace the high-pressure pipe.
1) Tighten fuel supply pump (27), bracket (26), and 2 high-pressure pipes (17) temporarily with your fingers. 2 Fuel supply pump mounting bolt: LOCTITE (LT-7) 2) Tighten 2 high-pressure pipes (17) to the following torque. 3 Common rail-side sleeve nut: 39.2 – 58.8 Nm {4.0 – 6.0 kgm} Supply pump-side sleeve nut: 39.2 – 49.0 Nm {4.0 – 5.0 kgm}
PC400/450(LC)-7
[*5]
3 Fuel tubes (14) and (15): 24.5 – 34.3 {2.5 – 3.5 kgm}
[*7]
3 Lubrication tube (20) Fuel supply pump side: 7.9 – 12.7 Nm {0.8 – 1.3 kgm} Cylinder block side: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}
[*8]
3 Cover: 14.7 – 17.6 Nm {1.5 – 1.8 kgm}
[*9]
3 Fuel supply pump drive gear: 127 – 147 Nm {13 – 15 kgm}
•
Checking for fuel leakage a Check the fuel system for leakage. For details, see TESTING AND ADJUSTING, Checking fuel system for leakage.
•
Bleeding air a Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.
30-29 (2)
DISASSEMBLY AND ASSEMBLY
FUEL INJECTOR
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
Part No.
A1
5. Remove gate-type bracket (4).
Part Name
795-799-1170 Puller
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOL
t 1
REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
[*4]
6. Remove injector-side covers (6) and common rail-side covers (5) from the high-pressure pipe joints according to the fuel injectors to be removed and installed. [*5] 7. Remove high-pressure pipe clamp cover (7) and its clamp (77) according to the fuel injectors to be removed and installed. [*6] a Do not remove bracket X. If it is removed, tighten it permanently after tightening the high-pressure pipe and all the high-pressure pipe clamps in the assembly procedure.
1. Open the engine hood. 2. Remove air cleaner tube (1) and the bracket together. [*1]
8. Loosen common rail-side sleeve nuts (8) and fuel injector-side sleeve nut (10) and remove high-pressure pipe (9). [*7] 3. Remove common rail cover (2).
[*2]
9. Remove head cover (11).
[*8]
4. Remove high-pressure pipe clamps (3) according to the fuel injectors to be removed and installed. [*3]
30-30 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
FUEL INJECTOR
10. Remove capture nuts (12) and disconnect wiring harness (13) from the fuel injector. [*9] 11. Remove holder mounting bolt (14), and then remove the holder and fuel injector assembly (16) together. [*10] a Do not grip the solenoid valve at the top of the injector with pliers, etc.
a Install high-pressure pipe (9) between the common rail and fuel injector according to the following procedure. 1) Tighten sleeve nuts (8) and (10) of highpressure pipe (9). 3 High-pressure pipe sleeve nut: 39.2 – 49.0 Nm {4.0 – 5.0 kgm} a If the fuel injector is not removed easily, use tool A1.
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Air cleaner tube band: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
2) Tighten high-pressure pipe clamps (3) and (77) temporarily with your fingers, and then tighten them permanently. 3) Install common rail cover (2) and gate-type bracket (4) temporarily. 4) Tighten common rail cover (2) (which is also used as a high-pressure pipe clamp) permanently first, then tighten gate-type bracket (4) permanently. 3 Common rail cover: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}
[*2] [*3] [*4] [*6] [*7] k Do not correct the high-pressure pipe by bending before installing it. k Be sure to use the genuine high-pressure pipe clamps and tighten them to the specified torque. k Install the wiring harnesses at least 10 mm apart from the high-pressure pipe. a When installing each high-pressure pipe, check the taper seal of its joint (Part "a": Part of 2 mm from the end) for visible lengthwise slit "b" and spot "c" and check part "d" (End of taper seal: Part of 2 mm from the end) for stepped-type wear caused by fatigue which your nail can feel. If there is any of those defects, it can cause fuel leakage. In this case, replace the high-pressure pipe.
PC400/450(LC)-7
30-31 (2)
DISASSEMBLY AND ASSEMBLY
[*5]
FUEL INJECTOR
a Install common rail-side cover (5) with the slit on the cylinder block side. a Set the slit on fuel injector-side cover (6) at position "a" in the figure and match it to the center of the clip.
[*8]
3 Head cover mounting bolt: 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*9]
3 Wiring harness mounting nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
•
Checking for fuel leakage Check the fuel system for leakage. For details, see TESTING AND ADJUSTING, Checking fuel system for leakage.
•
Bleeding air Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING, Bleeding air from fuel circuit.
[*10] a Install fuel injector assembly (16) according to the following procedure. 1) Insert gasket (b) and O-ring (c) in fuel injector (a). 2) Put holder (d) in injector (a) and install them to the rocker housing temporarily. a Matching key (g) of the injector to key way (h) of the rocker housing, insert the holder securely until the sealing surface of the injector touches the sealing surface on the cylinder head side. 3) Apply engine oil to the spherical part of spherical washer (e). 4) Tighten holder mounting bolt (f). 3 Holder mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
30-32 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
NOZZLE TIP
REMOVAL AND INSTALLATION OF NOZZLE TIP a [ERA Regulation] In a country where EPA Regulation is applied, replace the nozzle of the common rail engine by the assembly. In a country where EPA Regulation is not applied, however, only the nozzle tip can be replaced according to the following procedure. (EPA: Environmental Protection Agency)
3. Using 19-mm deep socket [3], loosen retaining nut (4).
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
A8 795T-471-1550 Wrench
q 1
REMOVAL 1. Grip tool A8 with vise [1]. a Do not grip the injector directly with the vice.
4. Remove retaining nut (4) from injector assembly (3). 5. Lift up and remove nozzle assembly (5) vertically. a Do not remove tip guide (6). (The tip guide cannot be disassembled.) a Take care that dirt will not stick to the parts.
2. Set injector assembly (3) to tool A8.
PC400/450(LC)-7
30-33 (2)
DISASSEMBLY AND ASSEMBLY
INSTALLATION 1. Grip tool A8 with vise [1]. a Do not hold the injector directly with the vice.
2. Set injector assembly (1) to tool A8. 3. Clean the lower body and the threads of retaining nut (2) throughly with parts cleaner and blow air against them.
NOZZLE TIP
5. Install nozzle assembly (3) and tighten retaining nut (2) with the fingers.
6. Set 19-mm deep socket [2] to a torque wrench and tighten the retaining nut according to the following procedure. a Apply rust-preventive oil to the nozzle body. 1) Tighten the retaining nut to 88.3 Nm {9.0 kgm}. 2) Make match marks (6) on retaining nut (2) and lower body (5). 3) Tighten the retaining nut by 45° (Angle tightening).
4. Install new nozzle assembly (3), matching it to the dowel pin of tip guide (4). a Take care not to drop the tip.
30-34 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
STARTING MOTOR
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
1. Open the engine hood. 2. Disconnect the following 2 starting motor wires. [*1] • (1) and (2): Terminal B
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Mounting nut of starting motor terminal B: 19.6 – 25.5 Nm {2 – 2.6 kgm}
3. Remove 3 mounting bolts (3) and starting motor assembly (4).
PC400/450(LC)-7
30-35 (2)
DISASSEMBLY AND ASSEMBLY
RADIATOR
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY REMOVAL 1. Remove cover (1).
4. Disconnect reservoir tank hose (6). a Disconnect the hose from the radiator. 2. Drain the coolant. 6
Coolant: Approx. 35 l
3. Erect the engine hood according to the following procedure. 1) Open engine hood (2) and sling it temporarily. a When slinging the engine hood, take care not to damage the rubber seal. 2) Prepare M10 bolt [1]. • When removing the radiator, L = 50 or longer. • When removing the oil cooler, L = 70 or longer. 3) Remove bolt (4). 4) Remove pin (5) from the lower part of stay (3). 5) Adjust the engine hood so that center hole A of stay (3) will be at the bolt (4). 6) Install stay (3) with bolt [1] and fix engine hood (2) vertically.
30-36 (2)
5. Disconnect radiator hoses (7), (8), and (9). [*1] 6. Remove covers (10) and (11).
7. Remove cover (12). 8. Disconnect radiator hose (13).
[*1]
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
9. Remove 2 mounting bolts (14).
RADIATOR
INSTALLATION •
Carry out installation in the reverse order to removal.
•
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5
[*1] 10. Lift off radiator assembly (15). 4
Radiator assembly: 30 kg
PC400/450(LC)-7
Coolant: Approx. 35 l
3 Radiator hose clamps (7): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm} (8): 4.4 ± 0.49 Nm {0.49 ± 0.05 kgm} (9), (13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
30-37 (2)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY REMOVAL 1. Remove cover (1).
4. Remove covers (3) and (4). 2. Remove plug (2) of the hydraulic oil cooler drain hose to drain the hydraulic oil. a Before draining, open the hydraulic tank cap to release the pressure in the tank. Then, drain the oil through the cooler hose.
5. Remove hydraulic oil cooler tube mounting bolts (5) and (6). 6. Remove right and left hydraulic oil cooler mounting bolts (7). 3. Erect the engine hood according to the following procedure. 1) Open engine hood (100) and sling it temporarily. a When slinging the engine hood, take care not to damage the rubber seal. 2) Prepare M10 bolt [1]. 3) Remove bolt (102). 4) Remove pin (103) from the lower part of stay (101). 5) Adjust the engine hood so that center hole A of stay (101) will be at the bolt (102). 6) Install stay (101) with bolt [1] and fix engine hood (100) vertically.
30-38 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
7. Remove 3 hydraulic oil cooler-side mounting bolts (8). a When removing 1 of the 3 bolts which is hidden behind cover B, pull cover B lightly. a Bolt [1] is used to fix the engine hood vertically.
HYDRAULIC OIL COOLER
INSTALLATION •
Carry out installation in the reverse order to removal.
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
8. Remove the net on the outside of the hydraulic oil cooler. 9. Lift off hydraulic oil cooler assembly (9). 4
Hydraulic oil cooler: 50 kg
PC400/450(LC)-7
30-39 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY
Part No.
B C
3. Drain the coolant.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
796-601-1110 Stopper
t 1 N
796-460-1210 Oil stopper
t 1
796-770-1320 Adapter
t 1
REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery. k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.
6
Coolant: Approx. 35 l
4. Close the fuel stop valve of the fuel tank. 5. Erect the engine hood according to the following procedure. 1) Open engine hood (100) and sling it temporarily. a When slinging the engine hood, take care not to damage the rubber seal. 2) Prepare M10 bolt [1]. 3) Remove bolt (102). 4) Remove pin (103) from the lower part of stay (101). 5) Adjust the engine hood so that center hole A of stay (101) will be at the bolt (102). 6) Install stay (101) with bolt [1] and fix engine hood (100) vertically.
1. Remove the 4 engine undercovers. 2. Remove the hydraulic tank strainer. Using tool C, stop the oil. a When not using tool C, remove the drain plug to drain the oil from the hydraulic tank and piping. 6
Hydraulic tank: Approx. 335 l 6. Remove tube (1). [*1] a Remove the tube and bracket together. 7. Disconnect clamp (2) and pipe (3). [*2] a Remove the clamp, pipe, and bracket (4) together.
30-40 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
8. Disconnect fuel inlet hose (5) and fuel return hoses (6) and (7). [*3]
15. Disconnect aftercooler hose (21) and heater hose (22). [*6] 9. Disconnect clamp (8) and radiator hoses (9), (10), and (11). [*4] 10. Remove covers (12) and (13). 11. Remove fan guard (14). a Bolt [1] is used to fix the engine hood vertically.
16. Remove cover (23). 17. Disconnect radiator hose (24).
[*4]
12. Loosen adjustment bolt (15) and remove belt (16). [*5] 13. Remove air conditioner compressor assembly (17). a Move the air conditioner compressor assembly toward the control valve top cover. 14. Disconnect fan (18). a Insert your hand through clearance A between the fan and the radiator and remove the 6 fan mounting bolts in order, turning the fan with your foot.
PC400/450(LC)-7
30-41 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
18. Disconnect heater hose (25).
20. Remove mounting bolts (28) and bracket (29).
24. Disconnect the following 2 pump wiring connectors. • (34): V22 (PC-EPC solenoid valve) Band color: Red • (35): V21 (LS-EPC solenoid valve) Band color: White
21. Open the main pump side cover.
25. Disconnect the following 10 hoses and 1 tube. • (36): EPC basic pressure port hose (Band color: Yellow) • (37): Rear pressure port hose (Band color: Yellow) • (38): Rear pump discharge port hose • (39): Front pump discharge port hose • (40): Drain port hose • (41): Front load pressure input port hose • (42): Rear load pressure input port hose (Band color: Red) • (43): Front pressure input port hose • (44): Pump suction port tube
19. Disconnect the following 2 wiring connectors. • (26): ERO2 (Various sensors) • (27): ERO3 (Each injector and fuel supply pump)
22. Lift off covers (30) and (31) together. 23. Remove cover (32) and stay (33).
30-42 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
28. Lift off engine and hydraulic pump assembly (48). a Check that all the wires and pipes have been disconnected. 4
Engine and hydraulic pump assembly: 1,700 kg
26. Disconnect engine ground cable (46) from the rear of the hydraulic pump. 27. Using tool B, remove 4 front and rear engine mounting bolts (47). [*7]
PC400/450(LC)-7
30-43 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Hose clamp: 9.8 ± 0.5 Nm {0.1 ± 0.05 kgm}
[*2]
3 Clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
3 Fuel hoses (5), (6), and (7): 14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*4]
3 Radiator hoses: (9): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm} (10): 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm} (11), (24): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
a See TESTING AND ADJUSTING, Testing and adjusting air conditioner compressor belt tension or REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.
[*6]
3 Air aftercooler hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*7]
3 Engine mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}
•
Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5
•
Coolant: Approx. 35 l
Hydraulic oil: Approx. 335 l
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
30-44 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
SWING CIRCLE
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY REMOVAL
INSTALLATION
1. Remove the revolving frame assembly. For d e t a i l s , s e e R E M O VA L O F R E V O LV I N G FRAME ASSEMBLY. 2. Sling swing circle assembly (1) by 3 points temporarily, remove 40 mounting bolts, and lift off the swing circle assembly. [*1] 4
Swing circle assembly: 600 kg
PC400/450(LC)-7
•
Carry out installation in the reverse order to removal.
[*1]
2 Mating face of swing circle: Gasket sealant (LG-6) 2 Threads of swing circle mounting bolt: Adhesive (LT-2) 3 Swing circle mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} Target: 927 Nm {94.5 kgm} a When installing the swing circle to the track frame, bring soft zone mark S of the inner race and soft zone mark P of the outer race to the right side of the chassis as shown below. 2 Quantity of grease in grease bath: Grease (G2-LI), 33 l (Use GLT2-LI for 50°C specification)
30-45 (2)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY REMOVAL k
Release the residual pressure in the hydraulic circuit. Refer to the Releasing of Residual Pressure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this manual. k Lower the work equipment to the ground for oil filler cap on the fuel tank to release the residual pressure inside the tank and move the safty lock lever to the LOCK position.
3. Lift and remove swing motor and swing machinery assembly (6). a When lifting the swing motor and swing machinery assembly for removal, do so slowly so that the hoses and other parts will not be damaged. a Take good care, when lifting the assembly, until the spigot joint portion is pulled out. 4
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)
Swing motor and swing machinery assembly: 550 kg
INSTALLATION •
Install in reverse order of removal.
[*1]
3 Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}
•
Refilling hydraulic oil Refill hydraulic oil through the oil filler port to the specfied level. Let the oil cirdulate in the hydraulic system by starting the engine. Then check the oil level again.
•
Air bleeding Refer to the Air Bleeding of Various Parts section in the TESTING AND ADJUSTING chapter of this manual.
2. Detach the swing motor and swing machinery assembly (6), using forcing screw [1] after removing the mounting bolts. [*1]
30-46 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1 796T-627-1630 Push tool
q 1
2 790-201-2350 Push tool
t 1
3 790-201-2510 Push tool
t 1
790-101-5401 Push tool kit D 4
3. No. 1 sun gear Remove No. 1 sun gear (2).
t 1
• 790-101-5531 • Plate
1
• 790-101-5421 • Grip
1
• 01010-51240 • Bolt
1 N
5 790-201-2870 Push tool
t
6 790-201-2770 Push tool
t
7 796T-626-1110 Push tool
t
4. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3).
Q
DISASSEMBLY 1. Draining oil Loosen the drain plug and drain the oil from the swing machinery case. 6
Swing machinery case: Approx. 21 l
2. Swing motor assembly 1) Set the swing motor and swing machinery assembly on block [1]. 2) Remove 10 mounting bolts and lift off swing motor assembly (1). 4
2) Disassemble the No. 1 carrier assembly according to the following procedure. Remove snap ring (4), and then remove shaft (5), gear (6), bearing (7), thrust washer (8), and plate (9).
Swing motor assembly: 115 kg
PC400/450(LC)-7
30-47 (2)
DISASSEMBLY AND ASSEMBLY
5. Ring gear Remove the mounting bolts and ring gear (10).
6. No. 2 sun gear Remove No. 2 sun gear (11).
SWING MOTOR AND SWING MACHINERY
8. No. 2 carrier assembly 1) Lift of No. 2 carrier assembly (13).
2) Disassemble the No. 2 carrier assembly according to the following procedure. i) Push in pin (14) and drive out shaft (15) from carrier (16). a After removing the shaft, remove pin (14). ii) Remove thrust washer (17), gear (18), bearing (19), and thrust washer (20). iii) Remove plate (21).
7. Bolt Remove holder mounting bolt (12).
9. Shaft assembly 1) Turn over case and pinion assembly (24) and remove 12 mounting bolts (23) of cover assembly (22).
30-48 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
2) Turn over case and pinion assembly (24) and set it on the press stand. Using push tool [2], D1 and the press, pull out pinion shaft assembly (25). a Set a wood block under the press so that the pinion shaft will not be damaged when it comes off. a A rough standard pressing force is 20 odd tons.
SWING MOTOR AND SWING MACHINERY
11. Bearing Using multiple push tools [3], remove bearing (30) from case (31). a Push tool to be set contact with bearing: D2
ASSEMBLY
10. Disassemble the pinion shaft assembly (25) according to the following procedure. 1) Using the push tool, remove cover assembly (22) and bearing (26) from shaft (27). a A rough standard pressing force is 30 tons. 2) Remove oil seal (28) from cover (29).
PC400/450(LC)-7
a Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1. Bearing Using push tool D3 and [4], press fit bearing (26) to case (31). a A rough standard pressing force is several tons.
30-49 (2)
DISASSEMBLY AND ASSEMBLY
2. Cover assembly 1) Using push tool D4, press fit oil seal (28) to cover (29).
2 Periphery of oil seal: Gasket sealant (LG-6) a Take care that the gasket sealant (LG-6) will not stick to the oil seal lip and shaft assembly (22).
2) Install cover assembly (22) to case (31) and tighten mounting bolts (23). a Match the oil path of cover (22) to the drilled hole of case (31). 2 Cover fitting face: Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 2 Oil seal lip: Grease (G2-LI)
30-50 (2)
SWING MOTOR AND SWING MACHINERY
3. Case assembly 1) Turn over case assembly (32) and set it to shaft (27). Using push tools D5 and D6 [5], press fit the bearing inner race. a When setting the case assembly to the shaft, take care extremely not to damage the oil seal. a A rough standard pressing force is 30 tons.
2) Bearing Using too D7, press fit bearing (30). a Press both inner race and outer race of the bearing simultaneously. Do not press only the inner race. a A rough standard pressing force is 20 odd tons. a After press fitting the bearing, check that the case turns smoothly.
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
4. No. 2 carrier assembly 1) Assemble the No. 2 carrier assembly according to the following procedure. a There is a caulking mark made when the pin was inserted at the end of carrier side hole "a" and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i) Install plate (21) to carrier (16). ii) Install bearing (19) to gear (18) and fit top and bottom thrust washers (17) and (20), and then set the gear assembly to carrier (16).
a When inserting the pin, do not set the 3 claws (parts "a") on the periphery to the thin part of the carrier (part "b"). The thin part may be on the opposite side, however. Check each carrier and avoid setting a claw to the thin part.
a After inserting the pin, caulk the pin part of the carrier. 2) Install No. 2 carrier assembly (13).
iii) Aligning the pin holes of shaft (15) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iv) Insert pin (14).
5. Bolt and O-ring 1) Tighten bolt (12). 2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 343 – 427 Nm {34 – 43.5 kgm}
2) Fit the O-ring to case (31). 6. No. 2 sun gear Install No. 2 sun gear (11).
PC400/450(LC)-7
30-51 (2)
DISASSEMBLY AND ASSEMBLY
7. Ring gear Using the eyebolt (M12 x 1.75), install ring gear (10).
SWING MOTOR AND SWING MACHINERY
8. No. 1 carrier assembly 1) Assemble the No. 1 carrier assembly according to the following procedure. i) Press fit shaft (5) to the carrier in the direction of the arrow until the snap ring groove is seen. ii) After installing snap ring (4), press back the shaft from the opposite side until the snap ring is fitted to face P of the carrier. At this time, take care not to press back too much.
a When installing ring gear (10), set its match mark (part "d") and the projection of the case flange (part "c") as shown in the following figure.
iii) After installing plate (9), install thrust washer (8), bearing (7), gear (6), and snap ring (4).
2) Install No. 1 carrier assembly (3).
a Degrease the mating faces of ring gear (10) and case (29). a Never stick gasket sealant to the mating faces of ring gear (10) and case (29). 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm} a Add engine oil (EO30-CD) at this time.
30-52 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING MACHINERY
9. No. 1 sun gear assembly Install No. 1 sun gear (2).
a Take care not to install the No. 1 sun gear upside down. a Install the No. 1 sun gear with the tooth (part "e") down.
•
Refilling with oil Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-30K for extremely cold district) through the oil filler to the specified level. 5
Swing machinery case: Approx. 21 l
10. Swing motor assembly Install swing motor assembly (1) to ring gear (10). a When installing the swing motor assembly, set the relief valve (part f) and the projection of the case (part c) as shown in the following figure. a Degrease the mating faces of swing motor assembly (1) and ring gear (10). 2 Mating faces of swing motor assembly (1) and ring gear (10): Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 4 Swing motor assembly: 115 kg
PC400/450(LC)-7
30-53 (2)
DISASSEMBLY AND ASSEMBLY
SPROCKET
REMOVAL AND INSTALLATION OF SPROCKET REMOVAL 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Swing work equipment 90°, push up chassis with work equipment and place block [1] between track frame and track shoe.
INSTALLATION •
Install in reverse order of removal.
[*1]
2 Thread of sprocket mounting bolt: Gasket sealant (LG-6) 3 Sprocket mounting bolt: 640 – 785 Nm {65 – 80 kgm}
3. Remove mounting bolts and lift off sprocket (1). [*1] 4 Sprocket: 70 kg
30-54 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR AND FINAL DRIVE
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY REMOVAL 1. Remove the sprocket. For details, see Removal of sprocket. k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank.
4. Remove the 24 mounting bolts and lift off the final drive assembly (6). [*1] a Take care extremely not to damage the nipple sealing faces of the hose joints. a When slinging the final drive assembly, do not use the tap hole for the cover. 4
Final drive assembly: 700 kg
2. Remove cover (1).
3. Disconnect drain hose (2), travel speed selector hose (3), and motor hoses (4) and (5). a Remove the nipples, too.
PC400/450(LC)-7
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
30-55 (2)
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
Part No.
Part Name
Wrench assembly
t 1
• 796-627-1220 • Wrench
1
• 796-427-1140 • Pin
3
• 01314-20612 • Screw
3
796-627-1210 1
2) Using eyebolt [2], remove cover (1). Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
796T-627-1230 Push tool
t 1
790-101-2510 Block
q 1
791-122-1130 Plate
q 1
790-101-2550 Leg
q 2
2 790-101-2740 Adapter
q 2
790-101-2570 Plate
q 4
790-101-2560 Nut
q 2
790-101-2102 Puller (30 tons)
t 1
790-101-1102 Pump
t 1
3 796-627-1020 Installer
t 1
E
Q
3. Spacer Remove spacer (2).
4. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3).
DISASSEMBLY 1. Draining oil Remove the drain plug to drain the oil from the final drive case. 6
Final drive case: Approx. 11 l
2. Cover 1) Place the final drive on block [1] and remove the mounting bolts and cover (1).
30-56 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
2) Disassemble the No. 1 carrier assembly according to the following procedure. i) Push in pin (5) to drive out shaft (6) from carrier (7). a After removing the shaft, remove pin (5). ii) Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11).
5. No. 1 sun gear shaft Remove spacer (4), No. 1 sun gear (12), and No. 2 sun gear (13).
6. Thrust washer Remove thrust washer (14).
PC400/450(LC)-7
FINAL DRIVE
7. No. 2 carrier assembly 1) Sling No. 2 carrier assembly (15) with wires, etc. and remove it.
2) Disassemble No. 2 carrier assembly according to the following procedure. i) Push in pin (16) to drive out shaft (17) from carrier (18). a After removing the shaft, remove pin (16). ii) Remove thrust washer (19), gear (20), bearing (21), and thrust washer (22).
8. Nut 1) Remove lock plate (23).
30-57 (2)
DISASSEMBLY AND ASSEMBLY
2) Using tool E1, remove nut (24).
9. Hub assembly 1) Using eyebolts [3], remove hub assembly (25) from the travel motor.
2) Disassemble hub assembly (25) according to the following procedure. i) Remove bearing (26) from hub (32).
30-58 (2)
FINAL DRIVE
ii)
Remove floating seal (27) from hub (32).
iii) Remove bearings (28) and (29) from hub (32).
3) Remove floating seal (30) from travel motor (31).
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
4) Using puller [4], remove bearing (34) and collar (33) together. a You can remove bearing (34) and collar (33) without using puller [4] in some cases.
3) Install collar (33) and bearing (34) to travel motor (31).
ASSEMBLY a Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing. 1. Hub assembly 1) Using the push tool, press fit bearings (28) and (29) to hub (32).
4) Using tool E3, install floating seal (30) (which is hidden and not seen behind tool E3) to travel motor (31). a Thoroughly degrease and dry the O-ring and O-ring fitting surface of the floating seal before installing. a After installing the floating seal, check that its slant is less than 1 mm. a After installing the floating seal, thinly apply engine oil to the sliding surfaces. 2) Using tool E3, install floating seal (27) to hub (32). a Thoroughly degrease and dry the O-ring and O-ring fitting surface of the floating seal before installing. a After installing the floating seal, check that its slant is less than 1 mm. a After installing the floating seal, thinly apply engine oil to the sliding surfaces.
PC400/450(LC)-7
30-59 (2)
DISASSEMBLY AND ASSEMBLY
5) 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. 1) Rotate the hub 2 – 3 turns. 2) Using tool E2, press the bearing inner race. a Pressing force: 29.4 – 38.3 kN {3.0 – 3.9 tons} 3) While the bearing is pressed, rotate the hub at least 5 turns in 1 direction. 4) Release the pressing force. 5) Press the bearing again. a Pressing force: 14.7 – 18.6 kN {1.5 – 1.9 tons}
FINAL DRIVE
7) Measure thickness "b" of nut (24). 8) Obtain a – b = c. 9) Using tool D1, tighten nut (24) until dimension "c" is as follows. a Dimension "c": c +0.07 –0.03 mm
10) Using push-pull gauge [5], measure the tangential force of the hub in its revolving direction on the motor case. a Tangential force: Max. 765 N {78 kg} a The tangential force means the maximum force at the beginning of rotation.
11) Install lock plate (23), fitting it to the motor spline.
6) Under the condition in 5) above, measure dimension "a".
30-60 (2)
2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE
3. No. 2 carrier assembly 1) Assemble the No. 2 carrier assembly according to the following procedure. a There is a caulking mark made when the pin was inserted at the end of carrier side hole "h" and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i) Install bearing (21) to gear (20) and fit top and bottom thrust washers (19) and (22), and then set the gear assembly to carrier (18).
4. Thrust washer Install thrust washer (14).
ii)
Aligning the pin holes of shaft (17) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iii) Insert pin (16). a After inserting the pin, caulk the pin part of the carrier. a After assembling the carrier assembly, check that the gear (20) turns smoothly.
2) Install No. 2 carrier assembly (15). a Install No. 2 carrier assembly (15) so that the 4 gear shaft ends will be in the 4 hollows at the motor case end.
PC400/450(LC)-7
5. No. 2 sun gear Install spacer (4) and No. 2 sun gear (13).
6. No. 1 carrier assembly 1) Assemble the No. 1 carrier assembly according to the following procedure. a There is a caulking mark made when the pin was inserted at the end of carrier side hole "h" and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance.
30-61 (2)
DISASSEMBLY AND ASSEMBLY
i)
Install bearing (10) to gear (9) and fit top and bottom thrust washers (8) and (11), and then set the gear assembly to carrier (7).
Aligning the pin holes of shaft (6) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iii) Insert pin (5). a After inserting the pin, caulk the pin part of the carrier. a After assembling the carrier assembly, check that the gear (9) turns smoothly.
FINAL DRIVE
7. No. 1 sun gear shaft Install No. 1 sun gear shaft (12). 8. Spacer Install spacer (2).
ii)
9. Cover Using eyebolts [2], install cover (1) and tighten the mounting bolts.
2 Cover mounting face: Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
• 2) Install No. 1 carrier assembly (4).
Refilling with oil a Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-30K for extremely cold district) through the oil filler. 5
Final drive case: Approx. 11 l
a After installing the final drive assembly to the chassis, check the oil level again at the specified position.
30-62 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY a Only precautions for assembling the carrier roller assembly are explained below.
•
Floating seal a When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. a Be sure to use the installer F to insert the floating seal assembly in the housing. a After installing the floating seal, check that its slant is less than 1 mm and its projection "a" is 5 – 7 mm.
•
Carrier roller a Using tool F, apply the standard pressure to the oil filler to check the seal for air leakage. a Keep the following standard pressure for 10 seconds and check that the pointer of the gauge does not lower. Standard pressure: 0.1 MPa {1 kg/cm2}
F
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1 791-430-3230 Installer
t 1
2 791-601-1000 Oil pump
t 1
4
Carrier roller assembly: 35 kg
ASSEMBLY •
Press fitting of support (2) 1) The threads of shaft (1) must be in the range of the following figure. 2) Press fitting dimension of shaft: (Shown in the following figure) 3) Using push tool [1], press fit support (2) to shaft (1). At this time, apply press fitting force of at least 79 kN {8.1 tons}.
PC400/450(LC)-7
30-63 (2)
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER
a Using tool F, fill the carrier roller assembly with oil and tighten the plug. 5
30-64 (2)
Carrier roller: 170 – 180 cc (EO30-CD)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY a Only precautions for assembling the track roller assembly are explained below.
G
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1 791-630-1780 Installer
t 1
2 791-601-1000 Oil pump
t 1
4
•
Track roller a Using tool G, apply the standard pressure to the oil filler to check the seal for air leakage. a Keep the following standard pressure for 10 seconds and check that the pointer of the gauge does not lower. Standard pressure: 0.1 MPa {1 kg/cm2}
Track roller assembly: 80 kg
ASSEMBLY •
Floating seal a When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. a Be sure to use the installer G to insert the floating seal assembly in the housing. a After installing the floating seal, check that its slant is less than 1 mm and its projection "a" is 5 – 7 mm.
PC400/450(LC)-7
a Using tool G, fill the track roller assembly with oil and tighten the plug.
5 Track roller: 280 – 310 cc (EO30-CD) 3 Plug: 10 – 20 Nm {1 – 2 kgm}
30-65 (2)
DISASSEMBLY AND ASSEMBLY
IDLER
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
H
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
791-575-1520 Installer
t 1
791-601-1000 Oil pump
t 1
4
4. Remove floating seal (7) on the opposite side from idler (5) and shaft and support assembly (6).
Idler assembly: 250 kg
DISASSEMBLY 5. Remove nut (8), pull out bolt (9), and then remove support (10) from shaft (11).
6. Remove bushing (12) from idler (5).
1. Remove nut (1) and pull out bolt (2) to remove support (3). 2. Remove floating seal (4) from support (3) and idler (5). 3. Pull out idler (5) from shaft and support assembly (6). a Idler is filled with oil of 345 ± 10 cc. Drain it or spread cloths to soak it at this time.
30-66 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
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).
IDLER
a When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. a Be sure to use the installer H to insert the floating seal assembly in the housing. a After installing the floating seal, check that its slant is less than 1 mm and its projection "a" is 9 – 11 mm.
a Install the shaft with the UP mark up.
4. Install shaft and support assembly (6) to idler (5).
3. Using tool H, install floating seal (7) to idler (5) and shaft and support assembly (6).
5. Similarly, using too H, install floating seal (4) to idler (5) and support (3).
PC400/450(LC)-7
30-67 (2)
DISASSEMBLY AND ASSEMBLY
IDLER
a Coat the sliding surface of the floating seal with oil and take care that dirt will not stick to it. a Degrease the floating seal and the O-ring contact surfaces. 6. Fit the O-ring, set support (3), install bolt (2), and tighten nut (1). 7. Add oil and tighten the plug. 5
Quantity of oil: Approx. 345 ± 10 cc (EO-30CD) 3 Plug: 130 – 180 Nm {13 – 18 kgm}
30-68 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
Part No.
1
Part Name
791-685-8006 Compressor
t 1
791-635-3160 Extension
t 1
790-101-1600
Cylinder (686 kN {70 t})
790-101-1102 Pump
J
790-201-1500 Push tool kit 2
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
1. Remove piston assembly (2) from recoil spring assembly (1). 2. Disassembly of recoil spring assembly 1) Set tool J1 to recoil spring assembly (1). k Since the installed load of the spring is large and dangerous, set the tool securely. a Installed load of spring: 239.037 kN {24,375 kg}
t 3 t 3 1
• 790-201-1660 • Plate • 790-101-5021 • Grip • 01010-50816 • Bolt
4
Recoil spring (Excluding idler): 900 kg
DISSASSEMBLY
2) Apply oil pressure gradually to compress the spring and remove lock plate (3) and nut (4). a Compress the spring to a degree that you can loosen the nut. a Release the oil pressure gradually to reduce the spring tension to 0 (zero). a Free length of spring: 845.3 mm 3) Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from spring (5). 3. Disassembly of piston assembly 1) Remove lock plate (11) from piston (10), and then remove valve (12). 2) Remove snap ring (13), U-packing (14), and ring (15).
PC400/450(LC)-7
30-69 (2)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
RECOIL SPRING
2) Install cylinder (7), collar (8), and yoke (6) to spring (5), and then set them to tool J1. 2 Sliding parts of cylinder: Grease (G2-LI)
3) Apply oil pressure gradually to compress the spring and tighten nut (4) so that installed length of the spring will be "a", and then secure it with lock plate (3). a Installed length of spring "a": Approx. 690 mm
1. Assembly of piston assembly 1) Install ring (15) and U-packing (14) to piston (10) and secure them with snap ring (13). 2) Tighten valve (12) temporarily and secure it with lock plate (11). 2. Assembly of recoil spring assembly 1) Using tool J2, install dust seal (9) to cylinder (7).
4) Remove recoil spring assembly (1) from tool J1. 3. Install piston assembly (2) to recoil spring assembly (1). 2 Sliding parts of piston: Grease (G2-LI) 2 Wear ring: Grease (G2-LI) a Install the piston assembly so that the position of the valve will be on outside. a Supply 320 cc of grease (G2-LI) to the cylinder, bleed air, and check that the grease flows out of the grease hole.
30-70 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY
K
Part No.
4. Using tool K, remove master pin (1).
Part Name
791-650-3000
Remover and installer
t 1
790-101-1300
Cylinder (980 kN {100 t})
t 1
790-101-1102 Pump
[*3]
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
t 1
EXPANSION OF TRACK SHOE 1. Start the engine and set the master pin to above the idler.
5. Move the master pin forward and set block [1] under the track shoe in front of the idler. 6. Pull out pusher K.
2. Remove track shoes (2) on the right and left sides of master pin (1). [*1] 3. Lower the work equipment to the ground and loosen lubricator (3) to slacken the track shoe. [*2] k Since the internal pressure of the adjustment cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not come out sufficiently, move the machine forward and in reverse. 7. Move the machine in reverse slowly to expand the track shoe. [*4]
PC400/450(LC)-7
30-71 (2)
DISASSEMBLY AND ASSEMBLY
TRACK SHOE
2 Apply grease to the contact faces of dust seal (5) and bushing (4) (all over the end face of the dust seal or bushing) (parts marked Q). Do not apply grease to the pars marked X, however. R: Detail of regular pin position M: Detail of master pin position (Pins are not inserted, however)
INSTALLATION OF TRACK SHOE •
Carry out installation in the reverse order to expansion.
[*1]
2 Mounting bolt: Anti-seizure compound (MARUZEN MOLYMAX No. 2 or equivalent) 3 Mounting bolt: Tighten the 4 bolts first to 392 ± 39 Nm {40 ± 4 kgm}. Check that the mating faces are fitted, then retighten each bolt by 120° ± 10°.
[*2]
a Adjust the tension of the track shoe. For detail, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension. 3 Tightening torque for lubricator: 58.8 – 88.3 Nm {6 – 9 kgm}
[*3]
a Using the tool, press fit the master pin so that its projection "a" will be as follows. • Dimension "a": 4.4 ± 2 mm
[*4] Set the track shoe and sprocket (4) as shown in the following figure (on both right and left sides).
2 Supply grease to the space between the bushing and pin so that filling rate will be 100%. Grease: NIGUTAITE LYK-2 manufactured by NIPPON GREASE CO., LTD. or equivalent
30-72 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
Q
799-703-1200 Service tool kit
t 1
799-703-1100
Vacuum pump (100V)
t 1
799-703-1110
Vacuum pump (220V)
t 1
799-703-1120
Vacuum pump (240V)
t 1
799-703-1401
Gas leak detect 1 tor
Sketch
Part Name
New/Remodel
Part No.
4. Remove rear covers (1), (2), (3), and (4). Necessity Q’ty
Symbol
SPECIAL TOOLS
REMOVAL k
5. Remove duct (5), cover (6), and plate (7). 6. Remove plate (8) and duct (9). a Remove the duct lock clip. 7. Remove ducts (10) and (11).
Disconnect the cable from the negative (–) terminal of the battery.
1. Swing the upper structure by 90°. 2. Open the engine hood. 3. Connect tool Q to cap [1] and collect the air conditioner refrigerant.
8. Disconnect connectors D01 (12), D02 (13), C09 (14), R22 (15), R20 (16), and K19 (17). 9. Remove and sling controller (18). 10. Remove plate (19). 11. Disconnect air conditioner unit connectors M27 (20) and M33 (21).
PC400/450(LC)-7
30-73 (5)
DISASSEMBLY AND ASSEMBLY
12. Remove the air conditioner unit undercover. a Part A
AIR CONDITIONER UNIT
INSTALLATION •
[*1]
Carry out installation in the reverse order to removal. a When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them. a When connecting each air conditioner hose, check that the O-ring is fitted to the joint. a Check that each O-ring is free from flaw and deterioration. a Apply compressor oil (ND-OIL8) to the threads of the refrigerant pipe joints and tighten each nut with double spanner.
3 Hose clamp (M6 bolt): 8 – 12 Nm {0.8 – 1.2 kgm}
13. Remove mounting bolt (24) and connector (25). [*1]
3 Hose screw of M16 x 1.5: 12 – 15 Nm {1.2 – 1.5 kgm}
14. Disconnect heater hoses (22) and (23) and air conditioner tube (26). [*1] a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.
3 Hose screw of M22 x 1.5: 20 – 25 Nm {2.0 – 2.5 kgm} 3 Hose screw of M24 x 1.5: 30 – 35 Nm {3.0 – 3.5 kgm} •
Charging air conditioner with refrigerant gas Using tool Q, charge the air conditioner circuit with refrigerant (HFC R134a) from the compressor. a Quantity of refrigerant: 950 ± 50 g
15. Remove the 7 mounting bolts and air conditioner unit assembly (27).
30-74 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
REMOVAL AND INSTALLATION OF OPERATOR’S CAB REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
1. Remove rear covers (1), (2), (3), and (4).
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.
2. Remove duct (5), cover (6), and plate (7). 3. Remove plate (8), duct (9) and the element. a Remove the duct lock clip.
4. Remove clip (10) and disconnect cab wiring connectors M45 (11), H08 (12), and H09 (13).
9. Remove cover (22) and floor mat (23).
10. Move right console (24) into the cab. 11. Remove monitor panel undercover (25).
5. Remove air conditioner connector plate (14).
PC400/450(LC)-7
30-75 (2)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB
12. Disconnect cab wiring connector W04 (26) (Wiper motor). 13. Remove ducts (27) and (28). a Both (27) and (28) are 2 in number. a Cut the tie-wrap on the monitor wiring harness. 14. Remove cover (29) and monitor assembly (30).
20. Using lever block [1], lift off operator's cab assembly (39). 4
Operator's cab assembly: 300 kg
15. Disconnect radio antenna (31). 16. Remove clip (32) and take wiring harness (33) out of grommet (34).
21. When starting the engine while the operator's cab is removed (for transportation, etc.), use the following brackets. 1) Bracket (41) for controller (40) Part No.: 208-53-13920
17. Take grommet (35) out of the right front of the cab. 18. Disconnect the windshield washer hose from (36). 19. Remove 4 mounting bolts (37) and 5 mounting bolts (38). a Check the types of the bolts. a In the initial period, 7 mounting bolts (38) are used.
30-76 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
2) Bracket (42) for monitor panel assembly (30) Part No.: 208-53-13910
PC400/450(LC)-7
OPERATOR’S CAB
INSTALLATION •
Carry out installation in the reverse order to removal.
30-77 (2)
DISASSEMBLY AND ASSEMBLY
MONITOR
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
INSTALLATION •
Carry out installation in the reverse order to removal.
1. Remove cover (1) and disconnect wiring connector P15 of air conditioner sunlight sensor (2). a Raise and remove the cover. 2. Remove the 3 mounting screws and monitor assembly (3). a Disconnect monitor panel wiring connectors P01, P02, and P70 before removing the monitor assembly.
30-78 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
PUMP CONTROLLER
REMOVAL AND INSTALLATION OF PUMP CONTROLLER REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
INSTALLATION •
Carry out installation in the reverse order to removal.
1. Remove covers (1), (2), and (3).
2. Disconnect pump controller wiring connectors C01 (4), C02 (5), and C03 (6). 3. Remove the 4 mounting bolts and pump controller assembly (7).
PC400/450(LC)-7
30-79 (2)
DISASSEMBLY AND ASSEMBLY
ENGINE CONTROLLER
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery.
INSTALLATION •
Carry out installation in the reverse order to removal.
1. Open the right side cover (cooler). 2. Remove bracket (1). 3. Remove the 4 mounting bolts and engine controller assembly (2).
4. Disconnect engine controller wiring connectors CB1 (3), CB2 (4), and CB3 (5).
30-80 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY REMOVAL k
Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position.
1. Remove the work equipment assembly. For details, see REMOVAL AND INSTALLATION OF WORK EQUIPMENT. 2. Remove the counterweight assembly. For details, see REMOVAL AND INSTALLATION OF COUNTERWEIGHT. 3. Disconnect 4 boom cylinder hoses (1). a Plug the hoses to stop oil.
4. Sling boom cylinder assembly (2) temporarily. 5. Remove plate (3) and pin (4) and lift off boom cylinder assembly (2). a Remove the boom cylinder on the opposite side similarly. 4
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.
Boom cylinder assembly: 360 kg
PC400/450(LC)-7
30-81 (2)
DISASSEMBLY AND ASSEMBLY
8. Remove 29 mounting bolts (13), leaving 3 each at the front and rear sides.
REVOLVING FRAME
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. 2 Mating face of swing circle: Gasket sealant (LG-6) 2 Threads of revolving frame mounting bolt: Adhesive (LT-2)
9. Using a lever block, sling the revolving frame assembly temporarily, balancing it in each direction. a Put wood liners to the rear side of the frame. • Rough standard length of sling: Front: 8 m in total Rear: 6 m a If the engine hood interferes with the sling, erect the engine hood, referring to REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY. 10. Remove the remaining 6 bolts and lift off revolving frame assembly (14). [*1] k When removing the revolving frame assembly, take care that it will not interfere with the center swivel joint assembly. 4
30-82 (2)
Revolving frame assembly: 10,000 kg
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY 3 Revolving frame mounting bolt 1. Tighten the bolts marked with A (at 4 places) according to the following steps 1) – 3). 1) Tighten each bolt to 392 Nm {40 kgm} first. 2) Then, tighten the bolt by 90° ± 5°. • Make a mark on the bolt head with a marker pen (to check the angle). 3) The tightening torque of the bolt tighten in 2) above must be 1,176 Nm {120 kgm} or larger.
REVOLVING FRAME
2. Tighten each bolt 208-25-71230 which is not marked with A according to above steps 1) – 3). If the tightening torque reaches 2,254 Nm {230 kgm} before completing the above steps and the tightening angle is 35° – 95°, however, stop tightening.
a Marks P and S are the soft zone points. •
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air Bleed air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
PC400/450(LC)-7
30-83 (2)
DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY REMOVAL
INSTALLATION
1. Set eyebolt [1] to counterweight assembly (1). 2. Remove 4 mounting bolts (2). a Check where shims have been used.
Carry out installation in the reverse order to removal. a If heat insulation cover (3) of the engine compartment is flattened, replace it.
[*1]
2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 3,430 – 4,212 Nm {350 – 430 kgm}
[*1]
3. Lift off counterweight assembly (1). [*2] a When lifting off the counterweight, take care not to strike it against the engine, radiator and cooler assembly, etc. 4
•
Counterweight assembly: 9,500 kg [*2]
30-84 (2)
a Installation and adjustment of counterweight 1) Adjust the level difference from the exterior parts (horizontal clearance) with shims. • Kinds of shim thickness: 0.5 mm, 1 mm 2) Insert the shims so that the clearance between the door and counterweight and that between the revolving frame and counterweight will be 10 ± 5 mm evenly.
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY REMOVAL
7. Disconnect drain hoses (8), (9), and (10).
1. Remove 3 lower covers (1).
8. Disconnect 2 clamps (11). 9. Remove side cover (12).
2. Drain the oil from the hydraulic tank. 6
Capacity of hydraulic tank: Approx. 335 l
3. Open engine hood (2) and remove control valve top cover (3).
10. Remove sensor (13). 11. Disconnect suction tube (14). 12. Sling the hydraulic tank assembly temporarily and remove 6 mounting bolts (15).
4. Remove cover (4). 5. Disconnect drain hoses (5) and (6). 6. Disconnect block (7).
PC400/450(LC)-7
13. Lift off hydraulic tank assembly (16). 4
Hydraulic tank assembly: 200 kg
30-85 (2)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
INSTALLATION •
Carry out installation in the reverse order to removal.
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5
•
Capacity of hydraulic tank: Approx. 335 l Quantity of oil in tank (Center of oil level gauge): 248 l
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
30-86 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
C
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
796-460-1210 Oil stopper
q 1
796-770-1320 Adapter
q 1
REMOVAL k
Disconnect the cable from the negative (–) terminal of the battery. k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Remove 2 lower covers (1).
3. Drain the oil from the flywheel housing. 4. Open the main pump side cover. 5. Open the engine hood. 6. Lift off covers (2) and (3) together. 7. Remove cover (4). 8. Remove stay (5).
2. Remove the hydraulic tank strainer. Using tool C, stop the oil. a When not using tool C, remove the drain plug to drain the oil from the hydraulic tank and piping. 6
Hydraulic tank: Approx. 335 l
PC400/450(LC)-7
30-87 (2)
DISASSEMBLY AND ASSEMBLY
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
30-88 (2)
HYDRAULIC PUMP
11. Sling hydraulic pump assembly (18) temporarily and remove 12 mounting bolts (17).
12. Lift off hydraulic pump assembly (18). 4
[*1]
Hydraulic pump assembly: 255 kg
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
INSTALLATION •
Carry out installation in the reverse order to removal.
[*1]
2 Hydraulic pump involute spline: Anti-friction compound (LM-G) 2 Mating face of hydraulic pump case: Gasket sealant (LG-6)
•
Refilling with oil 3 Flywheel housing drain plug: 42.1 – 70.6 Nm {4.3 – 7.2 kgm} Add oil through the oil filler to the specified level.
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5
•
Capacity of hydraulic tank: Approx. 335 l Quantity of oil in tank (Center of oil level gauge): 248 l
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
PC400/450(LC)-7
30-89 (2)
DISASSEMBLY AND ASSEMBLY
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT REMOVAL 1. Remove the hydraulic pump assembly. Refer to t h e R E M O VA L O F H Y D R A U L I C P U M P ASSEMBLY section. 2. Remove snap ring (1) and then remove spacer (2). 3. Pry off oil seal (3) with a screwdriver. [*1] a When attempting to pry off the seal, do not damage the shaft.
30-90 (2)
INSTALLATION •
Install in reverse order of removal.
[*1]
2 Oil seal lip portion: Grease (G2-LI) 2 Oil seal outer circumference: Grease (G2-LI) a Coat the oil seal outer circumference thinly with grease. a Press-fit oil seal (3), using tool .
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY REMOVAL k
Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank and set the safety lock lever to the LOCK position.. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Open engine hood (1). 2. Remove control valve top cover (2). 6. Disconnect the following 4 control valve hoses: • (16): Port PPS1 hose (Front pump) • (17): Port PLS2 hose (Hose band: Red) • (18): Port PLS1 hose • (19): Port PX1 hose (Hose band: Blue) 7. Remove relay bracket (20) and clamp (21). 8. Disconnect drain hose (22). (To tank)
3. Remove partition covers (3), (4), and (5) between the engine and control valve.
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)
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)
PC400/450(LC)-7
30-91 (2)
DISASSEMBLY AND ASSEMBLY
10. Disconnect 4 boom hoses (24). 11. Remove boom tube clamps (25) and (26).
CONTROL VALVE
15. Disconnect the following 6 right PPC hoses. • (30): Bucket DUMP (Hose band: Black) • (31): Left travel FORWARD (Hose band: Red) • (32): Boom LOWER (Hose band: Brown) • (33): Right SWING • (34): Right travel FORWARD (Hose band: Green) • (35): Arm IN (Hose band: Blue)
12. Disconnect port TSW hose (27) (Swing motor port S). 13. (28): In order from top Remove port A-1 tube (Boom Hi bottom side). Remove port A1 tube (Bucket bottom side). Disconnect port A2 hose (Swivel joint port A). After removing the hoses from ports B, remove port A3 tube (Boom bottom side). Remove port A4 hose (Swing motor port MB). Disconnect port A5 hose (Swivel joint port C). Remove port A6 tube (Arm head side).
16. Disconnect the following 3 control valve hoses. a Do not disconnect hose C. • (36): Port BP5 hose (To solenoid) • (37): Port PX2 hose • (38): Port TS hose
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).
30-92 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
17. Sling control valve assembly (40) temporarily and remove 3 mounting bolts (39).
CONTROL VALVE
INSTALLATION •
Carry out installation in the reverse order to removal.
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
•
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
18. Lift off control valve assembly (40). 4
Control valve assembly: 250 kg
PC400/450(LC)-7
30-93 (2)
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY a Only precautions for assembling the pressure compensation valve assembly and control valve assembly are explained below.
Part No.
Part Name
796-946-1310 Guide
21.8
(For 723-46-40100, 723-46-40601) 1
796-946-2110 Guide
20.9
(For 723-46-44100) 796-946-2210 Guide
20.6
(For 723-46-45100, 723-46-45500) 796-946-1320 Guide (For 723-46-40100, 723-46-40601) 796-946-1420 Guide 2 L
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 Sleeve
3
(For 723-46-42800) 796-946-2130 Sleeve (For 723-46-44100) 796-946-2230 Sleeve (For 723-46-45100, 723-46-45500)
30-94 (2)
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL
a Since there many types of the pressure compensation valves, make a mark on each valve to indicate from where it was removed. 1. Remove piston (2), plug (3), and spring (4) from pressure compensation valve (1). 2. Remove seal (5) and O-ring (6) from piston (2).
1 1 1 1 1 1 1 1 1
a There many types of the pistons. a Clean the pressure compensation valve thoroughly. Then, using the tool, install seals as shown in the figure. 3. Fit O-ring (6) to piston (2). 4. Set tool L1 to piston (2) and push it in with your hand slowly so that seal (5) will expand evenly. a You may push in the seal to the flat part of the tool first, and then install the tool to the piston and push in the seal further.
1 1
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
5. Set tool L2 to piston (1) for other seal (3) and push it in with your hand slowly so that seal (3) will expand evenly. a You may push in the seal to the flat part of the tool first, and then install the tool to the piston and push in the seal further.
CONTROL VALVE
ASSEMBLY • •
Apply engine oil to the sliding surfaces of the parts before installing. When installing spools (7) and (10) in the valve chamber, direct drilled holes (8) and (11) toward cylinder ports (9) and (12).
6. Install correcting tool L3 to piston (1) for about 1 minute to fit seals (2) and (3). a Check that the seal are not projected or broken.
•
Install filters (13) to the bottom of ports PLS1 and PLS2 as shown below.
7. Fit plug (3) and spring (4) to piston (2) and assemble pressure compensation valve (1). a If these parts are difficult to install, do not push them in forcibly, but install them to correcting tool L3 to fit the seals, and then install them to the piston. a After assembling, push the piston with your hand and check that it is returned by only the spring force.
PC400/450(LC)-7
30-95 (2)
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE 3 Mounting bolt of boom Hi check valve, quick return valve, lock valve, and arm plate: 58.8 – 73.6 Nm {6 – 7.5 kgm}
•
•
Control valve top and bottom covers 2 Mating faces of control valve top and bottom covers: SEALEND 242 or equivalent a Use 2 washers (W2) each for only 2 places of the control valve top cover. Tighten the mounting bolts of the control valve top and bottom covers in the following order. (A o D o C o B)
3 Mounting bolt of control valve top and bottom covers: 156.9 – 176.5 Nm {16 – 18 kgm}
•
•
Merge-divider valve
2 Mating face of merge-divider valve: SEALEND 242 or equivalent Tighten the mounting bolts of the merge-divider valve similarly to those of the control valve covers. 3 Mounting bolt of merge-divider valve: 156.9 – 176.5 Nm {16 – 18 kgm}
•
Tighten the mounting bolts of the boom Hi check valve, quick return valve, lock valve, and arm plate similarly to those of the control valve covers.
30-96 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
3 Mounting bolts of back-pressure valve, boom Hi check valve, quick return valve, lock valve and arm plate: 58.8 – 73.6 Nm {6 – 7.5 kgm} •
Pressure compensation valve a When installing each pressure compensation valve, check the mark made when it was removed.
•
Main relief valve assembly After installing the main relief valve to the control valve, see TESTING AND ADJUSTING, Testing and adjusting oil pressures in work equipment, swing, and travel circuits.
PC400/450(LC)-7
30-97 (2)
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY REMOVAL k
Replace the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, release of remaining pressure in hydraulic circuit. a Mark all the piping with tags to prevent mistakes in the mounting position when installing. 1. Disconnect six hoses (1) through (6) between travel motor and center swivel joint. • (1): Center swivel joint (T port) – Left travel motor (T port) • (2): Center swivel joint (T port) – Right travel motor (T port) • (3): Center swivel joint (B port) – Left travel motor (PA port) • (4): Center swivel joint (D port) – Right travel motor (PB port) • (5): Center swivel joint (A port) – Left travel motor (PB port) • (6): Center swivel joint (C port) – Right travel motor (PA port)
3. Pull out pin (16) on the side of center swivel joint and remove the jam plate from the center swivel joint.
4. Remove four mounting bolts (17).
5. Remove center swivel joint assembly (18). 4
[*1]
Center swivel joint assembly: 40 kg
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)
30-98 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
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.
PC400/450(LC)-7
30-99 (2)
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT ASSEMBLY
Part No.
1. Remove cover (1).
Part Name
790-101-2501 Push puller
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
q 1
• 790-101-2510 • Block
1
• 790-101-2520 • Screw
1
• 791-112-1180 • Nut
1
M • 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
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).
DISASSEMBLY ASSEMBLY 1. Assemble slipper seal (8) and O-ring (7) to swivel rotor (4). 2. Assemble seal (6) in swivel shaft (5). 3. Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install. 2 Contact surface of rotor, shaft: Grease (G0-LI or G2-LI) a When installing the rotor, be extremely careful not to damage the slipper seal and the Oring. 4. Install ring (3) ans secure with snap ring (2). 5. Install O-ring and cover (1). 3 Mounting bolt: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
30-100 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT PPC VELVE
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY a Only precautions for assembling the work equipment PPC valve assembly are explained below.
a When installing pistons (8), apply grease to their outside and the inside of the valve body holes. 3 Mounting bolt of plate (5): 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 2 Sliding parts of joint (4): 2 – 4 cc of Grease (G2-LI) 2 Female threads of body (A): Adhesive (LT-2) a Apply a drop (about 0.02 g) of LOCTITE to each of the 2 threaded parts of the body as shown in the figure, and then tighten joint (4). 3 Joint (4): 39 – 49 Nm {4 – 5 kgm} a Observe the tightening torque of the joint.
ASSEMBLY •
Work equipment PPC valve assembly a Install springs (11 ) with the small-diameter (inside diameter) end on the shim (12) side. a Springs (10 ) having different number of turns are used for the following hydraulic ports. Take care when installing them. Installed height: 31.9 mm (Common to all springs) Installed load: P1, P2: 35.3 N {3.6 kg} P3, P4: 21.6 N {2.2 kg}
2 Contact parts of piston and disc (2): Grease 0.3 – 0.8 cc (G2-LI) 3 Nut (1): 69 – 88 Nm {7 – 9 kgm} a When installing disc (2), adjust the play to 0.5 – 3mm at 200 mm from the turning center of the lever.
a The position of each port is stamped on the underside of valve body. 2 Piston (8): Grease (G2-LI)
PC400/450(LC)-7
30-101 (2)
DISASSEMBLY AND ASSEMBLY
TRAVEL PPC VALVE
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY DISASSEMBLY a Only precautions for assembling the travel PPC valve assembly are explained below.
ASSEMBLY •
Travel PPC valve assembly a Insert shim (3) of the thickness and quantity checked when disassembled. Standard shim thickness: 0.3 mm a Since spring (4) is not symmetric vertically, install it with the small-diameter (inside diameter) end on the shim side.
2 Periphery of piston (7) and inside of hole of body (1): Grease (G2-LI) 2 Sliding part of shaft (13) (4 – 8 cc), contact parts of lever (12) and piston (7), and contact part of pin of lever (26) and plate (24) (0.3 – 0.8 cc): Grease (G2-LI)
a Use the inserting jig described KES.D.07177 to insert bushing (19). a Use the inserting jig described KES.D.04025 to insert spring pin (25).
30-102 (2)
in in
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY
Part No.
1 790-502-1003
2
790-102-4300
Part Name
Cylinder repair stand
3 790-720-1000 Expander
4
t 1
t 2 q 1
Ring (For boom q 1 and bucket)
Clamp (For 07281-01589 boom and bucket)
q 1
796-720-1690 Ring (For arm)
q 1
07281-01919 Clamp (For arm) q 1 790-201-1702 Push tool kit N 5
t 1
• 790-201-1851
• Push tool (For bucket)
1
• 790-201-1861
• Push tool (For boom)
1
• 790-201-1871
• Push tool (For arm)
1
• 790-101-5021 • Grip
1
• 01010-50816 • Bolt
1
790-201-1500 Push tool kit
1
• 01010-50816 • Bolt
1
6 • 790-201-1660 • Plate (For bucket)
4) Disassemble the piston rod assembly according to the following procedure. i) Set piston rod assembly (2) to tool N1.
1
• 790-101-5021 • Grip
1
• 790-201-1670
• Plate (For boom)
1
• 790-201-1680
• Plate (For arm)
1
PC400/450(LC)-7
1. Piston rod assembly 1) Remove the piping from the cylinder assembly. 2) Remove the mounting bolts and disconnect cylinder head assembly (1). 3) Pull out piston rod assembly (2). a Put a container under the cylinder to receive oil.
Wrench assemt 1 bly
790-102-4310 Pin
796-720-1680
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
ii)
Remove piston assembly lock screw (3). a This work is common to the boom, arm, and bucket cylinders. Screw size: M12 x Pitch 1.75
30-103 (2)
DISASSEMBLY AND ASSEMBLY
a If screw (3) is so caulked that you cannot remove it, tighten it temporarily and tap the threads on it, and then remove it.
iii) Using tool N2, remove piston assembly (4). • When not using tool N2, loosen the piston assembly by using the drilled holes (Ø10: 2 places) (in which the pins of N2 are inserted in the following figure).
iv) Remove plunger (5). • Perform this work for only the boom and arm cylinder. v) Remove collar (6). • Perform this work for only the boom and arm cylinder. vi) Remove head assembly (7).
30-104 (2)
HYDRAULIC CYLINDER
vii) Remove cap (8), 11 balls (9), and plunger (10). • Perform this work for only the arm cylinder. a Since cap (8) is made of nylon, tighten a screw into it and pull it with pliers.
2. Disassembly of piston assembly 1) Remove rings (11). 2) Remove wear rings (12). 3) Remove piston ring (13). 4) Remove the O-ring and backup rings (14).
3. Disassembly of cylinder head assembly 1) Remove the O-ring and backup ring (15). 2) Remove snap ring (16) and dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove snap ring (21). 6) Remove bushing (20).
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
ASSEMBLY a Take care not to damage the packings, dust seals, O-rings, etc. a Clean the all parts. After installing them, cover the piping ports and pin holes to prevent dirt from entering. a Do not insert each backup ring forcibly, but warm it in water at 50 – 60°C and then insert it.
1. Assembly of cylinder head assembly 1) Using tool N5, press fit bushing (20). 2) Install buffer ring (19). 3) Install rod packing (18). 4) Using tool N6, install dust seal (17) and secure it with snap ring (16). 5) Install backup ring and O-ring (15). 6) Install snap ring (21).
PC400/450(LC)-7
HYDRAULIC CYLINDER
2. Assembly of piston assembly 1) Using tool N3, expand piston ring (13). a Set piston ring (13) to tool N3 and turn the handle 8 – 10 times to expand the piston ring. 2) Set tool N4 and contract piston ring (13).
3) Install backup ring and O-ring (14). 4) Install wear ring (12). 5) Install ring (11). a Do not increase the closed gap of the ring too much. 2 Ring groove: Grease (G2-LI)
30-105 (2)
DISASSEMBLY AND ASSEMBLY
3. Piston rod assembly 1) Set the piston rod to tool N1. 2) Install cylinder head assembly (7) to the piston rod. 3) Fit the O-ring and backup ring to collar (6), and then install them. • Perform this work for only the boom and arm cylinders. 4) Install plunger (5). • Perform this work for only the boom and arm cylinders.
HYDRAULIC CYLINDER
6) Assemble piston assembly (4) according to the following procedure. • When reusing the rod and piston assembly (4) i) Tighten piston assembly (4). Then, using tool N2, tighten piston assembly (4) until the screw holes are aligned. a Remove the burrs from the threads with a file. Go to iv).
•
5) Set plunger (10) to the piston rod. Install 11 balls (9) and secure them with cap (8). a After installing the plunger, check that it has a little play at its end. • Perform this work for only the arm cylinder.
When replacing either or both of the rod and piston assembly (4) with new ones a Make a mark of the cushion plug position on the end of the rod having the bottom cushion. • Perform this work for only the arm cylinder. ii) Using the tool, tighten piston assembly (4) until it reaches the end of the rod. 3 Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} a After tightening the piston, check that plunger (5) has some play. • Perform this work for only the boom and arm cylinders.
30-106 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER
iii) Make a screw hole to install screw (3). a Apply a drill to the V-groove of the threaded parts of piston (4) and rod (2) and make a hole. a When making a hole on the cylinder (arm cylinder) having the bottom cushion, make it around the cushion plug. • Dimensions of screw hole (mm) Tap drill diameter
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). a Clean the parts thoroughly and remove metal chips, dirt, etc.
2 Threads of screw: Adhesive (LOCTITE No. 262) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} v) Caulk the threaded part by 4 places with a punch.
7) Install piston rod assembly (2). a Set the abutment joint of the ring at a side and insert the piston rod, aligning it with the cylinder tube. a After inserting the piston rod, check that the ring is not broken or removed, and then insert to the end.
8) Tighten the mounting bolts of cylinder head assembly (7). 3 Mounting bolt: Cylinder name
Tightening torque
Bucket
530 ± 78.5 Nm {54.0 ± 8 kgm}
Arm
892 ± 137 Nm {91.0 ± 14 kgm}
Boom
530 ± 78.5 Nm {54.0 ± 8 kgm}
9) Install the piping.
PC400/450(LC)-7
30-107 (2)
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
P
Part No.
Part Name
Necessity Q’ty New/Remodel Sketch
Symbol
SPECIAL TOOLS
796-670-1100 Remover
q 1
• 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)
q 1
790-101-1102
Pump (294 kN {30t})
q 1
4. Start the engine and retract the piston rod. a Bind the rod with wires, etc. so that it will not be extracted and lower it onto a stand or put a wood block to the bottom side so that the cylinder will not lower. When putting the wood block, remove the grease fitting on the bottom side. a Disconnect the boom cylinder on the opposite side similarly. a When slinging the boom cylinder, if the sling interferes with the work equipment lamp, remove the work equipment lamp. 5. Disconnect intermediate connector A42 (6) for the work equipment lamp. 6. Disconnect 3 arm cylinder hoses (7) and 2 bucket cylinder hoses (8). a Put oil stopper plugs and secure the hoses to the valve side with ropes.
REMOVAL k
Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position. k See TESTING AND ADJUSTING, Releasing residual pressure in hydraulic circuit. 1. Disconnect grease hose (1). 2. Sling boom cylinder assembly (2) temporarily and remove lock bolt and nut (3). [*1] 3. Remove plate (4) and head pin (5). [*2] a Check the quantity and positions of the inserted shims.
30-108 (2)
7. Sling work equipment assembly (12) temporarily. 8. Remove cover (9), plate (10), and foot pin (11) to disconnect work equipment assembly (12). [*3]
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
•
When removing with tool P Remove plate (10). Sling and set tool P and remove foot pin (11) to disconnect work equipment assembly (12). a Check the quantity and positions of the inserted shims.
9. Move the machine in reverse to remove work equipment assembly (12). 4
Work equipment assembly: PC400-7, PC400LC-7: 7,400 kg PC450-7, PC450LC-7: 8,400 kg
PC400/450(LC)-7
WORK EQUIPMENT
INSTALLATION • [*1]
[*2]
Carry out installation in the reverse order to removal. a Tighten the locknut so that clearance "a" between the plate and nut will be 0.5 – 1.5 mm.
2 Inside wall of bushing before assembling pin: Anti-friction composition (LM-P) 2 Greasing after assembling pin: Grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a Adjust the shim thickness so that clearance "b" between cylinder rod (12) and plate (4) will be 1.5 mm or less. Standard shim: 1.0, 2.0 mm
30-109 (2)
DISASSEMBLY AND ASSEMBLY
[*3]
2 Inside wall of bushing before assembling pin: Anti-friction composition (LM-P) 2 Greasing after assembling pin: Grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a Adjust the shim thickness so that clearance "c" between boom (13) and bracket (14) will be 1 mm or less. Standard shim: 2.0, 2.5, 3.0, 3.5 mm
•
Bleeding air See TESTING AND ADJUSTING, Bleeding air from each part.
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
30-110 (2)
WORK EQUIPMENT
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)
a Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) – (4) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) For the procedure for replacing the front window assembly, see REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.
PC400/450(LC)-7
(1) : (2) : (3) : (4) : (5) :
Right side window glass Left side rear window glass Door lower window glass Front window glass Front window assembly (Front window glass + Front frame) (6) : Both-sided adhesive tape (16): Center trim seal
30-111 (2)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
Y
1 793-498-1210
Lifter (Suction cup)
2 20Y-54-13180 Adapter
(The figure shows the operator's cab of a wheel loader.) Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Symbol
SPECIAL TOOLS
t 2 t 2
REMOVAL
a 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).
a If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. a Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4]. (The figure shows the operator's cab of a wheel loader.)
a 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.
30-112 (2)
2. Remove the window glass.
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
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. a 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 shows the operator's cab of a wheel loader.)
OPERATOR’S CAB GLASS (STUCK GLASS)
3. Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a 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.) 1) Stir the primers for paint and glass sufficiently before using them. a 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.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry. (The figure shows the operator's cab of a wheel loader.)
PC400/450(LC)-7
30-113 (2)
DISASSEMBLY AND ASSEMBLY
3) 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. 2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
OPERATOR’S CAB GLASS (STUCK GLASS)
a 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) a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry.
a Parts to be coated with primer: Apply the primer all over dimension (a). • Dimension to apply primer (a): 25 mm
a Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
30-114 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
4) Evenly apply glass primer to the sticking surfaces of window glass (9). 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
a 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). a Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. a Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
PC400/450(LC)-7
OPERATOR’S CAB GLASS (STUCK GLASS)
4. Stick both-sided adhesive tape (6) along the inside edge of the glass sticking section. a Do not remove the release tape of the bothsided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.
a 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. 1) Stick both-sided adhesive tape (6) for right side window glass (1) as shown in the figure.
30-115 (2)
DISASSEMBLY AND ASSEMBLY
a 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
2) Stick both-sided adhesive tape (6) for left side rear window glass (2) as shown in the figure.
3) Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the figure.
30-116 (2)
OPERATOR’S CAB GLASS (STUCK GLASS)
a Stick both-sided adhesive tape (6b) additionally for door lower window glass (3). a Positions to stick additional both-sided adhesive tape for door lower window glass: (j) : 110 mm (k) : 90 mm (m) : 200 mm
4) Stick both-sided adhesive tape (6) for front window glass (4) as shown in the figure.
a 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.)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
5. Position the new window glass. 1) 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. 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line n. a 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. 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator's cab before installing the window glass.
OPERATOR’S CAB GLASS (STUCK GLASS)
a 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.
6. Apply adhesive. a Use either of the 2 types of the adhesive. 2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S" 2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER "W" a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part from the nozzle tip. 1) Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
PC400/450(LC)-7
30-117 (2)
DISASSEMBLY AND ASSEMBLY
2) 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
3) Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.
OPERATOR’S CAB GLASS (STUCK GLASS)
a 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 a Apply adhesive (15) higher than bothsided adhesive tape (6). a Apply the adhesive evenly.
a 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.
4) Remove the release tape of the both-sided adhesive tape on the glass side. 5) Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's cab.
30-118 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
7. Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly.
OPERATOR’S CAB GLASS (STUCK GLASS)
a 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 a When caulking, mask the glass side and form the adhesive with a rubber spatula as shown in the figure. a Wipe off projected adhesive. 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER 2 Adhesive: SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
a You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup Y1.
PC400/450(LC)-7
30-119 (2)
DISASSEMBLY AND ASSEMBLY
8. Fix the window glass. 1) 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.
OPERATOR’S CAB GLASS (STUCK GLASS)
9. After installing the window glass, remove the primer and adhesive from the operator's cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact to it. 10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20°C and humidity of 60%). 2) 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.
2) Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape to fit them completely.
30-120 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY k
Lower the work equipment to the ground and stop the engine. a 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.
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.
REMOVAL 1. Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides).
7. Remove rollers (8) and (9) under the both sides of the front window.
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. a This bolt will be used to hang the pull-up assist cable in step 8.
PC400/450(LC)-7
30-121 (2)
DISASSEMBLY AND ASSEMBLY
8. Remove left lower pin (10). [*3] a If left lower pin (10) is removed, plate (12) at the end of pull-up assist cable (11) comes off. a Hang plate (12) on the left striker bolt. k The return load of 58.8 N {6 kg} 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).
FRONT WINDOW
10. Lower front window assembly (13) completely. a Do not let the front window assembly touch the monitor.
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).
9. Put out the bottom of front window assembly (13) through the rail opening portion and lower it gradually.
30-122 (2)
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
FRONT WINDOW
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 mounting bolts of roller adjustment brackets (16) and (17) and adjust the condition of the front window, and then tighten the mounting bolts again. 3 Mounting bolt: 98 Nm {1.0 kgm}
PC400/450(LC)-7
30-123 (2)
DISASSEMBLY AND ASSEMBLY
3. Raise the front window assembly and fix it with the rear locks (on both sides). a 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). a Tighten the striker bolt securely after adjusting it in step 6. a Install the right corner block so that there will be no level difference at part (a). 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. a Secure roller clearance (c) at part PJ.
30-124 (2)
FRONT WINDOW
5. Install left corner blocks (1) and (2) and secure left corner bracket (6) with left striker bolt (4). a Tighten the striker bolt securely after adjusting it in step 6. a Install the left corner blocks so that there will be no level difference at 2 part (d). a Secure roller clearance (e).
PC400/450(LC)-7
DISASSEMBLY AND ASSEMBLY
6. Adjust the striker bolts according to the following procedure (Adjust the "CLOSE" positions of the front window assembly locks). 1) Tighten left striker bolt (4) and right striker bolt (5) at roughly right positions so that front window glass (18) will be fitted to cabside trim seal (19).
FRONT WINDOW
2) Open and close the front window assembly and check the working condition of both locks (20) and (21). i) If both locks do not work normally, move the striker bolts toward the rear of the cab and tighten them again. ii) After moving the striker bolts, check the fitness of the front window glass and cab-side trim seal which was checked in step 6. iii) Repeat the work in i) and ii) 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.
7. After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak into the cab.
PC400/450(LC)-7
30-125 (5)
DISASSEMBLY AND ASSEMBLY
8. Adjust the "opening" lock of the front window assembly. 1) After adjusting the "closing" lock of the front window in step 6, raise the front window assembly to the ceiling. 2) Set the right and left front window assembly locks at the rear of the operator's cab to the "OPEN" positions, and then check the following items. • Check that right and left locks (20) and (21) are closed normally. • Check that right and left locks (20) and (21) are inserted in parallel in right and left striker plates (22). • Check that right and left rubber stoppers (24) are in contact with the front window assembly and their deflection allowance is 1.5 – 3.0 mm. 3) After checking the above items, if necessary, adjust them by moving right and left striker plates (22) at the rear of the operator's cab.
FRONT WINDOW
9. Adjust the front window stoppers. 1) After adjusting "closing" lock of the front window assembly in step 9, check the contact of both front window stoppers (23). 2) If both stoppers (23) do not contact normally, adjust and fix them at places where they contact normally.
10. Check the latching effort of the front window assembly. 1) After finishing steps 6 – 9, check that latching efforts of both locks (20) and (21) are even. a 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]
3 Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm} 2 Mounting bolt: Adhesive (LT-2)
30-126 (5)
PC400/450(LC)-7
90 OTHERS HYDRAULIC CIRCUIT DIAGRAM (1/2)........................................................................................................90- 3 HYDRAULIC CIRCUIT DIAGRAM (2/2)........................................................................................................90- 5 ELECTRICAL CIRCUIT DIAGRAM (1/5) ......................................................................................................90- 7 ELECTRICAL CIRCUIT DIAGRAM (2/5) ......................................................................................................90- 9 ELECTRICAL CIRCUIT DIAGRAM (3/5) ......................................................................................................90- 11 ELECTRICAL CIRCUIT DIAGRAM (4/5) ......................................................................................................90- 13 ELECTRICAL CIRCUIT DIAGRAM (5/5) ......................................................................................................90- 15 AIR CONDITIONER ELECTRICAL CIRCUIT ...............................................................................................90- 17 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)..............................................................................................90- 19 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)........................................................90- 21
PC400/450(LC)-7
90-1 (6)
HYDRAULIC CIRCUIT DIAGRAM (1/2)
PC400/450(LC)-7
90-3
HYDRAULIC CIRCUIT DIAGRAM (2/2)
PC400/450(LC)-7
90-5
ELECTRICAL CIRCUIT DIAGRAM (1/5)
PC400/450(LC)-7
90-7 (4)
ELECTRICAL CIRCUIT DIAGRAM (2/5)
PC400/450(LC)-7
90-9 (4)
ELECTRICAL CIRCUIT DIAGRAM (3/5)
PC400/450(LC)-7
90-11 (4)
ELECTRICAL CIRCUIT DIAGRAM (4/5)
PC400/450(LC)-7
90-13 (4)
ELECTRICAL CIRCUIT DIAGRAM (5/5)
PC400/450(LC)-7
90-15 (4)
AIR CONDITIONER ELECTRICAL CIRCUIT
PC400/450(LC)-7
90-17
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)
PC400/450(LC)-7
PC400, 450-7
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)
PC400, 450-7
90-19 (6)
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE) Connector No.
Type
No. of pins
A01
X
4
A02
X
A03
PC400, 450-7
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)
Address
Connector No.
Type
No. of pins
Intermediate connector
T-1
M19
YAZAKI
2
Cigarette lighter
N-3
4
Intermediate connector
T-1
M21
PA
9
Radio
U-2
DT
12
Intermediate connector
N-2
M22
Y090
2
Horn switch
O-7
A04
SWP
6
Intermediate connector
O-1
M23
Y090
2
One-touch power maximizing switch
T-1
A05
SWP
14
Intermediate connector
T-1
M26
S
12
Intermediate connector
W-4
A06
SWP
14
Intermediate connector
O-1
M27
YAZAKI
18
Air conditioner unit
W-4
A07
SWP
16
Intermediate connector
S-1
M29
040
20
Air conditioner control panel
U-2
A09
SWP
8
Intermediate connector
N-2
M30
040
16
Air conditioner control panel
U-2
A10
Terminal
1
Revolving frame grounding
H-2
M31
M
2
Optional power supply (2)
W-7
A11
Terminal
1
Revolving frame grounding
I-2
M32
M
2
Optional power supply (1)
W-6
A12
Terminal
1
Revolving frame grounding
I-2
M33
M
2
Optional power supply (3)
V-9
A13
Terminal
1
Revolving frame grounding
I-2
M33
SUMITOMO
4
Air conditioner unit
W-4
A14
Terminal
1
Revolving frame grounding
F-1
M34
X
1
Air conditioner compressor electromagnetic clutch
I-9
A15
Terminal
1
Revolving frame grounding
J-3
M37
Terminal
1
Horn switch (High tone)
H-1
A16
Terminal
1
Revolving frame grounding
J-3
M38
Terminal
1
Horn switch (Low tone)
G-1
A20
Terminal
1
Battery relay (Terminal E)
D-1
M38
M
2
Machine push-up switch
Q-8
A21
Terminal
1
Battery relay (Terminal BR)
D-2
M40
M
2
Working lamp
Z-8
A22
Terminal
1
Battery relay (Terminal N)
F-2
M41
M
2
Working lamp (Additional)
Y-7
A23
Terminal
1
Battery relay (Terminal B)
F-2
M42
M
1
Intermediate connector
H-9
A31
D
2
Air cleaner clogging sensor
H-9
M43
M
1
Working lamp (Rear)
J-9
A33
X
2
Radiator water level sensor
H-9
M45
D
12
Intermediate connector
W-7
A34
L
2
Fusible link (65 A)
D-2
M46
X
4
RS232C junction connector
V-9
A35
M
2
Fusible link (30 A)
G-9
M71
M
2
Room lamp
A40
Terminal
1
Horn (Low tone)
G-9
M72
M
4
DC/DC converter
A41
Terminal
1
Horn (High tone)
G-9
M73
M
2
Speaker (Left)
A42
M
1
Intermediate connector
H-9
M79
M
2
12-V accessory outlet
V-9
A43
D
2
Travel alarm
J-3
NE
YAZAKI
2
Engine Ne sensor
AJ-5
A44
M
1
Right headlamp
D-5
OL
DT
2
Engine oil level sensor
AJ-3
A50
KES0
2
Windshield washer motor (Tank)
L-5
P01
070
12
Monitor panel
N-6
A51
D
3
F pump oil pressure sensor
L-8
P02
040
20
Monitor panel
N-5
A52
D
3
R pump oil pressure sensor
L-7
P03
M
2
Buzzer cancel switch
Q-8
A60
X
1
Fuel level sensor
G-9
P05
M
2
Rotary lamp switch
U-2
A61
D
2
Hydraulic oil temperature sensor
L-5
P15
Y050
2
Air conditioner daylight sensor
N-5
A70
D
3
Boom cylinder bottom pressure sensor for overload alarm
H-1
P70
040
16
Monitor panel
N-5
A73
D
2
Fuel priming pump
G-9
PCV1
SUMITOMO
2
Fuel supply pump PCV1
AH-2
A80
DT
8
Intermediate connector
S-1
PCV2
SUMITOMO
2
Fuel supply pump PCV2
AI-2
AL/B
Terminal
1
Alternator B terminal
AE-6
PSH
Terminal
1
Engine oil pressure switch (High pressure)
AH-2
AL/E
Terminal
1
Alternator E terminal
AE-6
PSL
Terminal
1
Engine oil pressure switch (Low pressure)
AG-1
AL/R
Terminal
1
Alternator R terminal
AE-6
PFUEL
AMP
3
Common rail pressure sensor
AJ-4
C01
DRC
24
Pump controller
U-9
PIM
SUMITOMO
3
Boost pressure sensor
AJ-8
C02
DRC
40
Pump controller
U-9
R10
R
5
Light relay
P-7
C03
DRC
40
Pump controller
W-9
R11
R
5
Starting motor cutout relay (PPC lock)
P-8
C09
S
8
Model selection connector (Pump controller)
W-9
R13
R
5
Starting motor cutout relay (Personal code)
Q-8
CB1
DRC
24
Pump controller
I-9
R20
R
5
ATT circuit selector relay
W-7
CB2
DRC
40
Pump controller
I-9
R22
R
5
Power supply relay for engine controller
W-6
CB3
DRC
40
Pump controller
J-9
R30
R
5
Air conditioner blower relay
W-4
CB5
DT
8
Model selection connector (Engine controller)
J-9
R31
R
5
Air conditioner compressor relay
W-3
CN1
DT
2
No. 1 fuel injector
AI-2
S01
D
4
Bucket CURL pressure sensor
K-3
CN2
DT
2
No. 2 fuel injector
AI-3
S02
X
2
Boom LOWER oil pressure switch
L-2
CN3
DT
2
No. 3 fuel injector
AJ-3
S03
X
2
Swing RIGHT oil pressure switch
L-2
CN4
DT
2
No. 4 fuel injector
AJ-5
S04
D
3
Arm IN pressure switch
K-3
CN5
DT
2
No. 5 fuel injector
AJ-6
S05
X
2
Bucket DUMP oil pressure switch
L-2
CN6
DT
2
No. 6 fuel injector
AJ-6
S06
X
2
Boom RAISE oil pressure switch
L-2
D01
SWP
8
Concentrated diode
W-7
S07
X
2
Swing LEFT oil pressure switch
L-2
D02
SWP
8
Concentrated diode
W-5
S08
X
2
Arm DUMP oil pressure switch
L-1
E06
M
3
Fuel control dial
P-7
S09
X
2
Service oil pressure switch (Intermediate connector)
L-1
ENE
DT
2
Engine speed sensor
AJ-5
S10
X
2
Service front oil pressure switch
K-1
ER02
HD30
31
Intermediate connector
AF-8
S11
X
2
Service rear oil pressure switch
L-1
ER03
HD30
31
Intermediate connector
AF-8
S14
M
3
Safety lock lever switch
S-1
F02
M
2
Rotary lamp
AA-9
S21
Terminal
6
Emergency pump drive switch
R-9
FB1
—
—
Fuse box
V-2
S22
Terminal
6
Swing holding brake release switch
R-8
G
YAZAKI
2
Engine G sensor
AH-2
S25
S090
16
Intermediate connector
R-9
GND
DT
2
Joint connector (with diode)
AJ-6
S30
X
2
Travel oil pressure switch
P-1
GND2
Terminal
1
Engine grounding
AJ-5
S31
X
2
Travel steering oil pressure switch
P-1
GND3
Terminal
1
Engine grounding
AE-7
ST
DT
2
Starting motor
AF-7
H08
M
8
Intermediate connector
W-6
ST/B
Terminal
1
Starting motor B terminal
AF-7
H09
S
8
Intermediate connector
W-6
T05
Terminal
1
Floor frame grounding
V-3
H10
S
16
Intermediate connector
T-9
T06
Terminal
1
Radio body grounding
S-9
H11
S
16
Intermediate connector
S-9
T06A
M
1
Intermediate connector
T-2
H12
S
12
Intermediate connector
S-9
T11
Terminal
1
Cab grounding
H15
S090
20
Intermediate connector
O-7
THL
DT
3
Spill fuel temperature sensor
AJ-4
HT/B
Terminal
1
Heater relay B terminal
AH-9
TWH
DT
2
Engine water temperature sensor (High temperature)
AE-7
HT/S
Terminal
1
Heater relay S terminal
AJ-7
TWL
DT
3
Engine water temperature sensor (Low temperature)
AG-8
J01
J
20
Junction connector (Black)
T-9
V01
DT
2
PPC oil pressure lock solenoid valve
J-3
J02
J
20
Junction connector (Black)
T-9
V02
DT
2
Travel junction solenoid valve
J-2
J03
J
20
Junction connector (Green)
U-9
V03
D
2
Merge-divider solenoid valve
J-2
J04
J
20
Junction connector (Green)
V-3
V04
D
2
Travel speed solenoid valve
J-2
J05
J
20
Junction connector (Pink)
V-3
V05
D
2
Swing holding brake solenoid valve
J-2
J06
J
20
Junction connector (Orange)
W-3
V06
D
2
Machine push-up solenoid valve
J-2
J07
J
20
Junction connector (Orange)
W-5
V08
D
2
2nd-stage relief solenoid valve
J-1
J08
J
20
Junction connector (Pink)
W-5
V12
D
2
ATT return selector solenoid valve
J-1
K19
M
2
Pump resistor (For driving pump in emergency)
W-5
V21
D
2
PC-EPC solenoid valve
L-6
K30
DT
3
CAN terminal resistance
K-9
V22
D
2
LS-EPC solenoid valve
L-6
K31
DT
3
CAN terminal resistance
N-4
V30
X
2
ATT flow adjustment EPC solenoid valve
P-1
M07
M
3
Light switch
P-8
W03
M
2
Rear limit switch (Window)
M09
M
1
Working lamp (Right front)
E-9
W04
M
6
Wiper motor
Y-5
M13
M
2
Speaker (Right)
AC-9
X05
M
4
Swing lock switch
Q-8
PC400/450(LC)-7
Name of device
Name of device
PC400, 450-7
Address
AA-8 U-2 AD-8
AB-9
90-21 (6)
