PC400-7L A86001 and Up PDF

CEBM012502
Shop
Manual
PC400LC-7L
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC400LC-7L A86001 and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
May 2004 Copyright 2004 Komatsu

Printed in USA DataKom Publishing Division
PC400LC-7L 00-1 2
FOREWORD CONTENTS
12
CONTENTS 00
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 2 PC400LC-7L
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB040500
OPERATION AND MAINTENANCE MANUAL:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM012900
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM012502
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM024208
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE03-2
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America Corp. Extranet Literature Ordering System.
If the Extranet Literature Ordering System is not available at the distributor location, then the following
Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown
on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax
orders.
PC400LC-7L R02 pubinfok.fm 5/19/04

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM DataKom Publications and Training Division

AND RETURN TO 440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
SHIP TO PURCHASE ORDER NO.
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT
ONLY CITY, STATE, ZIP CODE
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
QTY. PUBLICATION FORM NO. PARTS BOOK PUBLICATION MODEL NUMBER SERIAL NUMBER
P-Paper DESCRIPTION
➥
M-Microfiche
KDC91E 071403 CURRENT PRICES WILL BE CHARGED

FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 c 01-3 10-20 10-49
● 00-2 c 01-4 10-21 10-50
● 00-2-1 c 01-5 10-22 10-51
● 00-2-2 c 01-6 10-23 10-52
● 00-2-3 c 01-7 10-24 10-53
● 00-2-4 c 01-8 10-25 10-54
● 00-2-5 c 01-9 10-26 10-55
● 00-2-6 c 01-10 10-27 10-56
❍ 00-2-7 c 01-11 10-28 10-57
❍ 00-2-8 c 10-29 10-58
00-3 10-1 10-30 10-59
00-4 10-2 10-31 10-60
00-5 10-3 10-32 10-61
00-6 10-4 10-33 10-62
00-7 10-5 10-34 10-63
00-8 10-6 10-35 10-64
00-9 10-7 10-36 10-65
00-10 10-8 10-37 10-66
00-11 10-9 10-38 10-67
00-12 10-10 10-39 10-68
00-13 10-11 10-40 10-69
00-14 10-12 10-41 10-70
00-15 10-13 10-42 10-71
00-16 10-14 10-43 10-72
00-17 10-15 10-44 10-73
00-18 10-16 10-45 10-74
10-17 10-46 10-75
01-1 10-18 10-47 10-76
01-2 10-19 10-48 10-77
PC400LC-7L PC400LC-7L 00-2-1 2

FOREWORD
10-78 10-111 10-144 10-177
10-79 10-112 10-145 10-178
10-80 10-113 10-146 10-179
10-81 10-114 10-147 10-180
10-82 10-115 10-148 10-181
10-83 10-116 10-149 10-182
10-84 10-117 10-150 10-183
10-85 10-118 10-151 10-184
10-86 10-119 10-152 10-185
10-87 10-120 10-153 10-186
10-88 10-121 10-154 10-187
10-89 10-122 10-155 10-188
10-90 10-123 10-156 10-189
10-91 10-124 10-157 10-190
10-92 10-125 10-158 10-191
10-93 10-126 10-159 10-192
10-94 10-127 10-160 10-193
10-95 10-128 10-161 10-194
10-96 10-129 10-162 10-195
10-97 10-130 10-163 10-196
10-98 10-131 10-164
10-99 10-132 10-165 20-1 b
10-100 10-133 10-166 20-2 b
10-101 10-134 10-167 20-3 b
10-102 10-135 10-168 20-4 b
10-103 10-136 10-169 20-5 b
10-104 ● 10-137 c 10-170 20-6 b
10-105 ● 10-138 10-171 20-7 b
10-106 10-139 10-172 20-8 b
10-107 10-140 10-173 20-9 b
10-108 10-141 10-174 20-10 b
10-109 10-142 10-175 20-11 b
10-110 10-143 10-176 20-12 b
00-2-2 2 PC400LC-7L
FOREWORD
20-133 b 20-166 b 20-220 b
20-101 b 20-134 b 20-167 b 20-221 b
20-102 b 20-135 b 20-168 b 20-222 b
20-103 b 20-136 b 20-169 b 20-223 b
20-104 b 20-137 b 20-170 b 20-224 b
20-105 b 20-138 b 20-171 b 20-225 b
20-106 b 20-139 b 20-172 b 20-226 b
20-107 b 20-140 b 20-173 b 20-227 b
20-108 b 20-141 b 20-174 b 20-228 b
20-109 b 20-142 b 20-175 b 20-229 b
20-110 b 20-143 b 20-176 b 20-230 b
20-111 b 20-144 b 20-177 b 20-231 b
20-112 b 20-145 b 20-178 b 20-232 b
20-113 b 20-146 b 20-233 b
20-114 b 20-147 b 20-201 b 20-234 b
20-115 b 20-148 b 20-202 b 20-235 b
20-116 b 20-149 b 20-203 b 20-236 b
20-117 b 20-150 b 20-204 b 20-237 b
20-118 b 20-151 b 20-205 b 20-238 b
20-119 b 20-152 b 20-206 b 20-239 b
20-120 b 20-153 b 20-207 b 20-240 b
20-121 b 20-154 b 20-208 b 20-241 b
20-122 b 20-155 b 20-209 b 20-242 b
20-123 b 20-156 b 20-210 b 20-243 b
20-124 b 20-157 b 20-211 b 20-244 b
20-125 b 20-158 b 20-212 b 20-245 b
20-126 b 20-159 b 20-213 b 20-246 b
20-127 b 20-160 b 20-214 b 20-247 b
20-128 b 20-161 b 20-215 b 20-248 b
20-129 b 20-162 b 20-216 b 20-249 b
20-130 b 20-163 b 20-217 b 20-250 b
20-131 b 20-164 b 20-218 b 20-251 b
20-132 b 20-165 b 20-219 b 20-252 b
PC400LC-7L 00-2-3 2
FOREWORD
20-253 b 20-327 b 20-360 b 20-393 b
20-254 b 20-328 b 20-361 b 20-394 b
20-255 b 20-329 b 20-362 b 20-395 b
20-256 b 20-330 b 20-363 b 20-396 b
20-257 b 20-331 b 20-364 b 20-397 b
20-258 b 20-332 b 20-365 b 20-398 b
20-333 b 20-366 b 20-399 b
20-301 b 20-334 b 20-367 b 20-400 b
20-302 b 20-335 b 20-368 b 20-401 b
20-303 b 20-336 b 20-369 b 20-402 b
20-304 b 20-337 b 20-370 b 20-403 b
20-305 b 20-338 b 20-371 b 20-404 b
20-306 b 20-339 b 20-372 b 20-405 b
20-307 b 20-340 b 20-373 b 20-406 b
20-308 b 20-341 b 20-374 b 20-407 b
20-309 b 20-342 b 20-375 b 20-408 b
20-310 b 20-343 b 20-376 b 20-409 b
20-311 b 20-344 b 20-377 b 20-410 b
20-312 b 20-345 b 20-378 b 20-411 b
20-313 b 20-346 b 20-379 b 20-412 b
20-314 b 20-347 b 20-380 b 20-413 b
20-315 b 20-348 b 20-381 b 20-414 b
20-316 b 20-349 b 20-382 b 20-415 b
20-317 b 20-350 b 20-383 b 20-416 b
20-318 b 20-351 b 20-384 b 20-417 b
20-319 b 20-352 b 20-385 b 20-418 b
20-320 b 20-353 b 20-386 b 20-419 b
20-321 b 20-354 b 20-387 b 20-420 b
20-322 b 20-355 b 20-388 b 20-421 b
20-323 b 20-356 b 20-389 b 20-422 b
20-324 b 20-357 b 20-390 b 20-423 b
20-325 b 20-358 b 20-391 b 20-424 b
20-326 b 20-359 b 20-392 b 20-425 b
00-2-4 2 PC400LC-7L
FOREWORD
20-426 b 20-508 b 20-541 b 20-574 b
20-427 b 20-509 b 20-542 b
20-428 b 20-510 b 20-543 b 20-601 b
20-429 b 20-511 b 20-544 b 20-602 b
20-430 b 20-512 b 20-545 b 20-603 b
20-431 b 20-513 b 20-546 b 20-604 b
20-432 b 20-514 b 20-547 b 20-605 b
20-433 b 20-515 b 20-548 b 20-606 b
20-434 b 20-516 b 20-549 b 20-607 b
20-435 b 20-517 b 20-550 b 20-608 b
20-436 b 20-518 b 20-551 b 20-609 b
20-437 b 20-519 b 20-552 b 20-610 b
20-438 b 20-520 b 20-553 b 20-611 b
20-439 b 20-521 b 20-554 b 20-612 b
20-440 b 20-522 b 20-555 b 20-613 b
20-441 b 20-523 b 20-556 b 20-614 b
20-442 b 20-524 b 20-557 b 20-615 b
20-443 b 20-525 b 20-558 b 20-616 b
20-444 b 20-526 b 20-559 b 20-617 b
20-445 b 20-527 b 20-560 b 20-618 b
20-446 b 20-528 b 20-561 b 20-619 b
20-447 b 20-529 b 20-562 b 20-620 b
20-448 b 20-530 b 20-563 b 20-621 b
20-449 b 20-531 b 20-564 b 20-622 b
20-450 b 20-532 b 20-565 b 20-623 b
20-533 b 20-566 b 20-624 b
20-501 b 20-534 b 20-567 b 20-625 b
20-502 b 20-535 b 20-568 b 20-626 b
20-503 b 20-536 b 20-569 b
20-504 b 20-537 b 20-570 b ❍ 30-1 c
20-505 b 20-538 b 20-571 b ❍ 30-2 c
20-506 b 20-539 b 20-572 b ❍ 30-3 c
20-507 b 20-540 b 20-573 b ❍ 30-4 c
PC400LC-7L 00-2-5 2
FOREWORD
❍ 30-5 c ❍ 30-38 c ❍ 30-71 c ❍ 30-104 c
❍ 30-6 c ❍ 30-39 c ❍ 30-72 c ❍ 30-105 c
❍ 30-7 c ❍ 30-40 c ❍ 30-73 c ❍ 30-106 c
❍ 30-8 c ❍ 30-41 c ❍ 30-74 c ❍ 30-107 c
❍ 30-9 c ❍ 30-42 c ❍ 30-75 c ❍ 30-108 c
❍ 30-10 c ❍ 30-43 c ❍ 30-76 c ❍ 30-109 c
❍ 30-11 c ❍ 30-44 c ❍ 30-77 c ❍ 30-110 c
❍ 30-12 c ❍ 30-45 c ❍ 30-78 c ❍ 30-111 c
❍ 30-13 c ❍ 30-46 c ❍ 30-79 c ❍ 30-112 c
❍ 30-14 c ❍ 30-47 c ❍ 30-80 c ❍ 30-113 c
❍ 30-15 c ❍ 30-48 c ❍ 30-81 c ❍ 30-114 c
❍ 30-16 c ❍ 30-49 c ❍ 30-82 c ❍ 30-115 c
❍ 30-17 c ❍ 30-50 c ❍ 30-83 c ❍ 30-116 c
❍ 30-18 c ❍ 30-51 c ❍ 30-84 c ❍ 30-117 c
❍ 30-19 c ❍ 30-52 c ❍ 30-85 c ❍ 30-118 c
❍ 30-20 c ❍ 30-53 c ❍ 30-86 c ❍ 30-119 c
❍ 30-21 c ❍ 30-54 c ❍ 30-87 c ❍ 30-120 c
❍ 30-22 c ❍ 30-55 c ❍ 30-88 c ❍ 30-121 c
❍ 30-23 c ❍ 30-56 c ❍ 30-89 c ❍ 30-122 c
❍ 30-24 c ❍ 30-57 c ❍ 30-90 c ❍ 30-123 c
❍ 30-25 c ❍ 30-58 c ❍ 30-91 c ❍ 30-124 c
❍ 30-26 c ❍ 30-59 c ❍ 30-92 c ❍ 30-125 c
❍ 30-27 c ❍ 30-60 c ❍ 30-93 c ❍ 30-126 c
❍ 30-28 c ❍ 30-61 c ❍ 30-94 c ❍ 30-127 c
❍ 30-29 c ❍ 30-62 c ❍ 30-95 c ❍ 30-128 c
❍ 30-30 c ❍ 30-63 c ❍ 30-96 c ❍ 30-129 c
❍ 30-31 c ❍ 30-64 c ❍ 30-97 c ❍ 30-130 c
❍ 30-32 c ❍ 30-65 c ❍ 30-98 c ❍ 30-131 c
❍ 30-33 c ❍ 30-66 c ❍ 30-99 c ❍ 30-132 c
❍ 30-34 c ❍ 30-67 c ❍ 30-100 c ❍ 30-133 c
❍ 30-35 c ❍ 30-68 c ❍ 30-101 c ❍ 30-134 c
❍ 30-36 c ❍ 30-69 c ❍ 30-102 c
❍ 30-37 c ❍ 30-70 c ❍ 30-103 c 90-1
00-2-6 2 PC400LC-7L
FOREWORD
90-2 90-35
90-3 90-36
90-4 90-37
90-5 90-38
90-6 90-39
90-7 90-40
90-8 90-41
90-9 90-42
90-10 90-43
90-11 90-44
90-12 90-45
90-13 90-46
90-14 90-47
90-15 90-48
90-16 90-49
90-17 90-50
90-18
90-19
90-20
90-21
90-22
90-23
90-24
90-25
90-26
90-27
90-28
90-29
90-30
90-31
90-32
90-33
90-34
PC400LC-7L 00-2-7 2
FOREWORD
00-2-8 2 PC400LC-7L
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE
operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with
buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding
work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting.
Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct
places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK 00
1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the
control levers and hang warning signs on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
PC400LC-7L 00-3
FOREWORD SAFETY
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad-
ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK 00
1. When removing the oil filler cap, drain plug or

hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before
disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the cir-
cuit.
2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
water to cool before carrying out any work on the oil or water circuits.
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-)
terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing
electrical parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4 PC400LC-7L
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this
section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
PC400LC-7L 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00
REVISIONS 00
Shop manuals are issued as a guide to carrying out repairs.

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

Any additions, amendments or other changes will be sent to other precautions for preserving
★ Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
FILING METHOD 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Oil, water
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK 00
When a manual is revised, an edition mark (123…) is

recorded on the bottom outside corner of the pages.
00-6 PC400LC-7L
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc. In
the DISASSEMBLY AND
ASSEMBLY section, every part
weighing 25 kg or more is
indicated clearly with the symbol
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the 3. Do not sling a heavy load with one rope alone, but sling
relative parts. with two or more ropes symmetrically wound on to the
2. Check for existence of another part causing interface load.
with the part to be removed.
WARNING! Slinging with one rope may
WIRE ROPES 00 cause turning of the load during
hoisting, untwisting of the rope,
1. Use adequate ropes depending on the weight of parts to or slipping of the rope from its
be hoisted, referring to the table below: original winding position on the
load, which can result in a
Wire Ropes dangerous accident
(Standard “Z” or “S” twist ropes without galvanizing)
Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
mm kN tons two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
11.2 13.7 1.4
hoisting is made with two ropes, each of which is
12.5 15.7 1.6 allowed to sling up to 1000 kg vertically, at various
14 21.6 2.2 hanging angles. When two ropes sling a load vertically,
up to 2000 kg of total weight can be suspended. This
16 27.5 2.8 weight becomes 1000 kg when two ropes make a 120°
18 35.3 3.6 hanging angle. On the other hand, two ropes are subject
to an excessive force as large as 4000 kg if they sling a
20 43.1 4.4
2000 kg load at a lifting angle of 150°
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
PC400LC-7L 00-7
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber cushions
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 ● Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant purposes for
container
bolts and plugs.
790-129-9060
Adhesive: 1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent: 500 g
agent)
Adhesives
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals, rubbers,
plastics and woods.
● Quick hardening type adhesive.
Aron-alpha Polyethylene ● Quick cure type (max. strength after 30 minutes).
790-129-9130 50 g
201 container ● Used mainly for adhesion of rubbers, plastics
and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high
648-50 container
temperature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Features: Resistance to heat
Gasket sealant
●
● Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent
LG-3 790-129-9070 1 kg Can seizure.
● Used as sealant for heat resistant gasket for at
high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-8 PC400LC-7L
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

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

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

SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
PC400LC-7L 00-9
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 13.2 ± 1.4 9.2 ± 1.03
8 13 31.4 ± 2.9 23.1 ± 2.1
10 17 65.7 ± 6.8 48.4 ± 5.0
12 19 112 ± 9.8 82.6 ± 7.2
14 22 177 ± 19 130.5 ± 14.0
16 24 279 ± 29 205.7 ± 21.3
18 27 383 ± 39 282.4 ± 28.7
20 30 549 ± 58 404.9 ± 42.7
22 32 745 ± 78 549 ± 57.5
24 36 927 ± 98 683 ± 72.2
27 41 1320 ± 140 973.5 ± 103.2
30 46 1720 ± 190 1268.6 ± 140.1
33 50 2210 ± 240 1630.0 ± 177.0
36 55 2750 ± 290 2028.2 ± 213.8
39 60 3280 ± 340 2419.2 ± 250.7
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 7.85 ± 1.95 5.7 ± 1.4
8 13 18.6 ± 4.9 13.7 ± 3.6
10 14 40.2 ± 5.9 29.6 ± 4.3
12 27 82.35 ± 7.85 60.7 ± 5.7
00-10 PC400LC-7L
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 24.5 ± 4.9 18.0 ± 3.6
03 18 24 49 ± 19.6 36.1 ± 14.4
04 22 27 78.5 ± 19.6 57.8 ± 14.4
05 24 32 137.3 ± 29.4 101.2 ± 21.6
06 30 36 176.5 ± 29.4 130.1 ± 21.6
10 33 41 196.1 ± 49 144.6 ± 36.1
12 36 46 245.2 ± 49 180.8 ± 36.1
14 42 55 294.2 ± 49 216.9 ± 36.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm lbf ft
10 14 65.7 ± 6.8 48.4 ± 5.0
12 17 112 ± 9.8 82.6 ± 7.2
16 22 279 ± 29 205.7 ± 21.3
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 9 216.9 ± 36.1
PC400LC-7L 00-11
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of strand Cross section Applicable circuit
number (mm) rating (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
Primary
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 Black & Green &
Color White & Red — Red & White Yellow & Red Blue & White
White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow &
Color — Red & Black Green & Red Blue & Red
Black Yellow Black
Code WL — BR RY YG GY LY
Auxiliary
4 Red & Yellow & Green & Yel- Blue &

Color White & Blue — Black & Red
Yellow Green low Yellow
Code WG — — RG YL GB LB
5 White & Yellow & Green &
Color — — Red & Green Blue & Black
Green Blue Black
Code — — — RL YW GL —
6 Yellow &
Color — — — Red & Blue Green & Blue —
White
00-12 PC400LC-7L
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
METHOD OF USING THE CONVERSION TABLE 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
2
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
PC400LC-7L 00-13
12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-14 PC400LC-7L
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
PC400LC-7L 00-15
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-16 PC400LC-7L
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
PC400LC-7L 00-17
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-18 PC400LC-7L
01 GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
PC400LC-7L 01-1
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
Item Unit PC400LC-7L

Operating weight 44,600
(Variable gauge specification) (98,343)
Operating weight kg 43,700
(Fixed gauge specification) (lb) (96,359)
43,700
Operating weight
(96,359)
m3 1.9
Bucket capacity
(cu.yd) (2.5)
Name of engine - KOMATSU SAA6D125E-3 diesel engine
kW 246(330)
Rated horsepower of engine
(HP)/rpm /1,850
mm 12,040
A Overall length
(ft in) (39' 6“)
mm 3,670
B Overall height
(ft in) (12')
Overall width 3,690
C
(Variable gauge specification) mm (12' 1.2“)
Overall width (ft in) 3,640
C
(Fixed gauge specification) (11' 11.3“)
mm 800
D Track shoe width (Variable gauge)
(ft in) (2' 7.5“)
mm 900
D Track shoe width (Fixed gauge)
(ft in) (2' 11.4“)
mm 3,250
E Height of cab
(ft in) (10' 8“)
mm 3,645
F Radius of upper structure
(ft in) (11' 12“)
mm 5,355
G Overall length of track
(ft in) (17’ 7“)
mm 4,350
H Length of track on ground
(ft in) (14' 3“)
mm 685
Min. ground clearance
(ft in) (2' 3“)
km/h 3.0/4.4/5.5
Traveling speed (low/middle/high)
(MPH) (1.9/2.7/3.4)
Swing speed rpm 9.1
F/G 2740
Tg Track gage
V/G 2890
F/G ---
Tg (for transport)
V/G 2392
01-2 PC400LC-7L
12
● “Variable gauge specification” means the machine can extend and retract overall width (C) of the track frame.
“Fixed gauge specification” means the machine cannot extend or retract overall width (C) of the track frame.
01-3 PC400LC-7L
12
Working ranges Unit PC400LC-7
mm 12,030
A Max. digging reach
(ft in) (39' 6“)
mm 7,830
B Max. digging depth
(ft in) (25' 8“)
mm 10,930
C Max. digging height
(ft in) (35' 10“)
mm 6,870
D Max. vertical wall digging depth
(ft in) (22' 6“)
mm 7,625
E Max. dumping height
(ft in) (25')
mm
F Min. dump height -
(ft in)
mm 11,820
G Max. digging reached at ground level
(ft in) (38' 9“)
01-4 PC400LC-7L
12
Machine model PC400LC-7L
Serial Number A86001 and UP
m3 1.4
Bucket capacity
yd3 1.83
Fixed gauge spec. Variable gauge spec.
kg 43,700 44,600
Weight of machine
lb 96,342 98,326
Max. digging force kgf (lbf) 26,100 (57,541)

(using power max. function) kgf (lbf) 28,000 (61,729)
Swing speed rpm 9.1
Performance
Swing max. slope angle deg. 20

Travel speed km/h (mi/h) Lo: 3.0 (0.00186), Mi: 4.4 (0.00273),
Hi: 5.5 (0.00341)
Gradeability deg. 35
Ground pressure kg/cm2 (lbf/ft2) 0.82 (11.66) 0.67 (9.52)

(standard shoe width) mm (in) 900 (35.4) 800 (31.5)
Overall length (for transport) 12,040 (39’ 6") 12,040 (39’ 6")
Overall width 3,640 (11’ 11") 3,690 (12’ 1")
Overall width of track (for transport) --- 3,192 (10’ 6")
Overall width of track when extended --- 3,690 (12’ 1")
Overall height (for transport) 3,635 (11’ 11") 3,635 (11’ 11")
Overall height to top of machine 3,265 (10’ 9") 3,265 (10’ 9")
Dimensions
Ground clearance of upper structure 1,320 (4’ 4") 1,320 (4’ 4")
Min. ground clearance mm (ft in) 555 (1’ 10") 685 (2’ 3")
Tail swing radius 3,645 (12’ 0") 3,645 (12’ 0")
Min. swing radius of work equipment 4,735 (15’ 6") 4,735 (15’ 6")
Height of work equipment at min. swing radius 9,210 (30’ 3") 9,210 (30’ 3")
Length of track on ground 4,020 (13’ 2") 4,020 (13’ 2")
Track gauge (Tg) 2,740 (9’ 0’) 2,890 (9’ 6")
Track gauge (for transport) --- 2,392 (7’ 10")
Height of machine cab 3,265 (10’ 9") 3,265 (10’ 9")
Model SAA6D125E-3
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbocharger and aftercooler
No. of cylinders - bore x stroke mm (in) 6 - 125x150 (6 - 4.921x5.905)
Piston displacement L (in3) 11.045 (674.007)
Flywheel horsepower kW/rpm (HP/rpm) 246.4/1,850 (330/1,850)

Performance
Max. torque kgm/rpm (lbf ft/rpm) 136/1,400 (983.9/rpm)

Engine
Max. speed at no load rpm 1,930

Min. speed at no load rpm 1,000
Min. fuel consumption g/kWh (g/HPh) 203 (151)
Starting motor 24 V, 11 Kw
Alternator 24 V, 50 A
Battery 12 V, 110 Ahx2
Radiator core type ALW-4
★ The "Mi" mode is on the multi-monitor specification machine only.
PC400LC-7L 01-5
12
Carrier roller 2 on each side

Undercarriage
Track roller 8 on each side
Track shoe Assembly-type triple grouser, 49 on each side
Type x No. HPV190+190, variable displacement, piston type x2

Hydraulic pump
Delivery L/min (in3) 345x2 (21053.2)
Set pressure kgf/cm2 (lbf/in2) 380 (5404.87)
Type x No. 6-spool type + 1-spool type x 1

Control valve
Control method Hydraulic
Travel motor KMV200ADT-2, Variable displacement, piston type (with

Hydraulic motor
Hydraulic system
brake valve, parking brake): x 2
Swing motor KMF230ABE-5, Fixed displacement piston type (with safety

valve, holding brake, reverse rotation
preventive valve): x 1
Boom Arm Bucket

Hydraulic cylinder
Type Double-acting piston
Inside diameter of cylinder 160 (0’ 6") 185 (0’ 7") 160 (0’ 6")
Diameter of piston rod 110 (0’ 4") 120 (0’ 5") 110 (0’ 4")
Stroke mm (ft in) 1,570 (5’ 2") 1,820 (6’ 0") 1,270 (4’ 2")
Max. distance between pins 3,830 (12’ 7") 4,325 (14’ 2") 3,140 (10’ 4")
Min. distance between pins 2,260 (7’ 5") 2,505 (8’ 3") 1,870 (6’ 2")
Hydraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
01-6 PC400LC-7L
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
WARNING! This weight table is for use when handling components or when transporting the machine
Unit: kg (lb)
Engine assembly 1,500 (3,307)
● Engine 1,150 (2,535)
● Damper 14.7 (32)
● Hydraulic pump 210 (463)
Radiator, oil cooler assembly 195 (430)
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 (437)
Fuel tank (excluding fuel) 251 (554)
Revolving frame 3,297 (7,269)
Operator’s cab 279 (616)
Operator’s seat 35 (78)
Counterweight 9,500 (20,944)
Swing machinery (including swing motor) 526 (1,160)
Control valve (with service valve0 257 (567)
Swing motor 105 (232)
Travel motor 208 (459) x 2
Center swivel joint 40 (89)
Fixed gauge specification Variable gauge specification
Track frame assembly 10,965 (24,174) 11,934 (26,310)

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

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

● Standard triple grouser shoe (600 mm) 4,760 (10,494)
● Standard triple grouser shoe (700 mm) 5,210 (11,486)
● Wide triple grouser shoe (800 mm) 5,670 (12,500)
● Wide triple grouser shoe (900 mm) 6,130 (13,515)
Boom assembly 3,290 (7,254)
Arm assembly 1,374 (3,030)
Bucket assembly 1,366 (3,012)
Boom cylinder assembly 355 (783) x 2
Arm cylinder assembly 510 (1,125)
PC400LC-7L 01-7
GENERAL WEIGHT TABLE
Bucket cylinder assembly 280 (618)
Link assembly 258 (569)
Boom pin 92 (203) + 20 (45) x 2 + 73 (161) + 27 (60) + 54 (120)
Arm pin 17 (38) + 23 (51)
Bucket pin 38 (102) x 2
Link pin 34 (75) x 2
01-8 PC400LC-7L
GENERAL FUEL COOLANT AND LUBRICANTS
12
FUEL COOLANT AND LUBRICANTS
It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the
quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your distributor. The specified
fuel, coolant and lubricants recommended for this machine are as shown in the following table.
AMBIENT TEMPERATURE CAPACITY - L (gal)

KIND OF
RESERVOIR -22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 42 (11.09) 38 (10.03)
SAE 10W-30
SAE 15W-40
Damper case 1.07 (0.282) ---
Swing machinery case 13.4 (3.53)

Engine
Final drive case (each side) SAE 30 12 (3.17)
oil
Idler (1 each) 0.335-0.355 (0.0884-0.0937)
Track roller (1 each) 0.28-0.31 (0.0739-0.0818)
Carrier roller (1 each) 0.12-0.18 (0.0317-0.0475)
SAE 10W
SAE 10W-30
Hydraulic system 472 (124.6) 248 (65.5)
SAE 15W-40
Hydraulic
H046-HM (H)★★
oil
ASTM D975 No. 2

Diesel
Fuel tank 650 (171.7) ---
fuel
★
Cooling system Coolant Add antifreeze 36 (9.51) ---
★ ASTM D975 No. 1

★ ★ For the H-046-HM, use the oil recommended by Komatsu.
PC400LC-7L 01-9
GENERAL FUEL COOLANT AND LUBRICANTS
12
MEMORANDUM
01-10 PC400LC-7L
10 STRUCTURE AND FUNCTION
12
RADIATOR • OIL COOLER • AFTERCOOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
IDLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
CARRIER ROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
TRIPLE GROUSER SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
HYDRAULIC PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
LS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
PC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
LS(PS)-EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
VARIABLE VOLUME VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
SELF PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
REVERSAL PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
TRAVEL JUNCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
TRAVEL PPC SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
WORK EQUIPMENT • SWING PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
SERVICE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
PPC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
RETURN OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
BOOM HYDRAULIC DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
ARM HYDRAULIC DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
LIFT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
ATTACHMENT CIRCUIT SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
HOLDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
PC400LC-7L 10-1
STRUCTURE AND FUNCTION TABLE OF CONTENTS
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
DIMENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
DIMENSION OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
OPERATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
STOPPING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
COMPONENTS OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
TOTAL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
ENGINE AND PUMP CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
PUMP/VALVE CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
ONE-TOUCH POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION . . . . . . . . . . . . . . . . . . . . . . 10-158
AUTO-DECELERATION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
SWING CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
TRAVEL CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT) . . . . . . . . . . . . . . . . . . 10-168
SYSTEM COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
ENGINE REVOLUTION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
PPC OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
PUMP PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
MONITOR CONTROL, DISPLAY PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
MONITOR PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
MONITOR ITEMS AND DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
SELECT MODE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
MAINTENANCE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
SERVICE METER CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
DISPLAY LCD CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
ENGINE OIL LEVER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
10-2 PC400LC-7L
STRUCTURE AND FUNCTION RADIATOR • OIL COOLER • AFTERCOOLER
12
RADIATOR • OIL COOLER • AFTERCOOLER
1. Oil cooler 7. Radiator inlet hose Specifications

2. Radiator 8. Radiator outlet hose Radiator: ALW-4
3. Radiator cap 9. Aftercooler Oil cooler: CF40-1
4. Reservoir tank 10. Condenser
5. Net 11. Fuel cooler
6. Shroud
PC400LC-7L 10-3
STRUCTURE AND FUNCTION POWER TRAIN
12
POWER TRAIN
1. Idler 7. Hydraulic pump (HPV190+190)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing machinery
5. Travel motor (KMV 200ADT-2) 11. Swing motor (KMF230ABE-5)
6. Engine (SAA6D125-3E) 12. Swing circle
10-4 PC400LC-7L
STRUCTURE AND FUNCTION FINAL DRIVE
12
FINAL DRIVE
PC400LC-7L 10-5
STRUCTURE AND FUNCTION FINAL DRIVE
12
1. Level plug
2. Drain plug
3. No. 1 planetary gear (No. of teeth: 43)
4. No. 1 sun gear (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 18)
6. No. 1 planetary carrier
8. Cover
9. Ring gear (No. of teeth: 98)
10. Sprocket
11. Floating seal
12. Travel motor
13. No. 2 planetary gear (No. of teeth: 38)
Specification
Reduction ratio:
-((10 + 98)/10)x((18+98)/18)=-68.600
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun gear and No. 1 planetary Standard clearance Clearance limit
14 gear 0.15 - 0.54 1.10
15 Backlash between No. 1 planetary gear and ring gear 0.18 - 0.66 1.30
16 Backlash between No. 2 planetary carrier and motor 0.06 - 0.24 ---
Replace
Backlash between No. 2 sun gear and No. 2 planetary
17 0.15 - 0.51 1.00
gear
18 Backlash between No. 2 planetary gear and ring gear 0.17 - 0.60 1.20
Backlash between No. 2 planetary carrier and No. 2
19 sun gear 0.15 - 0.54 ---
20 Amount of wear on sprocket tooth Repair limit: 6

Standard size Repair limit Rebuild or replace
21 Width of sprocket tooth
90 87
Torque Nm Torque lbf ft
22 Bolt
59 - 78 44 - 57
23 Bolt 98 - 123 73 - 90
24 Bolt 59 - 74 44 - 54
25 Bolt 640 - 785 473 - 578
26 Bolt 490 - 608 362 - 448
10-6 PC400LC-7L
STRUCTURE AND FUNCTION SWING MACHINERY
12
SWING MACHINERY
PC400LC-7L 10-7
STRUCTURE AND FUNCTION SWING MACHINERY
12
1. Swing pinion (No. of teeth: 13)
2. Cover
3. Case
4. No. 2 planetary gear
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
13. Drain plug
Specification
Reduction ratio:
((19 +68)/19)x((16+68)/16)=24.039
Unit: mm
Backlash between swing motor shaft and No. 1 Standard clearance Clearance limit
14 sun gear 0.18 - 0.28 ---
Backlash between No. 1 sun gear and No. 1
15 0.15 - 0.51 1.00
planetary gear
Backlash between No. 1 planetary gear and ring
16 0.17 - 0.60 1.10
gear
Backlash between No. 1 planetary carrier and
17 0.40 - 0.75 1.20
No. 2 sun gear Replace
Backlash between No. 2 sun gear and No. 2
18 0.16 - 0.55 1.00
planetary gear
Backlash between No. 2 planetary gear and ring
19 0.17 - 0.60 1.10
gear
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 Apply hard chrome
Wear of swing pinion surface contacting with oil plating, recondition, or
23 seal 0
150 -0.100 --- replace
24 Bolt
824 - 1030 608 - 759
25 Bolt 343 - 427 253 - 314
26 Bolt 98 - 123 73 - 90
27 Bolt 245 - 309 181 - 228
28 Bolt 2.81 - 3.79 2.07 - 2.79
10-8 PC400LC-7L
STRUCTURE AND FUNCTION SWING CIRCLE
12
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 84) Specification
2. Ball Reduction ration: - 84 = -6.462

13
3. Swing circle outer race Amount of grease: 33 L (8.71 gal) {G2-LI}
a. Inner race soft zone “S” position
b. Outer race soft zone “S” position
Unit: mm
Axial clearance of bearing (when mounted on Standard clearance Repair limit

4 Replace
chassis) 0.5 - 1.6 3.2
PC400LC-7L 10-9
STRUCTURE AND FUNCTION TRACK FRAME AND RECOIL SPRING
12
TRACK FRAME AND RECOIL SPRING
1. Idler • The dimensions and the number of track rollers depend on the model, but the basic
2. Track frame structure is not different.
3. Carrier roller • Number of track rollers: 8
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Recoil spring
9. Front guard
10-10 PC400LC-7L
STRUCTURE AND FUNCTION TRACK FRAME AND RECOIL SPRING
12
Item Fixed gage Variable gage
Shoe width 900 mm 800 mm
Link pitch 228 mm 228 mm
No. on track (one side) 49 (Pieces) 49 (Pieces)
Unit: mm
Standard Tolerance Repair limit Rebuild or replace
size
10 Vertical width of idler guide +2
Track frame 123 127
-1
Idler support 120 ±0.5 118
+3
Track frame 266 271
-1
11 Horizontal width of idler guide Idler support 261 --- 259
Standard size Repair limit
Freelength x Installation Installation Installation Replace
Free length
OD length load load
12 Recoil spring
173.3 kN 138.56 kN
795 x 241 648 ---
{17,680 kg} {14,140 kg}
PC400LC-7L 10-11
STRUCTURE AND FUNCTION IDLER
12
IDLER
Unit: mm
1 Outside diameter of protruding
704 ---
2 Outside diameter of tread 660 648 Rebuild or
3 Depth of tread 22 28 replace
4 Total width 202 ---

5 Width of tread 48.5 ---
Tolerance Standard
Standard size clearance
Shaft Hole
6 Clearance between shaft and bushing
-0.120 +0.360
95 0.340-0.507
-0.207 +0.220 Replace
Tolerance bushing
Standard
Standard size
Shaft Hole interference
7 Interference between idler and bushing
+0.087 -0.027
102.6 0.064-0.149
+0.037 -0.079
8 Bolt
130 - 180 96 - 132
10-12 PC400LC-7L
STRUCTURE AND FUNCTION CARRIER ROLLER
CARRIER ROLLER
Unit: mm
1 Outside diameter of flange
175 ---
2 Outside diameter of tread 148 134
3 Width of tread 50.3 ---
4 Thickness of tread 32 25
5 Width of flange 19 ---
Standard Tolerance Standard Interference Replace
size Shaft Hole interference limit
6 Interference between shaft and bushing
-0.250 +0.099
50 -0.270 -0.032 0.218 - 0.369 ---
Interference between roller and bushing +0.117 +0.040 0.047 -

7 57 +0.087 0 0.177
Axial clearance of roller Standard clearance Clearance limit
8
0.5 - 0.7 ---
PC400LC-7L 10-13
STRUCTURE AND FUNCTION TRACK ROLLER
12
TRACK ROLLER
10-14 PC400LC-7L
STRUCTURE AND FUNCTION TRACK ROLLER
12
Unit: mm
1 Outside diameter of outer flange
240 ---
2 Outside diameter of inner flange 237 ---
(double flange)
3 Outside diameter of tread 200 188
4 Thickness of tread 56.2 50.2
5 Overall width 278 ---
Rebuild or replace
Singe flange 54.6 ---
6 Width of tread
Double flange 51.6 ---
Width of outer Singe flange 32.6 ---

7 flange Double flange 32.6 ---
8 Width of inner flange (Double 23.0 ---
flange)
9 Axial play 0.4 - 1.0 ---
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
10 bushing
-0.250 +0.174
80 0.279 -0.524 1.5
-0.350 +0.029 Replace bushing
Standard Interference
Interference between roller and +0.108 -0.006 interference limit
11 87.6
bushing +0.008 -0.036
0.014-0.144 ---
12 Bolt
10 - 20 8 - 14
13 Bolt 1st torque 200 ± 20 147 ± 14
13 Bolt 2nd torque 105 ± 5 77 ± 3
PC400LC-7L 10-15
STRUCTURE AND FUNCTION TRACK SHOE
12
TRACK SHOE
★ P portion shows the link of bushing press-fitting end.
10-16 PC400LC-7L
12
Unit: mm
1 Link pitch
228.9 231.9
Reverse or replace
Standard size When turned
2 Bushing outside diameter
71.5 66.5
3 Thickness of bushing metal 12 7 Adjust or replace
4 Link height
129 119 Repair or replace
Thickness of link metal (bushing press-fitting 34.5 24.5
5 portion)
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
9 Inside width 106
10 Link Overall width 51.6 Repair or replace
11 Tread width 44.8
12 Protrusion of pin 4.4
13 Protrusion of regular bushing 5.25
14 Overall length of pin 252 Adjust or replace
15 Overall length of bushing 164.5
16 Thickness of spacer ---
17 Bushing 118 - 304 kN {12 - 31 ton}
18 Press-fitting force Regular pin 176 - 451 kN {18 - 46 ton} ---
❈ 19 Master pin 137 - 284 kN {14 - 29 ton}
❈: Dry type track link
PC400LC-7L 10-17
12 Unit: mm
Tightening torque Additinal tightening angle
(Nm {lbf ft}) (deg.)
a. Regular link
393±39
Triple shoe 120±10
Shoe bolt {289±28} Retighten
20 Tightening torque Additinal tightening Lower limit torque
b. Master link (Nm {lbf ft}) angle (deg.) (Nm {lbf ft})
--- --- ---
No. of shoes (each side) 49 ---
Tolerance
Standard size Standard interference
Interference between bushing and Shaft Hole
21 link
+0.494 +0.074
71 0.380 - 0.494
+0.454 0
Interference between regular pin +0.235 -0.218
22 47 0.303 - 0.515
and link +0.085 -0.280
Tolerance
Standard size Standard clearance
Clearance between regular pin and Shaft Hole
23 bushing
+0.235 +0.915 Adjust or
47 0.180 - 0.830
+0.085 +0.415 replace
Tolerance
Standard size Standard interference
Interference between master pin Shaft Hole
24 and bushing
+0.03 -0.218
47 0.218 - 0.310
0 -0.280
Tolerance
Standard size Standard clearance
Clearance between master pin and Shaft Hole
25 bushing
-0.2 +0.915
47 0.615 - 1.315
-0.4 +0.415
10-18 PC400LC-7L
12
TRIPLE GROUSER SHOE
Unit: mm
1 Height
37 22
2 Thickness 13
3 33
Length at of base Rebuild or replace
4 27
5 25.5
6 Length at tip 17.5
7 23.5
PC400LC-7L 10-19
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
12
HYDRAULIC SYSTEM
HYDRAULIC PIPING DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve
13. Safety lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Holding valve
19. Accumulator
20. Solenoid valve assembly
20A. PPC lock solenoid
20B. Travel junction solenoid
20C. Pump merge/divider solenoid
20D. Travel speed solenoid
20E. Swing brake solenoid
20F. Machine push-up solenoid
20G. 2-stage relief solenoid
10-20 PC400LC-7L
12
PC400LC-7L 10-21
12
HYDRAULIC TANK
1. Oil filler cap Specifications

2. Breather Tank capacity: 335 L (88.4 gal)
3. Hydraulic tank Amount of oil inside tank: 248 L (65.5 gal)
4. Sight gauge Pressure valve
5. Strainer Relief cracking Pressure: 0.17 ± 0.07 kg/cm2 (2.47 ± 0.99 psi)
6. Filter element Suction cracking pressure: 0 - 0.005 kg/cm2 (0 - 0.071 psi)
7. Strainer Bypass valve set pressure: 1.5 ± 0.3 kg/cm2 (21.3 ± 4.26 psi)
8. Bypass valve Breather
Intake valve set pressure: 0.02 ± 0.003 kg/cm2 (0.284 ± 0.0426 psi)
Exhaust valve set pressure: 1.0 ± 0.15 kg/cm2 (14.2 ± 2.13 psi)
10-22 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 10-23
12
HYDRAULIC PUMP
HPV160+160(190)
1. Front main pump IM : PC mode selector current PENR : Rear pump control pressure detection port
2. Rear main pump ISIG : LS set selector current PLSF : Front load pressure input
3. LS valve PAF : Front pump delivery PLSFC : Front load pressure detection port
: Front pump delivery pressure
4. PC valve PFC PLSR : Rear load pressure input
detection
5. LS-EPC valve PAR : Rear pump delivery PLSRC :Rear load pressure detection port
: Rear pump delivery pressure
6. PC-EPC valve PRC PS : Pump suction
detection
7. Variable volume valve PBF : Front pump pressure input PLSCR: : LS set selector pressure detection port
PD1F : Case drain port PM : PC set selector pressure detection port
PENF : Front pump control pressure detection PEPC : EPC basic pressure input
PBR : Rear pump pressure input PDIR : Air bleeder
PD2F : Drain plug PEPB : EPC basic pressure detection port
PD2R : Drain plug
Outline
This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.
10-24 PC400LC-7L
12
1. Shaft (Front) 4. Rocker cam 7. Cylinder block 10. Shaft (Rear)

2. Cradle 5. Shoe 8. Valve plate 11. Case (Rear)
3. Case (Front) 6. Piston 9. End cap 12. Servo piston
Torque Nm Torque lbf ft Torque Nm Torque lbf ft

13. 58.8 - 78 43.3 - 57.5 19. 18.6 - 23.5 13.7 - 17.3
14. 132 - 157 97.3 - 115.7 20. 7.8 - 9.8 5.7 - 7.2
15. 11.8 - 14.7 8.7 - 10.8 21. 637 - 764.4 470 - 563.7
16. 6.9 - 9.8 5.0 - 7.2 22. 246.3 - 308.7 181.7 - 227.6
17. 98.1 - 122.6 72.3 - 90.4 23. 27 - 34 119.9 - 25.0
18. 19.6 - 27.4 14.5 - 20.2 24. 343 - 427 253 - 314
PC400LC-7L 10-25
12
Function
• The rotation and torque transmitted to the pump shaft are converted into hydraulic energy, and pressurized oil is
discharged according to the load.
• It is possible to change the discharge amount by changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings.
• The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a
spherical bearing.
• Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular
movement. Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is secured to the case, and
forms a static pressure bearing when it slides.
• Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
• The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).
10-26 PC400LC-7L
12
Operation
1. Operation of pump
A. Cylinder block (7) rotates together with shaft (1), and shoe (5)
slides on flat surface A. When this happens, rocker cam (4) moves
along cylindrical surface B, so angle between center line X of
rocker cam (4) and the axial direction of cylinder block (7)
changes. (Angle is called the swash plate angle.)
B. Center line X of rocker cam (4) maintains swash plate angle in

relation to the axial direction of cylinder block (7), and flat
surface A moves as a cam in relation to shoe (5).
In this way, piston (6) slides on the inside of cylinder block (7), so
a difference between volumes E and F is created inside cylinder
block (7). The suction and discharge is carried out by this
difference F – E.
In other words, when cylinder block (7) rotates and the volume of
chamber E becomes smaller, the oil is discharged during that
stroke. On the other hand, the volume of chamber F becomes
larger, and as the volume becomes bigger, the oil is sucked in.
C. If center line X of rocker cam (4) is in line with the axial direction
of cylinder block (7) (swash plate angle = 0), the difference
between volumes E and F inside cylinder block (7) becomes 0, so
the pump does not carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never becomes 0.)
PC400LC-7L 10-27
12
2. Control of discharge amount
• If the swash plate angle becomes larger, the difference between
volumes E and F becomes larger and discharge amount Q
increases.
• Swash plate angle is changed by servo piston (12).
• Servo piston (12) moves in a reciprocal movement (↔) according
to the signal pressure from the PC and LS valves. This straight
line movement is transmitted through rod (13) to rocker cam (4),
and rocker cam (4), which is supported by the cylindrical surface
to cradle (2), slides in a rotating movement in direction of arrow.
• 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).
10-28 PC400LC-7L
12
LS VALVE
1. Plug PA : Pump port

2. Locknut PP : Pump port
3. Sleeve PDP : Drain port
4. Spring PLP : LS control pressure output port
5. Seat PLS : LS pressure input port
6. Spool PPL : PC control pressure input port
7. Piston PSIG : LS mode selection pilot port
8. Sleeve
PC VALVE
1. Servo piston assembly PA : Pump port

2. Plug PA2 : Pump pressure pilot port
3. Pin PDP : Drain port
4. Spool PM : PC mode selector pressure pilot port
5. Retainer PPL : PC control pressure output port
6. Seat
7. Cover
8. Wiring
PC400LC-7L 10-29
12
Function
1. LS valve
The LS valve detects the load and controls the discharge amount.
This valve controls main pump discharge amount Q according to
differential pressure ∆PLS (=PP – PLS) [called the LS differential
pressure] (the difference between main pump pressure PP and control
valve outlet port pressure PLS).
Main pump pressure PP, pressure PLS {called the LS pressure}
coming from the control valve output, and pressure PSIG {called the
LS selector pressure} from the proportional solenoid valve enter this
valve. The relationship between discharge amount Q and differential
pressure ∆PLS, (the difference between main pump pressure PP and
LS pressure PLS) (= PP – PLS) changes as shown in the diagram at the right according to LS pressure selector current
PSIG of the LS-EPC valve.
When PSIG changes between 0 and 1A, the set pressure of the spring changes according to this, and the selector point for
the pump discharge amount changes at the rated central valve between 12 27 kg/cm2 (170.6 ↔ 384.0 psi).
2. PC valve
When the pump discharge pressure PP1 (self pressure) and PP2 (other
pump pressure) are high, the PC valve controls the pump so that no
more oil than the constant flow (in accordance with the discharge pres-
sure) 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 aver-
age of the front and rear pump discharge pressures (average discharge
amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount Q
is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The controller senses
the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge
amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set
value, the command current to the PC-EPC valve solenoid from the controller increases according to the drop in the
engine speed to reduce the pump swash plate angle.
10-30 PC400LC-7L
OPERATION
1. LS valve
A. When control valve is at neutral position

• The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the inlet port of the control
valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The
size of this LS pressure PLS + force Z of spring (4) and the main pump pressure (self pressure) PP determines
the position of spool (6). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC
valve for the LS valve entering port G also changes the position of spool (6). (The set pressure of the spring
changes).
• Before the engine is started, servo piston (12) is pushed to
the right. (See the diagram on the right)
• When the engine is started and the control lever is at the
neutral position, LS pressure PLS is 0 kg/cm2 (0 psi). (It is
interconnected with the drain circuit through the control
valve spool.)
At this point, spool (6) is pushed to the right, and port C and
port D are connected. Pump pressure PP enters the large
diameter end of the piston from port K and the same pump
pressure PP also enters port J at the small diameter end of the
piston, so the swash plate is moved to the minimum angle by
the difference in the area of the piston (12).
PC400LC-7L 10-31
12
B. Operation in increase direction for pump discharge amount

• When the difference between the main pump pressure PP and LS pressure PLS, in other words, LS differential
pressure PLS, becomes smaller (for example, when the area of opening of the control valve becomes larger and
pump PP drops), spool (6) is pushed to the left by the combined force of LS pressure PLS and the force of spring
(4).
• When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC
valve is connected to the drain port, so circuit D – K becomes drain pressure PT. (The operation of the PC valve
is explained later).
• For this reason, the pressure at the large diameter end of servo piston (12) becomes drain pressure PT, and pump
pressure PP enters port J at the small diameter end, so servo piston (12) is pushed to the right. Therefore, the
swash plate moves in the direction to make the discharge amount larger. If the output pressure of the EPC valve
for the LS valve enters port G, this pressure creates a force to move piston (7) to the right. If piston (7) is pushed
to the right, it acts to make the set pressure of spring (4) weaker, and the difference between PLS and PP changes
when ports D and E of spool (6) are connected.
10-32 PC400LC-7L
12
C. Operation in decrease direction for pump discharge amount

• The following explains the situation if the servo piston (12) moves to the right (the discharge amount becomes
smaller). When LS differential pressure ∆PLS becomes larger (for example, when the area of opening of the
control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (6) to the right.
• When spool (6) moves, main port pressure PP flows from port C and port D and from port K, it enters the large
diameter end of the piston.
• Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in
area between the large diameter end and the small diameter end of servo piston (12), servo piston (12) is pushed
to the right.
• As a result, the swash plate moves in the direction to make angle smaller.
• If LS selection pressure PSIG enters port G, it acts to make the set pressure of spring (4) weaker.
PC400LC-7L 10-33
12
D. When servo piston is balanced

• Let us take the area receiving the pressure at the large diameter end of the piston as A1, the area receiving the
pressure at the small diameter end as A0, and the pressure flowing into the large diameter end of the piston as
Pen. If the main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS
pressure PLS are balanced, and the relationship is A0 × PP = A1 × Pen, servo piston (11) will stop in that
position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the opening
of the throttle from port D to port E and from port C to port D of spool (6) is approximately the same.)
• At this point, the relationship between the area receiving the pressure at both ends of piston (12) is A0: A1 = 1:2,
so the pressure applied to both ends of the piston when it is balanced becomes PP: Pen = 2:1.
• The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is
adjusted so that it is determined when PP – PLS = 27 kg/cm2 (384 psi). However, if PSIG (the output pressure of
0 ↔ 30 kg/cm2 (426 psi) of the EPC valve of the LS valve) is applied to port G, the balance stop position will
change in proportion to pressure PSIG between PP – PLS = 27 ↔ 12 kg/cm2 (384 ↔ 170 psi).
10-34 PC400LC-7L
12
2. PC Valve
A. When pump controller is normal
i. When the load on the actuator is small and pump pressures PP1 and PP2 are low
a. Movement of PC-EPC solenoid (1)

• The command current from the pump controller flows to PC-EPC solenoid (1).This command current
acts on the PC-EPC valve and outputs the signal pressure. When this signal pressure is received, the force
pushing piston (2) is changed.
• On the opposite side to the force pushing this piston (2) is the spring set pressure of springs (4) and (6)
and pump pressure PP1 (self pressure) and PP2 (other pump pressure) pushing spool (3). Piston (2) stops
at a position where the combined force pushing spool (3) is balanced, and the pressure (pressure of port
C) output from the PC valve changes according to this position.
• The size of command current X is determined by the nature of the operation (lever operation), the
selection of the working mode, and the set value and actual value for the engine speed.
★ Other pump pressure
This is the pressure of the pump at the opposite end.
For the F pump, it is the R pump pressure
For the R pump, it is the F pump pressure
PC400LC-7L 10-35
12
b. Action of spring
• The spring load of springs (4) and (6) in the PC valve is determined by the swash plate position.
• If piston (9) moves to the right, spring (6) is compressed, and if it moves further to the right, spring (6)
contacts seat (5) and is fixed in position. In other words, the spring load is changed by piston (9)
extending or compressing springs (4) and (6).
• If the command circuit input to PC-EPC valve solenoid (1) changes further, the force pushing piston (2)
changes, and the spring load of springs (4) and (6) also changes according to the valve of the PC-EPC
valve solenoid command current.
• Port C of the PC valve is connected to port E of the LS valve (see (1) LS valve). Self pressure PP1 enters
port B and the small diameter end of servo piston (9), and other pump pressure PP2 enters port A.
• When pump pressures PP1 and PP2 are small, spool (3) is on the left. At this point, port C and D are
connected, and the pressure entering the LS valve becomes drain pressure PT. If port E and port G of the
LS valve are connected (see (1) LS valve), the pressure entering the large diameter end of the piston from
port J becomes drain pressure PT, and servo piston (9) moves to the left. In this way, the pump discharge
amount moves in the direction of increase.
• As servo piston (9) moves further, springs (4) and (6) expand and the spring force becomes weaker.
When the spring force becomes weaker, spool (3) moves to the right, so the connection between port C
and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure
at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of
piston (9) to the left is stopped.
• In other words, the stop position for piston (9) (= pump discharge amount) is decided at the point where
the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing
force created by the pressures PP1 and PP2 acting on the spool (3) are in balance.
10-36 PC400LC-7L
12
ii. When load on actuator is large and pump discharge pressure is high
• When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing spool (3) to
the right becomes larger and spool (3) moves to the position in the diagram above. When this happens, as
shown in the diagram above, part of the pressurized oil from port B flows out through port C where the LS
valve is actuated to port D, and the pressurized oil flowing from port C to the LS valve becomes
approximately half of main pump pressure PP.
• When port E and port G of the LS valve are connected (see (1) LS valve), the pressure from port J enters the
large diameter end of servo piston (9), and servo piston (9) stops.
• If pump discharge pressure PP and PP2 increases further and spool (3) moves further to the right, main
pump pressure PP1 flows to port C and acts to make the discharge amount the minimum. When piston (9)
moves to the right, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the
left, port C and port B are disconnected and port C and port D are interconnected. As a result, the pressure at
port C (= J) drops, and piston (9) stops moving to the right.
• The position in which piston (9) stops when this happens is further to the right than the position when pump
pressures PP1 and PP2 are low.
PC400LC-7L 10-37
12 • The relation of average pump pressure (PP1 + PP2)/2
and the position of servo piston (9) forms a bent line
because of the double-spacing effect of springs (4)
and (6). The relationship between average pump
pressure (PP1 + PP2)/2 and pump discharge amount
Q is shown in the figure at the right.
• If command voltage X sent to PC-EPC valve solenoid

(1) increases further, the relationship between average
pump pressure (PP1 + PP2)/2, and pump discharge
amount Q is proportional to the pushing force of the
PC-EPC valve solenoid and moves in parallel. In
other words, the pushing force of PC-EPC solenoid
(1) is added to the force pushing to the left because of
the pump pressure applied to the spool (3), so the
relationship between the average pump pressure (PP1
+ PP2)/2 and Q moves from to in accordance with the
increase in X.
10-38 PC400LC-7L
12
B. When pump controller is abnormal and emergency pump drive switch is ON
i. When load on main pump is light

• If there is a failure in the pump controller, turn emergency pump drive switch ON to switch to the resistor
side. In this case, the power source is taken directly from the battery. But if the current is used as it is, it is
too large, so use the resistor to control the current flowing to PC-EPC valve solenoid (1).
• When this is done, the current becomes constant, so the force pushing piston (2) is also constant.
• If the main pump pressure PP1 and PP2 are low, the combined force of the pump pressure and the force of
PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the
left.
• At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of
servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure
at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the
discharge amount larger.
PC400LC-7L 10-39
12
ii. When main pump load is heavy

• In the same way as in the previous item, when the emergency pump drive switch is ON, the command
current sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing
spool (3) is constant.
• If main pump pressures PP1 and PP2 increase, spool (3) moves further to the right than when the main pump
load is light, and is balanced at the position in the diagram above (See Fig. P).
• In this case, the pressure from port B flows to port C, so
servo piston (9) moves to the right (to make the
discharge amount smaller) by the same mechanism as
explained, and stops at a position to the right of the
position when the load on the pump is light (See Fig. Q).
In other words, even when the emergency pump drive
switch is ON, the curve for the pump pressure PP and
discharge amount Q is determined as shown in the
diagram for the valve of the current sent to the PC-EPC
valve solenoid through the resistor.
The curve when the emergency pump drive switch is ON
is curve c, which is to the left of curve b for when the
pump controller is normal.
10-40 PC400LC-7L
12
LS(PS)-EPC VALVE
1. Body 5. Coil PSIG : To LS(PC) valve

2. Spool 6. Plunger PT : To tank
3. Spring 7. Connector PEPC : From self-reducing pressure valve
4. Rod
PC400LC-7L 10-41
12
Function
• The EPC valve consists of the proportional solenoid portion and the
hydraulic valve portion.
• When it receives signal current i from the pump controller, it
generates the EPC output pressure in proportion to the size of the
signal, and outputs it to the LS valve.
Operation
1. When signal current is 0 (coil de-energized)

• When there is no signal current flowing from the controller to
coil (5), coil (5) is de-energized.
• For this reason, spool (2) is pushed to the left in the direction of
the arrow by spring (3).
• As a result, port PEPC closes and the pressurized oil from the
main pump does not flow to the LS valve.
At the same time, the pressurized oil from the LS valve passes
from port PSIG(PM) through port PT and is drained to the tank.
10-42 PC400LC-7L
12
2. When signal current is very small (coil energized)
• When a very small signal current flows to coil (5), coil (5) is
energized, and a propulsion force is generated which pushes
plunger (6) to the left.
• Push pin (4) pushes spool (2) to the left, and pressurized oil flows
from port PEPC to port PSIG(PM).
• When the pressure at port PSIG(PM) rises and the load of spring
(3) + the force acting on surface a of spool (2) becomes greater
than the propulsion force of plunger (6), spool (2) is pushed to the
right. The circuit between port PEPC and port PSIG(PM) is shut
off, and at the same time, port PSIG(PM) and port PT are
connected.
• As a result, spool (2) is moved up or down until the propulsion
force of plunger (6) is balanced with the load of spring (3) +
pressure of port PSIG(PM).
• Therefore, the circuit pressure between the EPC valve and the LS
valve is controlled in proportion to the size of the signal current.
3. When signal current is maximum (coil energized)

• When the signal current flows to coil (5), coil (5) is energized.
• When this happens, the signal current is at its maximum, so the
propulsion force of plunger (6) is also at its maximum.
• For this reason, spool (2) is pushed fully to the left by push pin
(4).
• As a result, the maximum flow of pressurized oil from port PEPC
flows to port PSIG(PM), and the circuit pressure between the
EPC valve and LS valve becomes the maximum.
At the same time, port PT closes and stops the oil from flowing to
the tank.
PC400LC-7L 10-43
12
VARIABLE VOLUME VALVE
1. Block PM : To PC valve
2. Plug PT : To tank
3. Spring PEPC : From self-reducing pressure valve
4. Piston
10-44 PC400LC-7L
12
Function
• This stabilizes the EPC output pressure.
Operation
• The output pressure from EPC flows to port PM, and when the
propulsion force of piston (4) becomes larger than the load of spring
(3), piston (4) is pushed to the left and the volume at port PM
increases.
When the propulsion force of piston (4) becomes less than the load on
spring (3), piston (4) is pushed to the right and the volume at port PM
goes down.
PC400LC-7L 10-45
12
CONTROL VALVE
1. 6-spool valve Outline
2. Cover 1 • 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
3. Cover 2
drift prevention valve, quick return valve, and Hi valve check valve are
4. Pump merge-divider valve installed to it.
5. Back pressure valve • Since all the valves are assembled together with connecting bolts and their
6. Boom lock valve passes are connected to each other inside the assembly, the assembly is
small in size and easy to maintain.
7. Boom, arm Hi valve
• Since one spool of this control valve is used for one work equipment unit,
8. Quick return valve its structure is simple.
9. Boom Hi check valve
A1 : To bucket cylinder bottom P11 : From arm PPC valve

A2 : o left travel motor P12 : From arm PPC valve
A3 : To boom cylinder bottom BP1 : Boom RAISE PPC output pressure
A4 : To swing motor PB5 : From 2-stage safety valve solenoid valve
A5 : To right travel motor PLS1 : To rear pump control
A6 : To arm cylinder head PLS2 : To front pump control
A-1 : To boom cylinder bottom PP1 : To rear pump control
A-2 : To attachment PP2 : To front pump control
B1 : To bucket cylinder head PPS1 : From rear main pump
B3 : To bottom cylinder head PPS2 : From front main pump
B4 : To swing motor PR : To solenoid valve, PPC valve, EPC valve
B5 : To right travel motor PS : From pump merge-divider solenoid valve
B6 : To arm cylinder bottom PST : From travel junction valve
B-1 : To arm cylinder bottom PX1 : From 2-stage solenoid valve
P1 : From bucket PPC valve PX2 : From 2-stage solenoid valve
P2 : From bucket PPC valve SA : Pressure sensor fitting port
P3 : From left travel PPC valve SB : Pressure sensor fitting port
P4 : From left travel PPC valve T : To tank
P5 : From boom PPC valve T1 : To tank
P6 : From boom PPC valve TS : To tank
P7 : From swing PPC valve TSW : To swing motor
P8 : From swing PPC valve
P9 : From right travel PPC valve
P10 : From right travel PPC valve
10-46 PC400LC-7L
12
7-SPOOL VALVE
(1/9)
PC400LC-7L 10-47
12
(2/9)
Item Torque Nm Torque lbf ft

1. Bolt 33.3 - 43.1 24.5 - 31.7
2. Bolt 156.9 - 176.5 115.7 - 130.1
3. Bolt 65.7 - 85.3 48.4 - 62.9
4. Bolt 58.8 - 73.6 43.3 - 54.2
10-48 PC400LC-7L
12
(3/9)
1. Unload valve 9. Pressure compensation valve (Arm IN)

2. Pressure compensation valve (Arm OUT) 10. Pressure compensation valve (Bucket DUMP)
3. Pressure compensation valve (Right travel reverse 11. Pressure compensation valve (Left travel forward)
4. Pressure compensation valve (Left swing) 12. Pressure compensation valve (Boom LOWER)
5. Pressure compensation valve (Boom RAISE) 13. Pressure compensation valve (Right swing)
6. Pressure compensation valve (Left travel reverse) 14. Pressure compensation valve (Right travel forward
7. Pressure compensation valve (Bucket CURL) 15. Pressure compensation valve (Arm IN)
8. Pressure compensation valve (Boom RAISE) 16. Main relief valve
PC400LC-7L 10-49
12
(4/9)
1. Spool (Arm) 6. Spool (Bucket)

2. Spool (Right travel) 7. Spool (Boom Hi)
3. Spool (Swing) 8. Spool (Arm Hi)
4. Spool (Boom) 9. Unload valve
5. Spool (Left travel) 10. Main relief valve
Unit: mm
Criteria Remedy
No. Check item
Free length Installed Installed Free Installed
x OD length load length load
11 Spool return spring
416.5 N 333.2 N
54.2 x 34.8 51.2 ---
{42.5 kg} {34 kg}
429.9 N 336.1 N If damaged or
12 Spool return spring 54.6 x 34.8 51.2 ---
{42.9 kg} {34.3 kg} deformed, replace
spring
393 N 314.6 N
{40.1 kg} {32.1 kg}
251 N 201.0 N
{25.1 kg} {20.5 kg}
416 N 333.2 N
15 Spool return spring 57.2 x 32.8 51 ---
{42.5 kg} {34.0 kg}
10-50 PC400LC-7L
12
(5/9)
1. Safety-suction valve (Arm OUT) 9. Safety-suction valve (2-stage) (Boom LOWER)

2. Suction valve (Right travel reverse) 10. Suction valve (Right travel forward)
3. Suction valve (Boom RAISE) 11. Safety-suction valve (Arm IN)
4. Suction valve (Left travel reverse) 12. LS shuttle valve (Arm, right travel)
5. Safety-suction valve (Boom Hi) 13. LS select valve
6. Safety-suction valve (Arm IN) 14. LS shuttle valve (Boom, left travel, bucket)
7. Safety-suction valve (Bucket DUMP) 15. LS check valve
8. Suction valve (Left travel forward) 16. Pressure relief plug
Unit: mm
Free length Installed Installed Free Installed If damaged or

17 Check valve spring x OD length load length load deformed, replace
spring
1.5 N 1.2 N
11.5 x 4.6 8.5 ---
{0.15 kg} {0.12 kg}
PC400LC-7L 10-51
12
(6/9)
ARM CONTROL VALVE R. H. TRAVEL CONTROL VALVE

1. Unload valve 5. Safety-suction valve 12. Suction valve
2. Main relief valve 6. Spool 13. Spool
3. Safety valve (Boom RAISE) 7. Pressure compensation valve (OUT) 14. Pressure compensation valve (Reverse)
4. Lift check valve 8. LS shuttle valve 15. LS shuttle valve
9. Pressure compensation valve (IN) 16. Pressure compensation valve (Forward)
10. Safety-suction valve 17. Suction valve
11. Check valve for regeneration circuit
10-52 PC400LC-7L
12
Unit: mm
Free length x OD Installed length Installed load Free length Installed load
18 Regeneration valve spring 6.2 N 4.9 N
31.5 x 10.3 19.5 --- If damaged or
{0.6 kg} {0.5 kg} deformed,
19 Piston return spring 29.4 N 23.5 N replacespring
36.9 x 11.1 28 ---
{3 kg} {2.4 kg}
20 Piston return spring 29.4 N 23.5 N
36.9 x 11.1 28 ---
{3 kg} {2.4 kg}

21. Valve 147.1 - 186.3 108.4 - 137.4
22. Valve 137.0 - 157.0 101.0 - 115.7
23. Valve 49.0 - 58.8 36.1 - 43.3
24. Valve 372.7 - 411.9 274.8 - 303.8
PC400LC-7L 10-53
12
(7/9)
SWING CONTROL VALVE ARM CONTROL VALVE L. H. TRAVEL CONTROL VALVE

1. Spool 5. Suction valve 13. Pump merge-divider valve (Travel junction valve)
2. Pressure compensation valve (Left) 6. Spool 14. Return spring
3. LS select valve 7. Pressure compensation valve (RAISE) 15. Suction valve
4. Pressure compensation valve (Right) 8. Hydraulic drift prevention valve 16. Spool
9. LS shuttle valve 17. Pressure compensation valve (Reverse)
10. Pressure compensation valve (Lower) 18. LS shuttle valve
11. Safety-suction valve 19. Pressure compensation valve (Forward)
12. Check valve for regeneration circuit 20. Suction valve
10-54 PC400LC-7L
12
Unit: mm
21 Regeneration valve spring
6.2 N 4.9 N
31.5 x 10.3 19.5 ---
{0.6 kg} {0.5 kg}
If damaged or
17.5 N 14.0 N deformed,
22 Piston return spring 48.1 x 10.8 28 ---
{1.8 kg} {1.4 kg} replace spring
29.4 N 23.5 N
23 Piston return spring 36.9 x 11.1 28 ---
{3 kg} {2.4 kg}
50.0 N 40.0 N
{5.1 kg} {4.1 kg}

25. Valve 372.7 - 411.9 274.8 - 303.8
26. Valve 107.9 - 147.1 79.5 - 108.4
27. Valve 323 - 402 238.2 - 296.5
28. Valve 196 - 240 144.5 - 177.0
29. Valve 147.1 - 186.3 108.4 - 137.4
30. Valve 137.3 - 156.9 101.2 - 115.7
PC400LC-7L 10-55
12
(8/9)
BUCKET CONTROL VALVE BOOM, ARM HI VALVE

1. Safety-suction valve 7. Boom Hi spool
2. Spool 8. Pressure compensation valve (Boom RAISE)
3. Pressure compensation valve (CURL) 9. Boom Hi check valve
4. LS shuttle valve 10. Quick-return valve
5. Pressure compensation valve (DUMP) 11. Pressure compensation valve (Arm IN)
6. Safety-suction valve 12. Arm Hi spool
13. Safety-suction valve
10-56 PC400LC-7L
12
Unit: mm
14 Piston return spring If damaged or
48.1 x 10.8 28 --- replace spring
{1.8 kg} {1.4 kg}
15 29.4 N 23.5 N
Piston return spring 36.9 x 11.1 28 ---
{3 kg} {2.4 kg}

16. Valve 372.7 - 411.9 274.8 - 303.8
17. Valve 176.6 - 196.2 130.2 - 144.7
18. Valve 137.3 - 156.9 101.2 - 115.7
PC400LC-7L 10-57
12
(9/9)
1. Unload valve 9. LS bypass plug

2. Main relief valve 10. Screw
3. Pump merge-divider valve (Main) 11. Poppet
4. Return spring 12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS) 13. Spring (Pressure reducing valve main)
6. Return spring 14. Valve (Pressure reducing valve)
7. Valve (Sequence valve) 15. Spring (Safety valve)
8. Spring (Sequence valve) 16. Ball
10-58 PC400LC-7L
12
Unit: mm
17 Check valve spring
1.5 N 1.2 N
11.5 x 4.6 8.5 {0.15 kg} {0.12 kg}
If damaged or
18 Spool return spring 46.6 x 21.8 3.3 {16.0 kg} {12.8 kg} replace spring
177.5 N 142.0 N
19 Spool return spring 64.5 x 32.3 63 {18.1 kg} {14.5 kg}
199.8 N 160.0 N
20 Sequence valve spring 70.9 x 18.0 59 {20.4 kg} {16.3 kg}

21. Plug 67.5 - 85.3 49.7 - 62.9
22. Valve 147.1 - 186.3 108.4 - 137.4
23. Valve 49 - 58.8 36.1 - 32.5
24. Valve 34.3 - 44.1 25.2 - 32.5
25. Valve 147.1 - 186.3 108.4 - 137.4
26. Valve 66 - 82 48.6 - 60.4
27. Valve 19.6 - 27.5 14.4 - 20.2
PC400LC-7L 10-59
12
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.
10-60 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 10-61
12
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)
Features
• CLSS stands for Closed Center Load Sensing System, and has the following features.
A. Fine control not influenced by load.
B. Control enabling digging even with fine control.
C. Ease of compound operation ensured by flow divider function using area of opening of spool during compound
operations.
D. Energy saving using variable pump control.
Structure
• The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment.
• The main pump body consists of the pump itself, the PC valve and LS valve.
10-62 PC400LC-7L
12
Basic principle
1. Control of pump swash plate

• The pump swash plate angle (pump discharge amount) is
controlled so that LS differential pressure ∆PLS (the
difference between pump pressure PP and control valve
outlet port LS pressure ∆PLS) (load pressure of actuator) is
constant.
(LS pressure ∆PLS = Pump discharge pressure PP – LS
pressure PLS)
• If LS differential pressure ∆PLS becomes lower than the set

pressure of the LS valve (when the actuator load pressure is
high), the pump swash plate moves towards the maximum
position; if it becomes higher than the set pressure of the LS
valve (when the actuator load pressure is low), the pump swash
plate moves towards the minimum position.
PC400LC-7L 10-63
12
2. Pressure compensation
• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
• When two actuators are operated together, this valve acts to make pressure difference ∆P between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure).
In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of opening S1 and S2 of
each valve.
10-64 PC400LC-7L
12
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.
PC400LC-7L 10-65
12
2. When in neutral or load pressure P2 is low
(When boom is lowered and arm is in IN position and they are
moving down under own weight)
Remark
When load pressure A2 is lower than self pressure
reducing valve output pressure PR.
• Valve (7) receives the force of spring (8) and PR pressure
(which is 0 MPa {0 kg/cm2} when the engine is stopped) in the
direction to close the circuit between ports P2 and A2. If the
hydraulic oil flows in port P2, the fdx P2 pressure becomes
equal to the total of the force of spring (8) and the value of area
of ød × PR pressure, then the area of the pass between ports P2
and A2 is so adjusted that the P2 pressure will be kept constant
above the PR pressure.
• If the PR pressure rises above the set level, puppet (11) opens
and the hydraulic oil flows from the PR port through orifice “a”
in spool (14) and open part of poppet (11) to seal drain port TS.
Accordingly, differential pressure is generated between before
and after orifice “a” in spool (14) and then spool (14) moves to
close the pass between port P2 and PR. The P2 pressure is
controlled constant (at the set pressure) by the area of the oil
pass at this time and supplied as the PR pressure.
3. When load pressure P2 is high

• If load pressure A2 rises and the pump discharge increases
because of operation of the work equipment, the fdx P2 pressure
rises higher than the total of the force of spring (8) and the value
of ød × PR pressure, and then valve (7) moves to the right stroke
end.
• As a result, the area of the pass between ports P2 and A2
increases and the pass resistance lowers and the loss of the
engine power is reduced.
• If the PR pressure rises above the set pressure, poppet (11) opens
and the hydraulic oil flows from the PR port through orifice “a”
in spool (14) and open part of poppet (11) to seal drain port TS.
Accordingly, differential pressure is generated between before
and after orifice “a” in spool (14) and then spool (14) moves to
close the pass between port P2 and PR. The P2 pressure is
controlled constant (at the set pressure) by the area of the oil
pass at this time and supplied as the PR pressure.
10-66 PC400LC-7L
12
4. When abnormal high pressure is generated
• If the PR pressure on the self-pressure reducing valve rises
abnormally high, ball (16) separates from the seat against the
force of spring (15) and the hydraulic oil flows from output port
PR to TS.
Accordingly, the PR pressure lowers. By this operation, the
hydraulic devices (PPC valves, solenoid valves, etc.) are
protected from abnormal pressure.
PC400LC-7L 10-67
12
SWING MOTOR
KMF230ABE-5
B : From swing lock solenoid valve

S : From control valve
T : To tank
MA : From control valve
MB : From control valve
10-68 PC400LC-7L
12
Specifications
Model KMF230ABE-5
Theoretical displacement 229.4 cm3/rev
285+0.5
0 kg/cm
2
Safety valve set
pressure
(396.8 +7.1
0 psi)
Rated revolving 1,413 rpm
speed
Brake release
pressure 19 ± 4 kg/cm2 (270.2 ±56.8 psi)

1. Bolt 27 - 34 19.9 - 25.0
2. Bolt 98.1 - 122.6 72.3 - 90.4
PC400LC-7L 10-69
12
1. Brake spring 8. Housing 15. Safety valve

2. Drive shaft 9. Piston 16. Check valve
3. Spacer 10. Cylinder block 17. Shuttle valve
4. Case 11. Valve plate
5. Disc 12. Reverse prevention valve
6. Plate 13. Center shaft
7. Brake piston 14. Center spring
10-70 PC400LC-7L
12
Unit: mm
Installed Installed
Free length x OD Free length Installed load
18 Check valve spring length load If damaged or
6.96 N 5.59 N deformed, replace
66.5 x 25.6 45 --- spring
{0.71 kg} {0.57 kg}
7.45 N 5.98 N
19 Shuttle valve spring 24.5 x 11.6 14.5 ---
{0.76 kg} {0.61 kg}

20. Valve 294 - 392 216.8 - 289.1
21. Valve 490.5 - 608.2 361.7 - 448.5
22. Valve 176.5 - 215.8 130.1 - 159.1
PC400LC-7L 10-71
12
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
A. When starting swing

When the swing control lever is operated to swing right, the
pressure oil from the pump passes through the control valve and
is supplied to port MA. As a result, the pressure at port MA
rises, the starting torque is generated in the motor, and the motor
starts to rotate. The oil from the outlet port of the motor passes
from port MA through the control valve and returns to the tank.
(Fig. 1)
B. When stopping swing

• When the swing control lever is returned to neutral, the
supply of pressure oil from the pump to port MA is stopped.
With the oil from the outlet port of the motor, the return
circuit to the tank is closed by the control valve, so the
pressure at port MB rises. As a result, rotation resistance is
generated in the motor, so the braking effect starts.
• If the pressure at port MB becomes higher than the pressure
at port MA, it pushes shuttle valve A (4) and chamber C
becomes the same pressure as port MB. The oil pressure
rises further until it reaches the set pressure of relief valve
(1).
As a result, a high braking torque acts on the motor and
stops the motor. (Fig.2)
• When relief valve (1) is being actuated, the relief oil and oil
from port S passes through check valve B (3) and is
supplied to port MA. This prevents cavitation at port MA.
10-72 PC400LC-7L
12
C. Operation of swing lock
i. When swing lock solenoid valve is deactivated

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

When the swing lock solenoid valve is activated, the valve
is switched and the pressure oil from the main pump enters
port B and flows to brake chamber a.
The pressure oil entering chamber a overcomes brake spring
(1) and pushes brake piston (7) up. As a result, discs (5) and
plates (6) are separated and the brake is released.
PC400LC-7L 10-73
12
REVERSAL PREVENTION VALVE
Outline diagram
Explanation of effect
10-74 PC400LC-7L
12
Outline
This valve reduces the swing back generated in the swing body by the
inertia of the swing body, the backlash and rigidity of the machinery
system, and the compression of the hydraulic oil when the swing is
stopped. This is effective in preventing spillage of the load and reducing
the cycle time when stopping the swing (the positioning ability is good
and it is possible to move swiftly to the next job.
Operation
1. When brake pressure is being generated at port MB

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

• The motor is reversed by the closing pressure generated at port
MB. (1st reversal)
When this happens, reversal pressure is generated at port MA.
Pressure MA goes to chamber a, so spool (2) pushes spring (3)
and moves to the right, and MA is connected to B. At the same
time, b is connected to f through the drill hole in spool (5), so the
reversal pressure at port MA is bypassed to port T to prevent the
2nd reversal.
PC400LC-7L 10-75
12
CENTER SWIVEL JOINT
1. Cover A1 : To LH travel motor port PB T2 : To tank

2. Body A2 : From control valve port A2 T1 : From LH and RH travel motors port T
3. Slipper seal C1 : To RH travel motor port PA D2 : From control valve port B5
4. O-ring B2 : From control valve port B2 B1 : To LH travel motor port PA
5. Shaft D1 : To RH travel motor port PB C2 : From control valve port A5
E : To LH and RH travel motors port P
Unit: mm
Standard Size Standard clearance Repair limit If damaged or deformed, replace
6 Clearance between rotor and shaft
80 --- --- spring
10-76 PC400LC-7L
12
TRAVEL MOTOR
KMV280ADT
Port T (to tank) Specifications KMV200ADT

Port PA (from control valve) Model: Min 130 cm3/rpm
Port PB (from control valve) Theoretical delivery Max 200 cm3/rpm
Port PI (from travel speed solenoid valve)
Brake releasing pressure: 10 ± 4 kg/cm2 (142.2 ±56.8 psi)
Travel speed switching pressure: 8 +4 kg/cm2 (113.7 +56.8

-14.2 psi)
(Differentical pressure)

1. Bolt 490 - 608 361.4 - 448.4
2. Valve 294 - 343 216.8 - 252.9
PC400LC-7L 10-77
12
1. Output shaft 8. Regulator piston 15. Safety valve

2. Motor case 9. Plate 16. Rgegulator valve
3. Piston 10. Disc 17. Spring
4. Cylinder 11. Check valve spring 18. Brake spring
5. Valve plate 12. Check valve 19. Brake piston
6. End cover 13. Counterbalance valve 20. Check valve
7. Slow return valve 14. Spool return spring
10-78 PC400LC-7L
12
Unit: mm
Freelength x OD Installed length Installed load Free length Installed load
21 Spool return spring
426.6N 341.3 N Replace
62.52 x 32.0 42.0 {43.5 kg} {32.2 kg} spring if dam
aged or
3.04 N 2.45 N deformed
22 Check valve spring 62.5 x 20.0 39.0 {0.31 kg} {0.25 kg}
98.1 N 78.5 N
23 Regulator piston spring 55.0x 9.0 50.0 {10 kg} {8 kg}

24. Valve 24.5 - 34.3 18.0 - 25.2
25. Valve 65.7 - 82.4 49.7 - 60.7
26. Valve 19.6 - 27.5 14.4 - 20.2
27. Bolt 147.1 - 186.3 108.4 - 137.4
28. Valve 373 - 466 275.1 - 343.7
29. Valve 324 - 402 238.9 - 296.5
PC400LC-7L 10-79
12
1. Operation of motor
A. At low speed (motor swash plate angle at maximum)
• The solenoid valve is de-energized, so the pilot pressure oil from the main pump does not flow to port P.
For this reason, regulator valve (16) is pushed down by spring (17).
• The main pressure oil from the control valve pushes check valve (20), goes to end cover (6), in regulator valve
(16) and acts also on chamber b.
• When this happens, the propulsion force of regulator piston (8) acts in a downward direction.
• As a result, valve plate (5) and cylinder block (4) move in the maximum swash plate angle direction, the motor
capacity becomes maximum, and the system is set to low speed.
10-80 PC400LC-7L
12
B. At high speed (motor swash plate angle at minimum)
• When the solenoid valve is energized, the pilot pressure oil from the main pump flows to port P, and pushes
regulator valve (16) up.
• As a result, the oil in chamber b is drained inside the case, and acts on chamber a via regulator valve (16).
• Because of this, the propulsion force of the pressure oil at chamber a of regulator piston (8) acts in a upward
direction.
• As a result, valve plate (5) and cylinder block (4) move in the minimum swash plate angle direction, the motor
capacity becomes minimum, and the system is set to high travel speed.
PC400LC-7L 10-81
12
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.
10-82 PC400LC-7L
12
2. When stopping travel
Operation
When the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and the
circuit to the parking brake is closed.
The pressurized oil in chamber e of brake piston (19) passes through the throttle of slow return valve (7) until spool
(13) of the counterbalance valve returns to neutral.
When spool (13) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from the
throttle f of brake piston (19) and brake piston (19) is pushed fully to the left by spring (18).
As a result, plate (9) and disc (10) are pushed together, and the brake is applied.
A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (7) when the brake
piston returns, and this ensures that the brake is applied after the machine stops.
PC400LC-7L 10-83
12
3. Operation of brake valve
The brake valve consists of a check valve (1), counterbalance valve
(2), and safety valve (3) in a circuit as shown in the diagram on the
right.
The function and operation of each component is as given below.
A. Counterbalance valve, check valve

Function
When traveling downhill, the weight of the machine makes it try
to travel faster than the speed of the motor.
As a result, if the machine travels with the engine at low speed,
the motor will rotate without load and the machine will run
away, which is extremely dangerous.
To prevent this, these valves act to make the machine travel
according to the engine speed (pump discharge amount).
i. 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.
10-84 PC400LC-7L
12 The pressurized oil at the supply side flows from orifice E1
in spool (13) and orifice E2 in the piston to chamber S1.
When the pressure in chamber S1 goes above the spool
switching pressure, spool (13) is pushed to the right. As a
result, port MB and port PB are connected, the outlet port
side of the motor is opened, and the motor starts to rotate.
ii. Operation of brake when traveling downhill

If the machine tries to run away when traveling downhill,
the motor will turn under no load, so the pressure at the
motor inlet port will drop, and the pressure in chamber S1
through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops below the spool
switching pressure, spool (13) is returned to the left by
spring (14), and outlet port MB is throttled.
As a result, the pressure at the outlet port side rises,
resistance is generated to the rotation of the motor, and this
prevents the machine from running away.
In other words, the spool moves to a position where the
pressure at outlet port MB balances the pressure at the inlet
port and the force generated by the weight of the machine. It
throttles the outlet port circuit and controls the travel speed
according to the amount of oil discharged from the pump.
B. Safety valve (2-direction operation, 2-stage set safety valve)

Function
When travel is stopped (or when traveling downhill), the circuits
at the inlet and outlet ports of the motor are closed by the
counterbalance valve. However, the motor is rotated by inertia,
so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping.
The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent
damage to the equipment.
PC400LC-7L 10-85
12 Operation in both directions
i. When pressure in chamber MB has become high (when

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

When the travel lever is placed at neutral, the pressure in
chamber PA drops and counterbalance valve spool (13)
returns to the neutral position. While the counterbalance
valve spool (13) is returning to the neutral position, the
pressurized oil in chamber J passes through passage H, and
escapes to chamber PA from chamber G. The piston moves
to the left, and the set load becomes smaller.
Because of this, the set pressure of the safety valve is
switched to the low-pressure setting and relieves the shock
when reducing speed.
[Set pressure of safety valve]

When starting or traveling: When stopping:
High-pressure setting Low-pressure setting
410 kg/cm2 (0.583 psi) 27.5 kg/cm2 (0.0391 psi)
10-86 PC400LC-7L
12
iii. When pressure in chamber MA has become high (when
rotating counterclockwise)
When the travel is stopped (or when traveling downhill),
chamber MA in the outlet port circuit is closed by the check
valve of the counterbalance valve, but the pressure at the
outlet port rises because of inertia.
If the pressure goes above the set pressure, the force

produced by the difference in area between D1 and D3
[x/4 (D32 – D12) × pressure] overcomes the force of the
spring and moves the poppet to the left, so the oil flows to
chamber MB in the circuit on the opposite side.
Operation of mechanism for varying set pressure
A. When starting travel (high-pressure setting)

When the travel lever is operated, the pressurized oil from the
pump actuates counterbalance valve spool (19), and opens the
pilot circuit to the safety valve. The oil passes from chamber G
to passage H and flows into chamber J, pushes the piston to the
right, and compresses the spring to make the set load larger.
Because of this, the set pressure of the safety valve is switched to
the high pressure setting, and a large draw bar pull is made avail-
able.
PC400LC-7L 10-87
12
TRAVEL JUNCTION VALVE
Function
• This valve connects both travel circuits to each other so that the hydraulic oil will be supplied evenly to both travel motors
and the machine will travel straight.
• When the machine is steered, outside pilot pressure PST closes the travel junction valve to secure high steering
performance.
Operation
When pilot pressure is turned ON
• If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (14), travel junction
spool (13) moves to the left stroke end and the junction circuit between port PTL (Left travel circuit) and PTR (Right
travel circuit) is closed.
10-88 PC400LC-7L
12
When pilot pressure is turned OFF
• If pilot pressure PST from the solenoid valve is 0, travel junction spool (13) is pressed by the force of spring (14) against
the right side and the pass between ports PTL and PTR is open.
• If the oil flow rates in both travel motors become different from each other, the oil flows through the route between port
PTL, travel junction spool (13), and port PTR so that the oil flow rates will be equalized again.
PC400LC-7L 10-89
12
CONTROL VALVE
Lever positions
1. Travel PPC valve 8. Solenoid valve (1) Hold (9) Swing RIGHT
2. Service PPC valve 9. Accumulator (2) Boom RAISE (10) Swing LEFT
3. Service pedal 10. Control valve (3) Boom LOWER (11) Neutral
4. L.H. travel lever 11. Hydraulic pump (4) Bucket DUMP (12) Travel REVERSE
5. R.H. travel lever 12. Junction box (5) Bucket CURL (13) Travel FORWARD
6. R.H. PPC valve 13. L.H. work equipment control lever (6) Hold
7. R.H. work equipment control lever 14. L.H. PPC valve (7) Arm IN
(8) Arm OUT
10-90 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 10-91
12
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).
10-92 PC400LC-7L
12
PC400LC-7L 10-93
12
2. When travel is operated
• When the travel lever is operated to right REVERSE (or FORWARD), the right (REVESE (or FORWARD) PPC
pressure pushes spool (7) to the left (or right).
• Spool (7) pushes piston (3), orifice (5) closes, and stroke limit signal chamber a is shut off from the drain circuit of
the travel PPC valve.
• At the same time, the right REVERSE (or FORWARD) PPC pressure passes through orifice (6) in piston (4), acts on
the right end face of piston (8), and pushes piston (8) to the left.
• If arm IN is operated, spool (1) moves to the right, but the maximum stroke of the spool is limited by the amount of
movement st2 of piston (8) and becomes st1.
• If boom RAISE is operated, spool (9) tries to move to the left, but the travel PPC pressure enters stroke control signal
chamber b, so the spool does not move.
10-94 PC400LC-7L
12
WORK EQUIPMENT • SWING PPC VALVE
P : From self pressure reducing valve P1 :Left PPC: Arm OUT / Right PPC: Boom LOWER
T : To tank P2 :Left PPC: Arm IN / Right PPC: Boom RAISE
P3 :Left PPC: Swing LEFT / Right PPC: Bucket CURL
P4 :Left PPC: Swing RIGHT / Right PPC: Boom LOWER
PC400LC-7L 10-95
12
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm
Centering spring
12 Free length x OD Installed length Installed load Free length Installed load
(For P3 and P4)
42.4 x 15.5 34 17.1 N {1.8 kg} --- 13.7 N {1.4 kg} If damaged or
deformed,
Centering spring 29.4 N 23.5 N replace spring
13 44.4 x 15.5 34 ---
(For P1 and P2) {3.0 kg} {2.4 kg}
16.7 N 13.7 N
14 Metering spring 26.5 x 8.2 24.9 ---
{1.7 kg} {1.4 kg}
10-96 PC400LC-7L
12

15. Bolt 11.8 - 14.7 8.7 - 10.8
16. Nut 69 - 88 50.8 - 64.9
17. Joint 34 - 44 25.0 - 32.4
18. Nut 39 - 49 28.7 - 36.1
19. Plug 6 - 11 4.4 - 8.1
20. Plug 4-9 2.9 - 6.6
PC400LC-7L 10-97
12
Operation
1. At neutral
Ports A and B of the control valve and ports P1 and P2 of the PPC
valve are connected to drain chamber D through fine control hole f in
spool (1)
2. During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5), retainer (9) is pushed;
spool (1) is also pushed by metering spring (2), and moves down.
When this happens, fine control hole f is shut off from drain chamber
D, and at almost the same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the main pump passes through
fine control hole f and goes from port P1 to port A.
When the pressure at port P1 becomes higher, spool (1) is pushed

back and fine control hole f is shut off from pump pressure chamber
PP. At almost the same time, it is connected to drain chamber D to
release the pressure at port P1.
When this happens, spool (1) moves up or down so that force of

metering spring (2) is balanced with the pressure at port P1. The
relationship in the position of spool (1) and body (10) (fine control
hole f is at a point midway between drain hole D and pump pressure
chamber PP) does not change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed proportionally to the

amount of movement of the control lever, so the pressure at port P1
also rises in proportion to the travel of the control lever. In this way,
the control valve spool moves to position where the pressure in
chamber A (the same as the pressure at port P1) and the force of the
control valve spool return spring are balanced.
10-98 PC400LC-7L
12
3. During fine control (when control lever is returned)
When disc (5) starts to be returned, spool (1) is pushed up by the
force of centering spring (3) and the pressure at port P1.
When this happens, fine control hole f is connected to drain chamber
D and the pressure oil at port P1 is released.
If the pressure at port P1 drops too far, spool (1) is pushed down by
metering spring (2), and fine control hole f is shut off from drain
chamber D.
At almost the same time, it is connected to pump pressure chamber
PP, and the pump pressure is supplied until the pressure at port P1
recovers to a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in drain chamber D
flows in from fine control hole f’ in the valve on the side that is not
working. The oil passes through port P2 and enters chamber B to fill
the chamber with oil.
4. At full stroke
When disc (5) pushes down piston (4), and retainer (9) pushes down
spool (1), fine control hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the main pump passes through
fine control hole f and flows to chamber A from port P1, and pushes
the control valve spool.
The oil returning from chamber B passes from port P2 through fine
control hole f’ and flows to drain chamber D.
PC400LC-7L 10-99
12
TRAVEL PPC VALVE
P : From self pressure reducing valve P3 : Right reverse

T : To tank P4 : Right forward
P1 : Left reverse P5 : Travel signal
P2 : Left forward P6 : Steering signal
10-100 PC400LC-7L
12
1. Plate 6. Centering spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Metering spring 10. Steering signal valve spring
PC400LC-7L 10-101
12

1 Metering spring 16.7 N 13.7 N
26.5 x 8.15 24.7 {1.7 kg} {1.4 kg} If damaged or
Centering spring 108 N 86.3 N deformed, replace
2 48.1 x 15.5 32.5 spring
{11 kg} {8.8 kg}
Steering signal spring 8.8 N 7.1 N
3 12.8 x 7.3 8.5 {0.9 kg} {0.72 kg}
10-102 PC400LC-7L
12

4. Bolt 28 ±3 20.6 ±2.2
5. Bolt 23.5 ±3.9 17.3 ±2.8
6. Bolt 30.9 ±2.5 22.7 ±2.5
7. Plug 29.4 ±4.9 21.6 ±3.6
PC400LC-7L 10-103
12
Travel signal/Steering function
• Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the travel signal.
Accordingly, if the machine is traveling is judged by the signal of port P5.
• Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the higher one of the
PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neutral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1. While in NEUTRAL
The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not output.
10-104 PC400LC-7L
12
2. While travelling straight
(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also operating
for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right spring chamber (I) of
steering signal valve (J) are set high. Accordingly, the steering signal valve is kept in neutral and the steering signal (Port
P6) is not output.
PC400LC-7L 10-105
12
3. When steered or pivot-turned
(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the difference of the
pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal.
In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2. The pressure
in right spring chamber (l) is P4.
If (P4 – P2) × (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow and the higher
one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.
10-106 PC400LC-7L
12
4. When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is operating for
forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of steering signal valve (j) is
set high. Accordingly, the steering signal valve moves to the left and outputs the steering signal (port P6).
PC400LC-7L 10-107
12
SERVICE PPC VALVE
★ Refer to the section WORK EQUIPMENT • SWING PPC VALVE for function of this valve.
Unit: mm
9 Centering spring If damaged or
124.5 N 100 N deformed, replace
33.9 x 15.3 28.4 ---
{12.7 kg} {10.2 kg} spring
Metering spring 16.7 N 13.7 N
10 22.7 x 8.1 22 ---
{1.7 kg} {1.4 kg}

11. Bolt 13.2 ±1.4 9.7 ±1.0
10-108 PC400LC-7L
12
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid valves.
1. PPC lock solenoid valve T : To tank A8 : To main valve (2-stage relief valve)
2. Travel junction solenoid valve A1 : To No. 1 pump (CO valve) P1 : From main pump
3. Merge-divider solenoid valve A2 : To main valve (Travel junction valve) ACC : To accumulator
4. Travel speed solenoid valve A3 : To main valve (Merge-divider valve)
5. Swing brake solenoid valve A4 : To both travel motors
6. Machine push-up solenoid valve A5 : To swing motor
8. 2-stage relief solenoid valve A6 : To 2-stage safety valve at boom
cylinder head
PC400LC-7L 10-109
12
Operation
WHEN SOLENOID IS TURNED OFF
• Since the signal current does not flow from the controller, solenoid
(3) is turned off.
Accordingly, spool (4) is pressed by spring (6) against the left side.
By this operation, the pass from P to A is closed and the hydraulic oil
from the main pump does not flow into the actuator.
At this time, the oil from the actuator is drained through ports A and
T into the tank.
WHEN SOLENOID IS TURNED ON

• The signal current flows from the controller to solenoid (3), and the
latter is turned on.
Accordingly, spool (4) is pressed against to the right side.
By this operation, the hydraulic oil from the main pump flows
through port P and spool (4) to port A, then flows into the actuator.
At this time, port T is closed and the oil does not flow into the tank.
10-110 PC400LC-7L
12
PPC ACCUMULATOR
PC400LC-7L 10-111
12
RETURN OIL FILTER
FOR BREAKER
Specifications
1. Drain plug Rated pressure : 70 kg/cm2 (995.6 psi)
2. Element Flow : 200 L/min (52.8 gal)
3. Case Relief valve cracking pressure: 3.5 ± 0.5 kg/cm2 (49.7 ±7.1 psi)
4. Head cover Filter mesh size : 6 µm
5. Relief valve Filtering area : 4,570 cm2 (708 in 2)
10-112 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 10-113
12
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 ring shaped area A
(= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2.
When it overcomes the force of spring (4), poppet (5) moves to the left.
In addition, the main pressure oil acts in the right direction on seat diameter d3 of valve (6). When it overcomes the force
of spring (4), valve (6) moves to the right.
As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom
end of the boom cylinder.
10-114 PC400LC-7L
12
PC400LC-7L 10-115
12
2. Boom at HOLD
• When the boom is raised and the control lever is returned to the HOLD position, the oil that has flowed into the inside
of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at
the bottom of the boom cylinder are shut off.
• At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped
area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat
diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and
hold pressure at the bottom of the boom cylinder are shut off.
• In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of
valve (6).
• Valve (6) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at
the bottom of the boom cylinder are shut off. As a result, the boom is held in position.
10-116 PC400LC-7L
12
PC400LC-7L 10-117
12
3. Boom LOWER
When boom LOWER is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil
chamber b inside the poppet is drained through orifice c.
The oil at the bottom end of the boom flows from orifice a to chamber b to orifice c to drain, so the oil pressure in
chamber b drops.
When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B
goes to port A and flows to the control valve.
10-118 PC400LC-7L
ARM HYDRAULIC DRIFT PREVENTION VALVE

(If equipped)
Function
• When the arm lever is not being operated, these valves act to prevent the oil at the arm head from leaking from spool (1)
and prevent the arm from moving down.
Operation
1. Arm DUMP
When the arm DUMP is operated, the main pressure oil acts in the left direction on ring shaped area A
(= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2.
When it overcomes the force of spring (4), poppet (5) moves to the left.
As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom
end of the boom cylinder.
PC400LC-7L 10-119
12
2. Arm at HOLD
• When the arm DUMP is operated and the control lever is returned to the HOLD position, the oil that has flowed into
the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold
pressure at the head of the arm cylinder are shut off.
• At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring shaped
area A (= Area of ød1 – Area of ød2) because of the difference in the outside diameter d1 of poppet (5) and seat
diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and
hold pressure at the head of the arm cylinder are shut off.
• In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of
valve (6).
As a result, the arm is held in position.
10-120 PC400LC-7L
12
3. Arm IN
• When arm IN is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber
b inside the poppet is drained through orifice c.
The oil at the head end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in
chamber b drops.
When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port
B goes to port A and flows to the control valve.
PC400LC-7L 10-121
12
4. When abnormally high pressure is generated
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the hydraulic oil in port B pushes check
valve (6) open, then safety valve (3) operates.
• If the hydraulic drift prevention valve for the arm cylinder head circuit is installed (optional), the hydraulic oil in the
boom cylinder bottom circuit or that in the arm cylinder head circuit, having higher pressure, pushes check valve (6)
open, then safety valve (3) operates.
10-122 PC400LC-7L
12
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.
PC400LC-7L 10-123
12
2. Arm at HOLD
The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at
the bottom end of the arm acts in the right direction on ring-shaped area C (= Area of ød1 – Area of ød2) because of the
difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) is closed by the total of this force and the
force of spring (3), so port A and port B are shut off.
10-124 PC400LC-7L
12
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 self pressure reducing
valve and valve (1) is pressed by only the force of spring (2) toward
the right and drain circuit “a” of the control valve is connected
through orifice “b” of valve (1) to port T.
2. While engine is running

• Output pressure PR of the self pressure reducing valve is applied
through the control valve to spring chamber “c” of the back
pressure valve.
• Output pressure PR applied to spring chamber “c” is applied to
the left end of valve (1) (area of ød) to push valve (1) to the right.
• At this time, pressure PA of drain circuit “a” of the control valve
is applied to the right end of valve (1) (area of ød1) to push valve
(1) to the left.
• Valve (1) is balanced so that the back pressure PA will be as
follows.
PA = {(Area of ød) × PR + Force of spring (2)} / (Area of ød1)
PC400LC-7L 10-125
12
ATTACHMENT CIRCUIT SELECTOR VALVE
1. Spool V :To control valve

2. Spring T :To hydraulic tank
ATT :To attachment
ACC :To accumulator
P1 :From attachment circuit selector solenoid valve
TS :To hydraulic tank
Unit: mm
Free length Installed load Replace spring if any
Free length x OD Installed length Installed load
3 Spool return spring damages or deformations
833 N 666 N are found
132.0 x 29 114.5 ---
{85.0 kg} {68.0 kg}

4. Bolt 59 - 74 43.5 - 54.5
10-126 PC400LC-7L
12
Function
When a breaker is installed, the return oil from the breaker does not pass
through the main valve, but returns directly to the hydraulic tank. When
other attachments (crusher, etc.) are installed, the attachment and the main
valve are interconnected.
Operation
1. When attachment other than breaker is installed

Spool (1) is pushed fully to the left by the force of spring (2), ATT
port and port V are interconnected, and ATT port and port T are shut
off, so the attachment and main valve are interconnected.
2. When breaker is installed

When the pilot pressure from the attachment circuit selector solenoid
valve overcomes the force of spring (2), the spool (1) moves fully to
the right. ATT port and port V are shut off and ATT port and port T
are interconnected, so the oil returning from the breaker does not
pass through the main valve, but passes through port T and returns
directly to the hydraulic tank.
PC400LC-7L 10-127
12
HOLDING VALVE
Downward movement prevention valve (For boom and arm)
V :From control valve

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

1. Bolt 30.9 ±3.4 22.7 ±2.5
10-128 PC400LC-7L
12
1. Pilot spool 4. Safety valve

2. Spring (1st stage of spool) 5. Check valve
3. Spring (2nd stage of spool) 6. Spring
Unit: mm
7 Check valve spring
12.7 N 9.8 N
20.8 x 12.2 13.5 ---
{1.3 kg} {1.0 kg}
If damaged of
58.8 N 47.0 N deformed, replace
{6.0 kg} {4.8 kg} spring
78.4 N 62.7 N
{8.0 kg} {6.4 kg}
125.4 N 100.4 N
{12.8 kg} {10.2 kg}

11. Valve 196 ±19.6 144.5 ±14.4
12. Valve 147 ±9.8 108.4 ±7.2
PC400LC-7L 10-129
12
Function
If the piping between the main valve and a work equipment cylinder bursts, this valve prevents the oil from flowing back from
the work equipment cylinder to prevent sudden fall of the work equipment.
Operation
1. When the work equipment is in neutral

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

• 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.

• If piping A between the main valve and the work equipment
cylinder bursts, the oil in chamber “a” flows out through the
burst part and pressure Pa in chamber “a” lowers.
• If Pa lowers below the total of pressure Pb in chamber “b” and
the force of spring (6), check valve (5) closes and chambers “a”
and “b” are shut off from each other. Accordingly, pressure Pb
in the cylinder is held and the work equipment does not fall
suddenly.
10-130 PC400LC-7L
12
3. When oil is returned from work equipment cylinder to main valve
• 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.

• If piping A between the main valve and work equipment
cylinder bursts, the oil in chamber “a” flows out through the
burst part. Since the oil supplied from chamber “b” to chamber
“a” flows through opening “c” of spool (1), however, the
cylinder does not fall suddenly.
PC400LC-7L 10-131
12
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-132 PC400LC-7L
12 Unit: mm
Tolerance Standard Clearance
Cylinder Standard size
Shaft Hole clearance limit
Boom -0.036 +0.261 0.083 -

Clearance 110 0.412
-0.090 +0.047 0.351
1 between piston Replace bushing
rod and bushing Arm -0.036 +0.263 0.084 -
120 0.412
-0.090 +0.048 0.353
Bucket -0.036 +0.257 0.083 -
100 0.447
-0.090 +0.047 0.347
Boom -0.036 +0.169 0.136 -
110 ---
-0.090 +0.100 0.259
Clearance
between piston Arm -0.036 +0.169 0.136 -
2 110 ---
rod support pin -0.090 +0.100 0.259
and bushing
Bucket -0.036 +0.187 0.133 -
100 ---
-0.090 +0.097 0.277 Replace pin or
Boom -0.036 +0.190 0.106 - bushing
100 ---
-0.090 +0.070 0.280
Clearance
between cylinder Arm -0.036 +0.195 0.135 -
3 110 ---
bottom support -0.090 +0.099 0.285
pin and bushing
Bucket -0.036 +0.187 0.133 -
100 ---
-0.090 +0.097 0.277
BOOM CYLINDER

4. 530 ±78.5 390.9 ±57.9
5. 294 ±29.4 216.8 ±21.6
6. 58.9 ±73.6 43.5 ±54.2
ARM CYLINDER

4. Bolt 892 ±137 657.9 ±101.0
5. Piston 294 ±29.4 216.8 ±21.6
6. Set screw 58.9 ±73.6 43.5 ±54.2
BUCKET CYLINDER

4. Bolt 530 ±78.5 390.9 ±57.9
5. Piston 294 ±29.4 216.8 ±21.6
6. Set screw 58.9 ±73.6 43.5 ±54.2
PC400LC-7L 10-133
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
WORK EQUIPMENT
10-134 PC400LC-7L
12
Unit: mm
Clearance between connecting pin Tolerance Standard Clearance
and bushing of revolving frame Standard size
Shaft Hole clearance limit
1 and boom
-0.036 +0.173 0.137 -
120 1.0
-0.090 +0.101 0.263
Clearance between connecting pin -0.036 +0.180 0.148 -
2 120 1.0
and bushing of boom and arm -0.090 +0.112 0.270
Clearance between connecting pin -0.036 +0.172 0.117 - Replace
3 100 1.0
and bushing of arm and link -0.090 +0.081 0.262
4 100 1.0
and bushing of arm and bucket -0.090 +0.077 0.228
5 100 1.0
and bushing of link and bucket -0.090 +0.081 0.262
6 100 1.0
and bushing of link and link -0.090 +0.097 0.280
7 Bucket clearance (a) 0.5 - 1.0
Adjust shims
8 Bucket clearance (b) 2.0
PC400LC-7L 10-135
12
DIMENSION ARM
10-136 PC400LC-7L
12 Unit: mm
1 φ110+0.1 -0.036
+0 / 0.090
-
2 φ129.3+1.5
0 / 126 ±1.2
3 φ355+0.5
0
/ 351-0.8
-0.3
4 φ120+00.1/ -0.090
-0.036
5 514.8
6 195
7 1,038
8 3,375
9 2,977.5
10 502
11 720
12 719
13 537.1
14 1,850
15 φ100+0.1 -0.036
0 / -0.090
16 φ371+10 / 370 ± 0.5
17 φ100+0.1 -0.036
0 / -0.090
Arm as individual part 0

355-0.5
18
When press fitting bushing 370
Cylinder Min. stroke 1,870
19
Cylinder Max. stroke 3,140
PC400LC-7L 10-137 2
12
DIMENSION OF BUCKET
10-138 PC400LC-7L
12 Unit: mm
1 534.1 ± 0.5
2 56.3 ± 0.5
3 96° 1’
4 537.1
5 1,839
6 190
7 ---
8 62°× 1’
A φ140.1 ± 8.1
B φ130+0.063
9 0
C φ100+0.1
0
10 371 +1
0
A 57
11
B 72
12 144
13 562.5+0.5
-2.5
14 φ26
A φ165
15
B ---
16 φ230
17 146.1
18 137.6
19 R115
20 R85
21 410 ± 1
22 64
PC400LC-7L 10-139
STRUCTURE AND FUNCTION AIR CONDITIONER
12
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Hot water pickup piping A. Fresh air

2. Receiver tank B. Recirculated air
3. Hot water return piping C. Hot air/cold air
4. Condenser
5. Air conditioner compressor
6. Refrigerant piping
7. Air conditioner unit
8. Duct
10-140 PC400LC-7L
STRUCTURE AND FUNCTION ENGINE CONTROL
12
ENGINE CONTROL
OPERATION OF SYSTEM
STARTING ENGINE
When the starting switch is turned to the START position, the starting
signal flows to the starting motor, and the starting motor turns to start the
engine.
When this happens, the engine controller checks the signal from the fuel
control dial and sets the engine speed to the speed set by the fuel control
dial.
ENGINE SPEED CONTROL

The fuel control dial sends signal voltages to the engine controller
according to its angle.
The engine controller sends drive signals to the supply pump according to
the signal voltages received from the fuel control dial and controls the fuel
injection pump to control the engine speed.
STOPPING ENGINE
When the engine controller detects that the starting switch is at the OFF
position, it cuts the signal to the supply pump drive solenoid to stop the
engine.
PC400LC-7L 10-141
12
COMPONENTS OF SYSTEM
FUEL CONTROL DIAL
Function
• The fuel control dial is installed at the bottom of the monitor panel. A
potentiometer is installed under the knob, and when the knob is turned,
it rotates the potentiometer shaft. When the shaft rotates, the resistance
of the variable resistor inside the potentiometer changes, and the
desired throttle signal is sent to the engine controller.
• The hatched area in the graph on the right is the abnormality detection
area and the engine speed is set at low idling.
10-142 PC400LC-7L
12
ENGINE CONTROLLER
PC400LC-7L 10-143
Input
12 and output signals
CN1 [CN-E11] CN2 [CN-E12]
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
CN1-1 POWER (+24V constant) CN2-1 GND
CN1-2 POWER (+24V constant) CN2-2 NC
CN1-3 Model selection 1 Input CN2-3 NC Input
CN1-4 GND CN2-4 RS232C_1RX Input
CN1-5 NC Input CN2-5 NC
CN1-6 NC Output CN2-6 NC
CN1-7 GND CN2-7 NC Input
CN1-8 GND CN2-8 NC Input
CN1-9 NC Input CN2-9 Sensor 5V power supply 2 Output
CN1-10 GND CN2-10 Fuel control dial Input
CN1-11 NC Input CN2-11 S_NET_SHIELD GND
CN1-12 NC Output CN2-12 CAN_SHIELD
CN1-13 Key switch (ACC) Input CN2-13 NC Output
CN1-14 NC Input CN2-14 RS232C_1TX Output
Engine oil pressure switch
CN1-15 Input CN2-15 G_SHIELD (GND)
(For high pressure)
CN1-16 Memory clear Input CN2-16 Ne_SHIELD (GND)
CN1-17 Model selection 3 Input CN2-17 Fuel temperature sensor Input
CN1-18 NC Output CN2-18 NC Input
CN1-19 Key switch (ACC) Input CN2-19 Sensor 5V power supply 1 Output
CN1-20 Starting switch (C) Input CN2-20 Boost pressure sensor Input
Engine oil pressure switch
CN1-21 Input CN2-21 S_NET (+) Input/Output
(For low pressure)
CN1-22 Auto deceleration signal Input CN2-22 CAN0_L Input/Output
CN1-23 Model selection 2 Input CN2-23 NC
CN1-24 NC Output CN2-24 FWE_switch Input
CN2-25 G pulse (ñ) Input
CN2-26 Ne pulse (ñ) Input
CN2-27 Coolant temperature sensor (High) Input
CN2-28 NC Input
CN2-29 Analog GND
CN2-30 NC Input
CN2-31 S_NET (+) Input/Output
CN2-32 CAN0_H Input/Output
CN2-33 NC
CN2-34 GND (232C_GND)
CN2-35 G pulse (+) Input
CN2-36 Ne pulse (+) Input
CN2-37 Coolant temperature sensor (Low) Input
CN2-38 NC Input
CN2-39 Analog GND
CN2-40 Common rail pressure sensor Input
10-144 PC400LC-7L
12
CN3 [CN-E13]
Pin No. Signal name Input/Output
CN3-1 Power supply for power
CN3-3 NC
CN3-4 NC
CN3-5 Injector #3 (+) Output
CN3-7 NC Input
CN3-8 Output mode selection 1 (Test mode) Input
CN3-9 Lever neutral flag (Test mode) Input
CN3-10 Engine rotation pulse output Output
CN3-11 Power GND Input
CN3-12 Supply pump 1 (+) Output
CN3-13 Supply pump 2 (+) Output
CN3-15 Injector #3 (ñ) Output
CN3-17 NC Input
CN3-18 Output mode selection 2 (Test mode) Input
CN3-19 NC Input
CN3-20 Q command output Output
CN3-22 Supply pump 1 (ñ) Output
CN3-23 Supply pump 2 (ñ) Output
CN3-27 NC Output
CN3-28 Auto deceleration flag (Test mode) Input
CN3-29 NC Input
CN3-30 GND
CN3-31 Power GND
CN3-32 Power GND
CN3-37 NC Output
CN3-38 Auto deceleration control (Test mode) Input
CN3-39 NC Input
CN3-40 GND
PC400LC-7L 10-145
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
12
ELECTRONIC CONTROL SYSTEM
CONTROL FUNCTIONS
★ For the self-diagnosis function, see “TROUBLE SHOOTING”
10-146 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 10-147
12
TOTAL SYSTEM DIAGRAM
10-148 PC400LC-7L
12
PC400LC-7L 10-149
12
ENGINE AND PUMP CONTROL FUNCTION
10-150 PC400LC-7L
12
Function
• The operator can set the work mode switch on the monitor panel to
mode A, E, or B (or L) and select proper engine torque and pump
absorption torque according to the type of work.
• The engine throttle and pump controller detects the speed of the
engine governor set with the fuel control dial and the actual engine
speed and controls them so that the pump will absorb all the torque at
each output point of the engine, according to the pump absorption
torque set in each mode.
❈: The L mode is on the multi-monitor specification machine only.
PC400LC-7L 10-151
12
1. Control method in each mode Mode A, Mode E
• Matching point in mode A: Rated speed
246.3 kW/1,850 rpm

Mode A {331 HP/1,850 rpm}
Mode E 213.3. kW/1,720 rpm

{286 HP/1,720 rpm}
• If the pump load increases and the pressure rises, the engine
speed lowers.
At this time, the controller lowers the pump discharge so that the
engine speed will be near the full output point. If the pressure
lowers, the controller increases the pump discharge so that the
engine speed will be near the full output point.
By repeating these operations, the controller constantly uses the
engine near the full output point.
10-152 PC400LC-7L
12
Mode B / (Mode ❈L)
Mode Mode B Mode L

Partial output point 82% 61%
Mode B 194.9 kW/1,730 rpm

{261 HP / 1,730 rpm}
Mode ❈L 150.8 kW/1,250 rpm
{202 HP / 1,250 rpm}
• 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.
PC400LC-7L 10-153
12
2. Function to control pump during travel
• When the travel is operated in A operation, or E or B working
mode, the working mode stays as it is, and the pump absorption
torque and engine speed rise to A travel mode.
• If the machine travels in mode L, the working mode and engine

speed do not change, but the pump absorption torque is
increased.
3. Function to control when emergency pump drive switch is turned ON

• Even if the controller or a sensor has a trouble, the functions of
the machine can be secured with pump absorption torque almost
equivalent to mode E by turning on emergency pump drive
switch (10).
In this case, a constant current flows from the battery to the EPC
valve for PC and the oil pressure is sensed by only the EPC
valve for PC.
10-154 PC400LC-7L
12
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.
PC400LC-7L 10-155
12
1. LS control function
• The change point (LS set differential pressure) of the pump discharge in the LS valve is changed by changing the
output pressure from the LSEPC valve to the LS valve according to the operating condition of the actuator.
• By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control
performance is improved.
2. Cut-off function
• When the cut-off function is turned on, the PCEPC current is
increased to near the maximum value.
• By this operation, the flow rate in the relief state is lowered to
reduce fuel consumption.
• Operating condition for turning on cut-off function
Condition
The average value of the front and rear pressure sensors is above
285 kg/cm2 (4053 psi) and the one-touch power maximizing
function is not turned on
The cut-off function does not work, however, while the machine is
travelling in mode A or the arm crane operation width swing lock switch
is turned on.
1. 2-stage relief function

• The relief pressure in the normal work is 355 kg/cm2 (5049 psi).
If the 2-stage relief function is turned on, however, the relief
pressure rises to about 380 kg/cm2 (5404 psi).
By this operation, the hydraulic force is increased further.
• Operating condition for turning on 2-stage relief function
Condition Relief pressure

• Condition
• During travel
• When swing lock switch is turned on 355 kg/cm2 (5049 psi)
• When boom is lowered ↓
When one-touch power maximizing function is 380 kg/cm (5404 psi)
2
•
turned on
• When L mode is operated
10-156 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 10-157
12
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.
10-158 PC400LC-7L
12
1. One-touch power maximizing function
• When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydrau-
lic force is increased about 7% to increase the digging force.
• If the left knob switch is turned on in working mode “A” or “E”, each function is set automatically as shown below.
Working mode Engine/Pump control 2-stage relief function Operation time Software cut-off function
355 kg/cm (5049 psi)
2
Automatically reset at 8.5
A, E Matching at rated output point ⇓ Cancel
sec
380 kg/cm2 (5404 psi)
2. Machine push-up function

• Operate switch (1) to increase the boom pushing force when
digging ditches or holes on hard ground.
Switch 2-stage safety valve function

OFF Setting of safety valve at boom cylinder
150 kg/cm2 (2133 psi)
ON Setting of safety valve at boom cylinder
290 kg/cm2 (4124 psi)
PC400LC-7L 10-159
12
AUTO-DECELERATION FUNCTION
Function
• If the all control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is lowered to the
medium level automatically to reduce the fuel consumption and noise.
• If any lever is operated, the engine speed rises to the set level instantly.
10-160 PC400LC-7L
12
Operation
WHEN CONTROL LEVERS ARE SET IN NEUTRAL
If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,300 rpm)
for 4 seconds, the engine speed lowers to the second deceleration level (about 1,300 rpm) and keeps at that level until any lever
is operated again.
WHEN ANY CONTROL LEVER IS OPERATED
If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly
to the level set with the fuel control dial.
PC400LC-7L 10-161
12
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.
10-162 PC400LC-7L
12
1. Auto-warm-up function
After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the
engine.
2. Overheat prevention function

If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to prevent
overheating.
This function is turned on when the coolant temperature rises above 95° C (203° F).
PC400LC-7L 10-163
12
SWING CONTROL FUNCTION
Function
The swing lock and swing holding brake functions are installed.
10-164 PC400LC-7L
12
1. Swing lock and swing holding brake functions
• The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake
function (automatic) is used to prevent hydraulic drift after the machine stops swinging.
• Swing lock switch and swing lock/holding brake
Lock switch Lock lamp Function Operation

If swing lever is set in neutral, swing brake operates in about 7 sec. If swing lever is
OFF OFF Swing holding brake operated, brake is released and machine can swing freely.
Swing lock operates and machine is locked from swinging. Even if swing lever is
ON ON Swing lock 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.
ON OFF
Swing holding brake release switch (When control has trouble) (When controller is normal)
Swing lock switch ON OFF ON OFF
Swing lock is turned Swing lock is Swing lock is
Swing brake Swing holding brake is turned on
on canceled turned on
★ Even if the swing holding brake release switch is turned on, if the swing lock switch is turned on, the swing brake is
not released.
★ If the swing lock is reset, swinging is stopped by only the hydraulic brake of the safety valve. Accordingly, if
swinging is stopped on a slope, the upper structure may drift hydraulically.
2. Quick hydraulic oil warm-up function when swing lock switch is

turned on
If swing lock switch (4) is turned on, the pump-cut function is
cancelled and the relief pressure rises from 355 kg/cm2 (5049 psi) to
380 kg/cm2 (5404 psi). If the work equipment is relieved under this
condition, the hydraulic oil temperature rises quickly and the warm-up
time can be shortened.
PC400LC-7L 10-165
12
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 job site during travel.
10-166 PC400LC-7L
12
Pump control function during travel
If the machine travels in a work mode other than mode A, the work mode and the engine speed are kept as they are and the
pump absorption torque is increased.
★ For details, see ENGINE/PUMP COMPOSITE CONTROL FUNCTION.
1. Travel speed change function
A. Manual change with travel speed switch If the travel speed switch is changed between Lo, (Mi), and Hi, the
governor/pump controller controls the pump capacity and motor capacity at each gear speed as shown at right to
change the travel speed.
Travel speed switch Lo (Low speed) (❈Mi) (Middle Speed) Hi (High speed)
Pump capacity (%) 90 82 100
Motor capacity Max. Max. Min.
Travel speed (km/h) 3.2 4.5 5.5
B. Automatic change according to engine speed If the fuel control dial is used to set the engine speed to less than 1,200
rpm:
• When traveling in Lo, it will not switch even when set to Hi or Mi.
• When traveling in Hi or Mi, it will switch automatically to Lo.
C. Automatic changes according to pump discharge pressure

When traveling with the travel speed switch set to Hi or Mi, it the
load increases, such as when traveling uphill, and the travel
pressure goes above 330 kg/cm2 (4693 psi) for more than 0.5 sec.,
the travel motor capacity will automatically change to low speed
(equivalent to Lo). (The travel speed switch will stay at Hi or Mi.)
After continuing to travel in Lo, if the load increases, such as
when traveling on level ground or traveling downhill, and the
travel pressure goes below 190 kg/cm2 (2702 psi) for more than
0.5 sec., the travel motor capacity will automatically change and
will return to Hi or Mi.
❈: The “Mi” mode is on the multi-monitor specification machine only.
PC400LC-7L 10-167
12
ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT)
Function
This function is available only with the ATT specification. The function acts as follows according to the flow command and
working mode from the monitor.
1. It throttles the ATT PPC pressure and controls the flow when the pedal is fully depressed.
2. In mode B and the other modes, it switches to ATT single acting (B) or double acting (other modes).
❈: The ATT flow control adjustment function is on the multi-monitor specification machine only.
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SYSTEM COMPONENT PARTS
ENGINE REVOLUTION SENSOR
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
Function
• The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the
gear teeth which pass in front of it and transmits the result to the engine throttle and pump controller.
• A magnet is used to sense the gear teeth. Each time a gear tooth passes in front of the magnet, a current is generated.
PC400LC-7L 10-169
12
PPC OIL PRESSURE SWITCH
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts

Operating (ON) pressure: 5.0 ±1.0 kg/cm2 (71 ±14 psi)
Resetting (OFF) Pressure: 3.0 ±0.5 kg/cm2 (42 ±7 psi)
Function
The junction block has 7 pressure switches, which check the operating condition of each actuator by the PPC pressure and
transmit it to the engine throttle and pump controller.
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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 kg/cm2 (psi) and output voltage (V) is as follows. V = 0.08 [0.008] × P + 0.5
PC400LC-7L 10-171
12
PUMP CONTROLLER
10-172 PC400LC-7L
12
Input and output signals
CN-1 CN-2
Pin No. Signal name Input/ Output Pin No. Signal name Input/ Output
1 NC 1 NC
2 R pump pressure sensor Input 2 Swing emergency switch Input
3 NC 3 NC Input
4 NC 4 232C_RxD Input
5 NC 5 NC
6 NC Input 6 NC
7 NC 7 Model selection 4 Input
8 F boom pressure sensor Input 8 Attachment circuit selector signal Output
9 NC 9 NC
10 Signal GND 10 NC
11 Knob SW Input 11 NC
12 NC 12 CAN shield
13 Buchet CURL PPC pressure sensor Input 13 Model selection 5 Input
14 NC 14 232C_TxD Output
15 NC Input 15 NC
16 NC 16 Travel steering signal pressure SW Input
17 Starting switch (Terminal C) Input 17 Model selection 3 Input
18 NC 18 NC
19 Arm IN PPC pressure sensor Input 19 Auto deceleration signal Output
20 NC 20 NC
21 NC 21 S_NET Input/output
22 POT_PWR Output 22 CAN0_L Input/output
23 Starting switch (terminal ACC) Input 23 NC
24 NC 24 FWE_SW Input
25 NC
26 NC
27 Model selection 2 Input
28 NC
29 GND (pulse GND)
30 NC
31 GND (S_NET GND)
32 CAN0_H Input/ output
33 NC
34 GND (232C GND)
35 Service valve pressure switch Input
36 NC
37 Model selection switch 1 Input
38 Swing lock switch Input
39 GND (pulse GND)
40 Engine speed sensor Input
PC400LC-7L 10-173
12
CN-3
Pin No. Signal name Input/Output
1 VB (controller power) Input
2 VIS (solenoid power) Input
3 SOL_COM (solenoid common gnd)
4 Battery relay drive Output
5 NC
6 LS-EPC Output
7 Travel junction SOL Output
8 NC
9 NC Input
10 Boom RAISE pressure SW Input
11 VB (controller power) Input
12 VIS (solenoid power) Input
13 SOL_COM (solenoid common gnd) Input
14 KEY_SIG Input
15 NC
16 PC-EPC Output
17 Pump merge/divider solenoid Output
18 Heater relay drive Output
19 Bucket DUMP pressure switch Input
20 Boom LOWER pressure switch Input
21 GND (controller GND) Input
22 NC
23 SOL_COM (solenoid common gnd) Input
24 KEY_SIG Input
25 NC
26 Service flow adjustment EPC (1) Output
27 Travel Hi/Lo selector solenoid Output
28 2-stage relief solenoid Output
29 Swing pressure switch Input
30 Arm IN pressure switch
31 NC Input
34 NC
35 NC
36 NC
37 Swing parking brake solenoid Output
38 NC
39 Travel pressure switch Input
40 Arm OUT pressure switch Input
10-174 PC400LC-7L
STRUCTURE AND FUNCTION MONITOR SYSTEM
12
MONITOR SYSTEM
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It
processes and immediately displays the obtained information on the panel notifying the operator of the condition of the
machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the machine has troubles
2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)
The monitor panel also has various mode selector switches and functions to operate the machine control system.
PC400LC-7L 10-175
12
1. Monitor panel
Outline
The monitor panel has the functions to display various items and the functions to select modes and electric parts.
The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information.
The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.
10-176 PC400LC-7L
Input
12 and output signals
CN-1 CN3
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 Key ON Input 1 NC Input
2 Key ON Input 2 NC Input
3 Washer motor output Output 3 NC Input
4 Starting signal Input 4 NC Input
5 Limit switch (W) Input 5 NC Input
6 GND 6 NC Input
7 GND 7 RS230C CTS Input
8 VB + Input 8 RS230C RXD Input
9 Wiper motor (+) Output 9 RS230C RXD Input/Output
10 Wiper motor (-) Output 10 RS230C RXD Input/Output
11 Buzzer ON signal Input 11 BOOTSW Input
12 Limit switch (P) Input 12 NC Input
13 GND
14 CAN (SHIELD) Input
CN-2 15 CAN (+) Input
Pin No. Signal name Input/output 16 CAN (-) Input
1 Engine coolant temperature Input
2 Fuel level Input
3 Radiator coolant level Input
4 (Hydraulic oil level) Input
5 Air cleaner clogging Input
6 NC Input
7 Engine oil pressure Input
8 Engine oil level Input
9 N/W signal Input/Output
10 N/W signal Input/Output
11 Battery charge Input
12 Hydraulic oil temperature (analog) Input
13 GND (for analog signal)
14 Buzzer drive Input
15 Limit SW (window) Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheat Input
19 Light switch Input
20 N/W GND
PC400LC-7L 10-177
12
MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION
1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power max. monitor
4. Engine coolant temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Radiator coolant level caution
6. Engine coolant temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Engine oil pressure caution
8. Service monitor 18. Engine oil level caution
9. Travel speed monitor 19. Air cleaner clogging
10. Fuel gauge 20. Maintenance time warning caution
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MONITOR ITEMS AND DISPLAY
Symbol Display item Display method

Swing holding brake release
Swing lock switch Swing lock monitor
switch
OFF OFF OFF
Swing lock ON OFF ON

OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status

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

Power Max Being pressed Lights up but goes out after approx. 9 sec when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic See gauge display on the next page
oiltemperature
Fuel level
PC400LC-7L 10-179
12
Gauge Range Temperature, volume Indicator Buzzer sound

A1 105 Red O
A2 102 Red
Engine coolant A3 100 Green

temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
B3 100 Green
Hydraulic oil temperature (°C)
B4 80 Green
B5 40 Green
B6 20 White
C1 467 Green
C2 381 Green
C3 295 Green
Fuel level (l)
C4 147.5 Green
C5 114 Green
C6 80.5 Red
10-180 PC400LC-7L
12
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature
gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed.
Check before starting
Symbol Display item When engine is stopped When engine is running
item
When abnormal, lights up and

Engine oil pressure ● --- buzzer sounds
Battery charge ● --- Lights up when abnormal
When abnormal, lights up and

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

Maintenance 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 ñ B2) No display
High temperature (below B2) White on red background
PC400LC-7L 10-181
12
Display Symbol Display item Display range Display method

category
Wiper Displays set condition
Working mode Displays set mode
Monitor
Travel speed Displays set speed
Auto-deceleration ON ⇔ OFF Displays actuation status
Service meter Lights up when service

Service meter When service meter is working
indicator meter is working
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12
SWITCHES
1. Selector switch
2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
PC400LC-7L 10-183
12
• Working mode selector switch Switch that is pressed Display Working mode status after setting
The condition of the machine changes
[A] A A mode (default)
according to the switch that is pressed (A, E, L,
B). It is possible to check the condition on the [E] E E mode
working mode monitor display. The relationship [L] L Heavy-lift mode
between each working mode and the monitor [B] B Swing priority mode
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 Display Setting
switched ON/OFF. Crawler symbol + Lo Low speed (default)
Use the auto-deceleration monitor display to Crawler symbol + Mi Medium speed
check the present condition.
Crawler symbol + Hi High speed
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 → Hi → Lo ……
Use the travel speed monitor display to check the present condition.
The relationship between the set speed and the monitor display in the table on the right.
• Wiper switch
Each time the wiper switch is pressed, the wiper
setting changes Display Setting Wiper actuation status
OFF → INT → ON → OFF → …… None OFF Stowing stopped or now stowing
Use the wiper monitor display to check the Wiper symbol + INT INT Intermittent actuation
present condition.
Wiper symbol + ON ON Continuous actuation
The relationship between the wiper setting and
the monitor display is as shown in the table on
the right.
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• Window washer switch
While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.
• Control switch
This is used for control when using the maintenance function or select function. (For details, see each function.)
• Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For
details, see each function.)
PC400LC-7L 10-185
12
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
★ Carry out the setting on the normal screen
1. A mode, E mode
A. Press select switch (1) on the monitor to move to the adjustment

screen.
B. Press control switch (2) to select the flow level.

Control switch Actuation
Flow level bar graph extends to the right
Flow level bar graph retracts to the left
C. After completing the level selection, press input confirmation

switch (3). The selection flow level is confirmed and the
screen moves to the normal screen. From the moment that the Flow level Flow (L/min.) Remarks
flow level is selected, the content of the selection is reflected 8 530 ❈ Default
for the attachment flow. 7 430
★ Before the input confirmation switch is pressed, the flow 6 370
level is not confirmed, so press return switch (4) to return
5 300
to the normal screen. This function can be used to return
to the previously set flow. The relationship between the 4 230
set flow level and the flow value is as shown in the table 3 165
on the right. 2 100
1 30
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2. B mode
A. Press select switch (1) on the monitor to move to the screen for
selecting the 3-stage flow level.
B. Press control switch (2), or input [01] – [03] with the numeral
10-key pad to choose one on the three flow levels.
No. 10-key pad operation
01
02
03
C. After completing the level selection, press input confirmation

switch (3). The selected flow level is selected.
★ Before the input confirmation switch is pressed, the flow
level is not confirmed, so press return switch (4) to return to
the operator screen. This function can be used to return to the No. Flow level (L/min.) Remarks
previously set flow. 01 230 Default
02 190
D. After the flow level is confirmed, the screen changes to the screen
03 150
shown in the diagram on the right. With this screen, it is possible
to make fine adjustment to the flow.
E. Press control switch (2) and select the flow level.

PC400LC-7L 10-187
12
F. After completing the level selection, press input confirmation
switch (3).
The selected flow level is confirmed and the screen moves to When flow When flow When flow
Flow is 140 L/ is 220 L/ is 300 L/ Remarks
the operator screen. From the moment that the flow level is level min. min. min.
selected, the content of the selection is reflected for the
7 200 280 360
attachment flow.
6 180 260 340
★ Before the input confirmation switch is pressed, the flow
level is not confirmed, se press return switch (4) to return 5 160 240 320
to the normal screen. This function can be used to return 4 140 220 300 Default
to the previously set flow. The relationship between the 3 120 200 280
set flow level and the flow value is as shown in the table
2 100 180 260
on the right.
1 80 160 240
G. Check the set value with the working mode monitor. The
relationship between the display level and the set value is as
shown in the table on the right, and it is possible to check the Display level Set value (L/min.)
level of the flow that can be set. 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
10-188 PC400LC-7L
12
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.
★ Maintenance items
No. Item Replacement interval (hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor 1000
07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
★ The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is
operated. The content of the caution display differs according to the remaining time. The relationship is as shown in the
table below.
Display Condition
None Remaining time for maintenance for all items is more than 30 hours
Notice display (black symbol displayed on yellow background) There is one or more items with less than 30 hours remaining time for
maintenance
Warning display (wiper symbol displayed on red background) There is one or more items with less than 0 hours remaining time for
maintenance
PC400LC-7L 10-189
12
METHOD OF CHECKING STATUS
MAINTENANCE ITEMS
★ Operate as follows when on the operator screen.
1. Press maintenance switch (1) and switch to the maintenance list

display screen.
★ The maintenance items are displayed as symbols on the screen.
2. Press control switch (2), or use the 10-key pad to input the number
(01 – 10) of the maintenance item to select the item.
★ The cursor moves and the item is highlighted.
★ The display method is the same as described on the previous page

(relationship between remaining time and caution display). If the
remaining time is less than 30 hours, the item is displayed in
yellow, and if it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION
1. After completing the selection, press input confirmation switch (3).

The screen will change to the maintenance reset screen.
2. Use the maintenance reset screen to check the content, and if there is
any problem, press input confirmation switch (3) to move to the check
screen. If the wrong item is selected, press return switch (4) to return
to the maintenance list screen.
3. Check the content on the check screen, and if there is no problem,

press input confirmation switch (3) to reset the maintenance time.
After the reset is completed, the screen returns to the maintenance list
display screen. To check the remaining time, or if the wrong item is
selected, press return switch (4) to return to the maintenance list
screen.
★ The check screen shows the symbol for the maintenance item and
the set time in large letters.
★ The background color of the symbol for the item where the
maintenance item was reset is the same as the background of the
screen, so it is possible to check that it has been reset.
10-190 PC400LC-7L
12
BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION
This function is used to adjust the brightness and contrast of the display.
ADJUSTMENT METHOD
★ Operate as follows when on the operator screen.
1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen.
★ Relationship between menu symbol and content.
No. Symbol Content
01 Return mark Return
02 Contrast
03 Brightness
2. Press control switch (2), or use the 10-key pad to input the number (00
– 02) to select either contrast or brightness. After completing the
selection, press input confirmation switch (3) and return to the
adjustment screen. Then press return switch (4) or use the 10-key pas
to set to [00] and press input confirmation switch (3) to return to the
normal screen.
3. Press control switch (2) and adjust the brightness and contrast as
desired.
PC400LC-7L 10-191
12
SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF position, press return switch (1)
and control switch (2) on the monitor at the same time, and the service
meter is shown on the display.
• This display is shown only while the two switches are being pressed.
When the switches are released, the display goes out. Note that it takes
3 – 5 seconds after the switches are pressed for the service meter
display to appear.
DISPLAY LCD CHECK FUNCTION

• On the password input screen or on the normal screen, if monitor
return switch (1) and working mode (A) switch are kept pressed at the
same time, all the LCD display will light up and the whole screen will
become white, so the display can be checked.
• If any part of the display is black, the LCD is broken.
10-192 PC400LC-7L
12
• While the user code is being displayed, if the input confirmation
switch is pressed, the service code and failure code can be displayed.
• If there is more than one service code or failure code, the display
switches every 2 seconds and displays all the service codes/failure
codes that caused the user code to be displayed. Even if service codes/
failure codes have occurred, if they did not cause the user code to be
displayed, this function does not display them.
• If the telephone number has been set using the telephone number input
on the service menu, it is possible to switch on the service code/failure
code and display the telephone symbol and telephone number.
For details of inputting and setting the telephone number, see
SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING
AND ADJUSTING section.
PC400LC-7L 10-193
STRUCTURE AND FUNCTION SENSOR
12
SENSOR
The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the
chassis ground.
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 --- ---
Air cleaner clogging Contact type OFF (open) ON (closed)
ENGINE OIL LEVER SENSOR
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)
10-194 PC400LC-7L
12
COOLANT TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
FUEL LEVEL SENSOR
PC400LC-7L 10-195
AIR CLEANER CLOGGING SENSOR
10-196 PC400LC-7L
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
TROUBLESHOOTING
TROUBLESHOOTING GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
TROUBLESHOOTING ERROR CODES IN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) . . . . . . . . . . . . 20-601
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP
MANUAL.
★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from the
factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.
3. These standard values are not the standards used in dealing with claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.
WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
PC400LC-7L 20-1 1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
12
STANDARD VALUE TABLE FOR ENGINE
Engine SAA6D125E-3
Item Measurement condition Unit Standard value Permissible value
High idling 1,930 ± 50 1,930 ± 50
Engine speed Low idling rpm 1,000 ± 25 1,000 ± 25
Rated speed 1,850 1,850
kPa
Intake air pressure At rated output Min 107 {Min. 800} 87 {650}
{mmHg}
Exhaust gas pressure All speed range (intake air temp: 20°C) °C Max. 700 Max. 700
At sudden acceleration Bosch Max. 4.0 6.0
Exhaust gas color At high idling index Max. 1.0 2.0
Valve clearance Intake valve 0.33 ---
mm
(normal temperature) Exhaust valve 0.71 ---
Compression Oil temperature: 40-60×C MPa {kg/cm2} Min. 2.9 {Min. 30} 2.0 {20}
pressure (Engine speed) (rpm) (150-200) (150-200)
(Coolant temperature: within operating kPa
Blow-by pressure {mmH2O} Max. 1.18 {Max. 120} 1.96 {200}
range) At rated output
(Coolant temperature: within operating
range) 0.39-0.69 {4.0- 7.0} 0.21 {2.1}
At high idling (SAE30) MPa 0.34-0.64 {3.5-6.5} 0.18 {1.8}
Oil pressure At high idling (SAE10W) {kg/cm2} Min. 0.15 {Min. 1.5} 0.08 {0.8}
At low idling (SAE30) Min. 0.1 {Min. 1.0} 0.07 {0.7}
At low idling (SAE10W)
Oil temperature All speed range (inside oil pan) °C 90-120 120
Fan, alternator belt Deflection when pressed with finger mm Approximately 13 Approximately 13
tension force of Approximately 58.8 N {6 kg}
Air conditioner Deflection when pressed with finger mm 14-16 14-16
compressor belt tension force of approximately 58.8 N {6 kg}
★ For further detailed information, refer to Engine Shop Manual
20-2 1 PC400LC-7L
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS
Cate Item Measurement conditions Unit Standard value Permissible value
gory
●Engine water temperature: Within
operating range
●Hydraulic oil temperature: Within
2 pumps at relief 1,930 ± 100 1,930 ± 100
operating range
●Engine at high idling
●Arm in relief condition
●Engine water temperature: Within
Engine speed
operating range
At 2-pump relief + one ●Hydraulic oil temperature: Within rpm
operating range 1,830 ± 100 1,830 ± 100
touch power up ●Engine at high idling
●Arm relief + One-touch power max.
switch in ON condition
Speed when auto ●Auto-deceleration switch in ON
deceleration is condition 1,300 ± 100 1,300 ± 100
operated ●All control levers in NEUTRAL
condition
Boom control valve
Travel of control levers Spool stroke
Arm control valve

Bucket control valve mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve
Travel control valve
Boom control lever 85 ± 10 85 ± 10

●Engine stopped
Arm control lever 85 ± 10 85 ± 10
●At center of control lever grip
Bucket control lever 85 ± 10 85 ± 10
●Max. reading up to stroke end mm
Swing control lever 85 ± 10 85 ± 10
(excepting lever play in NEUTRAL
Travel control lever 115 ± 12 115 ± 12
position)
Play of control levers Max. 10 Max. 15
15.7 ± 4.9 Max. 24.5

Boom control lever {1.6 ± 0.4} {Max. 2.5}
Operating effort of control levers
15.7 ± 4.9 Max. 24.5

Arm control lever {1.6 ± 0.4} {Max. 2.5}
operation range 12.7 ± 2.9 Max. 21.6
Bucket control lever ●Engine at high idling {1.3 ± 0.3} {Max. 2.2}
●Hydraulic oil temperature: Within N {kg}
operating range 12.7 ± 2.9 Max. 21.6
Swing control lever
●At center of control lever grip {1.3 ± 0.3} {Max. 2.2}
●Max. reading up to stroke end
24.5 ± 5.9 Max. 39.2
Travel control: Lever {2.5 ± 0.6} {Max. 4.0}
74.5 ± 18.6 Max. 107.6
Travel control: Pedal {7.6 ± 1.9} {Max. 11}
PC400LC-7L 20-3 1
12
Cate- Item Measurement conditions Unit Standard value Permissible value
gory
operation range
●Engine at high idling 4.2 ± 1.0 4.2 ± 1.0
Unload pressure ●Working mode: A mode {42 ± 10} {42 ± 10}
●Hydraulic pump output pressure with all
control levers in NEUTRAL position
34.81+1.47 33.34-36.77
-0.98
(37.27+1.47 )
-0.98
RAISE (35.79-39.23)
{355+15
-10
(380+15)} {340-375 (365- 400)}
Boom -10
At low-
●Hydraulic oil 18.14 ± 0.98 16.67-19.61
pressure {185 ± 10} {170-200}
temperature:
LOWER
setting
Within operation
range At high-
31.38 ± 1.47 29.2-33.34
●Engine at high pressure {320 ± 15} {300-340}
idling setting
●Working mode: A mode 34.81+1.47
●Hydraulic pump output pressure with all -0.98
33.34-36.77
measurement circuits relieved (37.27+1.47 )
●Values inside parenthesis: Hydraulic oil -0.98
Arm pressure with one-touch power max. (35.79-39.23)
{355+15
switch in ON mode (reference only) -10
+15
(380 )} {340-375 (365- 400)}
Hydraulic pressure
-10
MPa 34.81+1.47 33.34-36.77

-0.98
{kg/cm2}
(37.27+1.47 )
-0.98
Bucket (35.79-39.23)
{355+15
-10
(380+15)} {340-375 (365- 400)}
-10
30.89+1.47
Swing
-2.45 27.95-32.85
{315+15} {285-335}
- -25
37.27+2.94
-0.98 35.79-40.70
Travel
{380+30} {365-415}
-10

operation range
Control circuit source ●Engine at high idling 3.24 ± 0.2 2.84-3.43
pressure ●Self-reducing pressure valve output {33 ± 2} {29-35}
pressure with all control levers in
NEUTRAL position
●Hydraulic oil tem- When all
perature: Within control levers 4.2 ± 1.0 4.2 ± 1.0
operation range in NEUTRAL {42 ± 10} {42 ± 10}
●Engine at high idling position
LS differential pressure
●Working mode: A mode When trav-
●Traveling speed: Hi eling at half 2.65 ± 0.1 2.65 ± 0.1
●Hydraulic oil pump stroke {27 ± 1} {27 ± 1}
pressure-LS pressure (without load)
20-4 1 PC400LC-7L
12
gory
●Hydraulic oil temperature: Within operating deg.

Swing brake angle Max. 130 Max. 160
range (mm)
●Bucket: Empty
●Working mode: A mode
●Swing circle misalignment amount when
stopping after one turn
90° 3.7 ± 0.4 Max. 4.6
Time taken to start ●Hydraulic oil temperature: Within sec.

swing operation range
●Bucket: Empty
●Working mode: A mode 180° 5.4 ± 0.5 Max. 6.4
●Time required for passing points 90
and 180 degrees from starting point
Swing
Time taken to swing ●Hydraulic oil temperature: Within operating sec. 33.0 ± 3.3 Max. 38
range
●Bucket: Empty
●Time required for 5 more turns after making
initial one turn
●Hydraulic oil temperature: Within operation

Hydraulic drift of range mm 0 0
swing ●Engine stopped
●Keeping upper structure transverse on slope of
15 degrees
●Notching a mating mark on inner and outer
races of swing circle
●Mating mark misalignment amount during 5
minutes
PC400LC-7L 20-5 1
12

gory
operation range
Swing
Leakage from swing ●Engine at high idling

L/min Max. 5.5 Max. 11
motor ●Swing lock switch: ON
●Leakage amount for one minute during
swing relief
Lo 67.3 ± 13.5 45.0-84.5
Mi 48.1 ± 7.2 34.0-58.0

Travel speed ●Hydraulic oil temperature: sec.
(Idle travel) Within operation range
●Time required for track shoes to Hi 36.7 ± 3.6 32.0-44.0
make 5 turns after making one
initial idle turn
Lo 24.0 ± 4.8 18.9-31.0
Travel speed ●Hydraulic oil temperature: Mi sec. 17.1 ± 2.6 14.4-21.0

(Actual travel) Within operation range
Travel

●Flat ground
●Time required for traveling 20 m Hi 13.1 ñ 1.3 11.7-15.1
after 10 m trial run
Hydraulic oil temperature: Within

operation range
Engine at idling
Travel deviation Working mode: A mode mm Max. 200 Max. 300
Travel speed: Lo
Solid and flat ground
Swerving amount while traveling 20 m
(X) after initial 10 m trial run.
20-6 1 PC400LC-7L
12
gory
Hydraulic drift of travel ●Hydraulic oil temperature: Within mm 0 0

operating range
●Engine stopped
Travel
●Parking machine on slope 12 degrees

with sprocket facing upslope
●Sliding distance for 5 minutes
operating range
Leakage of travel ●Engine at high idling
L/min Max. 20 Max. 40
motor ●Travel: Lock sprocket.
●Oil leakage amount for one minute with
traveling in relief condition
Whole work equipment Max. 600 Max. 900
(tooth tip fall amount)
Hydraulic drift work equipment
Boom cylinder (cylinder Max. 25 Max. 38

retraction amount)
Arm cylinder (cylinder ●Hydraulic oil temperature: Within
Work equipment
operation range Max. 85 Max. 128

extension amount)
●Flat and level ground
●Work equipment in measurement mm
posture as illustrated above
●Bucket load: 3,060 kg (6746.15 lb)
Bucket cylinder (cylinder ●Engine stopped
●Work equipment control lever in Max. 30 Max. 45
retraction amount)
NEUTRAL position
●Fall amount for 15 minutes as measured
every 5 minutes starting immediately
after initial setting
PC400LC-7L 20-7 1
12
Cate Standard value for

- Item Measurement conditions Unit Service limit value
new machine
gory
RAISE
4.0 ± 0.4 Max. 4.8
Boom ●Hydraulic oil temperature: Within

operation range
LOWER
●Working mode: A mode 2.9 ± 0.3 Max. 3.4
●Time required from raise stroke
end till bucket touches ground
CURL
4.3 ± 0.4 Max. 5.0
Work equipment speed
Work equipment
Arm
●Hydraulic oil temperature: Within sec.
operation range
DUMP
●Working mode: A mode 3.6 ± 0.4 Max. 4.3
●Time required from dumping
stroke end to digging stroke end
CURL
3.6 ± 0.4 Max. 4.3
Bucket ●Hydraulic oil temperature: Within

operation range
DUMP
2.9 ± 0.3 Max. 3.5

●Time required from dumping
stroke end to digging
●stroke end
20-8 1 PC400LC-7L
12
Cate- Item Measurement Condition Unit Standard value Permissible value

gory
Boom Max. 3.0 Max. 3.6

range
●Engine at low idling
●Time required from raise stroke end till bucket
touches ground and pushes up machine front
Time lag
Arm Max. 3.0 Max. 3.6

●Hydraulic oil temperature: Within operation sec.
Work equipment
range
●Time required from dumping stroke end till
bucket stops momentarily after control lever is
tilted to digging and starts to move again
Bucket Max. 3.0 Max. 5.0

range
●Time required from dumping stroke end till
bucket stops momentarily after control lever is
tilted to digging and starts to move again
Cylinders ●Hydraulic oil temperature: Within operation
Internal leackage
4.5 20
range
●Leakage amount for one minute with cylinder cc/min
Center swivel or travel to be measured in relief condition 10 50
joint
PC400LC-7L 20-9 1
12
Cate- Item Measurement Condition Unit Standard value Permissible value

gory
Performance in compound operation
operation range
●Traveling speed: Lo
●Flat and level ground
Swerving amount in ●Swerving amount (X) when traveling
simultaneous operation 20 m after initial trial run of 10 m mm Max. 400 Max. 440
of work equipment and
travel
Performance of hydraulic pump
Hydraulic pump See next page L/min See next page

delivery
20-10 1 PC400LC-7L
12
Cate- Permissible
Item Measurement Condition Unit Standard value
gory value
Performance of hydraulic pump
Test pump discharge Discharge pressure Standard value for

Average pressure Judgement standard lower
Check point pressure of other pump discharge amount Q
(MPa {kg/cm2}) limit Q (L/min)
(MPa {kg/cm2}) (MPa {kg/cm2}) (L/min)
P1+P2
As desired P1 P2 See graph See graph
2
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with
the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a
base for calculating the pump discharge amount at the specified speed.
PC400LC-7L 20-11 1
12
MEMORANDUM
20-12 1 PC400LC-7L
TESTING AND ADJUSTING
12
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102
MEASURING ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
BLEEDING AIR FROM FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
HANDLING FUEL SYSTEM DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
RELEASING RESIDUAL FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ADJUSTING ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
INTAKE AIR PRESSURE (BOOST PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
FAN BELT AND ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
SWING CIRCLE BEARING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
TRACK SHOE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
CONTROL CIRCUIT - BASIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
PUMP PC CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
PUMP LS CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
SOLENOID VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
PPC VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
SWING PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-133
MEASURING OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-134
BLEEDING AIR FROM EACH PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
DIODE TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140
MONITOR PANEL - SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-141
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . 20-167
PREPARATION WORK FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-168
PM CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170
UNDERCARRIAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
PC400LC-7L 20-101 1
TESTING AND ADJUSTING SERVICE TOOLS
12
SERVICE TOOLS
Symbol
Qty
Testing/Adjusting item Part No. Part name Remarks
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 Pollution level: 0 - 70 % (With
Measuring exhaust gas color C Commercially standard color) (Pollution level x 1/10
2 Smoke meter 1 Bosch index)
available
Commercially 1 Air intake side: 0.35 mm, Exhaust side:
Adjusting valve clearance D Feeler gauge
available 0.57 mm
1 795-502-1590 Compression gauge 1 0 - 6.9 MPa {0 - 70 kg/cm2}
795-471-1410 Adapter 1
Measuring compression pressure E 2 For 125E-3 engine
6217-71-6112 Gasket
3 795-799-1170 Puller 1
Measuring blow-by pressure F 799-201-1504 Blow-by checker 1
(Pressure gauge): 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
(Pressure gauge): 58.8 MPa {600 kg/
Measuring engine oil pressure G 790-261-1203 Digital hydraulic tester 1
cm2}
(Pressure gauge): 0.98MPa {10 kg/
2 799-401-2320 Hydraulic tester 1
cm2}
1
Measuring fuel pressure H 790-261-1203 Digital hydraulic tester 1 Same as G
2 799-401-2320 Hydraulic tester 1
Commercially
Measuring clearance of swing circle bearing J Dial gauge 1 with magnet
available
1 Same as G
Measuring and adjusting oil pressures in work K 790-261-1203 Digital hydraulic tester 1
equipment, swing, and travel circuits 799-101-5220 Nipple 2
2 (Size): 10 x 1.25 mm
07002-11023 O-ring 2
1 Same as G1
790-261-1203 Digital hydraulic tester 1
Measuring basic pressure in control circuit L
799-101-5220 Nipple 2
2 Same as K2
07002-11023 O-ring 2
1 Same as G
Testing and adjusting oil pressure in pump PC M 790-261-1203 Digital hydraulic tester 1
control circuit 799-101-5220 Nipple 4
2
07002-11023 O-ring 4
20-102 1 PC400LC-7L
TESTING AND ADJUSTING SERVICE TOOLS
12
Symbol
Qty
Testing/Adjusting item Part No. Part name Remarks

1 Same as G1
Testing and adjusting pressure in pump LS N 799-101-5220 Nipple 4
control circuit 2 Same as M2
07002-11023 O-ring 4
3 799-401-2701 Differential pressure gauge 1
799-101-5002 Hydraulic tester 1 Same as G1
1
Measuring solenoid valve output pressure P
799-401-3100 Adapter 1 (Size): 02
2
799-401-3200 Adapter 1 (Size): 03
1 Same as G1
Measuring PPC valve output pressure Q 790-261-1203 Digital hydraulic tester 1
2 970-301-1740 Joint 1 (Size): PF1/4 + PT1/4
Commercially
Measuring oil leakage R Measuring cylinder 1
available
Testing wear of sprocket --- 799-627-1120 Wear gauge 1
Measuring water temperature and oil temperature --- 799-101-1502 Digital thermometer 1 Same as B
79A-264-0021 Push-pull scale 1 0 - 294 N {0 - 30 kg}
Measuring operating effort and pressing force ---
79A-264-0091 Push-pull scale 1 0 - 490 N {0 - 50 kg}
Commercially
Measuring stroke and hydraulic drift --- Scale 1
available
Commercially
Measuring work equipment speed --- Stopwatch 1
available
Commercially
Measuring voltage and resistance --- Tester 1
available
★ For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor panel, controllers,
sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connectors and electric circuit diagram of
each system.
PC400LC-7L 20-103 1
TESTING AND ADJUSTING MEASURING ENGINE SPEED
12
MEASURING ENGINE SPEED
1. Turn the starting switch ON and set the monitor panel to “Monitoring”.
★ For the operating method, see “Special functions of monitor panel”.
● Monitoring code: 01002 Engine Speed
01006 Engine Speed
★ Code 01002 is information of the engine controller and code 01006 is information of the pump controller. The engine
speed can be measured with either of those codes.
★ The engine speed is displayed in rpm.
2. Run the engine and raise the engine water temperature and hydraulic
oil temperature to the operating range.
3. Measure the engine speed under each measurement condition.
A. Measuring low idling speed:
i. Start the engine and set the fuel control dial in the low idling
position (MIN).
ii. Set the work equipment control, swing control, and travel
levers in neutral and measure the engine speed.
B. Measuring high idling speed:
i. Start the engine and set the fuel control dial in the high idling position (MAX).
ii. Set the working mode switch in the A-mode position.
iii. Turn the auto-decelerator switch OFF.
iv. Set the work equipment control, swing control, and travel levers in neutral.
C. Measuring 2-pump relief speed:
iii. Relieve the arm circuit by moving the arm in.
D. Measuring 2-pump relief + one-touch power maximizing speed (near rated speed):
iii. While relieving the arm circuit by moving the arm in, keep pressing the one-touch power maximizing switch.
★ The one-touch power maximizing function is reset automatically in about 8.5 seconds even if the switch is kept
held. Accordingly, measure the engine speed in that period.
E. Measuring auto-deceleration speed
ii. Turn the auto-deceleration switch ON.
iii. Set the work equipment control and swing control levers in neutral.
★ The engine speed lowers to a certain level about 5 seconds after all the levers are set in neutral. This level is the
auto-deceleration speed.
20-104 1 PC400LC-7L
TESTING AND ADJUSTING ENGINE
12
ENGINE
Remark
To tune, test and troubleshoot the following procedures you must refer to the ENGINE SHOP MANUAL for the
SAA6D125E-3 series engine, Section 12, for the tool requirements and proper procedures.
FUEL
BLEEDING AIR FROM FUEL CIRCUIT
FUEL PRESSURE
HANDLING FUEL SYSTEM DEVICES
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
RELEASING RESIDUAL FUEL SYSTEM PRESSURE
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING VALVE CLEARANCE
BLOW-BY PRESSURE
COMPRESSION PRESSURE
ENGINE OIL PRESSURE
ENGINE SPEED SENSOR
EXHAUST GAS COLOR
EXHAUST TEMPERATURE
INTAKE AIR PRESSURE (BOOST PRESSURE)
PC400LC-7L 20-105 1
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION
12
FAN BELT AND ALTERNATOR BELT TENSION
TESTING
1. Open the engine hood and remove belt protection covers (2 pieces).
2. Press the intermediate point between alternator pulley and fan pulley
with a finger and measure deflection “a” of the belt.
★ Deflection “a” when pressing force is approximately 58.8 N
{approximately 6 kg}: 13 mm
ADJUSTING
★ If the deflection is abnormal, adjust it according to the following
procedure.
1. Loosen bolts and nuts (1), (2), and (3).
2. Turn nut (4) to move alternator (5) and adjust the belt tension.
★ If nut (4) is:
● tightened clockwise, the belt tension is decreased.
● loosened counterclockwise, the belt tension is increased.
★ Check breakage of the pulleys, wear of the V-grooves and V-belts,
and contact of the belts and V-grooves.
★ If a belt is lengthened to the adjustment limit, cut, or cracked, replace it new one.
3. Tighten nuts and bolts (3), (2), and (1).

★ If a V-belt is replaced, adjust its tension again after 1 operating hour.
20-106 1 PC400LC-7L
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
12
AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING
1. Open the engine hood and remove belt protection covers (2 pieces).
2. Press the intermediate point between air conditioner compressor

pulley and crank pulley with a finger and measure deflection “a” of the
belt.
★ Deflection “a” when pressing force is approximately 58.8 N
{approximately 6 kg}: 14 mm - 16 mm
ADJUSTING
★ If the deflection is abnormal, adjust it according to the following
procedure.
1. Loosen bolts (1) and (2).
2. Move compressor (3) to adjust the belt tension.

★ Check breakage of the pulleys, wear of the V-grooves and V-belts,
and contact of the belts and V-grooves.
★ If a belt is lengthened to the adjustment limit, cut, or cracked,
replace it new one.
3. Tighten bolts (2) and (1).

★ If a V-belt is replaced, adjust its tension again after 1 operating hour.
PC400LC-7L 20-107 1
TESTING AND ADJUSTING SWING CIRCLE BEARING CLEARANCE
12
SWING CIRCLE BEARING CLEARANCE
★ Measuring instrument for clearance of swing circle bearing.
★ When measuring the clearance of the swing circle bearing on the Symbol Part Number Part Name
actual machine, observe the following procedure. Commercially
J Dial gauge
WARNING! While measuring, do not put your hands or available
foot under the undercarriage.
1. Fix dial gauge J to outer race (1) or inner race (2) of the swing circle
and apply the probe to the end face of inner race (2) or outer race (1)
on the opposite side.
★ Set dial gauge J on the front or at rear side of the machine.
2. Set the work equipment in the maximum reach position and set the
bucket tip at the height of the revolving frame bottom.
★ At this time, the front end of the upper structure lowers and the
rear end rises.
3. Set the dial gauge to 0 point.
4. Set the arm at almost right angle to the ground and lower the boom
until the track shoe at the front end of the machine rises.
★ At this time, the front end of the upper structure rises and the rear
end lowers.
5. Under this condition, read dial gauge J.

★ Dial gauge J indicates the clearance of the bearing.
6. Return the machine to the position of step 2 and check that dial gauge
J indicates 0 again.
★ If dial gauge J does not indicate 0, repeat steps 3 - 5.
20-108 1 PC400LC-7L
TESTING AND ADJUSTING TRACK SHOE TENSION
12
TRACK SHOE TENSION
TESTING
1. Run the engine at low idling and move the machine forward by the
length of track on ground and stop slowly.
2. Place square bar [1] on the track shoe between idler (1) and 1st carrier
roller (2).
★ As the square bar [1], use an L-shape steel, etc. which will be
deflected less.
3. Measure maximum distance “a” between square bar [1] and track
shoe.
● Standard maximum distance “a”: 10 - 30 mm
ADJUSTING
★ If the track shoe tension is abnormal, adjust it according to the
following procedure.
1. When tension is too high

Loosen valve (3) to discharge the grease.
WARNING! Since the valve may jump out because of
the high-pressure grease, do not loosen it
more than 1 turn.
2. When tension is low

Add grease through valve (3).
★ If the track shoe is not tensed well, drive the machine forward and in reverse slowly.
PC400LC-7L 20-109 1
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
12
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS
Testing and adjusting instruments for oil pressure in work equipment,
swing, and travel circuits.
Symbol Part Number Part Name
799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
K
799-101-5220 Nipple (10x1.25 mm)
2
07002-11023 O-ring
★ The oil pressure in work equipment, swing, and travel circuits can be
checked with the monitoring function of the monitor panel (For the
operating method, see “Special functions of monitor panel”).
● Monitoring code: 01100 F Pump Pressure
01101 R Pump Pressure
● The pump oil pressure is displayed in 1 kg/cm2 (1 psi).
MEASURING
1. Preparation work
WARNING! Lower the work equipment to the ground
and stop the engine. Operate the control
levers several times to release the residual
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure of the
hydraulic tank.
A. Open the pump room cover and remove oil pressure pick-up
plugs (1) and (2).
● (1): Front pump discharge pressure pickup plug.
● (2): Rear pump discharge pressure pickup plug.
B. Install nipple K2 and connect it to oil pressure gauge [1] of

hydraulic tester K1.
★ Use the oil pressure gauges of 600 kg/cm2, (8534 psi).
C. Run the engine and raise the hydraulic oil temperature to the
operating range.
20-110 1 PC400LC-7L
12
2. Combination of pump, actuator, and valve
★ When the oil from the pumps is divided, the front pump and rear pump act independently on each actuator. Note that
different actuators relieve different valves.
★ When the work equipment circuit or swing circuit is relieved singly, the oils of the pumps are merged. When the
travel circuit is relieved singly, the oils of the pumps are divided.
★ The actuators in the table are arranged in the order when the
control valve is seen from the front of the machine (and an
Pump Actuator Valve relieved
attachment is installed to the service valve).
(F unload valve) (F main relief valve)
3. Measuring unload pressure Service Safety valve for service
Boom Hi F main relief valve
A. Start the engine. Arm Hi
Front Bucket F main relief valve
B. Run the engine at high idling and set all the control levers in Left travel F main relief valve
neutral and measure the oil pressure.
RAISE: F main relief
★ The pressure measured when the unload valve is unloaded is valve
indicated. Boom LOWER: Safety-suction
valve
4. Measuring work equipment circuit relief pressure (Pump merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
A. Start the engine and move the cylinder to be measured to the Swing Swing motor safety valve
stroke end.
Rear Right travel R main relief valve
B. Run the engine at high idling and relieve the cylinder and measure Arm Lo R main relief valve
the oil pressure. (R unload valve) (R main relief valve)
★ The pressure measured when the main relief valve is relieved (Centralized safety valve) (Back pressure valve)
is indicated.
★ If the one-touch power maximizing switch is released, the
valve is relieved at low pressure. If the former is pressed, the lower is relieved at high pressure.
★ If the swing lock switch is turned ON, the 2-stage relief valve is kept turned ON and the valve is relieved at high
pressure. Accordingly, keep the swing lock switch turned OFF.
5. Measuring swing circuit relief pressure
A. Start the engine and turn the swing lock switch ON.
B. Run the engine at high idling and relieve the swing circuit and measure the oil pressure.
★ The pressure measured when the swing motor safety valve is relieved is indicated.
★ The swing motor relief pressure is lower than the main relief valve.
6. Measuring travel circuit relief pressure
A. Start the engine and lock the travel mechanism.

WARNING! Set pin [2] between the sprocket and track
frame to lock the travel mechanism
securely.
B. Run the engine at high idling and relieve the travel circuit and
measure the oil pressure.
★ The pressure measured when the main relief valve is relieved
is indicated. The travel circuit is always relieved at high
pressure.
PC400LC-7L 20-111 1
12
ADJUSTING
★ The unload valve cannot be adjusted.
1. Adjusting main relief pressure

★ If the relief pressure of the work equipment circuit and/or travel
circuit is abnormal, adjust main relief valves (3) and (4) according
to the following procedure.
● (3): Front main relief valve
● (4): Rear main relief valve
★ When adjusting the main relief valve on the front pump side,
remove the control valve top cover.
★ When adjusting the main relief valve on the rear pump side,
remove the control valve undercover (if the covers are installed).
★ Adjust only the low relief pressure of the main relief valve. (If the
low relief pressure is adjusted, the high relief pressure is adjusted
automatically.)
★ The low relief pressure is the pressure applied when the 2-stage
relief solenoid valve is turned OFF and the pilot pressure is not
applied to the selector port.
A. Disconnect pilot hose (5).
B. Fixing holder (6), loosen locknut (7).
C. Turn holder (6) to adjust the pressure.

★ If the holder is:
● turned to the right, the pressure rises.
● turned to the left, the pressure lowers.
★ Quantity of adjustment per turn of holder: Approximately 209 kg/cm2, (2972 psi)
D. Fixing holder (6), tighten locknut (7).

Locknut: 49.0 - 58.8 Nm (36.1 - 43.3 lbf ft)
E. Connect pilot hose (5).
F. After finishing adjustment, check again that the pressure is normal according to the procedure for measurement
described above.
2. Adjustment of boom LOWER relief pressure (High-pressure setting

side)
★ If the high relief pressure of the boom LOWER circuit is abnor-
mal, adjust the high pressure setting side of boom LOWER safety
suction valve (8) according to the following procedure.
★ The high relief pressure is the pressure applied when the machine
push-up switch is turned ON and the pilot pressure is not applied
to the selector port.
20-112 1 PC400LC-7L
12
★ If the holder is
★ Quantity of adjustment per turn of holder: Approximately 258 kg/cm2 (3669 psi).

Locknut: 93 - 123 Nm (68.59 - 90.72 lbf ft)
F. After finishing adjustment, check again that the pressure is normal

according to the procedure for measurement described above.
★ If the high pressure setting side is adjusted, the low pressure
setting side changes. Accordingly, adjust the low pressure
setting side.
3. Adjustment of boom LOWER relief pressure (Low-pressure setting

side)
★ If the low relief pressure of the boom LOWER circuit is abnormal or the high pressure setting side was adjusted,
adjust the low pressure setting side of boom LOWER safety-suction valve according to the following procedure.
★ The low relief pressure is the pressure applied when the machine push-up switch is turned OFF and the pilot pressure
is applied to the selector port.

★ If the holder is:
★ Quantity of adjustment per turn of holder: Approximately 258 kg/cm2 (3669 psi)

Locknut: 78 - 93 Nm (57.5 - 68.5 lbf ft)
F. After finishing adjustment, check again that the pressure is normal according to the procedure for measurement
described above.
4. Adjusting swing relief pressure

★ If the relief pressure of the swing circuit is abnormal, adjust swing
motor safety valve (14) according to the following procedure.
A. Fixing adjustment screw (15), loosen locknut (16).
B. Turn adjustment screw (15) to adjust the pressure.

★ If the adjustment screw is:
★ Quantity of adjustment per turn of adjustment screw:
47.9 kg/cm2 (681 psi).
PC400LC-7L 20-113 1
12
C. Fixing adjustment screw (15), tighten locknut (16).
Locknut: 147 - 196 Nm (108.4 - 144.5 lbf ft)
D. After finishing adjustment, check again that the pressure is normal

20-114 1 PC400LC-7L
TESTING AND ADJUSTING CONTROL CIRCUIT - BASIC PRESSURE
12
CONTROL CIRCUIT - BASIC PRESSURE
★ Measuring instruments for basic pressure in control circuit
Symbol Part No. Part Name
1
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers
several times to release the residual pressure in the piping, and then loosen the oil filler
cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.
1. Remove the control valve top cover and remove control circuit basic
pressure pick-up plug (1).
★ The figure shows the control valve seen from inside of the pump
room.
2. Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic

tester L1.
★ Use the oil pressure gauges of 60 kg/cm2 (853.4 psi)
3. Run the engine and raise the hydraulic oil temperature to the operating
range.
4. Run the engine at high idling and set all the control levers in neutral
and measure the oil pressure.
5. After finishing measurement, remove the measuring instruments and

return the removed parts.
★ The relief valve for the control circuit basic pressure is not
adjustable.
PC400LC-7L 20-115 1
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT
12
PUMP PC CONTROL CIRCUIT
★ Testing and adjusting instruments for oil pressure in pump PC control circuit
1
M
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
MEASURING
★ Before measuring the oil pressure in the pump PC control circuit, check that the oil pressure in the work equipment,
swing, and travel circuits and the basic pressure in the control circuit are normal.
1. Measuring PC valve output pressure (servo piston inlet pressure)

★ Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and
compare them.
A. Open the pump room cover and remove oil pressure pick-up plugs
(1), (2), (3), and (4).
● (3): Front PC valve output pressure pickup plug.
● (4): Rear PC valve output pressure pickup plug.
B. Install nipple M2 and connect it to oil pressure gauge [1] of

hydraulic tester M1.
★ Use the oil pressure gauges of 600 kg/cm2 (8534 psi).
● The figure shows the pump discharge pressure side.
20-116 1 PC400LC-7L
12 ● The figure shows the PC valve output pressure side.
operating range.
D. Run the engine at high idling and measure the pump discharge pressure and PC valve output pressure (servo piston
inlet pressure) at the same time under the following condition.
● Working mode: A
● Swing lock switch: ON (2-stage relief solenoid valve is turned ON and oil is relieved at high pressure)
● Work equipment, swing, and travel circuits: Relieve by moving arm IN.
★ Judging method: If the pump discharge pressure and PC valve output pressure (servo piston output pressure) are
as follows, they are normal.
Measured pressure Pressure ratio
Pump discharge pressure 1
PC valve output pressure Approximately 0.6 (3/5)
★ If the PC valve or servo piston is abnormal, the PC valve output pressure (servo piston output pressure) becomes
“the same as the pump discharge pressure” or “almost 0”.
E. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7L 20-117 1
12
2. Measuring PC-EPC valve output pressure
A. Open the pump room cover and remove PC-EPC valve output
B. Install nipple M2 and connect it to oil pressure gauge [1] of

hydraulic tester M1.
★ Use the oil pressure gauges of 60 kg/cm2 (853.4 psi).
operating range.
D. Set all the control levers in neutral and measure the oil pressure while running the engine at low idling and high
idling.
★ If the PC-EPC valve output pressure changes as shown below, it is normal.
Engine Control lever Oil pressure
Low idling 30 kg/cm2
(426.7 psi)
Neutral
High idling 0 kg/cm2
(0 psi)
20-118 1 PC400LC-7L
12
ADJUSTING
★ If any of the following phenomena occurs and the PC valve seems to be defective, adjust PC valves (6) and (7) according
to the procedure shown below.
● When the working load is increased, the engine speed lowers largely.
● The engine speed is normal but the work equipment speed is low.
● (6): Front pump PC valve.
● (7): Rear pump PC valve.
★ The width across flats of the locknut for the PC valve is 13 mm
and that of the adjustment screw (inside width) is 4 mm. Do not
turn any other locknut or adjustment screw since it has effects on
the hydraulic pumps.
1. Loosen locknut (8).

★ Before loosening the locknut, make match marks at the adjustment screw end so that you can see the position of the
locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse).
2. Turn adjustment screw (9) to the right or left to adjust.

★ Turn the adjustment screw in the following directions.
● If the work equipment speed is low, turn the adjustment screw to the right (to increase the pump absorption
torque).
● If the engine speed lowers, turn the adjustment screw to the left (to decrease the pump absorption torque).
★ The adjustable range of the adjustment screw is as follows.
● Counterclockwise: Max. 1 turn.
● Clockwise: Max. 1 turn.
3. Tighten locknut (8).

Locknut: 27.5 - 34.3 Nm (20.2 - 25.2 lbf ft)
4. After finishing adjustment, check that the PC valve output pressure

(servo piston inlet pressure) is normal according to the procedure for
measurement described above.
PC400LC-7L 20-119 1
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT
12
PUMP LS CONTROL CIRCUIT
★ Testing and adjusting instruments for oil pressure in pump LS control circuit
1
N 799-101-5220 Nipple (10 Þ 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
MEASURING
★ Before measuring the oil pressure in the pump LS control circuit, check that the oil pressure in the work equipment,
swing, and travel circuits and the basic pressure in the control circuit are normal.
1. Measuring LS valve output pressure (servo piston inlet pressure)

★ Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and
compare them.
(1), (2), (3), and (4).
● (3): Front LS valve output pressure pickup plug.
● (4): Rear LS valve output pressure pickup plug.
B. Install nipple N2 and connect it to oil pressure gauge [1] of

hydraulic tester N1.
20-120 1 PC400LC-7L
12 ● The figure shows the LS valve output pressure side.
operating range and push up the track shoe on the side to be
measured with the work equipment.
● When measuring front circuit: Left track shoe.
● When measuring rear circuit: Right track shoe.
WARNING! Since the track shoe pushed up will be

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

★ Measure the pump discharge pressure and LS pressure (actuator
load pressure) at the same time and calculate the difference
between them.
(1), (2), (5), and (6).
PC400LC-7L 20-121 1
12 ● (5): Front LS valve output pressure pickup plug.
● (6): Rear LS valve output pressure pickup plug.
B. Install nipple N2 and connect it to differential pressure gauge N3

or the oil pressure gauge of hydraulic tester N1.
★ When using differential pressure gauge: Connect the pump
discharge pressure to the high pressure side (back side) and
connect the LS pressure to the low pressure side (lower side).
Since the differential pressure gauge needs a 12-V power
source, connect it to a battery.
★ When using oil pressure gauge: Use the oil pressure gauge of
600 kg/cm2 (8534 psi). Since the differential pressure is about
30 kg/cm2 (427 psi) at maximum, measure it by installing the
same gauge to the pick-up plugs alternately.
● The figure shows the LS valve output pressure side.
operating range and push up the track shoe on the side to be
measured with the work equipment.
● When measuring front circuit: Left track shoe.
● When measuring rear circuit: Right track shoe
WARNING! Since the track shoe pushed up will be

driven idle for measurement, secure
sufficient work area.
D. Run the engine at high idling and measure the pump discharge
pressure and LS pressure (actuator load pressure) at the same time
under the following condition.
● Working mode: A
● Travel speed: Hi
● Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only
the travel lever operated halfway (with the track shoe on one side driven idle).
★ Check the safety around the machine, drive the track shoe pushed up idle.
★ Calculation of LS differential pressure (When oil pressure gauge is used): LS differential pressure = Pump
discharge pressure – LS pressure.
★ If the LS differential pressure is as follows, it is normal.
Operation of lever LS differential pressure
Set all levers in neutral Unload pressure (See standard values table)
Operate travel lever halfway (Run track shoe idle) Specified LS differential pressure (See standard values table)
20-122 1 PC400LC-7L
12
3. Measuring LS-EPC valve output pressure.
A. Open the pump room cover and remove LSEPC valve output
B. Install nipple N2 and connect it to oil pressure gauge [1] of

hydraulic tester N1.
operating range.
D. Operate the travel speed switch and travel lever and measure the
oil pressure while running the engine at high idling.
★ If the LS-EPC valve output pressure changes as shown below,
it is normal.
Travel speed Travel lever Oil pressure
Lo Neutral 30 kg/cm2 (427 psi)
Hi Fine operation (Remark) 0 kg/cm2 (0 psi)
Remark
Operate the travel lever to a degree that the PPC oil pressure
switch is turned ON (Stop before the machine starts
traveling).
PC400LC-7L 20-123 1
12
ADJUSTING
★ If the LS differential pressure is abnormal, adjust LS valves (8) and (9)
according to the following procedure.
● (8): Front pump LS valve.
● (9): Rear pump LS valve.
1. Fixing adjustment screw (10), loosen locknut (11).
2. Turn adjustment screw (10) to adjust the differential pressure.

★ If the adjustment screw is:
● turned to the right, the differential pressure rises.
● turned to the left, the differential pressure lowers.
★ Quantity of adjustment (LS differential pressure) per turn of
adjustment screw: Approximately 13.3 kg/cm2 (189 psi).
3. After finishing adjustment, check that the LS pressure is normal

20-124 1 PC400LC-7L
TESTING AND ADJUSTING SOLENOID VALVE - OUTPUT PRESSURE
12
SOLENOID VALVE - OUTPUT PRESSURE
★ Measuring instruments for solenoid valve output pressure
1
P
799-401-3100 Adapter (Size 02)
2
799-401-3200 Adapter (Size 03)
★ Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal.
1. Remove the control valve top cover and disconnect outlet hose (1) – (7) of the solenoid valve to be removed.
★ Since the outlet hoses of the PPC lock solenoid valves have quick couplers on the solenoid valve side, measure the
pressure on the PPC valve side (on the back side of the operator’s cab)
.
No. Solenoid valve to be measured
1 2-stage relief solenoid valve
2 Machine push-up solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed selector solenoid valve
5 Merge-divider solenoid valve
6 Travel junction solenoid valve
7 PPC lock solenoid valve
2. Install adapter P2 and connect the disconnected hose again.
3. Install nipple [1] of hydraulic tester P1 and connect it to hydraulic

gauge [2].
★ Use the oil pressure gauges of 60 kg/cm2 (853.4 psi).
★ The figure shows the measuring instruments connected to the
outlet hose of the 2-stage relief solenoid valve.
PC400LC-7L 20-125 1
12
4. Run the engine and raise the engine oil temperature to the operating
range.
5. Run the engine at high idling, operate the control levers and switches
to turn the solenoid valve ON or OFF, and measure the oil pressure.
★ For the conditions for turning the solenoid valve ON and OFF, see
the operations table of each solenoid valve.
★ The operating condition of the solenoid valve can be checked with
the monitoring function of the monitor panel (For the operating
method, see “Monitor Panel - Special Functions”).
★ If the output pressure is as follows, the solenoid valve is normal.

Solenoid valve Output pressure
OFF (Deenergized) 0 kg/cm (0 psi)
2
ON (Energized) Almost same as control basic pressure (See standard values table)
6. After finishing measurement, remove the measuring instruments and return the removed parts.
Operation table of 2nd-stage relief solenoid valve
Operating condition Operation

When overheating No. 1 setting is turned ON
OFF
When all of work equipment, swing, and travel signals are turned OFF
When swing lock switch is turned ON
When travel signal is turned ON
When in L-mode ON
When boom LOWER signal is turned ON
When signal other than swing single operation signal is turned
When in A/E-mode When left knob switch is turned ON ON
When swing single operation signal is turned ON
OFF
When not under above condition
Operation table of machine push-up solenoid valve

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

Work equipment, When all are turned OFF OFF
swing, travel signal When one of them is turned ON ON
20-126 1 PC400LC-7L
12
Operation table of travel speed shifting solenoid valve

When overheating No. 2 setting is turned ON
When fuel control dial is below 1,200 rpm
When travel speed switch is set to Lo
OFF
When travel signal is turned OFF
When F or R pump pressure is above 330 kg/
When travel speed switch is set to Mi or Hi cm2 (4693 psi)
When travel signal is turned ON
When F or R pump pressure is below 190
kg/cm2 (2702 psi) ON
Operation table of merge-divider solenoid valve

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

When travel steering signal is turned ON
When travel system is When F or R pump pressure is above 350 ON
When travel steering signal is turned OFF operated singly kg/cm2 (4978 psi)
When not under above condition OFF
Operation table of PPC lock solenoid valve
Operating condition
Lock OFF
Safety lock lever
Free ON
PC400LC-7L 20-127 1
TESTING AND ADJUSTING PPC VALVE - OUTPUT PRESSURE
12
PPC VALVE - OUTPUT PRESSURE
★ Measuring instruments for PPC valve output pressure
1
Q 790-261-1203 Digital hydraulic tester
2 790-301-1740 Joint (PF 1/4 + PT 1/8)
1. Remove the control valve top cover and operator’s cab undercover.
2. Disconnect PPC oil pressure switch or PPC pressure sensor (1) - (10) of the solenoid valve to be removed.
★ If the starting switch is turned ON while the arm IN or bucket
CURL PPC pressure sensor is disconnected, an electrical
equipment system error is detected. Accordingly, if the pressure
sensor is removed, connect it to the connector again and clamp it
to the nearest bracket, etc.
No. Circuit to be measured No. Circuit to be measured
1 Boom RAISE (S06) 7 Swing LEFT (S07)
2 Boom LOWER (S02) 8 Swing RIGHT (S03)
3 Arm IN (S04) 9 Travel (S30)
4 Arm OUT (S08) 10 Steering (S31)
5 Bucket CURL (S01)
6 Bucket DUMP (S05)
3. Install joint Q2 and nipple [1] of hydraulic tester Q1 and connect them
to oil pressure gauge [2].
★ Use joint Q2 only when measuring the pressure at the pressure
sensor mounting part.
★ Use the oil pressure gauges of 60 kg/cm2 (853 psi)
★ The figure shows the measuring instruments installed to the
mounting part of the arm IN PPC pressure sensor.
20-128 1 PC400LC-7L
TESTING AND ADJUSTING PPC VALVE - OUTPUT PRESSURE
12
4. Run the engine and raise the engine oil temperature to the operating
range.
5. Run the engine at high idling and measure the oil pressure while the control lever of the measured circuit is in neutral and
while it is operated to the stroke end.
★ If the PPC valve output pressure is as follows, the solenoid valve is normal.
Operation of lever Output pressure
In neutral 0 kg/cm2 (0 psi)
Almost same as control basic
Operated to stroke end pressure (See standard values table)
6. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7L 20-129 1
TESTING AND ADJUSTING WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT
12
WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT
SWING PPC VALVE - PLAY ADJUSTMENT
★ If the work equipment and swing levers have large play, adjust them according to the following procedure.
1. Remove the work equipment and swing PPC valve assembly.
2. Remove bellows (1).
3. Loosen locknut (2) and tighten disc (3) until it touches the heads of 4
pistons (4).
★ Do not move the piston at this time.
4. Fix disc (3) and tighten locknut (2) to the specified torque.
Locknut: 98 - 127 Nm (73 - 93 lbf ft)
5. Install bellows (1).
6. Install the work equipment and swing PPC valve assembly.
20-130 1 PC400LC-7L
TESTING AND ADJUSTING WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE
12
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE
★ If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylinder packing side or control
valve side according to the following procedure.
1. Testing boom cylinder and bucket cylinder.
A. Set the machine in the position of measuring hydraulic drift and

stop the engine.
★ Fill the bucket with a rated load or with dirt and sand.
B. When testing the boom cylinder, set the boom control lever in the
RAISE position. When testing the bucket cylinder, set the bucket
control lever in the CURL position.
● If the lowering speed is increased at this time, the cylinder
packing is defective.
● If the lowering speed does not change at this time, the control
valve is defective.
★ Operate the control lever while the starting switch is in the
ON position.
★ If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the
accumulator.
2. Testing arm cylinder.
A. Stop the arm cylinder about 100 mm before the IN stroke end and
stop the engine.
B. Operate the arm control lever in the IN position.

● If the lowering speed is increased at this time, the cylinder
packing is defective.
● If the lowering speed does not change at this time, the control
valve is defective.
★ Operate the control lever while the starting switch is in the
ON position.
★ If the pressure in the accumulator is lost, run the engine for
about 10 seconds to heighten the pressure in the accumulator.
Remark
Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the
hydraulic drift:
A. If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks
from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the
volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side.
B. As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then
the lowering speed is lowered.
C. If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is
closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is
unbalanced and the lowering speed is increased.
PC400LC-7L 20-131 1
TESTING AND ADJUSTING WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE
12
3. Testing PPC valve.
While the pressure in the accumulator is high, set the safety lock lever in the LOCK/FREE position and measure the
lowering distance.
★ Operate the control lever while the starting switch is in the ON position.
★ If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the
accumulator.
★ If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is
defective (it has an internal defect).
20-132 1 PC400LC-7L
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT
12
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT
1. Releasing residual pressure in hydraulic tank.
WARNING! Since the hydraulic tank is enclosed and pressurized, release the residual pressure in it
when removing a hose or a plug connected to it.
A. Lower the work equipment to the ground in a stable position and stop the engine.
B. Loosen oil filler cap (1) of the hydraulic tank gradually to release
the air in the tank.
2. Releasing residual pressure in hydraulic cylinder circuit.

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

★ The residual pressure in the swing motor circuit can be released by performing the operation for RELEASING
RESIDUAL PRESSURE IN HYDRAULIC CYLINDER CIRCUIT (Operate the lever in the swing direction only,
however).
4. Releasing residual pressure in travel motor circuit.

★ Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by
performing RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK.
PC400LC-7L 20-133 1
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
12
MEASURING OIL LEAKAGE
★ Measuring device for oil leakage
R Commercially available Measuring cylinder
1. Measuring oil leakage from boom cylinder.
A. Run the engine and raise the engine oil temperature to the operating range.
B. Move the boom cylinder to the RAISE stroke end and stop the engine.
WARNING! Release the residual pressure in the piping on the boom cylinder head side. For details,
see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in
the boom RAISE direction only, however).
C. Disconnect hose (1) on the cylinder head side and block the hose
side with a plate.
WARNING! Take care not to disconnect the hose on
the cylinder bottom side.
★ Use the following part to block the hose side. 07379-01044
(Flange #10)
D. Run the engine at high idling and relieve the boom circuit by
raising the boom.
WARNING! Take care not to “lower the boom”.
E. Measure the oil leakage for 1 minute after 30 seconds since

relieving is started.
F. After finishing measurement, return the removed parts.
2. Measuring oil leakage from arm cylinder.
B. Move the arm cylinder to the IN stroke end and stop the engine.
WARNING! Release the residual pressure in the piping on the arm cylinder head side. For details, see
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the
arm IN direction only, however).
side with a plate.
★ Use the following part to block the hose side. 07379-01044
(Flange #10)
D. Run the engine at high idling and relieve the arm circuit by
moving the arm IN.
WARNING! Take care not to “move the arm OUT”.

20-134 1 PC400LC-7L
12
3. Measuring oil leakage from bucket cylinder.
B. Move the bucket cylinder to the CURL stroke end and stop the engine.
WARNING! Release the residual pressure in the piping on the bucket cylinder head side. For details,
see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in
the arm CURL direction only, however).
side with a plate.
★ Use the following part to block the hose side.
07379-01044 (Flange #10)
D. Run the engine at high idling and relieve the bucket circuit by
curling the bucket.
WARNING! Take care not to “dump the bucket”.

4. Measuring oil leakage from swing motor.
B. Disconnect drain hose (4) and block the hose side with a plug.
07376-70522 (Plug #05)
C. Turn the swing lock switch ON.
D. Run the engine at high idling and relieve the swing circuit by
swinging.
★ Measure the oil leakage for 1 minute after 30 seconds since
★ After measuring 1 time, swing 180°, and then measure again.
E. After finishing measurement, return the removed parts.
PC400LC-7L 20-135 1
12
5. Measuring oil leakage from travel motor.
A. Remove the travel motor cover.
B. Run the engine and raise the engine oil temperature to the
operating range, and then lock the travel system and stop the
engine.
WARNING! Put pin [1] between the sprocket and track
frame to lock the travel system securely.
C. Disconnect drain hose (5) of the travel motor and block the hose
side with a plug.
07376-70522 (Plug #05)
D. Run the engine at high idling and relieve the travel circuit.
WARNING! Wrong operation of the lever can cause an
accident. Accordingly, make signs and
checks securely.
★ Measure the oil leakage for 1 minute after 30 seconds since
★ Measure several times, moving the motor a little (changing
the position of the valve plate and cylinder and that of the
cylinder and piston) each time.
E. After finishing measurement, return the removed parts.
20-136 1 PC400LC-7L
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
12
BLEEDING AIR FROM EACH PART
Air bleeding procedure
1 2 3 4 5 6
Air bleeding item
Bleeding air
Bleeding air Bleeding air Bleeding air
from Starting Check oil level and
from cylinder from swing from travel
hydraulic engine starting work
Work motor motor
pump
Replacing hydraulic oil • •
• • • •
(See Remark) (See Remark)
Replacing return filter element • → → → •
Replacing and repairing hydraulic pump • • • → → •
Removing suction piping
Replacing and repairing control valve • • → → •
Removing control valve piping
Replacing and repairing cylinder • • → → •
Removing cylinder piping
Replacing and repairing swing motor • → • → •
Removing swing motor piping
Replacing and repairing travel motor
Removing travel motor piping • → → • •
Replacing and repairing swivel joint • → → → •
Removing swivel joint piping
Remark
Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump.
A. Loosen bleeder (1) and check that oil flows out.
B. If the oil does not flow out, disconnect drain hose (2) and fill the
pump case with oil through the drain port.
★ Fix the drain hose adapter to a place higher than the oil level
in the hydraulic tank.
★ Fill the pump case with oil until oil containing no bubbles
flows out of the bleeder.
C. After oil containing no bubbles flows out of bleeder (1), tighten

air bleeder (1).
Air bleeder: 7.8 - 9.8 Nm (5.75 - 7.22 lbf ft)
★ If the drain hose has been disconnected, connect it after tightening the air bleeder.
2. Starting engine.
When running the engine after performing step 1, keep its speed at low idling for 10 minutes.
★ If the engine water temperature is low and the automatic warm-up operation is started, stop the engine temporarily
and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and
hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).
PC400LC-7L 20-137 1
12
3. Bleeding air from cylinder.
★ If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder
does not move to the lowering stroke end, if it is installed to the work equipment.
A. Run the engine at low idling for about 5 minutes.
B. Running the engine at low idling, raise and lower the boom 4 - 5 times.
★ Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil.
C. Running the engine at high idling, perform step B.
D. Running the engine at low idling, move the piston rod to the stroke end and relieve the oil.
E. Bleed air from the arm cylinder and bucket cylinder according to steps B - D.
4. Bleeding air from swing motor.
A. Run the engine at low idling.
B. Loosen hose (3) of port S slowly and check that oil flows out.
WARNING! At this time, do not perform the swinging
operation.
C. If the oil does not flow out, stop the engine and disconnect the
hose of port S and fill the pump case with oil.
★ After filling the pump case with oil, connect the hose of port
S, and then repeat steps A and B.
D. After oil containing no bubbles flows out, tighten the hose of port
S.
E. Swing slowly 2 turns or more in each direction.
5. Bleeding air from travel motor.
A. Remove the travel motor cover.
B. Run the engine at low idling.
C. Loosen bleeder (4) and check that oil flows out.
D. After oil containing no bubbles flows out, tighten bleeder (4).

Bleeder: 9.8 - 12.74 Nm (7.22 - 9.39 lbf ft)
E. Using the work equipment, raise the track shoe on either side.
F. Drive the raised track shoe idle slowly for about 2 minutes.
★ Drive the track shoe on the opposite side idle similarly.
20-138 1 PC400LC-7L
12
6. Check oil level and starting work.
A. Run the engine, retract the arm cylinder and bucket cylinder to the
stroke ends, lower the work equipment to the ground, and stop the
engine.
B. Check the oil level by sight gauge (5) of the hydraulic tank.
★ If the oil level is between lines H and L, it is normal.
★ If the oil level is below line L, add new oil.
PC400LC-7L 20-139 1
TESTING AND ADJUSTING DIODE TESTING PROCEDURE
12
DIODE TESTING PROCEDURE
★ Test an assembled-type diode or a diode unit according to the
★ The conductive direction of an assembled-type diode is marked as
shown in the figure.
★ The conductive direction of each diode is marked on its surface.
1. When using a digital tester.
A. Set the tester in the diode range and check the indicated value.
★ If an ordinary tester is used, the voltage of the battery in itself
is indicated.
B. Apply the red (+) test pin to the anode (P) side of the diode and
the black (–) test pin to the cathode (N) side and read the indicated
value.
C. Judge the condition of the diode from the indicated value.

● The indicated value does not change: There is not continuity
(Defective).
● The indicated value changes: There is continuity (Normal)
(Remark).
Remark
In the case of a silicon diode, the tester indicates a value of 460 –
600.
2. When using an analog tester.
A. Set the tester in the resistance range.
B. Apply the test pins as shown below and check movement of the
pointer.
i. Apply the red (+) test pin to the anode (P) side of the diode
and the black (–) test pin to the cathode (N) side.
ii. Apply the red (+) test pin to the cathode (N) side of the diode
and the black (–) test pin to the anode (P) side.
C. Judge the condition of the diode from movement of the pointer.

● The pointer does not move in i above but moves in ii: Normal
(Moving angle (Resistance) depends on the type and
measurement range of the tester, however)
● The pointer moves in both i and ii: Defective (Internal short circuit)
● The pointer does not move in either of i and ii: Defective (Internal disconnection)
20-140 1 PC400LC-7L
TESTING AND ADJUSTING MONITOR PANEL - SPECIAL FUNCTIONS
12
MONITOR PANEL - SPECIAL FUNCTIONS
[1] Numeral input switch 1 [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
PC400LC-7L 20-141 1
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ORDINARY FUNCTIONS AND SPECIAL FUNCTIONS OF MONITOR PANEL
The monitor panel has the ordinary functions and special functions and displays various pieces of information on the
multi-display unit.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by
operating switches.
1. Ordinary functions: Operator menu

The items in this menu are displayed normally. The operator can display and set them by operating switches.
2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating special switches.
Operator’s Menu Service Menu

1 Screen to display KOMATSU logo 15 Function of monitoring [01]
2 Function of check before starting Function of Electrical system
3 Function of displaying maintenance items 16 abnormality
record [02] Mechanical system
4 Function of displaying caution items
17 Function of maintenance record [03]
Function of checking working mode and travel
5 18 Function of maintenance mode change [04]
speed
6 Function of displaying ordinary screen 19 Function of phone No. entry [05]
Function of adjusting brightness and contrast Mode in which key is ON
7 of display Function of initial Language
Function of adjusting flow rate for breaker and 20 setting and default Unit
8 attachments [06]
With/Without service
9 Function of checking maintenance information circuit
10 Function of displaying service meter Pump absorption torque
11 Function of checking display LCD Function of Adjustment of flow for
21 adjustment [07]
12 Function of displaying cautions attachment during
compound operation
13 Function of displaying user code
Function of cylinder cut out mode operation
Function of displaying error code and failure 22 [09]
14 code
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OPERATION AND DISPLAY OF OPERATOR’S MENU
(OUTLINE)
★ Only outline of the operating method is described in this section. For
details of contents and operation of each menu, see OPERATION
MANUAL or the volume of STRUCTURE AND FUNCTION.
1. Screen to display KOMATSU logo.

When a password is input (if it is set) or when the starting switch is
turned ON, the KOMATSU logo is displayed for 2 seconds.
2. Function of check before starting.

After the KOMATSU logo is displayed, the screen for check before
starting is displayed for 2 seconds.
3. Function of displaying maintenance items.

After the screen for check before starting is displayed, if any oil or
filter is near or has passed the set maintenance time, the maintenance
mark is displayed for 30 seconds.
★ This screen is displayed only when the maintenance function is
set.
4. Function of displaying caution items.

After the screen for check before starting is displayed, if any check
item is abnormal, the corresponding symbol mark is displayed.
PC400LC-7L 20-143 1
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5. Function of checking working mode and travel speed.
After the screen for check before starting is displayed, the symbol
marks of the working mode and travel speed are displayed in large size
for 2 seconds to urge the operator to check the setting.
6. Function of displaying ordinary screen.

After the screen for checking the working mode and travel speed is
displayed, the ordinary screen is displayed.
★ When the ordinary screen is displayed, if the working mode or
travel speed is changed or if the auto deceleration or windshield
wiper is set effective, the corresponding symbol mark is displayed
in large size for 2 seconds.
★ The preheating monitor is displayed only when the pre-heater is
turned ON.
7. Function of adjusting brightness and contrast of display.

The operator can adjust the brightness and contrast of the display with
the screen adjustment switches.
8. Function of adjusting flow rate for breaker and attachments (for

machine with breaker or attachment).
The operator can adjust the pump flow rate for the breaker or an
attachment wit h the selector switch.
★ The symbol marks and description of the breaker and attachment
shown on the screen are partly different.
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9. Function of checking maintenance information.
The operator can check the detailed information about the
maintenance items (set time and elapsed time) and reset them after
checking with the maintenance switches.
★ The maintenance function is set and reset and the maintenance
time is set with the service menu.
10. Function of displaying service meter.

When the starting switch is turned OFF, the operator can display only
the service meter by operating the following switches.
● Operation of switches: [/] + [∆] (Operate these switches
simultaneously)
11. Function of checking display LCD.

On the password inputting screen or ordinary screen, the operator can
check the display LCD.
● Operation of switches: [/] + [A] (Operate these switches
simultaneously)
★ The whole LCD unit is turned ON and all the surface becomes
white. If there is not any black part, the LCD unit is normal.
★ If any switch is operated while the LCD unit is being checked, the
screen before the check is displayed again.
12. Function of displaying cautions.

If there is any abnormal one in the calculation items, the
corresponding symbol mark is displayed in large size for 2 seconds,
and then it is displayed in small size until the abnormal item is
repaired.
PC400LC-7L 20-145 1
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13. Function of displaying user code.
If the machine has any failure, the corresponding user code is
displayed to urge the operator to take a proper remedy, depending on
the degree of the failure.
★ If any switch is operated while the user code is displayed, the
service code and failure code screen appears (See 14).
★ User codes and instructions given to operator

User code Failure mode Instructions given to operator
If the emergency pump drive switch is set in the upper (emergency) position, the
E02 Error in pump control system machine can operate normally. Have the machine inspected immediately, however.
Set the swing holding brake release switch in the upper (release) position to release
the brake. Apply the swing brake manually with the swing lock switch, if necessary.
E03 Error in swing brake system The brake may not be released, depending on the cause of the failure. In any case,
have the machine inspected immediately.
Error in engine controller power supply
E10 or abnormality in engine controller Have the machine inspected immediately.
drive system circuit (Engine stops)
Error in engine controller system
E11 Set the machine in a safe position and have the machine inspected immediately.
(Engine protection output is down)
E14 Error in throttle system Set the machine in a safe position and have the machine inspected immediately.
Error in engine sensor (water Although the machine can operate normally, have the machine inspected
E15 temperature, fuel temperature, or oil immediately.
pressure)
E0E Error in network Set the machine in a safe position and have the machine inspected immediately.
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14. Function of displaying error code and failure code.
While a user code is displayed, if the following switches are operated,
the phone mark (if registered), phone No. (if registered), error code,
and failure code are displayed in order.
● Operation of switch: [✓]
★ The following are displayed in order repeatedly as the switch is
operated.
(1) Phone mark
⇓
(2) Phone No.
⇓
(3) Error code and failure code
★ The phone mark and phone No. are displayed only when the
phone No. is registered in the monitor panel. The phone No. is
registered, changed, or deleted with the service menu.
★ For details of the displayed error code and failure code, see the
error codes and failure codes table.
PC400LC-7L 20-147 1
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Table for Error and Failure Code Nos.
Error code Failure code
division
History
User
code
Code Contents 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 DY2CKB Windshield Washer Motor Short Circuit
--- E115 Wiper Working Abnormality DY20KA Wiper Motor Disconnection
--- E116 Wiper Parking Abnormality DY20MA Wiper Motor Malfunction
Defective communication
--- E117 Eng. Controller S-NET Comm Err. DAC0KR Engine Controller (Abnormality in related
component)
Defective communication
--- E118 Pump Controller S-NET Comm Err. DAB0KR Pump Controller (Abnormality in related
component)
Monitor CAN
E0E E128 Monitor Comm. Abnormality DAFRMC Defective Operation
Communication
Travel Neutral Solenoid
--- E201 Travel Junction Sol. S/C DW91KB Short Circuit
Valve
Swing Holding Brake
E03 E203 Swing Brake Sol. S/C DW45KB Short Circuit
Solenoid Valve
Pump Merge-divider
--- E204 Merge-divider Sol. S/C DWJ0KB Short Circuit
Solenoid Valve
2-stage Relief Solenoid
--- E205 2-stage Relief Sol. S/C DWK0KB Short Circuit
Valve
Electrical system
Travel Speed Hi/Lo
--- E206 Travel Speed Sol. S/C DW43KB Short Circuit
Selector Solenoid Valve
Travel Neutral Solenoid
--- E211 Travel Junction Sol. Disc. DW91KA Disconnection
Valve
Swing Holding Brake
E03 E213 Swing Brake Sol. Disc. DW45KA Disconnection
Solenoid Valve
Pump Merge-divider
--- E214 Merge-divider Sol. Disc. DWJ0KA Disconnection
Solenoid Valve
2-stage Relief Solenoid
--- E215 2-stage Relief Sol. Disc. DWK0KA Disconnection
Valve
Travel Speed Hi/Lo
--- E216 Travel Speed Sol. Disc. DW43KA Disconnection
Selector Solenoid Valve
--- E217 Model Selection Abnormality DA2SKQ Pump Controller Model Disagreement of Model
Selection Wiring Harness Selection Signals
Pump Controller S-NET
E0E E218 S-Net Comm. Disc. DA2SKA Disconnection
Communication
--- 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 DHPAMA F Pump Pressure Sensor Malfunction
--- E225 R Pump P. Sensor Abnormality DHPBMA R Pump Pressure Sensor Malfunction
Pump Controller Power
--- E226 Press. Sensor Power Abnormality DA25KP Lowering of Output Voltage
Supply Output
--- E227 Engine Speed Sensor Abnormality DLE2MA Engine Speed Sensor Malfunction
--- E228 Service Return Relay S/C D196KB ATT Selector Relay Short Circuit
E02 E232 PC-EPC Sol. S/C DXA0KB TVC Solenoid Valve Short Circuit
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division
History
User
code

E02 E233 PC-EPC Sol. Disc. 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
Bucket CURL PPC Pressure
--- E248 Bucket Curl PPC Sen. Abnormality DHS4MA Malfunction
Sensor
--- E251 Overload Sensor Abnormality DHX1MA Malfunction
Pump Controller CAN
E0E E257 Pump Comm. Abnormality DA2RMC Defective Operation
Communication
--- E315 Battery Relay Drive S/C D110KB Battery Relay Short Circuit
Disagreement of Speed
E11 E91B Engine Ne Sensor Problem DLE3LC NE Speed Sensor Signal
Disagreement of Speed
E11 E91C Engine G Sensor Problem DLH1LC G Speed Sensor Signal
Engine Controller Model Disagreement of Model
E11 E920 Engine Type Selection Error DB29KQ Selection Wiring Harness Selection Signals
Disagreement of Model
E11 E921 Engine Type Mismatch DB20KQ Engine Controller Selection Signals
E14 E931 Fuel Dial sys. error DK10KX Throttle Angle Sensor Out of input signal range
Electrical system
Engine Coolant Temperature
E15 E934 Engine Coolant Sensor Hi Error DGE2KX Out of input signal range
Sensor
Disagreement of signal
E15 E936 Engine Oil Press. Sw. Error DDE2L6 Engine Oil Pressure Switch with operation of engine
E11 E93C Engine Boost Sensor Error DH30KX Boost Pressure Sensor Out of input signal range
E15 E93D Engine Fuel Temp. Sensor Error DGE4KX Fuel Temperature Sensor Out of input signal range
Engine Controller CAN
E0E E953 Engine Comm. Abnormality DB2RMC Defective Operation
Communication
--- E954 Short Engine Starter SW. DD11KB Starter SW. Short circuit
Engine Controller S-NET
E0E E955 Engine S-NET error DB2SMC Defective Operation
Communication
Engine Controller Load Power Lowering of source
E10 E956 Engine Power Failure (1) DB22KK Supply Line voltage (Input)
Engine Controller Load Power
E15 E957 Engine Power Failure (2) D1D0KB Short Circuit
Supply Relay
Rotary Switch in Engine
--- E95A Engine Q-adj. Sw. Signal Error DB2AMA Malfunction
Controller
Engine Coolant Temperature Disagreement of signal
E15 E96A Engine Coolant Sensor Lo Error DGE3L6 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
PC400LC-7L 20-149 1
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division
History
User
code
Abnormally High Fuel
E11 E979 Rail Press. High 1 AD00L2 Common Rail Pressure
E11 E97A Rail Press. High 2 AD00MA Common Rail Malfunction
E15 E97B Rail press. low AD10L3 Supply Pump Out of control
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 Engine Controller Abnormality in Controller
Electrical
E11 E981 Fuel Injector 1 Disc. ADA1KA Injector 1 Solenoid Valve Disconnection
system
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
--- Eng. Lo Out of Std A000N2 Engine Out of input signal range
--- Aircleaner Clogging AA10NX Air Cleaner Element Clogging
Mechanical system
--- Charge Voltage Low AB00KE Alternator Defective Charge
--- Eng. Oil Press. Low B@BAZG Engine Oil Lowering of Oil Pressure
--- Eng. Oil LvI. Low B@BAZK Engine Oil Lowering of level
--- Eng. Water Overheat B@BCNS Coolant Overheating
--- Eng. Water Lvl Low B@BCZK Coolant Lowering of level
--- Hydr. Oil Overheat B@HANS Hydraulic Oil Overheating
★ The items in this table are arranged in the order of the error codes.
★ The error codes having no numbers in the user code column and the failure codes having no numbers in the user code
column and error code column are not displayed on the normal screen, even if abnormality related to them occurs. They
are simply recorded in the failure history of the service menu (Electrical equipment system or mechanical equipment
system).
★ The history division column shows in which division each failure is classified, the electrical equipment system or
mechanical equipment system, when it is recorded in the failure history.
★ Letter “E” at the head of each error code indicates the following condition.
● With E: The failure has not been repaired yet.
● Without E: The failure has been repaired.
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OPERATION AND DISPLAY OF SERVICE MENU
How to select service menu
★ When using the service menu, perform the following special operation
to change the screen.
A. Checking display.
Check that the ordinary screen is displayed.
★ The service menu can be selected only while the ordinary
screen is displayed.
B. Operating switches.
Operate the following switches.
● Operation of switches: [∆] → [1] → [2] → [3] (While
pressing [∆], press the numeral keys)
C. Displaying menu screen.

The initial screen of the service menu is displayed. Select a menu
which you will use.
No. Service menu

00 Return (Finish service menu)
01 Monitoring
02 Abnormality record
03 Maintenance record
04 Maintenance mode change
05 Phone number entry
06 Initial setting/Default
07 Adjust
09 Cylinder cut out mode operation
D. Finishing menu and function.

To finish the service menu screen or each menu screen, perform one of the following operations.
(1) Press the [/] switch (This operation is effective on all screens).
(2) When the “Return” switch is displayed, press it.
(3) When the “Return” menu is displayed, select it and press the [✓] switch.
PC400LC-7L 20-151 1
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15. Function of monitoring [01].
The monitor panel monitors the signals from various switches,
sensors, and actuators installed to various parts of the machine. The
operator can display and check the monitoring information in real time
by the following operation.
A. Selecting menu.
On the initial screen of the service menu, select “01 Monitoring”
and press the [✓] switch.
B. Setting monitoring items.

Select and register monitoring items with the following switches.
● [∆] switch: Select
● [∇] switch: Select
● [✓] switch: Register
★ You can set up to 4 monitoring items (You cannot set up to 4
monitoring items, however, depending on the selected items).
★ When monitoring up to 3 items, go to the monitoring
information screen by either of the following operations after
registering those items.
● Hold the [✓] switch (for about 3 seconds).
● Select menu “99999” and press the [✓] switch.
★ If all of the settleable items are registered, the monitoring information screen appears automatically after
registering those items.
★ For the detail, display units, etc. of the monitoring items, see the monitoring items table.
C. Operating for monitoring.

After the monitoring information screen appears, operate the
machine to check the monitoring information.
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D. Function of holding monitoring information.
If the [∆] switch is pressed during the monitoring operation, all
the monitoring information is held. If the [∇] switch is pressed
while the monitoring information is held, the monitoring
information is released.
E. Function of selecting machine setting mode.

To change settings of the working mode, travel speed, or auto
deceleration during the monitoring operation, press the switches
for those items, and the mode checking screen appears.
★ After checking the settings, press the [✓] switch, and the
monitoring screen appears again.
★ If the settings are changed during the monitoring operation,
the new settings are held even after monitoring is finished
and the service menu disappears and the operator menu
appears again.
PC400LC-7L 20-153 1
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Monitoring items list
Unit (Default: ISO)

Code No. Monitoring item Remarks
SI meter inch
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/cm2 psi
07200 Arm Curl PPC Pressure MPa kg/cm2 psi
07300 Bucket Curl PPC Pressure MPa kg/cm 2 psi
04102 Engine Water 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
01006 Engine Speed r/min rpm rpm
04107 Engine Water Temp. Low ×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 Eng. Water Temp. Vol. Hi V V V
04105 Eng. Water 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
17200 PCV Close Angle CA CA CA
17300 Eng. Control Mode Numeral
31701 Throttle Level % % %
36100 Fuel Delivery Command mm /st
3 mm /st
3 mm3/st
36200 Rail Pressure Command MPa kg/cm 2 psi
36300 Injection Timing Angle CA CA CA
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Unit (Default: ISO)
Code No. Monitoring item Remarks
SI meter inch
Swing ON/OFF
Travel ON/OFF
Boom Lower ON/OFF
01900 Pressure Switch 1
Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
01901 Pressure Switch 2
Service ON/OFF
Travel Steering ON/OFF
Travel Junction ON/OFF
Swing Brake ON/OFF
02300 Solenoid 1 Merge-divider ON/OFF
2-stage Relief ON/OFF
Travel Speed ON/OFF
02301 Solenoid 2 Service Return ON/OFF
Lever Sw. ON/OFF
02200 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake Sw. ON/OFF
Model Select 1 ON/OFF
02201 Switch Input 2 Model Select 3 ON/OFF
02202 Switch Input 3 Key Switch (ACC) ON/OFF
03700 Controller Output 1 Batt. Relay Dr. ON/OFF
Key Switch ON/OFF
Start ON/OFF
04500 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Rad. Level ON/OFF
Aircleaner ON/OFF
04501 Monitor Input 2 Eng. Oil Level ON/OFF
Battery Charge ON/OFF
Swing Brake Sw. ON/OFF
Bzzr Cancel Sw. ON/OFF
04502 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
PC400LC-7L 20-155 1
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Unit (Default: ISO)
Codem No. Monitoring item Remarks
SI meter inch
Key SW (C) ON/OFF
Eng. Oil Press. Lo ON/OFF
Eng. Oil Press. Hi ON/OFF
17400 Eng. Controller Input
Machine Sel. 1 ON/OFF
36800 Q Adjust Switch R (ROT-SW1) Alphanumerals
36801 Q Adjust Switch L (ROT-SW2) Alphanumerals
Pump Controller ON/OFF
05100 S-NET Connection
Eng. Controller ON/OFF
20200 Monitor Prog. Version Numerals
20212 Pump Con. Prog. Version Numerals
20209 Eng. Con. Prog. Version Numerals
★ As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be selected.
The unit of display can be changed with “Selecting unit” in the “Setting initial values” function of the service menu.
★ “CA” of the unit of display denotes the crankshaft angle.
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16. Function of abnormality record [02].
The monitor panel classifies and records the past failures into the elec-
trical system group and mechanical system group. The operator can
display and check those failures by the following operation.
A. Selecting menu.
On the initial screen of the service menu, select “02 Abnormality
Record” and press the [✓] switch.
B. Selecting sub-menu.
On the abnormality record menu screen, select a sub-menu and
press the [✓] switch.
No. Sub-menu of abnormality record
00 Return (Finish sub-menu)
01 Electrical systems
02 Mechanical systems
C. Contents of electrical system abnormality record screen

[1]: Reverse sequential order/Total number of records
[2]: Error code
[3]: Failure code (Component: 4 characters, Trouble: 2 characters)
[4]: Advance of service meter after 1st occurrence
[5]: Contents of failure
★ See “Error codes and failure codes table” in the operator
menu.
D. Contents of mechanical system abnormality record screen

[1]: Record No.
[2]: Contents of failure
[3]: Failure code (Component: 4 characters, Trouble: 2 characters)
[4]: Total number of occurrences
[5]: Service meter reading at 1st occurrence
★ See “Error codes and failure codes table” in the operator
menu.
PC400LC-7L 20-157 1
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E. Resetting electrical system abnormality record.
★ Only the abnormality record of the electrical system can be
reset (deleted). The abnormality record of the mechanical
system cannot be reset.
★ If necessary, reset each item or all items of the abnormality
record of the electrical system according to the following
procedure.
i. While the electrical system abnormality record screen is

displayed, operate the following switches to display the reset
screen.
● Operation of switches: [∆] + [1] [2] [3]
★ This operation is the same as that for selecting the service
menu.
ii. Operate the switches according to the direction shown on the

reset screen.
★ When resetting only 1 item, be sure display it with the [∆]
switch or [∇] switch, and then perform the reset
procedure.
★ When resetting all the items, you can perform the reset
procedure, regardless of the item displayed on the screen.
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17. Function of maintenance record [03].
The monitor panel records the maintenance information about the
filters and oils. The operator can display and check that information by
the following operation.
A. Selecting menu.
On the initial screen of the service menu, select “03 Maintenance
Record” and press the [✓] switch.
B. Displayed information.
(1) Names of oils and filters.
(2) Number of replacement times up to now.
(3) Service meter reading at previous replacement.
18. Function of maintenance mode change [04].

The condition for setting the operation of the maintenance display
function can be changed according to the following procedure.
● Set the function effective or ineffective.
● Change the set replacement interval.
A. Selecting menu.
On the initial screen of the service menu, select “04 Maintenance
Mode Change” and press the [✓] switch.
B. Selecting item to be changed.

On the screen of maintenance mode changing menu, select an
item to be changed.
No. Item of maintenance mode change
00 Return
01 Use/Disuse maintenance mode
02 Replacement interval of engine oil
03 Replacement interval of engine oil filter
04 Replacement interval of fuel filter
05 Replacement interval of hydraulic oil filter
06 Replacement interval of hydraulic tank breather
07 Replacement interval of corrosion resistor (if equipped)
08 Check and refill interval of damper case oil
09 Replacement interval of final drive case oil
10 Replacement interval of machinery case oil
11 Replacement interval of hydraulic oil
12 Return all items to initial values
PC400LC-7L 20-159 1
★ Menus “01” and “12” are used to set the whole maintenance mode and menus “02” - “11” are used to set the
items one by one.
C. Contents of setting of “maintenance mode On/Off”.

● On: The function of displaying all the oil and filter items
becomes effective (This setting is applied, even if On/Off
is set for each item).
● Off: The function of displaying all the oil and filter items
becomes ineffective (This setting is applied, even if On/
Off is set for each item).
D. Contents of setting of each item.
i. Default: Maintenance time set in monitor. (Value

recommended by manufacturer. Constant value.)
ii. Set value: Maintenance time which operation can set freely.
Monitor panel operates according to this value in
maintenance mode. (This value can be changed by 50 hours
with [∆] and [∇] switches.)
iii. Off: Function of displaying this maintenance item becomes

ineffective.
iv. On: Function of displaying this maintenance item becomes

effective.
★ The lower limit of the set time is 50 h.
E. Contents of setting “Return all items to initial values”.

If this menu is selected and the [✓] switch is pressed, all the information items are changed to the initial values.
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19. Function of phone number entry [05].
The operator can input a phone No. and change it according to the
following procedure. Once the phone No. is input, it and service code
are displayed alternately when the user code is displayed.
★ If a phone No. is not input, the phone No. screen is not displayed.
A. Selecting menu.
On the initial screen of the service menu, select “05 Phone
Number Entry” and press the [✓] switch.
B. Selecting input screen.

Select “Entry” to display the phone No. input screen.
★ Even if a phone No. has been registered, if the phone No.
input screen is displayed, the registered phone No. is cleared.
C. Inputting and setting phone No.

On the phone No. input screen, input a phone No. according to the
following procedure (The phone No. is input from the cursor at
the left end automatically).
i. Input a No. with the numeral keys from the cursor at the left
end.
ii. After finishing inputting the No., press the [✓] switch.
★ Up to 12 digits can be input. You do not need to input a digit
to an unnecessary place, however.
★ If you input a wrong No., press the [B] switch, and the cursor
returns 1 place by 1.
★ If the phone No. is input, the “Entry” screen above is
displayed again. If the phone No. is displayed on this screen, it is input normally.
PC400LC-7L 20-161 1
12
20. Function of initial setting and default [06].
The operator can change the following items related to the monitor
panel and machine, if necessary.
● Working mode when starting switch is turned ON.
● Language displayed on service menu.
● Unit displayed in monitoring function mode.
● With/Without attachment.
A. Selecting menu.
On the initial screen of the service menu, select “06 Function of
initial setting and default” and press the [✓] switch.
Select a sub-menu to change its setting and press the [✓] switch.
No. Sub-menu of initial value/default

00 Return (Finish initial value/default)
01 Key-on mode
02 Language
03 Unit
04 With/Without service circuit
C. Function of selecting mode when key is ON.

When the starting switch is turned ON, a working mode is
displayed on the monitor panel. The operator can change this
working mode.
● A-mode, E-mode, L-mode, B-mode: If any of these mode is
set, the machine is started in the selected mode when the
starting switch is turned ON.
● Mode when key was turned off last: If this mode is set, the
machine is started in the mode used last when the starting
switch is turned ON.
● Initial value: If this mode is set, the machine is started in the
default mode set in the factory when the starting switch is
turned ON.
★ If the machine having an attachment is stopped in the B-mode, it is started in the B-mode when the starting
switch is turned ON next time, regardless of this setting.
20-162 1 PC400LC-7L
12
D. Function of setting language.
The operator can select Japanese or English as the language
displayed on the service menu.
★ The default language of the monitor panel is English.
★ When using a spare monitor panel in the Japanese language
area, select Japanese with this function.
E. Function of selecting unit.

The operator can select 1 of the 3 unit systems as the unit system
used for the data displayed by the monitoring function of the
service menu.
★ The default unit system of the monitor panel is the SI unit
system.
F. Function of selecting “with/without service circuit”.

The operator can set “with/without service circuit”.
● With service circuit: When attachment is installed.
● Without service circuit: When attachment is not installed.
★ When an service circuit is installed, if “With service circuit”
is not set on this screen, the operator cannot use the select
function (adjustment of oil flow for the attachment) in the
operator mode.
PC400LC-7L 20-163 1
12
21. Function of adjustment [07].
The operator can adjust various items of the machine on the monitor
panel.
A. Selecting menu.
On the initial screen of the service menu, select “07 Adjustment”
and press the [✓] switch.
Select a sub-menu to change its setting and press the [✓] switch.
No. Sub-menu of adjustment
00 Return (Finish adjustment)
01 Pump absorption torque
Adjustment of oil flow for attachment in compound
02 operation
C. 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 +6.0 kgm 226 -4.0 kgm
222 +4.0 kgm 227 -6.0 kgm
223 +2.0 kgm 228 -8.0 kgm
224 0.0 kgm
D. Function of adjustment of oil flow for attachment in compound

operation.
The operator can adjust the oil flow for the attachment in
compound operation within the ranges shown in the following
table.
Adjustment value Oil flow for attachment

370 0.5 times
371 0.7 times
372 1.0 times
373 0.4 times
20-164 1 PC400LC-7L
12
22. Function of cylinder cut out mode operation [09].
The operator can operate the machine in the cylinder cut out mode
with the monitor panel. Cylinder cut out mode operation means to run
the engine with 1 or more fuel injectors disabled electrically to reduce
the number of effective cylinders. This operation is used to find out a
cylinder which does not output power normally (or, combustion in it is
abnormal).
A. Selecting menu.
On the initial screen of the service menu, select “09 Cylinder cut
out mode operation” and press the [✓] switch.
B. Setting cylinders to be disabled.

Press switches [1] - [6] on the monitor panel corresponding to the
cylinder Nos. to be disabled.
★ After a switch is pressed, if the cylinder No. corresponding to
it on the monitor panel is displayed white in a white frame,
the cylinder is disabled (If setting is wrong, press the same
switch again).
★ Only one or more cylinders can be disabled for the reduced
cylinder mode operation.
C. Cancellation of disabled cylinders.

Press switches [1] - [6] on the monitor panel corresponding to the
disabled cylinder Nos. to cancel disabling of those cylinders.
★ After a switch is pressed, if the cylinder No. corresponding to
it on the monitor panel is displayed black in a black frame,
disabling of the cylinder is cancelled.
PC400LC-7L 20-165 1
12
D. Function of holding engine speed.
If the [∆] switch is pressed while the reduced cylinder mode
operation screen is used, the engine speed is held and displayed on
the lower line. If the [∇] switch is pressed while the engine speed
is held, holding of the engine speed is cancelled and the engine
speed displayed on the lower line goes off.
★ If the holding function is used, the held engine speed is
displayed in ( ) on the lower line and the current engine speed
is displayed on the upper line.
★ The holding function can be used both in and out of the
cylinder cut out mode.
[Reference]: How to use holding function effectively
The engine speed displayed by the holding function is held on the screen
until the holding function is cancelled, regardless of setting and
cancellation of the cylinder cut out mode. Accordingly, a defective cylinder
can be found out effectively according to the following procedure.
1. Run the engine normally (without disabling any cylinder) and hold the
engine speed.
2. Disable a cylinder to be checked.
3. Run the engine under the same condition as the normal operation in
step (1) and compare the engine speed at this time with the held engine
speed.
4. Cancel the cylinder cut out mode, regardless of the change of the
engine speed.
5. Repeat steps (2) - (4) to check the other cylinders.

★ If the engine speed does not lower at all or lowers less when a cylinder
is selected for the cylinder cut out mode operation, combustion in that
cylinder must be abnormal.
20-166 1 PC400LC-7L
TESTING AND ADJUSTING HANDLING OF ENGINE CONTROLLER
12
HANDLING OF ENGINE CONTROLLER
WARNING! The engine controller has a high-voltage
circuit (110 - 130 V) to drive the fuel
injector. This circuit is connected to the
wiring harness and connectors between
the engine controller and fuel injector.
★ Normally, the engine controller outputs the high voltage to the fuel
injector only while the engine is running and stops outputting if the
engine stops.
WARNING! If you touch the high-voltage circuit directly, you may get an electric shock. To avoid this,
observe the following precautions.
1. The following connectors are used in the high voltage circuit.

● Engine controller connector: CB3.
● Junction connector: ER03.
● Injector connectors: CN1, CN2, CN3, CN4, CN5, CN6.
● Injector head terminal (in head cover).
2. When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF.
3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start
the engine.
★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
PC400LC-7L 20-167 1
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLESHOOTING
12
PREPARATION WORK FOR TROUBLESHOOTING
★ When carrying out troubleshooting for an electric circuit related to the
monitor panel, engine controller, or pump controller, expose the
related connectors according to the following procedure.
1. Monitor panel.
A. Remove cover (1).

★ The cover is fixed with the upper and lower 2 clips. You can
remove the cover by pulling it up.
★ If the sunlight sensor for the air conditioner is installed,
disconnect connector P15 on the back side of the cover.
B. Remove the 3 mounting screws and disconnect monitor panel (2)

from the mount.
★ Take care not to drop the mounting screws in the console.
C. Insert or connect T-adapters in or to connectors P01, P02, P70 of

the monitor panel.
2. Engine controller.
A. Open the right side cover and remove radiator sub tank (3) and
bracket together.
B. Remove the 4 mounting bolts and pull out engine controller (4).
C. Insert or connect T-adapters in or to connectors CB1, CB2, and

CB3 of the engine controller.
★ Since the connectors are secured with screws, loosen those
screws before disconnecting.
★ When connecting the connectors again, tighten their screws
to the specified torque.
Screw: 2.82 Nm (2.07 lbf ft)
20-168 1 PC400LC-7L
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLESHOOTING
12
3. Pump controller.
★ The pump controller is installed inside the cover at the rear of the
operator’s seat.
A. Remove the 3 mounting bolts and cover (5).
B. Insert or connect T-adapters in or to connectors C01, C02, and

C03 of the pump controller.
★ Since the connectors are secured with screws, loosen those
screws before disconnecting.
★ When connecting the connectors again, tighten their screws
to the specified torque.
Screw: 2.82 Nm (2.07 lbf ft)
PC400LC-7L 20-169 1
TESTING AND ADJUSTING PM CLINIC SERVICE
12
PM CLINIC SERVICE
20-170 1 PC400LC-7L
12
Positions to install measuring devices (Related to engine)
PC400LC-7L 20-171 1
12
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
20-172 1 PC400LC-7L
12
PC400LC-7L 20-173 1
12
20-174 1 PC400LC-7L
12
Pm-CLINIC SERVICE PC400 (LC)
Visual check of welded structures

★ If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket
❑ Left ❑ Right ❑ Left ❑ Right ❑ Left ❑ Right
2. Arm foot 5. Boom cylinder bracket
❑ Left ❑ Right ❑ End plate ❑ Left ❑ Right Track frame
3. Arm top boss 6. Arm cylinder bracket 10. Circle bracket
❑ Left ❑ Right ❑ Left ❑ Right ❑ Front ❑ Rear
7. Boom lower plate ❑ Left ❑ Right
❑ Left ❑ Right
8. Boom foot
❑ Left ❑ Right
PC400LC-7L 20-175 1
20-176 1 PC400LC-7L
TROUBLESHOOTING GENERAL
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-205
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 20-206
HANDLING WIRING HARNESSES AND CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES . . . . 20-208
HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS . . . . . . . . . . . . . . . 20-212
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-212
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215
CLASSIFICATION OF TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215
STEPS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NOS. . . . . . . . . . . . . 20-216
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231
PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-233
T-BRANCH BOX AND T-BRANCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-254
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258
PC400LC-7L 20-201 b
TROUBLESHOOTING
12
MEMORANDUM
20-202 b PC400LC-7L
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot water may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, water, or
air, always release the internal pressure first. When installing measuring equipment, be
sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes
of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately any failure occurs:
● Parts that have no connection with the failure or other unnecessary parts will be disassembled.
● It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil or grease, and at the same time, will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask user or operator
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F. Has the same kind of failure occurred before?
3. Check before troubleshooting
A. Check the oil level
B. Check for any external leakage of oil from the piping or hydraulic equipment.
PC400LC-7L 20-203 b
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming failure
● Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
● Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure, then use the
troubleshooting flow chart to locate the position of the failure exactly. The basic procedure for troubleshooting is as
follows.
A. Start from the simple points.
B. Start from the most likely points.
C. Investigate other related parts or information.
6. Measures to remove root cause of failure

● Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To
prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-204 b PC400LC-7L
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC400LC-7L 20-205 b
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
12
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly
with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives
sections on Handling electric equipment and Handling hydraulic equipment, particularly gear oil and hydraulic oil.
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT
HANDLING WIRING HARNESSES AND CONNEC-
TORS
Wiring harnesses consist of wiring connecting one component to another
one, connectors used for connecting and disconnecting one wire from
another wire, and protectors or tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring
harnesses are more likely to be affected by the direct effects of rain, water,
heat, or vibration. Furthermore, during inspection and repair operations,
they are frequently removed and installed again, so they are likely to suffer
deformation or damage. For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
MAIN FAILURES OCCURRING IN WIRING HARNESS
1. Faulty Contact of Connectors, Faulty Contact Between Male and

Female
Problems with faulty contact are likely to occur because the male
connector is not properly inserted into the female connector, or
because one or both of the connectors is deformed or the position is
not correctly aligned, or because there is corrosion or oxidation of the
contact surfaces.
2. Faulty Crimping or Soldering of Connectors

The pins of the male and female connectors are in contact at the
crimped terminal or soldered portion, but if there is excessive force
brought to bear on the wiring, the plating at the joint will peel and
cause improper connection or breakage.
20-206 b PC400LC-7L
12
3. Disconnections in Wiring
If the wiring is held and the connectors are pulled apart, or
components are lifted with a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of the connector may
separate, or the soldering may be damaged, or the wiring may be
broken.
4. High Pressure Water Entering Connector

The connector is designed to make it difficult for water to enter, drip
proof structure, but if high pressure water is sprayed directly on the
connector, water may enter the connector, depending on the direction
of the water jet. As already said, the connector is designed to prevent
water from entering, but at the same time, if water does enter, it is
difficult for it to be drained. Therefore, if water should get into the
connector, the pins will be short-circuited by the water, so if any water
gets in immediately dry the connector or take other appropriate action
before passing electricity through it.
5. Oil or Dirt Stuck to Connector

If oil or grease are stuck to the connector and an oil film is formed on
the mating surface between the male and female pins, the oil will not
let the electricity pass, so there will be faulty contact. If there is oil or
grease stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
★ When wiping the mating portion of the connector, be careful not
to use excessive force or deform the pins.
★ If there is oil or water in the compressed air, the contacts will
become even dirtier, so remove the oil and water from the
compressed air completely before cleaning with compressed air.
PC400LC-7L 20-207 b
12
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES
DISCONNECTING CONNECTORS
1. Hold the Connectors When Disconnecting

When disconnecting the connectors hold the connectors and not the
wires. For connectors held by a screw, loosen the screw fully, then
hold the male and female connectors in each hand and pull apart. For
connectors which have a lock stopper, press down the stopper with
your thumb and pull the connectors apart. Never pull with one hand.
2. When Removing from Clips

When removing a connector from a clip, pull the connector in a
parallel direction to the clip.
★ If the connector is twisted up and down or to the left or right, the
housing may break.
3. Action to Take after Removing Connectors

After removing any connector, cover it with a vinyl bag to prevent any
dust, dirt, oil, or water from getting in the connector portion.
★ If the machine is left disassembled for a long time, it is
particularly easy for improper contact to occur, so always cover
the connector.
20-208 b PC400LC-7L
12
CONNECTING CONNECTORS
1. Check the Connector Visually
A. Check that there is no oil, dirt, or water stuck to the connector pins
(mating portion).
B. Check that there is no deformation, faulty contact, corrosion, or

damage to the connector pins.
C. Check that there is no damage or breakage to the outside of the

connector.
★ If there is any oil, water, or dirt stuck to the connector, wipe it off
with a dry cloth. If any water has got inside the connector, warm
the inside of the wiring with a dryer, but be careful not to make it
too hot as this will cause short circuits.
★ If there is any damage or breakage, replace the connector.
2. Fix the Connector Securely

Align the position of the connector correctly, then insert it securely.
For connectors with lock stopper, push in the connector until the
stopper clicks into position.
3. Correct any protrusion of the boot and any misalignment of the wiring
harness For connectors fitted with boots, correct any protrusion of the
boot. In addition, if the wiring harness is misaligned, or the clamp is
out of position, adjust it to its correct position.
★ If the connector cannot be corrected easily, remove the clamp and
adjust the position.
4. If the connector clamp has been removed, be sure to return it to its

original position. Check also that there are no loose clamps.
5. Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors have 2 latches
respectively, push them in until they click 2 times.
A. Male connector, 2. Female connector

● Normal locking state (Horizontal): a, b, d
● Incomplete locking state (Diagonal): c
PC400LC-7L 20-209 b
12
DRYING WIRING HARNESS
If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth.
Avoid washing it in water or using steam. If the connector must be washed
in water, do not use high pressure water or steam directly on the wiring
harness. If water gets directly on the connector, do as follows.
1. Disconnect the connector and wipe off water with a dry cloth.
★ If the connector is blown dry with compressed air, there is the risk
that oil in the air may cause faulty contact, so remove all oil and
water before blowing with air.
2. Dry the inside of the connector with a dryer. If water gets inside the
connector, use a dryer to dry the connector.
★ Hot air from the dryer can be used, but regulate the time that the
hot air is used in order not to make the connector or related parts
too hot, as this will cause deformation or damage to the connector.
3. Carry out a continuity test on the connector. After drying, leave the
wiring harness disconnected and carry out a continuity test to check
for any short circuits between pins caused by water.
★ After completely drying the connector, blow it with contact
restorer and reassemble.
20-210 b PC400LC-7L
12
HANDLING CONTROL BOX
1. The control box contains a microcomputer and electronic control

circuits. These control all of the electronic circuits on the machine, so
be extremely careful when handling the control box.
2. Do not open the cover of the control box unless necessary.
3. Do not place objects on top of the control box.
4. Cover the control connectors with tape or a vinyl bag. Never touch the
connector contacts with your hand.
5. During rainy weather, do not leave the control box in a place where it
is exposed to rain.
6. Do not place the control box on oil, water, or soil, or in any hot place,
even for a short time, place it on a suitable dry stand.
7. Precautions when carrying out arc welding. When carrying out arc
welding on the body, disconnect all wiring harness connectors
connected to the control box. Fit an arc welding ground close to the
welding point.
PC400LC-7L 20-211 b
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS
1. Always turn the power OFF before disconnecting or connect connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3. Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits; measuring the voltage, resistance, continuity, or current, move the related
wiring and connectors several times and check that there is no change in the reading of the tester.
★ If there is any change, there is probably faulty contact in that circuit.
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
BE CAREFUL OF THE OPERATING ENVIRONMENT
Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of
dust.
DISASSEMBLY AND MAINTENANCE WORK IN THE FIELD
If disassembly or maintenance work is carried out on hydraulic equipment

in the field, there is danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs, so it is desirable to use
unit exchange. Disassembly and maintenance of hydraulic equipment
should be carried out in a specially prepared dust proof workshop, and the
performance should be confirmed with special test equipment.
SEALING OPENINGS
After any piping or equipment is removed, the openings should be sealed

with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If
the opening is left open or is blocked with a rag, there is danger of dirt
entering or of the surrounding area being made dirty by leaking oil so never
do this. Do not simply drain oil out on to the ground, collect it and ask the
customer to dispose of it, or take it back with you for disposal.
20-212 b PC400LC-7L
12
DO NOT LET ANY DIRT OR DUST GET IN DURING REFILLING
OPERATIONS.
Be careful not to let any dirt or dust get in when refilling with hydraulic oil.
Always keep the oil filler and the area around it clean, and also use clean
pumps and oil containers. If an oil cleaning device is used, it is possible to
filter out the dirt that has collected during storage, so this is an even more
effective method.
CHANGE HYDRAULIC OIL WHEN THE TEMPERATURE IS HIGH.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit
together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old
hydraulic oil must be drained out. Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the
drain plug in the circuit. If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the
life of the hydraulic oil.
FLUSHING OPERATIONS
After disassembling and assembling the equipment, or changing the oil,

use flushing oil to remove the contaminants, sludge, and old oil from the
hydraulic circuit. Normally, flushing is carried out twice: primary flushing
is carried out with flushing oil, and secondary flushing is carried out with
the specified hydraulic oil.
CLEANING OPERATIONS
After repairing the hydraulic equipment; pump, control valve, etc. or when
running the machine, carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil cleaning equipment is
used to remove the ultra fine [about 3] particles that the filter built into the
hydraulic equipment cannot remove, so it is an extremely effective device.
PC400LC-7L 20-213 b
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel --- Add fuel
2. Check for impurities --- Clean, drain
3. Check hydraulic oil level --- Add oil
4. Check hydraulic strainer --- Clean, drain
Lubricating 5. Check swing machinery oil level --- Add oil
oil, coolant 6. Check engine oil level, type of oil --- Add oil
7. Check coolant level --- Add water
8. Check dust indicator for clogging --- Clean or replace
9. Check hydraulic filter --- Replace
10. Check final drive oil level --- Add oil
1. Check for looseness, corrosion of battery terminal, wiring --- Tighten or replace
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring --- Tighten or replace
equipment
3. Check for looseness, corrosion of starter motor terminal, wiring --- Tighten or replace
Hydraulic 1. Check for abnormal noise, smell --- Repair
mechanical 2. Check for oil leakage --- Repair
equipment 3. Carry out air bleeding --- Bleed air
1. Check battery voltage, engine stopped 20 to 30 V Replace
2. Check battery electrolyte level --- Add or replace
3. Check for discolored, burnt, exposed wires --- Replace
4. Check for missing wiring clamps, hanging wiring --- Repair
5. Check for water leaking on wiring (be particularly careful attention to water
Electronics, --- Disconnect and dry
leaking on connectors or terminals)
electrical
6. Check for blown, corroded fuses --- Replace
equipment
After running
for several
7. Check alternator voltage, ½ throttle or above Replace
minutes:
27.5 to 29.5 V
8. Check operating sound of battery, when switch is turned On/Off --- Replace
20-214 b PC400LC-7L
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
12
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION OF TROUBLESHOOTING
Mode Content
Code display Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL
STEPS FOR TROUBLESHOOTING

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed
to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [✓] switch to display Error Code. Following displayed Error Code for the
electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is recorded in the failure
history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system Failure Code,
using the failure history function of the monitor panel.
★ If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to
check if the same abnormality still persists.
★ Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor
panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case,
reexamine the phenomenon, find out the most similar phenomenon from among “Failure like Phenomena and
Troubleshooting No.” and carry out E mode or H mode troubleshooting related to the phenomenon in question.
PC400LC-7L 20-215 b
12
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING
NOS.
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL.
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
According to
1 User code is displayed on monitor panel displayed code
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
Possible faults related to engine
4 Engine does not start easily (It always takes time to start) S-1
5 Engine does not start - Engine does not crank E-1 S-2 a)
6 Engine does not start - Engine cranks but exhaust smoke does not come out S-2 b)
7 Engine does not start - 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 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 E-5 H-3
28 Abnormal sound comes out from around hydraulic pump H-4
29 Fine control performance or response is low H-6
20-216 b PC400LC-7L
12
Troubleshooting
No. Phenomena considered to be failures Display of E-mode H-mode S-mode
code
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
When a work equipment device is relieved singly, other work equipment device
36 H-13
moves
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
PC400LC-7L 20-217 b
12
Troubleshooting
No. Phenomena considered to be failures Display of E-mode H-mode S-mode
code
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
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
Monitoring function does not indicate “Travel differential pressure“
73 E-28
normally.
74 Monitoring function does not indicate "Service" normally. E-29
Other failure
Air conditioner does not operate (Troubleshooting for air conditioner
75 E-31
system)
20-218 b PC400LC-7L
TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING
12
CONNECTOR ARRANGEMENT DRAWING
CONNECTORS LIST
★ The address of each connector roughly shows the place of the connector in the connectors stereogram and the circuit
diagram of each system.
Address
Connector No. of
Type Name of device M E P
No. pins Stereogram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 D-7 G-7
A02 X 4 Intermediate connector T-1 H-6 G-7
A03 DT 12 Intermediate connector N-2 H-6 D-7 G-7
A04 SWP 6 Intermediate connector O-1 G-6
A05 SWP 14 Intermediate connector T-1 H-5 G-6
A06 SWP 14 Intermediate connector O-1 H-5 G-5
A07 SWP 16 Intermediate connector S-1 A-4 D-7 G-5
A09 SWP 8 Intermediate connector N-2 G-5
A10 Terminal 1 Revolving frame grounding H-2 I-1 F-1 J-8
A11 Terminal 1 Revolving frame grounding I-2 F-1
A12 Terminal 1 Revolving frame grounding I-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-8
A14 Terminal 1 Revolving frame grounding F-1 I-1 J-8
A15 Terminal 1 Revolving frame grounding J-3 I-1 J-8
A16 Terminal 1 Revolving frame grounding J-3 I-1 K-8
A20 Terminal 1 Battery relay (Terminal E) D-1 L-5 K-9
A21 Terminal 1 Battery relay (Terminal BR) D-2 J-6 K-9
A22 Terminal 1 Battery relay (Terminal N) F-2 J-5 D-8 K-9
A23 Terminal 1 Battery relay (Terminal B) F-2 J-6 K-9
A31 D 2 Air cleaner clogging sensor H-9 K-4
A33 X 2 Radiator water level sensor H-9 K-5
A34 L 2 Fusible link (65 A) D-2 K-6 K-9
A35 M 2 Fusible link (30 A) G-9 K-6 D-9 K-9
A40 Terminal 1 Horn (Low tone) G-9
A41 Terminal 1 Horn (High tone) G-9
A42 M 1 Intermediate connector H-9 J-7
A43 D 2 Travel alarm J-3 K-5
A44 M 1 Right headlamp D-5 K-7
A50 KES0 2 Windshield washer motor (Tank) L-5 K-5
A51 D 3 F pump oil pressure sensor L-8 L-5
A52 D 3 R pump oil pressure sensor L-7 L-5
A60 X 1 Fuel level sensor G-9 K-4
A61 D 2 Hydraulic oil temperature sensor L-5 K-5
A73 D 2 Fuel priming pump G-9
A80 DT 8 Intermediate connector S-1 H-3 D-6 G-4
AL/B Terminal 1 Alternator B terminal AE-6
AL/E Terminal 1 Alternator E terminal AE-6
AL/R Terminal 1 Alternator R terminal AE-6
C01 DRC 24 Pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Pump controller U-9 A-3 A-8 A-7
C03 DRC 40 Pump controller W-9 A-2 A-6
C09 S 8 Model selection connector (Pump controller) W-9 B-1
CB1 DRC 24 Pump controller I-9 K-1 A-6 L-8
CB2 DRC 40 Pump controller I-9 K-1 A-5 L-8
CB3 DRC 40 Pump controller J-9 A-3
PC400LC-7L 20-219 b
12
Address
Connector No. of
CB5 DT 8 Model selection connector (Engine controller) J-9 A-7
CN1 DT 2 No. 1 fuel injector AI-2 K-3
CN2 DT 2 No. 2 fuel injector AI-3 K-2
CN3 DT 2 No. 3 fuel injector AJ-3 K-2
D01 SWP 8 Concentrated diode W-7 A-9 A-4
D02 SWP 8 Concentrated diode W-5 A-8 A-4
E06 M 3 Fuel control dial P-7 K-7
ENE DT 2 Engine speed sensor AJ-5
ER02 HD30 31 Intermediate connector AF-8 J-3 I-5 K-6
ER03 HD30 31 Intermediate connector AF-8 I-3
F02 M 2 Rotary lamp AA-9
FB1 ó ó Fuse box V-2 I-9 E-7 G-8
G YAZAKI 2 Engine G sensor AH-2 K-3
GND DT 2 Joint connector (with diode) AJ-6
GND2 Terminal 1 Engine grounding AJ-5
GND3 Terminal 1 Engine grounding AE-7
H08 M 8 Intermediate connector W-6 J-8
H09 S 8 Intermediate connector W-6 J-8
H10 S 16 Intermediate connector T-9 D-6 I-7 E-2
H11 S 16 Intermediate connector S-9 D-6 E-2
H12 S 12 Intermediate connector S-9 D-5 I-6 E-2
H15 S090 20 Intermediate connector O-7 C-2 I-7 A-2
HT/B Terminal 1 Heater relay B terminal AH-9
HT/S Terminal 1 Heater relay S terminal AJ-7
J01 J 20 Junction connector (Black) T-9 C-9 H-9 B-9
J02 J 20 Junction connector (Black) T-9 D-9 C-1
J03 J 20 Junction connector (Green) U-9 D-9 H-9 C-9
J04 J 20 Junction connector (Green) V-3 E-9 H-9 C-9
J05 J 20 Junction connector (Pink) V-3 E-9 D-9
J06 J 20 Junction connector (Orange) W-3 F-9 I-9 D-9
J07 J 20 Junction connector (Orange) W-5 F-9 I-9 D-9
J08 J 20 Junction connector (Pink) W-5 I-9 E-9
K19 M 2 Pump resistor (For driving pump in emergency) W-5 B-1
K30 DT 3 CAN terminal resistance K-9 A-2 A-9 I-3
K31 DT 3 CAN terminal resistance N-4 A-4 K-6 E-1
M07 M 3 Light switch P-8 C-1
M09 M 1 Working lamp (Right front) E-9 K-7
M13 M 2 Speaker (Right) AC-9
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch O-7
M23 Y090 2 One-touch power maximizing switch T-1 F-9
M26 S 12 Intermediate connector W-4
M27 YAZAKI 18 Air conditioner unit W-4
M29 040 20 Air conditioner control panel U-2
M30 040 16 Air conditioner control panel U-2
M31 M 2 Optional power supply (2) W-7
M32 M 2 Optional power supply (1) W-6
20-220 b PC400LC-7L
12
Address
Connector No. of
M33 M 2 Optional power supply (3) V-9
M33 SUMITOMO 4 Air conditioner unit W-4
M34 X 1 Air conditioner compressor electromagnetic clutch I-9
M37 Terminal 1 Horn switch (High tone) H-1
M38 Terminal 1 Horn switch (Low tone) G-1
M38 M 2 Machine push-up switch Q-8 A-1
M40 M 2 Working lamp Z-8 K-8
M41 M 2 Working lamp (Additional) Y-7 K-8
M42 M 1 Intermediate connector H-9 J-7, K-7
M43 M 1 Working lamp (Rear) J-9 K-7
M45 D 12 Intermediate connector W-7
M46 X 4 RS232C junction connector V-9 A-4
M71 M 2 Room lamp AA-8
M72 M 4 DC/DC converter U-2
M73 M 2 Speaker (Left) AD-8
M79 M 2 12-V accessory outlet V-9
NE YAZAKI 2 Engine Ne sensor AJ-5 K-4
OL DT 2 Engine oil level sensor AJ-3 K-2
P01 070 12 Monitor panel N-6 A-7 K-7 E-1
P03 M 2 Buzzer cancel switch Q-8 D-1
P05 M 2 Rotary lamp switch U-2
P15 Y050 2 Air conditioner daylight sensor N-5
PCV1 SUMITOMO 2 Fuel supply pump PCV1 AH-2 K-1
PCV2 SUMITOMO 2 Fuel supply pump PCV2 AI-2 K-1
PSH Terminal 1 Engine oil pressure switch (High pressure) AH-2 L-5
PSL Terminal 1 Engine oil pressure switch (Low pressure) AG-1 L-5
PFUEL AMP 3 Common rail pressure sensor AJ-4 K-5
PIM SUMITOMO 3 Boost pressure sensor AJ-8 K-5
R10 R 5 Light relay P-7 E-1
R11 R 5 Starting motor cutout relay (PPC lock) P-8 E-1
R13 R 5 Starting motor cutout relay (Personal code) Q-8 F-1
R20 R 5 ATT circuit selector relay W-7 E-9
R22 R 5 Power supply relay for engine controller W-6 G-9
R30 R 5 Air conditioner blower relay W-4
R31 R 5 Air conditioner compressor relay W-3
S01 D 4 Bucket CURL pressure sensor K-3 K-3
S02 X 2 Boom LOWER oil pressure switch L-2 K-2
S03 X 2 Swing RIGHT oil pressure switch L-2 K-2
S04 D 3 Arm IN pressure switch K-3 K-3
S05 X 2 Bucket DUMP oil pressure switch L-2 K-2
S06 X 2 Boom RAISE oil pressure switch L-2 K-2
S07 X 2 Swing LEFT oil pressure switch L-2 K-2
S08 X 2 Arm DUMP oil pressure switch L-1 K-2
S09 X 2 Service oil pressure switch (Intermediate connector) L-1 K-1
S10 X 2 Service front oil pressure switch K-1 K-1
S11 X 2 Service rear oil pressure switch L-1 K-1
S14 M 3 Safety lock lever switch S-1 K-9 E-9
S21 Terminal 6 Emergency pump drive switch R-9 C-1
S22 Terminal 6 Swing holding brake release switch R-8 D-1
PC400LC-7L 20-221 b
12
Address
Connector No. of
S25 S090 16 Intermediate connector R-9 C-2
S30 X 2 Travel oil pressure switch P-1 A-9
S31 X 2 Travel steering oil pressure switch P-1 A-9
ST DT 2 Starting motor AF-7 K-3 K-6
ST/B Terminal 1 Starting motor B terminal AF-7
T05 Terminal 1 Floor frame grounding V-3 J-8
T06 Terminal 1 Radio body grounding S-9
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Cab grounding K-8
THL DT 3 Spill fuel temperature sensor AJ-4 K-3
TWH DT 2 Engine water temperature sensor (High temperature) AE-7 K-5
TWL DT 3 Engine water temperature sensor (Low temperature) AG-8 K-5
V01 DT 2 PPC oil pressure lock solenoid valve J-3 K-5
V02 DT 2 Travel junction solenoid valve J-2 K-5
V03 D 2 Merge-divider solenoid valve J-2 K-4
V04 D 2 Travel speed solenoid valve J-2 K-4
V05 D 2 Swing holding brake solenoid valve J-2 K-4
V06 D 2 Machine push-up solenoid valve J-2 K-4
V08 D 2 2nd-stage relief solenoid valve J-1 K-4
V12 D 2 ATT return selector solenoid valve J-1 K-4
V21 D 2 PC-EPC solenoid valve L-6 L-7
V22 D 2 LS-EPC solenoid valve L-6 L-7
V30 X 2 ATT flow adjustment EPC solenoid valve P-1 F-1
W03 M 2 Rear limit switch (Window) AB-9 K-8
W04 M 6 Wiper motor Y-5 B-9
X05 M 4 Swing lock switch Q-8 D-2 A-1
20-222 b PC400LC-7L
12
Connector type Detailed information
D or DT 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 Yazaki-made connector
SUMITOMO Product of Sumitomo Wiring Systems 6098 type connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
PC400LC-7L 20-223 b
12
CONNECTOR LOCATION DIAGRAM
20-224 b PC400LC-7L
12
PC400LC-7L 20-225 b
12
20-226 b PC400LC-7L
12
PC400LC-7L 20-227 b
12
20-228 b PC400LC-7L
12
PC400LC-7L 20-229 b
12
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT)
Remark
This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging system,
light system, and communication network system from the general electric circuit diagram.
See FOLDOUT 17 & 18 on pages 90-35 and 90-37.
20-230 b PC400LC-7L
12
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT)
Remark
This circuit diagram is made by extracting the engine controller system from the general electric circuit diagram.
See FOLDOUT 19 & 20 on pages 90-39 and 90-41.
PC400LC-7L 20-231 b
12
PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT)
Remark
This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine push-up
solenoid system, and boom shockless solenoid system from the general electric circuit diagram.
See FOLDOUT 21, 22, 23 & 24 on pages 90-43 thru 90-49.
20-232 b PC400LC-7L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
X type connector
No.of pins
Male (female housing) Female (male housing) T-adapter Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
Electric wire size: 0.85 Electric wire size: 0.85
--- ---
Grommet: Black Grommet: Black
Q’ty: 20 Q’ty : 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410
--- ---
Grommet: Red Grommet: Red
Q’ty: 20 Q’ty: 20
PC400LC-7L 20-233 b
12
SWP type connector

No.of
pins T-adapter
Male (female housing) Female (male housing) Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
20-234 b PC400LC-7L
12
SWP type connector

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

Terminal part No.: Terminal part No.:
--- ---
Grommet: Black Grommet: Black
Q’ty: 20 Q’ty: 20
Terminal part No.: Terminal part No.:
--- ---
Grommet: Red Grommet: Red
Q’ty: 20 Q’ty: 20
PC400LC-7L 20-235 b
12
No.of M type connector
pins Male (female housing) Female (male housing) T-adapter Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
20-236 b PC400LC-7L
12
No.of S type connector
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10 799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12 799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16 799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
PC400LC-7L 20-237 b
12
No.of S type connector
10 ---
(Blue)
--- ---
12 799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16 799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
20-238 b PC400LC-7L
12
No.of MIC type connector
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) ---
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) ---
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
PC400LC-7L 20-239 b
12
No.of MIC type connector

17 799-601-2730
21 799-601-2740
Terminal part No.: 79A-222-2770 (Q’ty: 50) Terminal part No.: 79A-222-2760 (Q’ty: 50) ---
20-240 b PC400LC-7L
12
No.of AMP040 type connector
8 799-601-7180
--- Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220

★ Terminal part No.: 79A-222-3470 (No relation with number of pins)
PC400LC-7L 20-241 b
12
No.of AMP070 type connector
10 799-601-7510
--- Part No.: 08195-10210
12 799-601-7520
--- Part No.: 08195-12210
14 799-601-7530
--- Part No.: 08195-14210
18 799-601-7540
--- Part No.: 08195-18210
20 799-601-7550
--- Part No.: 08195-20210
20-242 b PC400LC-7L
12
No.of L type connector
2 ---
--- ---
No.of Connector for PA

9 ---
--- ---
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing) No.
10 799-601-3460
--- ---
PC400LC-7L 20-243 b
12
No.of KES 1 (Automobile) connector
2 ---
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 ---
Part No.:08027-10310 Part No.:08027-10360
4 ---
08027-10420 (Black) 08027-10470 (Black)
6 ---
08027-10620 (Black) 08027-10670 (Black)
20-244 b PC400LC-7L
12
No.of KES 1 (Automobile) connector
8 ---
08027-10820 (Black) 08027-10870 (Black)
No.of Connector for relay (Socket type)

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

4 ---
--- ---
PC400LC-7L 20-245 b
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type HD30 Series connector

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

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

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

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

08191-22205, 08191-22206 08191-23105, 08191-23106
20-246 b PC400LC-7L
12
Remark

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

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

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

18-21 799-601-9240
(4)
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC400LC-7L 20-247 b
12
Remark

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

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

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

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

08191-62205, 08191-62206 08191-63105, 08191-63106
20-248 b PC400LC-7L
12
Remark

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

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

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

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

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC400LC-7L 20-249 b
12
Remark

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

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

08191-92205, 08191-92206 08191-93105, 08191-93106
20-250 b PC400LC-7L
12
Remark
DT Series connector
No.of
pins T-adapter
Body (plug) Body (receptacle) Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC400LC-7L 20-251 b
12
Remark
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12BR: 799-601-9140
20-252 b PC400LC-7L
12
Remark
DTM Series connector

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

pins Body (plug) Body (receptacle) T-adapter Part No.
2 ---
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC400LC-7L 20-253 b
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
12
T-BRANCH BOX AND T-BRANCH TABLE
★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of
Harness Checker Assembly.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Connector type or part name No. of pins
---
799-601-2600 Measurement box Econo-21P O OO OO O
799-601-3100 Measurement box MS-37P O
799-601-3200 Measurement box MS-37P O
799-601-3300 Measurement box Econo-24P O
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P O O
799-601-3420 BENDIX (MS) 24P O O
799-601-3430 BENDIX (MS) 17P O O
799-601-3440 BENDIX (MS) 17P O O
799-601-3450 BENDIX (MS) 5P O O
799-601-3460 BENDIX (MS) 10P O O
799-601-3510 BENDIX (MS) 5P O O
799-601-3520 BENDIX (MS) 14P O O
799-601-3530 BENDIX (MS) 19P O O
799-601-2910 BENDIX (MS) 14P O O
799-601-3470 Case O
799-601-2710 MIC 5P O O O O
799-601-2720 MIC 13P O O O O
799-601-2730 MIC 17P O OOO OO O
799-601-2740 MIC 21P O OOO OO O
799-601-2950 MIC 9P OOO O
799-601-2750 ECONO 2P O O
799-601-2760 ECONO 3P O O
799-601-2770 ECONO 4P O O
799-601-2780 ECONO 8P O O
799-601-2790 ECONO 12P O O
799-601-2810 DLI 8P O O
799-601-2820 DLI 12P O O
799-601-2830 DLI 16P O O
799-601-2840 Additional cable O O O
799-601-2850 Case O
799-601-7010 X 1P O O
799-601-7020 X 2P O O O O
799-601-7030 X 3P O O O O
799-601-7040 X 4P O O O O
799-601-7050 SWP 6P O O O
799-601-7060 SWP 8P O O O
20-254 b PC400LC-7L
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Connector type or part name No. of pins
---
799-601-7310 SWP 12P O
799-601-7070 SWP 14P O O
799-601-7320 SWP 16P O
799-601-7080 M 1P O O
799-601-7090 M 2P O O O O
799-601-7110 M 3P O O O O
799-601-7120 M 4P O O O O
799-601-7130 M 6P O O O O
799-601-7340 M 8P O
PC400LC-7L 20-255 b
12
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Connector type or part No. of pins
---
name
799-601-7140 S 8P O O O O O
799-601-7150 S 10P-White O O O O
799-601-7160 S 12P-Blue O O O
799-601-7170 S 16P-Blue O O O O
799-601-7330 S 16P-White O
799-601-7350 S 12P-White O
799-601-7180 AMP040 8P O
799-601-7190 AMP040 12P O O
799-601-7210 AMP040 16P O O O O
799-601-7220 AMP040 20P O O O O
799-601-7230 Short connector X-2 O O O O
799-601-7240 Case O O
799-601-7270 Case O
799-601-7510 070 10P O
799-601-7520 070 12P O
799-601-7530 070 14P O
799-601-7540 070 18P O
799-601-7550 070 20P O
799-601-7360 Relay connector 5P O
799-601-7370 Relay connector 6P O
799-601-7380 JFC connector 2P O
799-601-9010 DTM 2P O O
799-601-9020 DT 2P O O
799-601-9030 DT 3P O O
799-601-9040 DT 4P O O
799-601-9050 DT 6P O O
799-601-9060 DT 8P-Gray O O
799-601-9070 DT 8P-Black O O
799-601-9080 DT 8P-Green O O
799-601-9090 DT 8P-Brown O O
799-601-9110 DT 12P-Gray O O
799-601-9120 DT 12P-Black O O
799-601-9130 DT 12P-Green O O
799-601-9140 DT 12P-Brown O O
799-601-9210 HD30 18-8 O O
20-256 b PC400LC-7L
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Connector type or part No. of pins
---
name
799-601-9220 HD30 18-14 O O

799-601-9230 HD30 18-20 O O
799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 24-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 Measurement box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
799-601-9420 For fuel, boost press. 3P O
799-601-9430 PVC socket 2P O
PC400LC-7L 20-257 b
TROUBLESHOOTING CONNECTION TABLE OF FUSE BOX
12
CONNECTION TABLE OF FUSE BOX
★ This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power
supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a
device which supplies power while the starting switch is at the OFF position).
★ When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if
the power is supplied normally.
Type of power supply Fuse No. Fuse capacity Destination of powerDestination of power
Pump controller (Controller power supply)
Swing holding brake solenoid
1 10 A (When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
Pump controller (Solenoid power supply)
Switch power supply 2 20 A Machine push-up solenoid
(Fusible link: A34) ATT return selector relay & solenoid
Starting motor cutout relay (For PPC lock)
3 10 A
PPC lock solenoid
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn
6 10 A (Spare)
7 10 A Rotary lamp
Switch power supply 8 10 A Right front working lamp & boom working lamp
(Fusible link: A34) One-touch power maximizing switch (Input to pump controller input)
9 10 A
Radio
10 10 A (Spare)
11 20 A Air conditioner unit
Monitor panel
12 20 A
Starting motor cutout relay (For personal code)
Switch power supply Light relay (For right front working lamp & boom working lamp)
13 20 A
(Fusible link: A34) Headlamp & additional headlamp
14 10 A Service power supply 1 (M32 connector)
Travel alarm
15 10 A
Service power supply 2 (DC/DC converter)
16 10 A Radio (For backing up)
17 10 A Monitor panel (For backing up)
Constant power supply 18 10 A Starting switch
(Fusible link: A35)
19 10 A Room lamp
20 10 A (Spare)
20-258 b PC400LC-7L
TROUBLESHOOTING ERROR CODES IN MONITOR
SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306

POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF . . . . . . . . . . . . 20-307
USER CODE MEMORY RETENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307
INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-308
E101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310
ERROR IN DATA HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310
E112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
E113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-314
SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE . . . . . . . . . . . . . . . . . . . . . 20-314
E114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
SHORT OR OPEN IN WINDOW WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
E115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
ABNORMAL WIPER MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
E116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
ABNORMALITY IN PARKING WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
E117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322
ENGINE CONTROLLER S-NET COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322
E118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324
PUMP CONTROLLER S-NET COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324
E128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
MONITOR COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
E201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
E203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-330
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . 20-330
E204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
SHORT IN MERGE/DIVIDE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
E205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
SHORT IN 2-STAGE RELIEF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
E206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336
SHORT IN TRAVEL SPEED SHIFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336
E211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338
OPEN IN TRAVEL INTERLOCKING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338
E213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
OPEN IN SWING HOLDING BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
E214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342
OPEN IN MERGE/DIVIDE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342
E215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344
OPEN IN 2-STAGE RELIEF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344
E216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
OPEN IN TRAVEL SPEED SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
E217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348
ABNORMAL INPUT MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348
E218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350
OPEN IN S-NET COMMUNICATION SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350
E222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352
PC400LC-7L 20-301 1
TROUBLESHOOTING TABLE OF CONTENTS
SHORT IN LS-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352
E223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354
OPEN IN LS-EPC SOLENOID SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354
E224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356
E225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
E226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
ABNORMAL PRESSURE SENSOR POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
E227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
E228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
SHORT IN ATTACHMENT RETURN SWITCHING RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
E232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
SHORT IN PC-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
E233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
OPEN IN PC-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
E238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
OPEN IN ATTACHMENT RETURN SWITCHING RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
E245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM . . . . . . . . . . . . . . . . . . . . 20-372
E246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-374
OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20-374
E247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376
ABNORMALITY IN ARM IN PPC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376
E248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378A
BNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
E257 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
ABNORMALITY IN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
E315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
SHORT IN BATTERY RELAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
E91B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
ENGNE NE SENSOR PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
E91C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
ENGINE G SENSOR PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
E920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
ENGINE TYPE SELECTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
E921 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390
ENGINE TYPE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390
E931 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
FUEL DIAL SYSTEM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
E934 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
ENGINE COOLANT SENSOR HI ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
E96A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
ENGINE COOLANT SENSOR LO ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
E936 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
ENGINE OIL PRESSURE SWITCH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
E93C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
ENGINE BOOST SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
E93D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
ENGINE FUEL TEMPERATURE SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
E953 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
ENGINE COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
E954 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
SHORT IN ENGINE IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
E955 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
ENGINE S-NET ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
20-302 1 PC400LC-7L
E956 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
ENGINE POWER FAILURE (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
E957 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
ENGINE POWER FAILURE (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
E95A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
E970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
PCV1 OVER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
E971 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
PCV2 OVER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
E974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
PCV1 LINE CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
E975 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
PCV2 LINE CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
E977 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
RAIL PRESSURE SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
E979 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
RAIL PRESSURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
E97A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427
RAIL PRESSURE ABNORMAL HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427
E97B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
RAIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
E97C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
RAIL PRESSURE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
E97D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
RAIL PRESSURE OUT OF CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
E980 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
ENGINE CONTROLLER ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
E981 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
FUEL INJECTOR 1 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
E982 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435
E983 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
E984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-437
E985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438
E986 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439
E98A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
FUEL INJECTOR 1 - 3 S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
E98B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
FUEL INJECTOR 4 - 6 S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
A000N1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444
ENGINE HIGH IDLING SPEED OUT OF STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444
A000N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445
ENGINE LOW IDLING SPEED OUT OF STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445
AA10NX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
AIR CLEANER CLOGGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
AB00KE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
CHARGE VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
B@BAZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
ENGINE OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
B@BAZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
ENGINE OIL LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
B@BCNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
PC400LC-7L 20-303 1
ENGINE WATER OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
B@BCZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
ENGINE WATER LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
B@HANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
HYDRAULIC OIL OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
20-304 1 PC400LC-7L
TROUBLESHOOTING
12
MEMORANDUM
PC400LC-7L 20-305 1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
1. Always turn power OFF before disconnecting or connecting connectors.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
★ If power is turned ON with the connectors still disconnected, unnecessary displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
5. When checking a single diode circuit:

★ Isolate the diode from the circuit.
★ using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red lead
positive and black lead negative.
6. When checking a dual diode circuit:

★ Isolated the diode from the circuit.
7. Always be aware of what you are measuring. Voltage, Ohms or Amps.

Always use caution when measuring a circuit.
★ When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are measuring.
★ When measuring ohms, be sure the circuit is dead and has no
voltage in it before you take any readings. Be sure the meter is set
in the proper ohms range.
★ When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage you equipment or possibly cause injury.
Always study the operators manuel for the meter you will be
using.
20-306 1 PC400LC-7L
12
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY
ITSELF
There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully.
1. If any abnormality returns to normal by itself.
2. If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned
to its original position when carrying out troubleshooting on the failure, and the service code is no longer displayed, or if
the monitor display returns to normal.
3. After completing troubleshooting, always erase the user code from memory.
USER CODE MEMORY RETENTION FUNCTION

When displaying the codes in the memory and carrying out troubleshooting, record the content of the display first, then erase
the display. After re-enacting the problem, carry out troubleshooting according to the failure codes that are now displayed.
There are cases where mistaken operation or abnormalities occur when a connector is disconnected. Erasing the data in this
way saves any wasted work.
PC400LC-7L 20-307 1
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
12
INFORMATION CONTAINED IN TESTING PROCEDURES
★ The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to
isolate each part of the circuit.
• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.
Tools and Procedures
• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while
performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or actuator
• With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Resistance Ω Test procedure for component only. readings 1 information
A. What you are
or
testing Voltage Your
Test procedure for component only. readings 2
information
2. Diode test
• With ignition switch in the OFF position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm electrical
flow. Electrical flow should be one way only.
At a diode, between point (x) and (x) reverse meter lead Continuity one
A.Diode test Resistance Ω polarity each time to check diode. way only? 3 Yes or No
3. Wiring harness assembly test
Your
Resistance Ω Test procedure for harness. (connector) to (connector) readings 4
A.Open or high information
or
resistance Voltage Your
Test procedure for harness. (connector) to (connector) readings 5
information
Your
B.Short to chas- Resistance Ω Test procedure for harness. (connector) to (connector) readings 6 information
sis ground or or
Voltage Your
within harness Test procedure for harness. (connector) to (connector) readings 7
information
4. Additional components to be tested
A.What you are Resistance Ω Your
or Test procedure for any additional components. readings 8
testing Voltage information
20-308 1 PC400LC-7L
12
Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC400LC-7L 20-309 1
TROUBLESHOOTING E101
12
E101
ERROR IN DATA HISTORY
• Data chain error
Contents Of Trouble • Failure code DAF0KT displayed.
• Can not access failure codes on monitor.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
Steps Circuit Diagnostic Procedures For Code [E101] Specifications No. Readings
Check condition of batteries and connections before pro- Good
Batteries — 1 Yes or No
ceeding with these tests. Condition?
Check condition of fuse links A34(L-2) and
A35(M-2) Good
Fuse link and fuses — 2 Yes or No
Check condition of fuses in fuse box FB1 12 (20A) and Condition?
17 (10A).
1. Fuse link and fuses (FB1)
• With ignition switch in the OFF position.
• Disconnect A34 and A35 fuse link connectors.
• Zero meter leads for proper Ω readings.
At fuse link A34, between (1) and (2) 0.0 to 1.0Ω 3
A. Fuse tests Resistance Ω At fuse link A35, between (1) and (2) 0.0 to 1.0Ω 4
Check condition of fuses at (FB1) Good? 5 Yes or No
• Disconnect H10 connector from monitor panel.
• * Turn ignition switch to the ON position for these tests only.
* At connector H10, between (1) and chassis ground 30 to 20V 6
A. Open or high Voltage
* At connector H10, between (5) and chassis ground 30 to 20V 7
resistance
Resistance Ω At connector H10, between (4) and chassis ground 0.0 to 1.0Ω 8
At connector H10, between (1) and chassis ground (OL) open 9
B. Short to chassis At connector H10, between (5) and chassis ground (OL) open 10
ground or within har- Resistance Ω
At connector H10, between (4) and (5) (OL) open 11
ness
At connector H10, between (1) and (5) (OL) open 12
3. Monitor panel test
• With ignition in the OFF position.
• Disconnect P01 connector from monitor panel and install T-adapter between P01 wiring harness connector and monitor panel.
• Turn ignition switch to the ON position.
Between P01, (1) (2) and chassis ground 30 to 20V 13
Voltage
A. Monitor panel Between P01, (8) and chassis ground 30 to 20V 14
Resistance Ω Between P01, (6) (7) and chassis ground 0.0 to 1.0Ω 15
20-310 1 PC400LC-7L
12
Electrical circuit diagram for E101 error in data history
PC400LC-7L 20-311 1
12
E112
SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM
• Possible short or open in wiper motor drive system.
Contents Of Trouble • Failure code DY2DBK.
• No wiper operation.

1. Wiper motor
• Disconnect W04 connector from motor and install T-adapter between motor and connector W04.
• * Turn ignition switch to the ON position for this test.
* At connector W04, between (1) and (3), wiper switch
Voltage 20 to 30V cycling 1
A. Wiper motor set ON.
Resistance Ω At connector W04, (1) and chassis ground. (OL) open 2
• Disconnect W04 connector from wiper motor.
• Disconnect P01 connector from controller and install T-adapter between P01 connector and monitor panel.
Between connectors W04, (1) and P01, (10) 0.0 to 1.0Ω 3
A. Open or high Between connectors W04, (4) and P01, (12) 0.0 to 1.0Ω 5
Resistance Ω
resistance Between connectors W04, (5) and chassis ground 0.0 to 1.0Ω 6
At connector W04, (1) and chassis ground (OL) open 9
B. Short to chassis
ground or within Resistance Ω
harness At connector W04, (1) and (3) (4) (5) (6) (OL) open 14
At connector W04, (4) and (5) (6) (OL) open 15
At connector W04, (5) and (6) (OL) open 16
At connector P02 (15) and W03 (2) (OL) open 17
At connector W04 (5) and W03 (1) (OL) open 18
• Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.
Between P01, (9) and chassis ground, wiper ON 20 to 30V cycling 19
A. Monitor panel Voltage
Between P01, (9) and chassis ground, wiper OFF 0V 20
20-312 1 PC400LC-7L
12
Electrical circuit diagram for the windshield wiper motor
PC400LC-7L 20-313 1
12
E113
SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE
Contents Of Trouble • Failure code DY2EKB.

1. Wiper motor
* At connector W04, between (1) and (3), wiper switch
Voltage 20 to 30V cycling 1
A. Wiper motor set ON.
Resistance Ω At connector W04, (1) and chassis ground. (OL) open 2
A. Open or high Between connectors W04, (4) and P01, (12) 0.0 to 1.0Ω 5
Resistance Ω
resistance Between connectors W04, (5) and chassis ground 0.0 to 1.0Ω 6
B. Short to chassis
At connector P02 (15) and W03 (2) (OL) open 17
At connector W04 (5) and W03 (1) (OL) open 18
Between P01, (9) and chassis ground, wiper ON 20 to 30V cycling 19
Between P01, (9) and chassis ground, wiper OFF 0V 20
20-314 1 PC400LC-7L
12
Circuit diagram for monitor panel wiper motor.
PC400LC-7L 20-315 1
12
E114
SHORT OR OPEN IN WINDOW WASHER SYSTEM
Contents Of Trouble • Failure code DY2CKB.

1. Washer motor
• Disconnect A05 connector from motor and install T-adapter between motor and connector A05.
* At connector A05, between (13) and (14), washer
20 to 30V 1
switch set ON.
A. Washer motor Voltage
At connector A05, between (13) and (14), washer switch
0V 2
set OFF.
• Disconnect A05 connector from washer motor.
• Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.
A. Open or high Voltage * Between connector A05, (13) and chassis ground 20 to 30V 3
resistance Resistance Ω Between connectors A05, (14) and P01, (3) 0.0 to 1.0Ω 4
B. Short to chassis At connector A05, (13) and chassis ground (OL) open 5
At connector A05, (14) and chassis ground (OL) open 6
harness
3. Diode test
• Disconnect D04 diode connector and isolate diode
At diode D04, between (4) and (8) reversing meter lead Continuity one
A. Diode test Resistance Ω 7 Yes or No
polarity each time to check. way only?
Between P01, (3) and chassis ground, washer OFF 20 to 30V 8
Between P01, (3) and chassis ground, washer ON 0V 9
20-316 1 PC400LC-7L
12
Monitor panel window washer motor circuit diagram
PC400LC-7L 20-317 1
12
E115
ABNORMAL WIPER MOTOR OPERATION
• Abnormal wiper motor operation.
Contents Of Trouble • Failure code DY20KA.

1. Wiper motor park system
At connector W04, between (6) and (5), wiper at far end
0.0 to 1.0Ω 1
of operation.
A. Wiper motor Resistance Ω
At connector W04, between (6) and (5), wiper at mid
(OL) open 2
point on windshield.
Between W04, (1) and P01, (10) 0.0 to 1.0Ω 3
A. Open or high Between W04, (4) and P01, (12) 0.0 to 1.0Ω 5
Resistance Ω
resistance Between W04, (5) and chassis ground 0.0 to 1.0Ω 6
Between P02, (15) and chassis ground 0.0 to 1.0Ω 8
B. Short to chassis
At connector W04, (3) and (4) (5) (6) (OL) open 14
Between P01, (5) and chassis ground, wiper end 0V 17
Between P01, (5) and chassis ground, wiper at mid point 20 to 30V 18
20-318 1 PC400LC-7L
12
Monitor panel windshield wiper motor circuit diagram
PC400LC-7L 20-319 1
12
E116
ABNORMALITY IN PARKING WIPER ARM
• Abnormal in parking wiper motor arm.
Contents Of Trouble • Failure code DY20MA.
• Wiper will not park.

1. Wiper motor park system
At connector W04, between (6) and (5), wiper at far end
0.0 to 1.0Ω 1
of operation.
A. Wiper motor Resistance Ω
At connector W04, between (6) and (5), wiper at mid
(OL) open 2
point on windshield.
A. Open or high Between W04, (4) and P01, (12) 0.0 to 1.0Ω 5
Resistance Ω
resistance Between W04, (5) and chassis ground 0.0 to 1.0Ω 6
Between P02, (15) and chassis ground 0.0 to 1.0Ω 8
B. Short to chassis
At connector W04, (3) and (4) (5) (6) (OL) open 14
Between P01, (12) and chassis ground, wiper parked 0V 17
Between P01, (12) and chassis ground, wiper at mid point 20 to 30V 18
20-320 1 PC400LC-7L
12
Monitor panel wiper motor circuit diagram
PC400LC-7L 20-321 1
12
E117
ENGINE CONTROLLER S-NET COMMUNICATION ERROR
• The monitor panel detected communication failure in the S-NET communication circuit to the engine controller.
Contents Of Trouble
• Failure code DAC0KR.
• The engine is fixed to the E mode and the pump absorption torque is limited to about 80%.
Response from monitor panel
• When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on • The output lowers (The pump absorption torque is reduced).
machine • If the working load increases, the engine may stall.
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
Relative information
(Code No. 05100: Connection of S-NET)
• Digital Volt Ohm Meter.

• T-adapter kit if appropriate.

• With ignition switch in OFF position.
Between pump controller C02 (21) and monitor panel P02
0.0 to 1.0Ω 1
(9) or (10)
A. Open or high
Resistance Ω Between pump controller C02 (21) and engine controller
resistance 0.0 to 1.0Ω 2
CB2 (21) and (31)
Between monitor panel P02 (20) and chassis ground 0.0 to 1.0Ω 3
Between monitor panel P02 (9), (10) and engine
B. Grounding fault of controller CB2 (21), (31) and related circuits and Above 1 MΩ 4
wiring harness
Resistance Ω grounding
(Contact with
Between monitor panel P02 (9), (10) and pump controller
grounding circuit) Above 1 MΩ 5
C02 (21) and related circuits and grounding
• With ignition switch in OFF position, make the test preparations.
• During test hold ignition switch in the ON position.
controller CB2 (21), (31) and related circuits and 0V 6
A. Short-circuit (Contact
Voltage grounding
with 24V circuit)
0V 7
3. Engine controller
• Turn the engine ignition switch OFF for the preparations.
• Disconnect CB2 connector and install T-adapter.
• Hold ignition switch in the ON position during the troubleshooting.
A. Defective controller CB2 (21) [S-NET (+)] and (11) [GND] 6 - 9V 8
Voltage
test CB2 (21) [S-NET (+)] and (11) [GND] 6 - 9V 9
• Disconnect P02 connector from monitor and install T-adapter.
• Turn ignition switch to the ON position during the troubleshooting.
Between P02 (9) [N/W signal] and (20) [N/W GND] 6 - 9V 10
A. Monitor panel test Voltage
20-322 1 PC400LC-7L
12
Engine controller S-net communication circuit diagram
PC400LC-7L 20-323 1
12
E118
PUMP CONTROLLER S-NET COMMUNICATION ERROR
• The monitor panel detected communication failure in the S-NET communication circuit to the pump controller.
Contents Of Trouble
• Failure code DAB0KR.


Between P02 (9), (10) monitor panel and CB2 (21), (31)
0.0 to 1.0Ω 1
engine controller
A. Open or high
Resistance Ω Between P02 (9), (10) monitor panel and C02 (21) pump
resistance 0.0 to 1.0Ω 2
controller
Between P02 (20) monitor panel and chassis ground 0.0 to 1.0Ω 3
B. Grounding fault of controller CB2 (21), (31) and related circuits and Above 1 MΩ 4
wiring harness
Resistance Ω grounding
(Contact with
grounding circuit) Above 1 MΩ 5
controller CB2 (21), (31) and related circuits and 0V 6
Voltage grounding
with 24V circuit)
0V 7
3. Pump controller
• Disconnect C02 connector and install T-adapter.
A. Defective controller
Voltage C02 (21) S-NET and (31) S-NET GND 6 - 9V 8
test
20-324 1 PC400LC-7L
12
Pump controller S-net communication circuit diagram
PC400LC-7L 20-325 1
12
E128
MONITOR COMMUNICATION ABNORMALITY
• The monitor panel detected communication failure in the CAN communication circuit to the engine controller or pump
Contents Of Trouble controller.
• Failure code DAF0MC.
Relative information ---


Between P70 (16) monitor panel and CB2 (22) engine
0.0 to 1.0Ω 1
controller
Between P70 (16) monitor panel and C02 (22) pump
0.0 to 1.0Ω 2
controller
A. Open or high Between P70 (15) monitor panel and CB2 (32) engine
Resistance Ω 0.0 to 1.0Ω 3
resistance controller
Between P70 (15) monitor panel and C02 (32) pump
0.0 to 1.0Ω 4
controller
Between P70 (14) monitor panel and chassis ground
0.0 to 1.0Ω 5
Between monitor panel P70 (16) and engine controller

Above 1 MΩ 6
CB2 (22)
Above 1 MΩ 7
C02 (22)
B. Grounding fault of Between monitor panel P70 (16) and related circuits and
Above 1 MΩ 8
wiring harness grounding
Resistance Ω
(Contact with Between monitor panel P70 (15) and engine controller
Above 1 MΩ 9
grounding circuit) CB2 (32)
Above 1 MΩ 10
C02 (32)
Between monitor panel P70 (15) and related circuits and
Above 1 MΩ 11
grounding
0V 6
CB2 (22)
Between monitor panel P70 (16) and pump controller C02
0V 7
(22)
0V 8
A. Short-circuit (Contact grounding
Voltage
with 24V circuit) Between monitor panel P70 (15) and engine controller
0V 9
CB2 (32)
Between monitor panel P70 (15) and pump controller C02
0V 10
(32)
0V 11
grounding
20-326 1 PC400LC-7L
3. CAN terminal resistors
• Turn the engine ignition switch OFF.
• Hold the ignition switch in the OFF position for this test
A. Defective CAN K30 between (A) and (B) 40 - 80Ω 12
Resistance Ω
resistor tests K31 between (A) and (B) 40 - 80Ω 13
4. Monitor panel, engine controller or pump controller
• If causes 1 - 3 are not detected, monitor panel, engine controller or pump controller may be defective. (Since trouble is in those devices,
troubleshooting cannot be carried out.)
Monitor Communication related to CAN communication
PC400LC-7L 20-327 1
12
E201
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID
• When power was turned on, there was abnormal current supplied to the travel interlocking circuit.
Contents Of Trouble
• Failure code DW91KB.
• Power supply to the travel interlocking circuit is switched OFF.
Response from controller • Even if the failure cause disappears of itself, the solenoid circuit does not return to normal, unless the engine starting
switch is turned OFF.
Phenomenon occurring on
• It is difficult to steer the machine at turns. (LH and RH travel circuits cannot be disconnected).
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)


1. Solenoid test
• Disconnect V02 connector from solenoid.
At solenoid V02, between (1) and (2) 20 to 60Ω 1
A. Solenoid test Resistance Ω
At solenoid V02, between (1) and chassis ground (OL) open 2
• Hold ignition switch in OFF position during troubleshooting.
A. Ground fault test
Between pump controller C03 (7) to travel junction
(Contact with Resistance Ω Above 1MΩ 3
solenoid V02 (2) connection and ground
grounding circuit)
3. Pump controller
• Ignition switch in the ON position, engine running during the troubleshooting.
• Move RH & LH travel control levers
A. Defective controller C03 (7) and ground - Levers - Neutral position 0V 4
Voltage
test C03 (7) and ground - Levers - Steering actuated 20 - 30V 5
Travel interlocking solenoid circuit diagram
20-328 1 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 20-329 1
12
E203
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM
• When power was turned on, there was abnormal current supplied to the swing holding brake solenoid circuit.
Contents Of Trouble
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from controller • Even if the failure cause disappears of itself, the swing and steering brake does not return to normal, unless the engine
starting switch is turned OFF.
• The upper structure cannot swing. (The swing holding brake cannot be released.
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
Relative information • If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing
holding brake release switch to the RELEASE position.
(In this case, however, the holding brake does not work, when stopping the machine.)


1. Solenoid test
A. Swing holding brake At solenoid V05, between (1) and (2) 20 to 60Ω 1
solenoid test (Internal Resistance Ω
At solenoid V05, between (2) and ground Above 1MΩ 2
short or ground fault)
2. Diode test
• Disconnect D01 diode connector and isolate.
A. Diode test Resistance Ω 3
• Disconnect S25 and X05 connectors from swing lock and park brake switches.
• Disconnect C03 and C02 connectors from controller and install T-adapter on C03 and C02 wire harness connectors only.
Between connectors C03 (37) and S25 (8) Above 1MΩ 4
Between connectors C03 (37) and X05 (3) Above 1MΩ 5
A. Open or high Between connectors C02 (2) and S25 (9) Above 1MΩ 6
Resistance Ω
resistance Between connectors V05 (2) and X05 (4) Above 1MΩ 7
Between connectors V05 (1) and S25 (8) Above 1MΩ 8
Between connectors V05 (1) and chassis ground Above 1MΩ 9
B. Short to chassis At connectors V05 (2) and chassis ground (OL) open 10
harness At connector V05 between (1) and (2) (OL) open 11
4. Pump controller
Voltage
test C03 (37) and ground - Levers - Steering actuated 20 - 30V 13
20-330 1 PC400LC-7L
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400LC-7L 20-331 1
12
E204
SHORT IN MERGE/DIVIDE SOLENOID
• Short in merge/divide solenoid circuit (Pump controller system).
Contents Of Trouble
• Failure code DWJ0KB.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from controller • Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.
Phenomenon occurring on • In L mode, the work equipment moves slowly or the swing speed is slow in single operation. (F•R pumps cannot be
machine disconnected).
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.


1. Solenoid test
• Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only.
A. Open or high
Resistance Ω Between connectors C03 (17) and V01 (2) Above 1MΩ 3
resistance
B. Short to chassis At connector V02, between (1) and chassis ground (OL) open 4
harness At connector V02, between (1) and (2) (OL) open 5
3. Pump controller
Voltage
test C03 (17) and ground - Levers - operating one side only 20 - 30V 7
20-332 1 PC400LC-7L
Electrical Circuit Diagram for Merge/Divide Solenoid
PC400LC-7L 20-333 1
12
E205
SHORT IN 2-STAGE RELIEF SOLENOID
• Short in 2-stage relief solenoid circuit (Pump controller system).
Contents Of Trouble
• Failure code DWK0KB.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Phenomenon occurring on • The one-touch power max. switch does not work.
machine (The main relief valve cannot be set to high-pressure set.)
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.


1. Solenoid test
• Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only.
A. Open or high
resistance
3. Pump controller
• Turn ignition switch ON.
A. Defective controller C03 (28) and ground - Other than L mode 0V 6
Voltage
test C03 (28) and ground - L mode 20 - 30V 7
20-334 1 PC400LC-7L
Electric Circuit Diagram for 2-stage Relief Solenoid
PC400LC-7L 20-335 1
12
E206
SHORT IN TRAVEL SPEED SHIFT SOLENOID
• Short in travel speed shifting solenoid circuit (Pump controller system).
Contents Of Trouble
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Phenomenon occurring on • The travel speed does not turn to HI.
machine (The travel motor swash plate angle does not turn to minimum.)
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.


1. Solenoid test
A. Travel speed shifting At solenoid V04, between (1) and (2) 20 to 60Ω 1
• Disconnect C03 connector from governor pump controller an install T-adapter.
A. Open or high
resistance
3. Pump controller
• Turn ignition switch ON.
C03 (27) and ground - travel speed Lo + travel lever
0V 6
A. Defective controller Neutral
Voltage
test C03 (27) and ground - travel speed Hi + travel lever
20 - 30V 7
in operation
20-336 1 PC400LC-7L
12
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
PC400LC-7L 20-337 1
12
E211
OPEN IN TRAVEL INTERLOCKING SOLENOID
• No current flows to the travel interlocking solenoid circuit, when power is supplied (Pump controller system).
Contents Of Trouble
• Failure code DW91KA.
• None in particular (The solenoid does not function because there is no current).
Response from controller
Phenomenon occurring on • It is difficult to steer the machine while traveling.
machine (LH and RH travel circuits cannot be disconnected.)
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
• The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs.
(For how to turn power ON or OFF, refer to the troubleshooting under Error Code E201).


1. Solenoid test
A. Travel speed shifting At solenoid V02, between (1) and (2) 20 to 60Ω 1
A. Open or high
Resistance Ω Between connectors C03 (7) and V02 (2) Below 1Ω 3
resistance
B. Short to chassis
ground or within Resistance Ω Between C03 (3), (13), (23) and V02 (1) Below 1Ω 4
harness
3. Pump controller
• Hold ignition in the OFF position.
Voltage Between C03 (7) and (3), (13), (23) 20 - 60Ω 5
test
20-338 1 PC400LC-7L
12
Electrical Circuit Diagram for Travel Interlocking Solenoid
PC400LC-7L 20-339 1
12
E213
OPEN IN SWING HOLDING BRAKE SOLENOID
• No current flows to the swing holding brake solenoid circuit, when power is supplied (Pump controller system).
Contents Of Trouble
• The upper structure cannot swing. (The swing holding brake cannot be released.
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing
holding brake release switch to the RELEASE position.
Relative information (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 posi-
tion.
• The controller detects disconnection, when solenoid power is ON. Therefore be sure to check it with power ON after the
repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code E203.)


1. Solenoid test
2. Swing lock switch test
• Disconnect X05 connector and install T-adapter.
Swing lock switch
OFF Below 1Ω 3
A. Swing lock switch test Resistance Ω Between X05 (3) and (4)
ON Above 1MΩ 4
3. Diode test
• Disconnect D01 diode connector and isolate.
A. Diode test Resistance Ω 5
• Disconnection or defective contact with connector.
• Disconnect S25 and X05 connectors from swing lock and park brake switches.
• Disconnect C03 and C02 connectors from controller and install T-adapter on C03 and C02 connectors.
Between connectors C03 (37) and D01 (7) Below 1Ω 6
A. Open or high Between connectors D01 (3) to J02 to X05 (3) Below 1Ω 7
Resistance Ω
resistance Between connectors X05 (4) to V05 (2) Below 1Ω 8
Between connectors C03 (3), (13), (23) and V05(1) Below 1Ω 9
B. Short between wires or ground
• With ignition switch in OFF position for preparation.
• Hold ignition switch in ON position during trouble shooting.
20-340 1 PC400LC-7L
--- --- Voltage At connectors C03 (37) and D01 (7) and ground Below 1V 10
5. Pump controller
• Disconnect C03 connector from controller and install T-adapter on C03connector.
• Disconnect D01 and connect pins (3) and (7) of female side for test.
A. Defective pump
Resistance Ω At C03 (17) and between pins (3), (13), (23) 20 - 60Ω 11
controller test
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400LC-7L 20-341 1
12
E214
OPEN IN MERGE/DIVIDE SOLENOID
• No current flows to the merge/divide solenoid circuit, when power is supplied (Pump controller system).
Contents Of Trouble
• Failure code DWJ0KA.
Phenomenon occurring on • In L mode, speeds of the work equipment and swing in its single operation are too fast.
machine (F• R pumps cannot be disconnected.)
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.


1. Solenoid test
A. Merge/divide solenoid At solenoid V02, between (1) and (2) 20 to 60Ω 1
test (Internal short or Resistance Ω
ground fault)
• Checking for disconnection or defective contact with connector.
A. Open or high
resistance
B. Short to chassis
harness
3. Short in wiring harness (Contact with 24V circuit).
• Hold ignition switch in ON position during troubleshooting.
A. Short & contact with Check wiring harness from C03 (17) to V03 (2) and
Voltage Below 1V 5
24V circuit grounding
4. Pump controller
Resistance Ω Between C03 (17) and (3), (13), (23) 20 - 60Ω 6
test
20-342 1 PC400LC-7L
12
Electrical Circuit Diagram for Merge/Divide Solenoid
PC400LC-7L 20-343 1
12
E215
OPEN IN 2-STAGE RELIEF SOLENOID
• No current flows to the 2-stage relief solenoid circuit, when power is supplied (Pump controller system).
Contents Of Trouble
• Failure code DWK0KA.
Phenomenon occurring on • The one-touch power max. switch does not work.
machine (The main relief valve cannot be set to high-pressure set.)
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.


1. Solenoid test
A. 2-stage relief solenoid At solenoid V08, between (1) and (2) 20 to 60Ω 1
ground fault)
A. Open or high
resistance
B. Short to chassis
harness
Voltage Below 1V 5
4. Pump controller
test
20-344 1 PC400LC-7L
12
Electrical Circuit Diagram for 2-stage Relief Solenoid
PC400LC-7L 20-345 1
12
E216
OPEN IN TRAVEL SPEED SOLENOID
• No current flows to the travel speed solenoid circuit, when power is supplied (Pump controller system).
Contents Of Trouble
Phenomenon occurring on • The travel speed does not shift to Hi.
machine (The travel motor swash plate angle does not turn to minimum.)
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.


1. Solenoid test
A. Travel speed solenoid At solenoid V04, between (1) and (2) 20 to 60Ω 1
ground fault)
A. Open or high
resistance
B. Short to chassis
harness
Voltage Below 1V 5
4. Pump controller
test
20-346 1 PC400LC-7L
12
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
PC400LC-7L 20-347 1
12
E217
ABNORMAL INPUT MODEL CODE
• A model code signal for a model which is not registered in the controller is inputted. (Pump controller system).
Contents Of Trouble
• Failure code DA2SKQ.
• The controller controls the machine as a default model (PC750).
Response from controller • Even after the failure cause disappears of itself, the machine operation does not return to normal, unless the engine
starting switch is turned OFF.
• Since the controller controls the machine as PC750/800, the working speed changes and operation becomes difficult.
machine
• 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.)


1. Model selection connector
• Disconnect C09 connector and use T-adapter.
• Hold ignition switch in OFF position for troubleshooting.
A. Model selection At C09, between (4), (5), (6), (8) Μin. 1MΩ 1
connector test (Internal Resistance Ω
short or ground fault) At C09, between (1), (2), (3), (7), (8) Μax. 1Ω 2
C02 (37) and C09 (1) Μax. 1Ω 3
C02 (27) and C09 (2) Μax. 1Ω 4
A. Open or high
Resistance Ω C02 (17) and C09 (3) Μax. 1Ω 5
resistance
C02 (13) and C09 (7) Μax. 1Ω 6
C09 (8), J05, and ground (A13) Μax. 1Ω 7
3. Short in wiring harness.
A. Short & contact Resistance Ω Check wiring harness from C02 (7) to C09 (4) and ground Μin. 1MΩ 8
4. Pump controller
• Hold ignition in the ON position during troubleshooting.
A. Defective controller Between C02 (7) and ground 5 - 30V 9
Voltage
test Between C02 (37), (27), (17), (13) and ground Max. 1V 10
20-348 1 PC400LC-7L
12
Electrical circuit diagram related to model selection connector (for pump controller)
PC400LC-7L 20-349 1
12
E218
OPEN IN S-NET COMMUNICATION SIGNAL
• The pump controller detected communication failure in the S-NET communication circuit to the monitor panel or
Contents Of Trouble engine controller.
• Failure code DA2SKA.


• Hold in the OFF position during troubleshooting.
Between P02 (9), (10) monitor panel and CB2 (21), (31)
Max. 1Ω 1
engine controller
A. Open or high
Resistance Ω Between P02 (9), (10) monitor panel and C02 (21) pump
resistance Max. 1Ω 2
controller
Between P02 (20) monitor panel and chassis ground Max. 1Ω 3
Min. 1MΩ 4
B. Grounding fault of controller CB2 (21), (31)
Resistance Ω
wiring harness Between monitor panel P02 (9), (10) and pump controller
Min. 1MΩ 5
(Contact with C02 (21) and related circuits and grounding
grounding circuit) Between monitor panel P02 (9), (10) related circuits and
Min. 1MΩ 6
grounding
controller CB2 (21), (31) and related circuits and Max. 1V 7
grounding
Voltage Between monitor panel P02 (9), (10) and pump controller
with 24V circuit) Max. 1V 8
Between monitor panel P02 (9), (10) related circuits and
Max. 1V 9
grounding
A. Monitor panel test Voltage Between P02 (9), (10) [N/W signal] and (20) [N/W GND] 6 - 9V 10
4. Engine controller test
Voltage CB2 (21), (31) and (11) 6 - 9V 11
test
20-350 1 PC400LC-7L
5. Pump controller test
• Disconnect C02 connector from monitor and install T-adapter.
A. Monitor panel test Voltage C02, between (21) and (31) 6 - 9V 12
Electrical Circuit Diagram for S-NET Communication
PC400LC-7L 20-351 1
12
E222
SHORT IN LS-EPC SOLENOID
• Short in LS-EPC solenoid circuit.
Contents Of Trouble
• Failure code DXE0KB.
• The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from controller • Even if the failure cause disappears, the current does not return to normal, unless the engine ignition switch is turned
OFF.
Phenomenon occurring on • The travel speed is slow at Mi and Lo or in L mode, speeds of the work equipment and swing are too fast
machine (The LS valve set pressure cannot be controlled.)
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01500 LS-EPC solenoid current.)


1. LS-EPC solenoid
• Turn the engine ignition switch OFF for preparations
• Disconnect V22 connection.
• Hold ignition switch OFF during troubleshooting.
A. LS-EPC solenoid test At connection V22, between (1) and (2) 7 - 14Ω 1
(internal short or Resistance Ω
At connection V22, Between (1) and ground Above 1 MΩ 2
ground fault)
2. Wiring harness assembly
• Disconnect pump controller C03 and install T-adapter.
• Ignition switch should remain in the OFF position during troubleshooting.
A. Open or high
Resistance Ω Between C03 (6) and V22 (1) and ground Above 1 MΩ 3
resistance
B. Grounding fault of At connector V22, between (1) and ground (OL) open 4
wiring harness At connector V22, between (2) and ground (OL) open 5
Resistance Ω
(Contact with
grounding circuit) At connector V22, between (1) and (2) (OL) open 6
3. Pump controller
Between C03 (6) and (3), (13), (23) 7 - 14Ω 7
A. Pump controller Resistance Ω
Between C03 (6) and ground Above 1 MΩ 8
20-352 1 PC400LC-7L
Electrical Circuit Diagram for LS-EPC Solenoid
PC400LC-7L 20-353 1
12
E223
OPEN IN LS-EPC SOLENOID SYSTEM
• Open (no current flow) in LS-EPC solenoid circuit.
Contents Of Trouble
• Failure code DXE0KA.
• None in particular (The solenoid does not function as there is no current flow to it).
• When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on • The travel speed is slow at Mi and Lo or in L mode, speeds of the work equipment and swing are too fast
machine (The LS valve set pressure cannot be controlled.)
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01500 LS-EPC solenoid current.)


1. LS-EPC solenoid
• Disconnect V22 connection.
• Hold ignition switch OFF during troubleshooting.
A. LS-EPC solenoid test At connection V22, between (1) and (2) 7 - 14Ω 1
(internal short or Resistance Ω
ground fault) At connection V22, Between (1) and ground Above 1 MΩ 2
★ Ignition switch ON during this test.
A. Open or high Between C03 (6) and V22 (1) and ground Below 1Ω 3
Resistance Ω
resistance Between C03 (3), (13), (23) and V22 (2) Below 1Ω 4
B. Grounding fault of
wiring harness
(Contact with 24V
Voltage ★ Between C03 (6) and V22 (1) and ground Below 1V
grounding circuit)
3. Pump controller
A. Pump controller Resistance Ω Between C03 (6) and (3), (13), (23) 7 - 14Ω
20-354 1 PC400LC-7L
Electrical Circuit Diagram for LS-EPC Solenoid
PC400LC-7L 20-355 1
12
E224
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL
• Signal voltage from the front pump pressure sensor is below 0.3V or above 4.42V. (Pump controller system.)
Contents Of Trouble
• Failure code DHPAMA.
• The controller sets the F pump to 0 kg/cm2 (0 psi) for control.
• The travel speed does not shift automatically (The travel load pressure cannot be detected).
machine
★ 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.)


1. Sensor power supply system defective If error code 226 is displayed, carry out troubleshooting for it first. 1
2. Front pump pressure sensor defective (Internal defect)
★ Ignition switch ON or keep the engine running during troubleshooting.
★ At connection A51, between (B) and (A) - power 4.5 - 5.5V 2
supply
A. Front pump pressure
Voltage ★ At connection A51, Between (C) and (A) - signal 0.5 - 4.5v 3
sensor test
The pressure voltage is measured with the wiring harness connected. According, if the voltage is
abnormal, check the wiring harness and controller, too, for another cause of the trouble, then judge.
• Disconnect A51 connector from sensor.
★ Ignition switch should be in the ON position during troubleshooting.
A. Disconnection or Between C01 (22) and A51 (B) Max. 1Ω 4
defective contact with Between C01 (10) and A51 (A) Max. 1Ω 5
Resistance Ω
connector (Wiring
harness) Between C01 (8) and A51 (C) Max. 1Ω 6
B. Ground fault of wiring
harness (Contact with Resistance Ω Between C01 (8) and A51 (C) and ground Min. 1 MQ 7
ground circuit)
C. Short in wiring harness ★ Between C01 (22) and A51 (B) and ground Max. 1V 8
(Contact with 24V Voltage
circuit) ★ Between C01 (8) and A51 (C) and ground Max. 1V 9
4. Pump controller
★ Ignition switch should be in the ON position or keep the engine running during troubleshooting.
★ Between C01 (22) and (10) 4.5 - 5.5V 10
A. Pump controller test Voltage
★ Between C01 (8) and (10) 0.5 - 4.5V 11
20-356 1 PC400LC-7L
12
Electrical circuit diagram related to front pump pressure sensor
PC400LC-7L 20-357 1
12
E225
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL
• Signal voltage from the rear pump pressure sensor is below 0.3V or above 4.42V. (Pump controller system.)
Contents Of Trouble
• Failure code DHPBMA.
• The controller sets the R pump to 0 kg/cm2 (0 psi) for control.
• The travel speed does not shift automatically (The travel load pressure cannot be detected).
machine
★ If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be
• Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No.: 01101: Rear pump pressure.)


1. Sensor power supply system defective If error code 226 is displayed, carry out troubleshooting for it first. 1
2. Front pump pressure sensor defective (Internal defect)
★ Ignition switch ON or keep the engine running during troubleshooting.
★ At connection A52, between (B) and (A) - power 4.5 - 5.5V 2
supply
A. Front pump pressure
Voltage ★ At connection A52, Between (C) and (A) - signal 0.5 - 4.5v 3
sensor test
The pressure voltage is measured with the wiring harness connected. According, if the voltage is
abnormal, check the wiring harness and controller, too, for another cause of the trouble, then judge.
• Disconnect A52 connector from sensor.
★ Ignition switch should be in the ON position during troubleshooting.
A. Disconnection or Between C01 (22) and A52 (B) Max. 1Ω 4
defective contact with Between C01 (10) and A52 (A) Max. 1Ω 5
Resistance Ω
connector (Wiring
harness) Between C01 (2) and A52 (C) Max. 1Ω 6
B. Ground fault of wiring
harness (Contact with Resistance Ω Between C01 (2) and A52 (C) and ground Min. 1 MQ 7
ground circuit)
C. Short in wiring harness ★ Between C01 (22) and A52 (B) and ground Max. 1V 8
(Contact with 24V Voltage
circuit) ★ Between C01 (2) and A52 (C) and ground Max. 1V 9
4. Pump controller
★ Ignition switch should be in the ON position or keep the engine running during troubleshooting.
★ Between C01 (22) and (10) 4.5 - 5.5V 10
★ Between C01 (2) and (10) 0.5 - 4.5V 11
20-358 1 PC400LC-7L
12
Electrical circuit diagram related to rear pump pressure sensor
PC400LC-7L 20-359 1
12
E226
ABNORMAL PRESSURE SENSOR POWER SUPPLY
• Abnormal pressure sensor power supply (5V).
Contents Of Trouble
• Failure code DH25KP.
• Power to the power supply (5V) circuit is switched OFF.
Phenomenon occurring on • The pressure sensor signal is not input normally.
machine • The error code of abnormality in the pressure sensor is displayed.


1. Pressure sensor defective (Internal short)
• Ignition switch ON during troubleshooting.
If the error code goes off when one Front pump pressure sensor - connector A51 1
A. Pressure sensor test
of the listed items (in order listed) Rear pump pressure sensor - connector A52 2
Disconnect the parts
is disconnected, that part is Arm IN PPC pressure sensor - connector S04 3
shown at right in order.
defective. Bucket CURL PPC pressure sensor - connector S01 4
Between C01 (22) and A51 (B) and ground (F pump) Min. 1 MQ 5
Between C01 22) and A52 (B) and ground (R pump) Min. 1 MQ 6
A. Ground fault of wiring
harness (Contact with Resistance Ω Between C01 (22) and S04 (A) and ground (Bucket
Min. 1 MQ 7
CURL PPC)
ground circuit)
Between C01 (22) and S01 (A) and ground (Arm IN
Min. 1 MQ 8
PPC)
3. Pump controller
• Ignition switch should be in the ON position for troubleshooting.
A. Pump controller test Voltage Between C01 (22) and (10) 4.5 - 5.5V 9
20-360 1 PC400LC-7L
12
Electrical circuit diagram related to pressure sensor power supply
PC400LC-7L 20-361 1
12
E227
ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR
• A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Contents Of Trouble
• Failure code DLE2MA.
• The controller exercises a control equivalent to E mode.
• If the failure cause disappears by itself, the signal input returns to normal.
Phenomenon occurring on • The machine lacks power a bit. (The engine rotation sensing does not work.)
machine • The engine speed (in the pump controller system) is not monitored on the monitor panel.
• Input from the engine rotation sensor (RPM) can be confirmed in the monitor function.
(Code No.: 01006 Engine RPM)


1. Engine rotation sensor (Internal short)
• Ignition switch OFF during troubleshooting.
A. Engine rotation sensor Between ENE (1) and (2) 500 - 1,000Ω 1
test - internal short or Resistance Ω
Between ene (1) and ground Above 1MΩ 2
disconnected
2. Engine rotation sensor adjustment
Refer to the section “Adjusting Engine Rotation Sensor” in this manual for inspection and adjustment.
improper
★ Ignition switch should remain in the ON position during troubleshooting.
A. Wiring harness Between C02 (40) and ENE (1) Below 1Ω 3
Disconnection or
Resistance Ω
defective contact with Between C02 (29), (39) and ENE (2) Below 1Ω 4
connector
B. Wiring harness
Short (Contact with Voltage ★ Between C02 (40) and ENE (1) and ground Below 1V 5
24V circuit)
4. Pump controller
Between C02 (40) and (29), (39) 500 - 1,000Ω 6
A. Pump controller test Resistance Ω
Between C02 (40) and ground Above 1MΩ 7
20-362 1 PC400LC-7L
12
Electrical Circuit Diagram for Engine Rotation Sensor
PC400LC-7L 20-363 1
12
E228
SHORT IN ATTACHMENT RETURN SWITCHING RELAY
• Short in attachment return switching relay. (Pump controller system)
Contents Of Trouble
• Failure code D196KB.
• The controller turned OFF power to the attachment return switching relay circuit.
• Even when the failure cause disappears by itself, the current does not return to normal.
Phenomenon occurring on • The hydraulic circuit for attachments is not switched to the single operation circuit.
machine (The switching valve is not switched to the tank circuit.)
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF).
• This error code detects abnormal on the primary side (coil side) of the attachment return selector relay and cannot detect
abnormality on the secondary side (contact side).


1. Attachment return switching relay (Internal short)
A. Attachment return
switching relay test -
Resistance Ω Between R20, between (1) and (2) 100 - 500Ω 1
internal short or dis-
connected
• Ignition switch should remain in the ON position during troubleshooting.
A. Wiring harness
Short (Contact with Voltage Between C02 (8) and R20 (2) and ground Below 1V 2
24V circuit)
3. Pump controller
C02 (8) and Working mode - Other than B mode 20 − 30V 3
ground Working mode - B mode Below 1V 4
20-364 1 PC400LC-7L
12
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400LC-7L 20-365 1
12
E232
SHORT IN PC-EPC SOLENOID
• Short in PC-EPC solenoid. (Pump controller system)
Contents Of Trouble
• Failure code DXA0KB.
• The controller reduces the output to the PC-EPC solenoid circuit to OFF.
Response from controller • Even when the failure cause disappears by itself, the current does not return to normal, unless the engine ignition switch
is turned OFF.
Phenomenon occurring on • As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
machine (The pump absorption torque cannot be controlled.)
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01300 PC-EPC solenoid current)
• If there is no abnormality with the solenoid or any of the wiring harness, the machine can be operated in a working mode
equivalent to E mode by turning the emergency pump drive switch to the emergency position. (At that time the monitor
panel continues to display Error Code No. E233, but this is not abnormal.)
• Have the emergency driving switch in normal during the troubleshooting.


1. PC-EPC solenoid (Internal short)
A. PC-EPC solenoid test - At V21, between (1) and (2) 7 - 14Ω 1
internal short or Resistance Ω
At V21, between (1) and ground Above 1 MΩ 2
disconnected
2. Emergency pump driving switch
• Disconnect pump controller S25 and install T-adapter.
A. Emergency pump
Emergency At S25, between (3) and (4) Above 1 MΩ 3
drive switch test -
Resistance Ω pump drive
internal short or
switch - Normal At S25, between (3) and ground Above 1 MΩ 4
disconnected
A. Wiring harness Between C03 (16) and S25 (3) and ground Above 1 MΩ 5
Short (Contact with Resistance Ω
Between S25 (2) and V21 (1) and ground Above 1 MΩ 6
grounding circuit)
4. Pump controller
• Ignition switch should be in the OFF position for troubleshooting.
At C03, between (16) and (3), (13), (23) 7 - 14Ω 7
At C03, between (16) and ground Above 1 MΩ 8
20-366 1 PC400LC-7L
12
Electrical Circuit Diagram for PC-EPC Solenoid
PC400LC-7L 20-367 1
12
E233
OPEN IN PC-EPC SOLENOID
• No current flow to PC-EPC solenoid circuit. (Pump controller system)
Contents Of Trouble
• Failure code DXA0KA.
• None in particular (the solenoid does not function because there is no current flow to it.)
• When the failure cause disappears by itself, the current returns to normal.
Phenomenon occurring on • As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
machine (The pump absorption torque cannot be controlled.)
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01300 PC-EPC solenoid current)
• If there is no abnormality with the solenoid or any of the wiring harness, the machine can be operated in a working mode
equivalent to E mode by turning the emergency pump drive switch to the emergency position.


1. PC-EPC solenoid (Internal short)
A. PC-EPC solenoid test - At V21, between (1) and (2) 7 - 14Ω 1
At V21, between (1) and ground Above 1 MΩ 2
disconnected
2. Emergency pump driving switch
• Disconnect pump controller S25 and install T-adapter.
Emergency pump drive switch
A. Emergency pump - Normal Below 1Ω 3
At S25, between (2) and (3)
drive switch test - - Emergency Above 1 MΩ 4
Resistance Ω
internal short or - Normal Below 1Ω 5
disconnected At S25, between (5) and (6)
- Emergency Above 1 MΩ 6
• Disconnect pump controller C03 and S25 RH console emergency switch and install T-adapters.
A. Wiring harness Between C03 (16) and S25 (3) Below 1Ω 7
Disconnection or Between S25 (2) and V21 (1) Below 1Ω 8
defective contact with Resistance Ω
At C03, between (3), (13), (23) and S25 (6) Below 1Ω 9
connector
Between S25 (5) and V21 (2) Below 1Ω 10
B. Wiring harness ★ Between C03 (16) and S25 (3) and ground Below 1V 11
Short (Contact with Voltage
24V circuit) ★ Between S25 (2) and V21 (1) and ground Below 1V 12
4. Pump controller
A. Pump controller test Resistance Ω At C03, between (16) and (3), (13), (23) 7 - 14Ω 13
20-368 1 PC400LC-7L
12
Electrical Circuit Diagram for PC-EPC Solenoid
PC400LC-7L 20-369 1
12
E238
OPEN IN ATTACHMENT RETURN SWITCHING RELAY
• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24V voltage is not
Contents Of Trouble generated. (Pump controller system)
• Failure code D196KA.
• None in particular.
• When the failure cause disappears by itself, the current returns to normal.
Phenomenon occurring on • The hydraulic circuit for attachments cannot be switched to the single operation.
machine (The switching valve cannot be switched to the tank circuit.)
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF).
• This code detects abnormality on the primary side (coil side) of the attachment return selector relay and cannot detect
abnormality on the secondary side (contact side).


1. Fuse No. 2 fault If fuse No. 2 has been blown, there is a big possibility that a grounding fault occurred in the relay circuit. (See Step 3B)
2. Attachment return switching relay (Internal short)
• Disconnect R20 and install T-adapter.
A. Attachment return
switching relay test -
Resistance Ω At R20, between (1) and (2) 100 - 500Ω 1
internal short or
disconnected
• Disconnect pump controller C02 and R20 and install T-adapters.
A. Wiring harness Between C02 (8) and R20 (2) Below 1Ω 2
Disconnection or
Resistance Ω
defective contact with At R20 (1) to J03 to FB1-2 outlet Below 1Ω 3
connector
B. Wiring harness Between C02 (8) and R20 (2) and ground Above 1ΜΩ 4
Short (Contact with Resistance Ω Between R20 (1) to J03 to FB1-2 and ground Above 1ΜΩ 5
grounding circuit)
4. Pump controller
Working mode
Other than B
mode 20 - 30V 6
A. Pump controller test Voltage At C02, between (8) and ground
B mode Below 1V 7
20-370 1 PC400LC-7L
12
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400LC-7L 20-371 1
12
E245
SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM
• Short in attachment oil flow rate adjusting EPC solenoid circuit. (Pump controller system)
Contents Of Trouble
• Failure code DXE4KB.
• The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF.
Response from controller • Even when the failure cause disappears, the EPC solenoid circuit does not return to normal, unless the engine ignition
switch is turned OFF.
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
machine
• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting
Relative information EPC solenoid circuit.
(Code No.: 01700 Service solenoid current)


1. Attachment oil flow rate EPC valve (Internal short)
• Disconnect V30 and install T-adapter.
A. Attachment oil flow At V30, between (1) and (2) 7 - 14Ω 1
rate EPC valve test -
Resistance Ω
internal short or At V30, between (1) and grounding Above 1ΜΩ 2
disconnected
• Disconnect pump controller C03 and install T-adapters.
A. Wiring harness
Short (Contact with Resistance Ω Between C03 (26) and V30 (1) and ground Above 1ΜΩ 3
grounding circuit)
3. Pump controller
At C03, between (26) and (3), (13), (23) 7 - 14Ω 4
At C03, between (26) and grounding Above 1ΜΩ 5
20-372 1 PC400LC-7L
12
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400LC-7L 20-373 1
12
E246
OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM
• No current flow to the attachment oil flow rate adjusting EPC solenoid circuit. (Pump controller system)
Contents Of Trouble
• Failure code DXE4KA.
• None in particular (The solenoid does not work, as there is no current flowing to it.)
• If the failure cause disappears, the EPC solenoid circuit returns to normal by itself.
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
machine
• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting
Relative information EPC solenoid circuit.
(Code No.: 01700 Service solenoid current)


1. Attachment oil flow rate EPC valve (Internal short)
A. Attachment oil flow At V30, between (1) and (2) 7 - 14Ω 1
rate EPC valve test -
Resistance Ω
internal short or At V30, between (1) and grounding Above 1ΜΩ 2
disconnected
A. Wiring harness test Between C03 (26) and V30 (1) and grounding Below 1Ω 3
Disconnection or
Resistance Ω
defective contact with Between C03 (3), (13), (23) and V30 (2) and grounding Below 1Ω 4
connector
B. Wiring harness
Short (Contact with Voltage ★ Between C03 (26) and V30 (1) and ground Below 1V 5
24V circuit)
3. Pump controller
A. Pump controller test Resistance Ω At C03, between (26) and (3), (13), (23) 7 - 14Ω 6
20-374 1 PC400LC-7L
12
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400LC-7L 20-375 1
12
E247
ABNORMALITY IN ARM IN PPC PRESSURE SENSOR
• Signal voltage from the arm IN PPC pressure sensor is below 0.3V or above 4.42V.
Contents Of Trouble
• Failure code DHS3MA.
• The controller sets the arm IN PPC pressure to 0 kg/cm2 (0 psi) for control.
• If the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on • If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The arm IN PPC circuit
machine pressure cannot be detected).
★ If the 5V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be
• Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function.
(Code No.: 07200 Arm IN PPC pressure)


1. Sensor power supply system If error code 226 is displayed, carry out troubleshooting for it first.
2. Arm IN PPC pressure sensor (Internal short)
• Disconnect S04 and install T-adapter.
• Ignition switch ON or keep engine running during troubleshooting.
A. Arm IN PPC pressure S04 Power supply, between (A) and (C) 4.5 − 5.5V 1
sensor test - internal Voltage
S04 Signal, between (B) and (C) 0.5 − 4.5V 2
short or disconnected
A. Wiring harness test Between C01 (22) and S04 (A) Max. 1Ω 3
Disconnection or Between C01 (10) and S04 (C) Max. 1Ω 4
Resistance Ω
defective contact with
connector Between C01 (19) and S04 (B) Max. 1Ω 5
B. Wiring harness test
ground fault (Contact Resistance Ω Between C01 (19) and S04 (B) and ground Min. 1MΩ 6
with grounding circuit)
C. Wiring harness test ★ At C01 (22) and S04 (A) and ground Max. 1V 7
24V circuit) ★ At C01 (19) and S04 (B) and ground Max. 1V 8
4. Pump controller
★ Ignition switch should remain in the ON position or keep the engine running during troubleshooting.
★ At C01, between (22) and (10) 4.5 − 5.5V 9
★ At C01, between (19) and (10) 0.5 − 4.5V 10
20-376 1 PC400LC-7L
12
Circuit diagram related to arm IN PPC pressure sensor
PC400LC-7L 20-377 1
12
E248
ABNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR
• Signal voltage from the bucket CURL PPC pressure sensor is below 0.3V or above 4.42V.
Contents Of Trouble
• Failure code DHS4MA.
• The controller sets the bucket CURL PPC pressure to 0 kg/cm2 (0 psi) for control.
Phenomenon occurring on • If auto deceleration is operated, auto deceleration cannot be released when moving the bucket CURL (The bucket
machine CURL PPC circuit pressure cannot be detected).
★ If the 5V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be
• Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function.
(Code No.: 07300 Bucket CURL PPC pressure)


1. Sensor power supply system If error code 226 is displayed, carry out troubleshooting for it first.
2. Bucket CURL (Dig) PPC pressure sensor (Internal defect)
• Ignition switch ON or keep engine running during troubleshooting.
A. Bucket CURL (Dig) S01 Power supply, between (1) and (3) 4.5 − 5.5V 1
PPC pressure sensor
Voltage
test - internal short or S01 Signal, between (2) and (3) 0.5 − 4.5V 2
disconnected
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller for another cause of the trouble and then
judge.
• Disconnect pump controller C01, S01 and install T-adapters.
A. Wiring harness test Between C01 (22) and S01 (1) Max. 1Ω 3
Disconnection or Between C01 (10) and S01 (3) Max. 1Ω 4
Resistance Ω
connector Between C01 (19) and S01 (2) Max. 1Ω 5
ground fault (Contact Resistance Ω Between C01 (19) and S01 (2) and ground Min. 1MΩ 6
C. Wiring harness test ★ At C01 (22) and S01 (1) and ground Max. 1V 7
24V circuit) ★ At C01 (19) and S01 (2) and ground Max. 1V 8
4. Pump controller
★ Ignition switch should remain in the ON position or keep the engine running during troubleshooting.
★ At C01, between (22) and (10) 4.5 − 5.5V 9
★ At C01, between (19) and (10) 0.5 − 4.5V 10
20-378 1 PC400LC-7L
12
Circuit diagram related to bucket CURL PPC pressure sensor
PC400LC-7L 20-379 1
12
E257
ABNORMALITY IN PUMP
• The pump controller detected communication failure in the CAN communication circuit to the monitor panel or engine
• Failure code DA2RMC.
• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.


• Disconnect P70, C02, CB2 and install T-adapters.
A. Wiring harness test Between P70 (16) and CB2 (22) Below 1Ω 1
Disconnection or Between P70 (16) and C02 (22) Below 1Ω 2
Between P70 (15) and CB2 (32) Below 1Ω 3
connector
Between P70 (15) and C02 (32) Below 1Ω 4
B. Wiring harness test Between P70 (16) and CB2 (22) Above 1MΩ 5
ground fault (Contact Between P70 (16) and C02 (22) Above 1MΩ 6
Between P70 (16) and related circuits and grounding Above 1MΩ 7
Resistance Ω
Between P70 (15) and CB2 (32) Above 1MΩ 8
Between P70 (15) and C02 (32) Above 1MΩ 9
Between P70 (15) and related circuits and grounding Above 1MΩ 10
C. Wiring harness test Between P70 (16) and CB2 (22) Below 1V 11
Short (Contact with Between P70 (16) and C02 (22) Below 1V 12
24V circuit)
Between P70 (16) and related circuits and grounding Below 1V 13
Voltage
Between P70 (15) and CB2 (32) Below 1V 14
Between P70 (15) and C02 (32) Below 1V 15
Between P70 (15) and related circuits and grounding Below 1V 16
2. CAN terminal resistor
• Turn the ignition switch OFF for the preparations.
• Disconnect K30 and K31 CAN connectors and install T-adapter.
• Hold ignition switch in the OFF position during the troubleshooting.
A. CAN terminal resistor At K30, between (1) and (2) 40 - 80Ω 17
Resistance Ω
test At K31, between (1) and (2) 40 - 80Ω 18
3. Monitor panel, engine controller or pump controller
• If 1 - 2 are not detected, monitor panel, engine controller or pump controller may be defective. (Since trouble is in those devices, troubleshooting
cannot be carried out.)
20-380 1 PC400LC-7L
12
Electrical circuit diagram related to CAN communication
PC400LC-7L 20-381 1
12
E315
SHORT IN BATTERY RELAY SYSTEM
• Short in battery relay system
Contents Of Trouble
• Failure code D110KB.
• The controller turns OFF the output to the battery relay drive circuit.
• There may be a trouble in writing data into ROM (non-volatile memory) of each controller.
machine
• Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
(Code No.: 03700 Controller output 1)


1. Battery relay
• Turn the ignition switch OFF for the preparations.
• Disconnect A20 and A21 wires from battery relay.
• Hold the ignition switch in the OFF position during the troubleshooting.
Approximately
At battery relay Between BR and E 1
A. Battery relay test Resistance Ω 100Ω
unit
Between BR and grounding Min. 1MΩ 2
2. Diode
• Disconnect D01 diode connector and isolate diode.
3 Yes or No
A. Diode test Resistance Ω
4 Yes or No
• Disconnect C03 and install T-adapters.
A. Wiring harness test Between C03 (4), D01, J01, battery relay terminal BR and
grounding Min. 1MΩ 5
ground fault (Contact
with grounding circuit) Resistance Ω Between C03 (4) and ignition switch terminal BR and
Min. 1MΩ 6
grounding
Between C03 (4) and D01 (2) and grounding Min. 1MΩ 7
4. Pump controller
A. Pump controller Ignition switch 20 - 30V
Voltage ON → OFF At C03, between (4) and grounding 8
(for 0.5 sec.)
20-382 1 PC400LC-7L
12
Electrical circuit diagram related to battery relay drive
PC400LC-7L 20-383 1
TROUBLESHOOTING E91B
12
E91B
ENGNE NE SENSOR PROBLEM
• Cranking angle cannot be judged from engine Ne speed sensor signal. (Engine controller system)
Contents Of Trouble
• Failure code DLE3LC.
• The machine is driven with limited output.
• 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).
machine
• The engine speed does not rise above lower idling.
• Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function.
(Code No.: 01002 Engine speed)


Steps Circuit Diagnostic Procedures For Code [E91B] Specifications No. Readings
1. Engine Ne speed sensor
• Disconnect NE and install T-adapter.
A. Engine Ne speed At NE, between (1) and (2) 85 - 210Ω 1
sensor test - internal Resistance Ω
At NE, between (1), (2) and grounding Above 1ΜΩ 2
• Disconnect engine controller CB2 and install T-adapters.
A. Wiring harness test Between CB2 (36) and NE (2) Below 1Ω 3
Disconnection or
Resistance Ω
defective contact with Between CB2 (26) and NE (1) Below 1Ω 4
connector
B. Wiring harness Between CB2 (36) aand NE (2) and ground Above 1ΜΩ 5
grounding circuit) Between CB2 (26) aand NE (1) and ground Above 1ΜΩ 6
• Disconnect engine controller CB2 and install T-adapter.
At CB2, between (36) and (26) 85 - 210Ω 7
A. Engine controller test Resistance Ω
At CB2, between (36), (26) and grounding Above 1ΜΩ 8
20-384 1 PC400LC-7L
12
Electrical circuit diagram related to engine Ne speed sensor
PC400LC-7L 20-385 1
TROUBLESHOOTING E91C
12
E91C
ENGINE G SENSOR PROBLEM
• Cylinder cannot be judged from the engine G speed sensor signal. (Engine controller system)
Contents Of Trouble
• Failure code DLH1LC.
• Control is carried out with the Ne sped sensor signal.
machine
Relative information • Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.


Steps Circuit Diagnostic Procedures For Code [E91C] Specifications No. Readings
1. Engine G speed sensor
• Disconnect G connector and install T-adapter.
A. Engine G speed At G, between (1) and (2) 1.4 - 3.5kΩ 1
sensor test - internal Resistance Ω
short or disconnected At G, between (1), (2) and grounding Above 1ΜΩ 2
A. Wiring harness test Between CB2 (35) and G (2) Below 1Ω 3
Disconnection or
Resistance Ω
defective contact with Between CB2 (25) and G (1) Below 1Ω 4
connector
B. Wiring harness Between CB2 (35) aand G (2) and ground Above 1ΜΩ 5
Between CB2 (25) aand G (1) and ground Above 1ΜΩ 6
grounding circuit)
At CB2, between (35) and (25) 1.4 - 3.5kΩ 7
A. Engine controller test Resistance Ω At CB2, between (35) and grounding Above 1ΜΩ 8
At CB2, between (25) and grounding Above 1ΜΩ 9
20-386 1 PC400LC-7L
12
Electrical circuit diagram related to engine G speed sensor
PC400LC-7L 20-387 1
12
E920
ENGINE TYPE SELECTION ERROR
• The model selection signal directly taken by the engine controller does not conform to the model in the controller or is
Contents Of Trouble not confirmed. (Engine controller system)
• Failure code DB29KQ.
• Control is carried out with the default model (PC400).
Response from controller • Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine start-
ing switch is once turned OFF.
machine
• The model name (figure) recognized by the controller can be checked in the monitoring function.
(Code No.: 00201 Controller model code)
• Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Coed No.: 17400 Engine controller input state)


1. Model selection connector
At CB5, between (2) and (8) Above 1ΜΩ 1
A. Model selection At CB5, between (4) and (8) Above 1ΜΩ 3
connector test -
Resistance Ω At CB5, between (5) and (8) Above 1ΜΩ 4
internal short or
disconnected At CB5, between (6) and (8) Above 1ΜΩ 5
At CB5, between (1) and (8) Below 1Ω 7
• Disconnect engine controller CB1 and CB2 and install T-adapters.
A. Wiring harness test Between CB1 (3) and CB5 (1) Below 1Ω 8
Disconnection or
Resistance Ω
defective contact with Between CB2 (1) and CB5 (8) Below 1Ω 9
connector
B. Wiring harness Between CB1 (23) aand CB5 (2) and ground Above 1ΜΩ 10
grounding circuit) Between CB1 (17) aand CB5 (3) and ground Above 1ΜΩ 11
• Ignition switch should be held in the ON position for troubleshooting.
CB1, CB2
Between CB1 (23) and CB2 (1) 20 − 30V 12
A. Engine controller test Voltage Between CB1 (17) and CB2 (1) 20 − 30V 13
Between CB! (3) and CB2 (1) Below 1V 14
20-388 1 PC400LC-7L
12
Electrical circuit diagram related to model selection connector (for engine controller)
PC400LC-7L 20-389 1
12
E921
ENGINE TYPE MISMATCH
• The model information taken by the engine controller through the model selection connector does not conform to the
Contents Of Trouble model information taken from the pump controller by communication. (Engine controller system)
• Failure code DB20KQ.
• The normal operation is continued.
Response from controller • Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine igni-
tion switch is turned OFF.
machine
• The model name (figure) recognized by the controller can be checked in the monitoring function.
• The model name (figure) recognized by the pump controller can be checked in the monitoring function.
1. Model selection connector system defective If error code E920 is displayed, carry out troubleshooting for it.
Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be
2. Engine controller defective
carried out.)
Pump controller may be defective. (Since trouble is in the controller, troubleshooting cannot be
3. Pump controller defective
carried out.)
20-390 1 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 20-391 1
12
E931
FUEL DIAL SYSTEM ERROR
• The signal voltage from the fuel control dial is below 0.3V or above 4.5V. (Engine controller system)
Contents Of Trouble
• Failure code DK10KX.
• If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or 100% after the
engine is started.
Response from controller • If the abnormality is detected while the engine is running, the fuel control dial signal just before the abnormality is
detected is kept.
• The engine speed cannot be controlled.
machine
• Input from the fuel control dial (voltage) can be checked in the monitoring function.
(Code No.: 03000 Fuel control dial voltage)


1. Fuel control dial defective
• Disconnect E06 connector and install T-adapter.
• Ignition switch ON or keep the engine running during troubleshooting.
A. Fuel control dial test - At E06, between (1) and (3) 4.0 − 6.0kΩ 1
internal short or Resistance Ω At E06, between (1) and (2) 0.25 − 7.0kΩ 2
disconnected At E06, between (3) and (2) 0.25 − 7.0kΩ 3
• Disconnect engine controller CB2 and E06 and install T-adapters.
A. Wiring harness test Between CB2 (19) and E06 (1) Below 1Ω 4
Disconnection or Between CB2 (10) and E06 (2) Below 1Ω 5
Between CB2 (29) and E06 (3) Below 1Ω 6
connector
Between CB2 (39) and E06 (3) Below 1Ω 7
B. Wiring harness Between CB2 (19) and E06 (1) and ground Above 1ΜΩ 8
Between CB2 (10) and E06 (2) and ground Above 1ΜΩ 9
grounding circuit)
C. Wiring harness ★ Between CB2 (19) and E06 (1) and ground Below 1V 10
Contact with 24V Voltage
circuit ★ Between CB2 (10) and E06 (2) and ground Below 1V 11
At CB2, Between (19) and (29) 4.6 - 5.4V 12
A. Engine controller test Voltage
20-392 1 PC400LC-7L
Electrical circuit diagram related to fuel control dial
PC400LC-7L 20-393 1
12
E934
ENGINE COOLANT SENSOR HI ERROR
• The signal voltage from the engine water high temperature sensor is below 0.5V or above 4.5V. (Engine controller
Contents Of Trouble system)
• Failure code DGE2KX.
• The signal of the engine water high temperature sensor is kept at 90°C.
• When the failure cause disappears, the machine operation returns to normal.
• The engine does not start easily when the temperature is low.
• The overheat protection function does not operate.
machine
• If the controller is also defective, the engine does not stop.
• Input from the engine high temperature sensor (voltage and water temperature) can be checked in the monitoring
function.
(Code No.: 04106 Engine water temperature sensor Hi,
Code No.: 04102 Engine water temperature (High temperature))


1. Engine water high temperature sensor defective
• Disconnect TWH connector and install T-adapter.
A. Engine water high At TWH, between (1) and (2) 3.5 − 90kΩ 1
temperature sensor test At TWH, between (1) and grounding Above 1ΜΩ 2
Resistance Ω
- internal short or
disconnected At TWH, between (2) and grounding Above 1ΜΩ 3
• Disconnect engine controller CB2 and TWH and install T-adapters.
A. Wiring harness test Between CB2 (27) and TWH (1) Below 1Ω 4
Disconnection or Between CB2 (29) and TWH (2) Below 1Ω 5
Resistance Ω
connector Between CB2 (39) and TWH (2) Below 1Ω 6
B. Wiring harness
Short (Contact with Resistance Ω Between E12 (27) and TWH (1) and ground Above 1ΜΩ 7
grounding circuit)
At CB2, Between (27) and (39) 3.5k - 90kΩ 8
At CB2, Between (29) and (39) 3.5k - 90kΩ 9
A. Engine controller test Resistance Ω At CB2, Between (27) and grounding Above 1ΜΩ 10
At CB2, Between (29) and grounding Above 1ΜΩ 11
At CB2, Between (39)and grounding Above 1ΜΩ 12
20-394 1 PC400LC-7L
12
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
PC400LC-7L 20-395 1
TROUBLESHOOTING E96A
12
E96A
ENGINE COOLANT SENSOR LO ERROR
• The signal voltage from the engine water low temperature sensor is above 4.5V. (Engine controller system)
Contents Of Trouble
• Failure code DGE3L6.
• The signal of the engine water low temperature sensor is kept at 20°C. (If the signal of the high temperature sensor is
Response from controller effective, it is used as a substitute.)
• When the failure cause disappears, the machine operation returns to normal.
machine
• Input from the engine low temperature sensor (voltage and water temperature) can be checked in the monitoring
function.
(Code No.: 04105 Engine water temperature sensor Lo,
Code No.: 04107 Engine water temperature (Low temperature))


Steps Circuit Diagnostic Procedures For Code [E96A] Specifications No. Readings
1. Engine water high temperature sensor defective
• Disconnect TWL connector and install T-adapter.
A. Engine water low At TWL, between (1) and (2) 0.3 − 9kΩ 1
temperature sensor test At TWL, between (1) and grounding Above 1ΜΩ 2
Resistance Ω
- internal short or
disconnected At TWL, between (2) and grounding Above 1ΜΩ 3
• Disconnect engine controller CB2 and TWL and install T-adapters.
A. Wiring harness test Between CB2 (37) and TWL (1) Below 1Ω 4
Disconnection or Between CB2 (29) and TWL (2) Below 1Ω 5
Resistance Ω
connector Between CB2 (39) and TWL (2) Below 1Ω 6
B. Wiring harness
Short (Contact with Resistance Ω Between E12 (37) and TWL (1) and ground Above 1ΜΩ 7
grounding circuit)
At CB2, Between (37) and (39) 0.3 − 9kΩ 8
At CB2, Between (29) and (39) 0.3 − 9kΩ 9
A. Engine controller test Resistance Ω At CB2, Between (29) and grounding Above 1ΜΩ 10
At CB2, Between (37) and grounding Above 1ΜΩ 11
At CB2, Between (39)and grounding Above 1ΜΩ 12
20-396 1 PC400LC-7L
12
temperature)
PC400LC-7L 20-397 1
12
E936
ENGINE OIL PRESSURE SWITCH ERROR
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the
high-pressure switch is opened (disconnected from grounding) while the engine is running.
• The signal circuit of the low-pressure switch is opened (disconnected from ground) while the engine is stopped (the
Contents Of Trouble starting signal is OFF).
• The signal circuit of the high-pressure switch is opened (disconnected from ground) while the engine is stopped (the
starting signal is OFF).
• Failure code DDE2L6.
machine
• 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)


1. Engine low oil pressure switch defective
• Ignition switch OFF or keep the engine running during troubleshooting.
A. Engine water low oil Engine PSL
pressure switch test - Stopped Below 1Ω 1
Resistance Ω
internal short or Between terminal and grounding
disconnected Low idling Above 1ΜΩ 2
B. Engine water high oil Engine PSH
pressure switch test - Stopped Below 1Ω 3
Resistance Ω
internal short or Running at 1,300 Between terminal and grounding
disconnected Above 1ΜΩ 4
rpm or higher
A. Wiring harness test Between CB1 (21) and PSL Below 1Ω 5
Disconnection or
Resistance Ω
defective contact with Between CB1 (15) and PSH Below 1Ω 6
connector
B. Wiring harness Between CB1 (21) and PSL and ground Above 1ΜΩ 7
grounding circuit) Between CB1 (15) and PSH and ground Above 1ΜΩ 8
• Ignition switch ON and start the engine during troubleshooting.
Engine CB1 −−−
Stopped Between (21) and ground (Low Below 1V 9
Low idling pressure switch signal) 20 - 30V 10
Stopped Below 1V 11
Between (21) and ground (Low
Running at 1,300 pressure switch signal)
20 - 30V 12
rpm or higher
--- Carry out troubleshooting while the engine is running 15 seconds after the engine is started.
20-398 1 PC400LC-7L
12
Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)
PC400LC-7L 20-399 1
12
E93C
ENGINE BOOST SENSOR ERROR
• The signal voltage from the boost pressure sensor is below 0.3V or above 4.7V.
Contents Of Trouble
• Failure code DH30KX.
machine
• The engine speed does not rise above idling.
• Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36501 Boost pressure sensor voltage,
(Code No.: 36500 Boost pressure)
• Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor.


Steps Circuit Diagnostic Procedures For Code [E93C] Specifications No. Readings
1. Boost pressure sensor defective
• Turn the engine ignition switch OFF for preparations.
• Disconnect PIM boost pressure sensor.
A. Engine boost PIM
pressure sensor test - Power supply Between (3) and (1) 4.6 − 5.4V 1
Voltage
internal short or
disconnected Signal Between (2) and (1) 0.5 - 4.5V 2
A. Wiring harness test Between CB2 (9) and PIM (3) Below 1Ω 3
Disconnection or Between CB2 (29) and PIM (1) Below 1Ω 4
Between CB2 (39) and PIM (1) Below 1Ω 5
connector
Between CB2 (20) and PIM (2) Below 1Ω 6
B. Wiring harness Between CB2 (9) and PIM (3) and ground Above 1ΜΩ 7
Short (Contact with Resistance Ω Between CB2 (9) and related circuits and ground Above 1ΜΩ 8
grounding circuit) Between CB2 (20) and PIM (2) and ground Above 1ΜΩ 9
C. Wiring harness ★ Between CB2 (9) and PIM (3) Below 1V 10
Contact with 24V
circuit
Voltage ★ Between CB2 (9) and related circuits and ground Below 1V 11
★ Between CB2 (20) and PIM (2) and ground Below 1V 12
• Ignition switch ON and start the engine during troubleshooting.
At CB2, between (9) and (29) 4.6 - 5.4V 13
20-400 1 PC400LC-7L
12
Electrical circuit diagram related to boost pressure sensor
PC400LC-7L 20-401 1
TROUBLESHOOTING E93D
12
E93D
ENGINE FUEL TEMPERATURE SENSOR ERROR
• The signal voltage from the fuel temperature sensor is above 4.5V.
Contents Of Trouble
• Failure code DGE4KX.
• The engine does not start easily when temperature is low.
machine
• Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
(Code No.: 14201 Fuel temperature sensor voltage)


Steps Circuit Diagnostic Procedures For Code [E93D] Specifications No. Readings
1. Fuel temperature sensor defective
• Disconnect THL connection and install T-adapter.
A. Fuel temperature At THL, between (1) and (2) 0.3k - 9kΩ 1
sensor test - internal Resistance Ω At THL, between (1) and grounding Above 1ΜΩ 2
short or disconnected At THL, between (2) and grounding Above 1ΜΩ 3
A. Wiring harness test Between CB2 (17) and THL (13) Below 1Ω 4
Disconnection or Between CB2 (29) and THL (2) Below 1Ω 5
Resistance Ω
connector Between CB2 (39) and THL (2) Below 1Ω 6
B. Wiring harness
Short (Contact with Resistance Ω Between CB2 (17) and THL (1) and ground Above 1ΜΩ 7
grounding circuit)
At CB2, between (17) and (39) 0.3k - 9kΩ 8
At CB2, between (17) and (39) and grounding Above 1ΜΩ 10
20-402 1 PC400LC-7L
12
Electrical circuit diagram related to fuel temperature sensor
PC400LC-7L 20-403 1
12
E953
ENGINE COMMUNICATION ABNORMALITY
• The engine controller detected communication failure in the CAN communication circuit to the monitor panel or pump
• Failure code DB2RMC.


• Disconnect P70, C02, CB2 connectors and install T-adapters.
Resistance Ω
defective contact with Between P70 (15) and CB2 (32) Below 1Ω 3
connector Between P70 (15) and C02 (32) Below 1Ω 4
Between P70 (16) and CB2 (22) and ground Above 1ΜΩ 5
Between P70 (16) and C02 (22) and ground Above 1ΜΩ 6
B. Wiring harness
Between P70 (16) and related circuits and ground Above 1ΜΩ 7
grounding circuit) Between P70 (15) and CB2 (32) and ground Above 1ΜΩ 8
★ Between P70 (16) and CB2 (22) Below 1V 11
★ Between P70 (16) and C02 (22) Below 1V 12
C. Wiring harness ★ Between P70 (16) and related circuits and ground Below 1V 13
circuit ★ Between P70 (15) and CB2 (32) and ground Below 1V 14
★ Between P70 (15) and C02 (32) and ground Below 1V 15
★ Between P70 (15) and related circuits and ground Below 1V 16
2. CAN terminal resister
• Disconnect K30 and K31 connectors and install T-adapter.
A. CAN terminal resister At K30, between (1) and (2) 40 - 80Ω 17
Resistance Ω
test At K31, between (1) and (29) 40 - 80Ω 18
3. Monitor panel, engine controller or pump If causes 1A, 1B, 1C are not detected, monitor panel, engine controller or pump controller may be
controller defective defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
20-404 1 PC400LC-7L
12
Electrical circuit diagram related to CAN communication
PC400LC-7L 20-405 1
12
E954
SHORT IN ENGINE IGNITION SWITCH
• Ignition switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Contents Of Trouble
• Failure code DD11KB.
• Ignition switch signal is recognized to be OFF.
• The machine operates normally.
machine
• Input from ignition switch signal C (ON or OFF) can be checked in the monitoring function.


1. Ignition switch defective
• Disconnect THL connection and install T-adapter.
A. Ignition switch test - Ignition switch −−−
internal short or Resistance Ω Between OFF Above 1ΜΩ 1
disconnected terminal B and terminal C START Below 1Ω 2
Between ignition switch terminal C, J01 and CB1 Below 1V 3
Between ignition switch terminal C and C01 (17) Below 1V 4
A. Wiring harness test
Between ignition switch terminal C and P01 (4) Below 1V 5
Between ignition switch terminal C and R11 (5) Below 1V 6
24V ground circuit)
Between ignition switch terminal C and related circuits Below 1V 7
Between ignition switch terminal C and grounding Below 1V 8
CB1 Ignition switch ---
Between (20) and grounding ON (Engine is running) Below 1V 9
20-406 1 PC400LC-7L
12
Electrical circuit diagram related to engine preheating, starting, charging
PC400LC-7L 20-407 1
12
E955
ENGINE S-NET ERROR
• The engine controller detected communication failure in the S-NET communication circuit to the monitor panel or
Contents Of Trouble pump controller (Engine controller system).
• Failure code DB2SMC.
(Code No.: 05100 Connection of S-NET)


• Disconnect P02, C02, CB2 connectors and install T-adapters.
Resistance Ω
connector Between P02 (10) and C02 (21) Below 1Ω 3
B. Wiring harness Between P02 (9) and C02 (21) and ground Above 1ΜΩ 6
grounding circuit)
★ Between P02 (9) and CB2 (21) and ground Below 1V 10
★ Between P02 (10) and CB2 (31) and ground Below 1V 11
C. Wiring harness ★ Between P02 (9) and C02 (21) and ground Below 1V 12
circuit ★ Between P02 (10) and C02 (21) and ground Below 1V 13
2. Monitor panel
• Disconnect P02 connector and install T-adapter.
At P02, between (9) and (20) 6 - 9V 16
At P02, between (10) and (20) 6 - 9V 17
• Disconnect CB2 connector and install T-adapters.
At CB2, between (21) and (11) 6 - 9V 18
At CB2, between (31) and (11) 6 - 9V 19
20-408 1 PC400LC-7L
4. Pump controller
• Disconnect C02 connector and install T-adapters.
A. Pump controller test Voltage At C02, between (21) and (31) 6 - 9V 20
Electrical circuit diagram related to S-NET communication
PC400LC-7L 20-409 1
12
E956
ENGINE POWER FAILURE (1)
• When the ignition switch is turned ON, the source voltage of the controller is below 10V. (Engine controller system)
Contents Of Trouble
• Failure code DB22KK.
Phenomenon occurring on • The engine stalls.
machine • The engine cannot be started.


1. Circuit breaker 7 defective If circuit breaker is turned OFF, the circuit probably has grounding fault, etc. (See cause 3B.)
2. Engine controller power supply relay defective
A. Engine controller
power supply relay test Replace the power supply relay, R22, with another one. If the condition becomes normal, the relay is
---
- internal short or defective.
disconnected
• Disconnect engine controller CB3 and R22 and install T-adapters.
Between CB3 (1) and R22 (5) Below 1Ω 1
Disconnection or
Resistance Ω Between R22 (3) and CB3 (1), (2), (21) Below 1Ω 4
connector Between R22 (1) and H15 (5) and CB1 (13), (19) Below 1Ω 5
Between R22 (2) and CB1 (7), (8) and CB2 (11) and A10
ground Below 1Ω 6
Between CB3 (1), (2), (21) and R22 (3) Above 1MΩ 7
B. Wiring harness test Between R22 (5) and battery relay B and ground Above 1MΩ 8
Short (Contact with Resistance Ω Between R22 (1) and H15 (5) Above 1MΩ 9
ground circuit) Between R22 (1) and BCB1 (13), (19) Above 1MΩ 10
Between R22 (1) and related circuits and grounding Above 1MΩ 11
A. Engine controller test Voltage Between (1), (2), (21) and OFF Below 1V 12
(11), (31), (32) ON 20 - 30V 13
20-410 1 PC400LC-7L
12
Electrical circuit diagram related to engine controller power supply
PC400LC-7L 20-411 1
12
E957
ENGINE POWER FAILURE (2)
• When the ignition switch is turned OFF, the source voltage of the controller is above 10V. (Engine controller system)
Contents Of Trouble
• Failure code D1D0KB.
• The over heat protection function does not operate.
machine


1. Engine controller power supply relay defective
A. Engine controller
power supply relay test Replace the power supply relay, R22, with another one. If the condition becomes normal, the relay is
---
- internal short or defective.
disconnected
• Disconnect engine controller CB3 and R22 and install T-adapters.
A. Wiring harness test Between CB3 (1), (2), (21) and R22 (3) and ground Below 1V 1
Between R22 (1) and J03 or related circuits and ground Below 1V 2
24V ground circuit)
A. Engine controller test Voltage Between (1), (2), (21) and OFF Below 1V 3
(11), (31), (32) ON 20 - 30V 4
20-412 1 PC400LC-7L
12
PC400LC-7L 20-413 1
12
E95A
ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR
• The fuel injection adjustment switch of the controller is not set to the correct position. (Engine controller system)
Contents Of Trouble
• Failure code DB2AMA.
• Setting of the fuel injection amount adjustment switch cannot be changed.
machine
• Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring function.
Relative information (Code No.: 36800 Right fuel injection amount adjustment switch
Code No.: Left fuel injection amount adjustment switch)


1. Setting of fuel injection amount adjustment
If fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting is wrong.
switch of engine controller defective
2. Engine controller defective If the cause is not detected, engine controller may be defective.
20-414 1 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 20-415 1
12
E970
PCV1 OVER CURRENT
• Abnormal current flowed in the fuel supply pump PCV1 circuit. (Engine controller system)
Contents Of Trouble
• Failure code AD11KB.
• Power to the fuel supply pump PCV1 circuit is switched OFF.
ignition switch is first turned OFF.
Phenomenon occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • 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.


1. Fuel supply pump PCV1 defective
• Disconnect PCV1 connection and install T-adapter.
A. Fuel supply pump At PCV1, between (1) and (2) 2.3 - 5.3Ω 1
PCV1 test - internal Resistance Ω
At PCV1, between (1) and grounding Above 1ΜΩ 2
• Disconnect engine controller CB3 and PCV1 and install T-adapters.
Contact with Resistance Ω Between CB3 (12) and PCV1 (1) Above 1ΜΩ 3
grounding circuit
B. Wiring harness ★ Between CB3 (2) and PCV1 (1) Below 1V 4
24V grounding circuit) ★ Between CB3 (22) and PCV1 (2) Below 1V 5
At CB3, between (12) and (22) 2.3 - 5.3Ω 6
20-416 1 PC400LC-7L
Electrical circuit diagram related to fuel supply pump PCV1
PC400LC-7L 20-417 1
12
E971
PCV2 OVER CURRENT
• Abnormal current flowed in the fuel supply pump PCV2 circuit. (Engine controller system)
Contents Of Trouble
• Failure code AD51KB.


At PC2, between (1) and grounding Above 1ΜΩ 2
grounding circuit
B. Wiring harness ★ Between CB3 (13) and PCV2 (1) Below 1V 4
24V grounding circuit) ★ Between CB3 (23) and PC2 (2) Below 1V 5
At CB3, between (13) and 3) 2.3 - 5.3Ω 6
20-418 1 PC400LC-7L
12
PC400LC-7L 20-419 1
12
E974
PCV1 LINE CUT
• Fuel supply pump PCV1 circuit is disconnected. (Engine controller system)
Contents Of Trouble
• Failure code AD11KA.


A. Wiring harness test Between CB3 (12) and PCV1 (1)
Below 1Ω 3
Disconnection or
Resistance Ω
Between CB3 (22) and PCV1 (2) Below 1Ω 4
connector
grounding circuit
20-420 1 PC400LC-7L
12
PC400LC-7L 20-421 1
12
E975
PCV2 LINE CUT
• Fuel supply pump PCV2 circuit is disconnected. (Engine controller system)
Contents Of Trouble
• Failure code AD51KA.


A. Wiring harness test Between CB3 (13) and PCV2 (1)
Below 1Ω 3
Disconnection or
Resistance Ω
Between CB3 (23) and PCV2 (2) Below 1Ω 4
connector
grounding circuit
20-422 1 PC400LC-7L
12
PC400LC-7L 20-423 1
12
E977
RAIL PRESSURE SENSOR ERROR
• The signal voltage from the common rail fuel pressure sensor is below 0.7V or above 4.5V. (Engine controller system)
Contents Of Trouble
• Failure code DH40KX.
machine
• The engine speed does not rise above low idling.
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36401 Common rail pressure sensor voltage
Code No.: 36400 Common rail fuel pressure)
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.


1. Common rail fuel pressure sensor defective
• Disconnect PFUEL connection and install T-adapter.
At PFUEL, between (3) and (1), power supply 4.6 - 5.4V 1
A. Common rail fuel
At PFUEL, (2) and (1), signal 0.7 - 4.5V 2
pressure sensor test -
Voltage The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the
internal short or
disconnected voltage is abnormal, check the wiring harness and controller for another cause of the trouble and then
judge.
• Disconnect engine controller CB2 and PFUEL and install T-adapters.
A. Wiring harness test Between CB2 (9) and PFUEL (3) Below 1Ω 3
Disconnection or Between CB2 (39) and PFUEL (1) Below 1Ω 4
Resistance Ω
connector Between CB2 (40) and PFUEL 2) Below 1Ω 5
B. Wiring harness test Between CB2 (9) and PFUEL (3) Above 1ΜΩ 6
Contact with Resistance Ω Between CB2 (9) and related circuits and grounding Above 1ΜΩ 7
grounding circuit
Between CB2 (40) and PFUEL (2) and grounding Above 1ΜΩ 8
C. Wiring harness test Between CB2 (9) and PFUEL (3) Below 1V 9
Contact with 24V cir- Voltage Between CB2 (9) and related circuits and grounding Below 1V 10
cuit
Between Cb2 (40) and PFUEL (2) and grounding Below 1V 11
20-424 1 PC400LC-7L
12
Electrical circuit diagram related to common rail fuel pressure sensor
PC400LC-7L 20-425 1
12
E979
RAIL PRESSURE HIGH
• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1). (Engine controller
• Failure code AD00L2.
machine
Relative information (Code No.: 36401 Common rail pressure sensor voltage
Steps Cause Standard value in normal and references for troubleshooting

1. Related systems defective If any other error code or failure code is displayed, carry out troubleshooting for it first.
2. Fuel used improper Fuel used may be improper. Check it directly.
3. Electric system or common rail fuel
Carry out troubleshooting for error code E977.
pressure sensor defective
4. Mechanical system of common rail fuel
The common rail fuel pressure sensor may have a mechanical defect. Check it directly.
pressure sensor defective
5. Overflow valve defective The overflow valve may have trouble of breakage of spring, wear of seat or fixing of ball. Check it
directly.
6. Overflow piping clogged The overflow piping may be clogged. Check it directly.
7. Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
20-426 1 PC400LC-7L
12
E97A
RAIL PRESSURE ABNORMAL HIGH
• The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2). (Engine controller system)
Contents Of Trouble
• Failure code AD00MA.
machine

1. Common rail related device defective Carry out troubleshooting for error code E979.
PC400LC-7L 20-427 1
12
E97B
RAIL PRESSURE LOW
• No pressure feed by fuel supply pump (level 1) occurred. (Engine controller system)
Contents Of Trouble
• Failure code AD10L3.
machine

1. Related systems defective If any other error code or failure code is displayed, carry out troubleshooting for it first.
2. Fuel used improper Fuel used may be improper. Check it directly.
3. Fuel low pressure circuit device defective A low pressure circuit device may be defective. Referring to Note 1, carry out troubleshooting.
4. Fuel filter/strainer clogged The fuel filter /strainer may be clogged. Referring to Note 2, carry out troubleshooting.
5. Electrical system of fuel supply pump PCV1
Carry out troubleshooting for error codes E970, E971,E974 and E975.
defective
6. Fuel supply pump defective The fuel supply pump may be defective. Check it directly.
7. Common rail fuel pressure sensor defective 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 The fuel injector may be defective. Referring to Note 3. Check it directly.
Note 1: Check the low-pressure circuit devices for the following points.
1. Insufficiency of fuel.
2. Fixing and wear of feed pump and clogging of filter.
3. Leakage from and clogging of low-pressure fuel piping.
4. Malfunction of bypass valve and installation of wrong part (See Fig. 1).
5. Clogging of fuel filter.
6. Entry of fuel in oil pan (Fuel leakage in head cover).

• Fuel low-pressure circuit pressure: 0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}(21.3 - 42.6 psi).
20-428 1 PC400LC-7L
12
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1. 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.
WARNING! When performing the follow work, take care not to scald yourself with the fuel which
becomes hot (up to 90°C).
1. Disconnect the hose connected to the centralized return spill tube adapters (at the rear of the engine).
2. Connect another hose to the spill tube end so that spill fuel can be received in a container.
3. Run the engine and stall at each speed (relieve the arm circuit by moving the arm in). Measure the quantity of the fuel
spilling in 1 minute under this condition.
★ Limit of spill of fuel (Total of spill from 6 cylinders.
Stall speed (rpm) Limit of spill (cc/min)

1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
PC400LC-7L 20-429 1
12
E97C
RAIL PRESSURE TOO LOW
• No pressure feed by fuel supply pump (level 2) occurred. (Engine controller system)
Contents Of Trouble
• Failure code AD10MB.
machine

1. Common rail related device defective Carry out troubleshooting for error code E97B.
20-430 1 PC400LC-7L
12
E97D
RAIL PRESSURE OUT OF CONTROL
• Abnormal fuel pressure was generated in the common rail. (Engine controller system)
Contents Of Trouble
• Failure code AD10MA.
• The machine is driven under the normal control.
machine

1. Common rail related device defective Carry out troubleshooting for error code E97B.
PC400LC-7L 20-431 1
12
E980
ENGINE CONTROLLER ABNORMALITY
• The controller has an abnormality in it. (Engine controller system)
Contents Of Trouble
• Failure code DB20KT.
• The machine is driven with limited output or all output is turned OFF.
machine


A. Wiring harness test Between CB3 (11) and grounding Below 1Ω 1
Disconnection or Between CB3 (31) and grounding Below 1Ω 2
Resistance Ω
connector Between CB3 (32) and grounding Below 1Ω 3
2. Engine controller defective If cause 1 is not detected, the engine controller may be defective.
(Since trouble is in the engine controller, troubleshooting cannot be carried out.)
20-432 1 PC400LC-7L
12
PC400LC-7L 20-433 1
12
E981
FUEL INJECTOR 1 DISCONNECTION
• Fuel injector 1 circuit is disconnected. (Engine controller system)
Contents Of Trouble
• Failure code ADA1KA.
• Power to the fuel injector 1 circuit is switched OFF


1. Fuel injector 1 defective
• Disconnect CN1 connection and install T-adapter.
A. Fuel injector 1 test -
internal short or Resistance Ω At CN1, between (1) and (2) 0.4 - 1.1Ω 1
disconnected
A. Wiring harness test Between CB3 (14) and CN1 (1) Below 1Ω 2
Disconnection or
Resistance Ω
defective contact with Between CB3 (24) and CN1 (2) Below 1Ω 3
connector
A. Engine controller test Resistance Ω At CB3, between (14) and (24) 0.4 - 1.1Ω 4
Electrical circuit diagram related to fuel injector 1
20-434 1 PC400LC-7L
12
E982
Contents Of Trouble
• Failure code ADB1KA.


disconnected
Disconnection or
Resistance Ω
connector
PC400LC-7L 20-435 1
12
E983
Contents Of Trouble
• Failure code ADC1KA.


disconnected
Disconnection or
Resistance Ω
connector
20-436 1 PC400LC-7L
12
E984
Contents Of Trouble
• Failure code ADD1KA.


disconnected
Disconnection or
Resistance Ω
connector
PC400LC-7L 20-437 1
12
E985
Contents Of Trouble
• Failure code ADE1KA.


disconnected
Disconnection or
Resistance Ω
connector
20-438 1 PC400LC-7L
12
E986
Contents Of Trouble
• Failure code ADF1KA.


disconnected
Disconnection or
Resistance Ω
connector
PC400LC-7L 20-439 1
12
E98A
FUEL INJECTOR 1 - 3 S/C
• Abnormal current in the fuel injector 1 circuit, fuel injector 2 circuit and fuel injector 3 circuit. (Engine controller
• Failure code ADAZKB.
• Power to the fuel injector 1 circuit, fuel injector 2 circuit and fuel injector 3 circuit is switched OFF


A. Fuel injector 1 test - At CN1, between (1) and (2) 0.4 - 1.1Ω 1
disconnected At CN1, between (1) and (2) and grounding Above 1MΩ 2
At CN2, between (1) and (2) and grounding Above 1MΩ 4
disconnected
disconnected
Between CB3 (14) and CN1 (1) and grounding Above 1MΩ 7
Contact with Resistance Ω
grounding circuit
20-440 1 PC400LC-7L
Between CB3 (14) and CN1 (1) and grounding Below 1V 13
circuit
At CB3, between (5) and grounding Above 1MΩ 22
A. Engine controller test Resistance Ω At CB3, between (6) and grounding Above 1MΩ 23
Electrical circuit diagram related to fuel injectors 1, 2, and 3
PC400LC-7L 20-441 1
12
E98B
FUEL INJECTOR 4 - 6 S/C
• Abnormal current in the fuel injector 4 circuit, fuel injector 5 circuit and fuel injector 6 circuit. (Engine controller
• Failure code ADDZKB.
• Power to the fuel injector 4 circuit, fuel injector 5 circuit and fuel injector 6 circuit is switched OFF


disconnected At CN4, between (1) and (2) and grounding Above 1MΩ 2
disconnected
disconnected
grounding circuit
20-442 1 PC400LC-7L
circuit
Electrical circuit diagram related to fuel injectors 4, 5, and 6
PC400LC-7L 20-443 1
TROUBLESHOOTING A000N1
12
A000N1
ENGINE HIGH IDLING SPEED OUT OF STANDARD
User Code Error Code Failure Code Failure Engine high-idling speed out of standard
E22 E922 A000N1 phenomenon (Mechanical system)
Failure content • While the engine is running, its speed above 2,350 rpm is detected.
Response from • None in particular.
controller
Phenomenon occurring
• If the machine is used as it is, the engine may be damaged.
on machine
• Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(Code No. 01006: Engine speed)
Step Cause Standard value in normal and references for troubleshooting

Check for an external or an internal factor which heightens the engine high idling speed and then
1. Overrun of engine (While system is normal)
check the mechanical system of the engine.
2. Engine speed sensor system abnormal If error code E227 is displayed, carry out troubleshooting it first.
• Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting.
Engine Monitoring 1,880 − 1,980
A. Engine controller test Engine speed 1
High idling 01006 Engine speed rpm
20-444 1 PC400LC-7L
TROUBLESHOOTING A000N2
12
A000N2
ENGINE LOW IDLING SPEED OUT OF STANDARD
User Code Error Code Failure Code Failure Engine low-idling speed out of standard
--- --- A000N2 phenomenon (Mechanical system)
Failure content • While the engine is running, its speed below 500 rpm is detected.
Response from • None in particular.
controller • When the failure cause disappears by itself, the machine returns to normal.
Phenomenon occurring
on machine
• Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(Code No. 01006: Engine speed)
Step Cause Standard value in normal and references for troubleshooting

Check for an external or an internal factor which heightens the engine low idling speed and then
1. Engine mechanical system defective
check the mechanical system of the engine.
2. Engine speed sensor system abnormal If error code E227 is displayed, carry out troubleshooting it first.
• Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting.
Engine Monitoring
A. Engine controller test Engine speed 975 − 1,025 rpm 1
Low idling 01006 Engine speed
PC400LC-7L 20-445 1
TROUBLESHOOTING AA10NX
12
AA10NX
AIR CLEANER CLOGGED
• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine is running.
Contents Of Trouble (Mechanical system)
• Failure code AA10NX.
Response from controller • None in particular.
machine
• 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)


Steps Circuit Diagnostic Procedures For Code [AA10NX] Specifications No. Readings
1. Air cleaner clogged (While
Check the air cleaner. If it is clogged, clean or replace it.
system is normal)
2. Air cleaner clogging switch defective
• Disconnect A31 connection and install T-adapter.
A. Air cleaner clogging At A31, between (1) and (2) - Normal Below 1Ω 1
switch test - internal
Resistance Ω
short or At A31, between (1) and (2) - Clogged Above 1MΩ 2
disconnected
• Disconnect engine controller P02 and install T-adapters.
A. Wiring harness test Between P02 (5) and A31 (1) Below 1Ω 3
Disconnection or
Resistance Ω
defective contact with Between A31 (2) and grounding Below 1Ω 4
connector
4. Monitor panel defective
• Turn the ignition switch OFF for preparations.
• Disconnect P02 and install T-adapter.
• Hold the ignition switch in the ON position or keep the engine running during the troubleshooting.
Between P02 (5) and grounding - Normal Below 1V 5
Between P02 (5) and grounding - Clogged 20 - 30V 6
20-446 1 PC400LC-7L
TROUBLESHOOTING AA10NX
12
Electrical circuit diagram related to air cleaner clogging switch
PC400LC-7L 20-447 1
TROUBLESHOOTING AB00KE
12
AB00KE
CHARGE VOLTAGE LOW
• Signal voltage from alternator is below 20V while the engine is running. (Mechanical system)
Contents Of Trouble
• Failure code AB00KE.
machine
• If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure code is
recorded.
Relative information • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function.
(Code No.: 04300 Charge voltage
Code No.: 04501 Monitor input 2)


Steps Circuit Diagnostic Procedures For Code [AB00KE] Specifications No. Readings
1. Alternator defective
• Disconnect terminal R connection and install T-adapter.
• Keep the engine running during troubleshooting.
A. Alternator test - inter- At Alternator, between (terminal R) and grounding Above 20V 1
nal short or Voltage
disconnected If the voltage is abnormal, also check the belt tension.
Disconnection or
Resistance Ω Between P02 (11), J02 and Alternator terminal R Below 1Ω 2
connector
Between P02 (11), J02 and Alternator terminal R Above 1MΩ 3
A. Wiring harness test Between P02 (11), D01, J01 and ignition switch terminal
Above 1MΩ 4
Contact with Resistance Ω BR
grounding circuit Between P02 (11), battery relay terminal BR and
Above 1MΩ 5
grounding
4. Monitor panel defective
• Turn the ignition switch OFF for preparations.
• Hold the ignition switch in the ON position or keep the engine running during the troubleshooting.
A. Monitor panel test Voltage Between P02 (11) and grounding Above 20V 6
20-448 1 PC400LC-7L
TROUBLESHOOTING AB00KE
12
Electrical circuit diagram related to engine preheating, starting, charging
PC400LC-7L 20-449 1
TROUBLESHOOTING B@BAZG
12
B@BAZG
ENGINE OIL PRESSURE LOW
• The signal circuit of the low pressure switch is closed (connected to ground) and the signal circuit of the high pressure
switch is closed (connected to ground) while the engine speed is above 600 rpm.
Contents Of Trouble • The signal circuit of the low pressure switch is opened (disconnected from ground) and the signal circuit of the high
pressure switch is closed (connected to ground) while the engine speed is above 1,300 rpm. (Mechanical system)
• Failure code B@BAZG.
machine
• 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.


Steps Circuit Diagnostic Procedures For Code [B@BAZG] Specifications No. Readings
1. Engine oil pressure lowered (While system is Check the engine oil pressure. If it is abnormal, find out the cause and check the engine for damage, if
normal) need be, repair it.
2. Engine oil pressure switch system defective Carry out troubleshooting for error code E936.
• Hold ignition switch in the ON position or start engine during the troubleshooting.
Engine CB1 −−−
Stopped Between (21) and grounding (Low Below 1V 1
Low idling pressure switch signal) 20 - 30V 2
Stopped Below 1V 3
Between (15) and grounding (High
Above 1,300
pressure switch signal) 20 - 30V 4
rpm
20-450 1 PC400LC-7L
TESTING AND ADJUSTING B@BAZG
12
Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
PC400LC-7L 20-451
TESTING AND ADJUSTING B@BAZK
12
B@BAZK
ENGINE OIL LEVEL LOW
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the engine is stopped.
Contents Of Trouble (Mechanical system)
• Failure code B@BAZK.
machine
• 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.


Steps Circuit Diagnostic Procedures For Code [B@BAZK] Specifications No. Readings
1. Engine oil level low (While system is Check the engine oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently find out
normal) the cause.)
2. Engine oil level switch
• Hold ignition switch in the OFF position during troubleshooting.
A. Engine oil level switch Engine oil level OL ---
defective Resistance Ω Normal level Below 1Ω 1
Internal disconnection Between (1) and ground
Below normal level Above 1MΩ 2
3. Wiring harness
Disconnection or
Resistance Ω Between P02 (8) and OL (1) Below 1Ω 3
connector
4. Monitor panel
Between P02 (8) and Engine oil level - Normal Below 1V 4
grounding Engine oil level - Below normal 20 - 30V 5
20-452 PC400LC-7L
TESTING AND ADJUSTING B@BAZK
12
Electrical circuit diagram related to engine oil level switch
PC400LC-7L 20-453
TESTING AND ADJUSTING B@BCNS
12
B@BCNS
ENGINE WATER OVERHEAT
• The signal circuit of the engine water temperature sensor detected temperature above 105°C. (Mechanical system)
Contents Of Trouble
• Failure code B@BCNS.
machine
• If the engine water temperature monitor on the monitor panel lights up in red while the engine is running, this failure
code is recorded.
• Input from the engine water high temperature sensor (water temperature and voltage) can be checked in the monitoring
function.
(Code No.: 04102 Engine water temperature (High),
Code No.: Engine water temperature sensor voltage Hi)


Steps Circuit Diagnostic Procedures For Code [B@BCNS] Specifications No. Readings
1. Engine overheated (While system is Check the engine for overheating. If it has been overheated, find out the cause and check the engine
normal) for damage, then repair.
2. Engine water high temperature sensor Carry out troubleshooting for “Display of engine water temperature gauge on monitor panel is
system defective abnormal” in E mode.
At CB2, between (27)
3.28kΩ 1
and (29) Engine water temperature
At CB2, between (27) 105°C
3.28kΩ 2
and (39)
20-454 PC400LC-7L
TESTING AND ADJUSTING B@BCNS
12
temperature)
PC400LC-7L 20-455
TESTING AND ADJUSTING B@BCZK
12
B@BCZK
ENGINE WATER LEVEL LOW
• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the engine is run-
Contents Of Trouble ning. (Mechanical system)
• Failure code B@BCZK.
machine
• If the radiator water level monitor on the monitor panel lights up red while the engine is stopped (the ignition switch is
at the ON position), this failure code is recorded.
• Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function.


Steps Circuit Diagnostic Procedures For Code [B@BCZK] Specifications No. Readings
1. Sub-tank water level low (While system is Check the radiator sub-tank water level. If it is low, add water. (If it is reduced frequently, find out the
normal) cause.
2. Radiator water level switch
A. Radiator water level Sub-tank water level A33 ---
switch defective Resistance Ω Within normal level Below 1Ω 1
Internal disconnection Between (1) and (2)
Below normal level Above 1MΩ 2
3. Wiring harness
Disconnection or
Resistance Ω
defective contact with Between A33 (2), J08, J12 and grounding Below 1Ω 4
connector
4. Monitor panel
Sub-tank water level - Within
Below 1V 4
Between P02 (3) and normal
grounding Sub-tank water level - Below
20 - 30V 5
LOW level
20-456 PC400LC-7L
TESTING AND ADJUSTING B@BCZK
Electrical circuit diagram related to radiator water level switch
PC400LC-7L 20-457
TESTING AND ADJUSTING B@HANS
12
B@HANS
HYDRAULIC OIL OVERHEAT
• The signal of the hydraulic oil temperature sensor rises above 102°C, while the engine is running. (Mechanical system)
Contents Of Trouble
• Failure code B@HANS.
machine
• If the hydraulic oil temperature monitor on the monitor panel lights up red while the engine is running, this failure code
is recorded.
• Input from the hydraulic oil temperature sensor can be checked in the monitoring function.
(Code No.: 04401 Hydraulic oil temperature)


Steps Circuit Diagnostic Procedures For Code [B@HANS] Specifications No. Readings
1. Hydraulic oil overheated (While system is Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the
normal) hydraulic equipment for damage, then repair.
2. Hydraulic oil temperature sensor
A. Hydraulic oil tempera- A61 Hydraulic oil temperature ---
ture sensor test Between (1) and (2) 90 - 3.5kΩ 1
Internal disconnection Resistance Ω
Between (2) and 10 - 100°C
Above 1MΩ 2
grounding
3. Wiring harness
Contact with Resistance Ω Between P02 (12) and A61 (2) Above 1MΩ 3
grounding circuit
4. Monitor panel
Between P02 (12) and
90 - 3.5kΩ 4
(13) Hydraulic oil temperature
A. Monitor panel test Resistance Ω
Between P02 (12) and 10 - 100°C
Above 1MΩ 5
grounding
20-458 PC400LC-7L
Electrical circuit diagram related to hydraulic oil temperature sensor
PC400LC-7L 20-459
12
MEMORANDUM
20-460 PC400LC-7L
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
12
BEFORE CARRYING OUT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-503
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF . . . . . . . . . . . . 20-504
USER CODE MEMORY RETENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-505
E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
THE ENGINE DOES NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
PREHEATER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
PREHEATING MONITOR DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
HEATER UNIT DOES NOT WARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-511
E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
AUTO ENGINE WARM-UP DEVICE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
AUTO-DECELERATOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
E-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . 20-516
E-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
E-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . 20-520
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520
MACHINE PUSH-UP FUNCTION IS NOT TURNED OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521
E-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523
ATTACHMENT CIRCUIT DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523
E-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525
NO DISPLAY IN MONITOR PANEL AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525
E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527
PART OF DISPLAY ON MONITOR PANEL IS MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527
E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL . . . . . . . . . . . . . . . . . . 20-527
E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-528
FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING . . . . . . . . . . . . . . 20-528
E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-529
ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . 20-529
E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-531
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . 20-531
E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
FUEL GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535
E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-537
WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . 20-537
E-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539
WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539
WINDSHIELD WIPER DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539
PC400LC-7L 20-501 1
WINDSHIELD WASHER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-541
E-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543
ALARM BUZZER CANNOT BE CANCELLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543
E-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-545
“BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . 20-545
E-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-547
“BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . 20-547
E-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-549
“ARM IN” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . . . . . . . . 20-549
E-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-550
“ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . 20-550
E-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552
“BUCKET CURL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . 20-552
E-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-553
“BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . 20-553
E-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-555
“SWING” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . . . . . . . . 20-555
E-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-557
“TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . . . . . . 20-557
E-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559
“TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559
E-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-561
“SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . . . . . 20-561
E-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-563
TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING . . . . . . . . . . . . . . . . . . . . 20-563
E-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . 20-565
TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
E-32-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 20-566
E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-566
E-32-E15 DISCONNECTION IN WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . 20-567
E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . 20-567
E-32-E18 SHORT IN DAYLIGHT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568
E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568
E-32-E44 ABNORMALITY IN AIR MIX DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-569
E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER . . . . . . . . . . . . . . 20-569
E-32 - TROUBLESHOOTING BY FAILURE PHENOMENON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-571
20-502 1 PC400LC-7L
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING
12
BEFORE CARRYING OUT TROUBLESHOOTING
CONNECTION TABLE OF FUSE BOX
★ This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power
supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a
device which supplies power while the starting switch is at the OFF position).
★ When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if the power is
supplied normally.
Type of power supply Fuse No. Fuse capacity Destination of power

Pump controller (Controller power supply)
1 10 A Swing holding brake solenoid (When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
Pump controller (Solenoid power supply)
2 20 A Machine push-up solenoid
Switch power supply ATT return selector relay & solenoid
(Fusible link: A34)
Starting motor cutout relay (For PPC lock)
3 10 A
PPC lock solenoid
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn
6 10 A (Spare)
7 10 A Rotary lamp
Switch power supply 8 10 A Right front working lamp & boom working lamp
(Fusible link: A34) One-touch power maximizing switch (Input to pump controller input)
9 10 A
Radio
10 10 A (Spare)
11 20 A Air conditioner unit
Monitor panel
12 20 A
Starting motor cutout relay (For personal code)
Switch power supply Light relay (For right front working lamp & boom working lamp)
13 20 A
(Fusible link: A34) Headlamp & additional headlamp
14 10 A Service power supply 1 (M32 connector)
Travel alarm
15 10 A
Service power supply 2 (DC/DC converter)
16 10 A Radio (For backing up)
17 10 A Monitor panel (For backing up)
Constant power
supply 18 10 A Starting switch
(Fusible link: A35)
19 10 A Room lamp
20 10 A (Spare)
PC400LC-7L 20-503 1
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
1. Always turn power OFF before disconnecting or connecting connectors.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
★ If power is turned ON with the connectors still disconnected, unnecessary displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
5. When checking a single diode circuit:

★ Isolate the diode from the circuit.
6. When checking a dual diode circuit:

★ Isolated the diode from the circuit.
7. Always be aware of what you are measuring. Voltage, Ohms or Amps.

Always use caution when measuring a circuit.
★ When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are measuring.
★ When measuring ohms, be sure the circuit is dead and has no
voltage in it before you take any readings. Be sure the meter is set
in the proper ohms range.
★ When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage you equipment or possibly cause injury.
Always study the operators manuel for the meter you will be
using.
20-504 1 PC400LC-7L
12
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY
ITSELF
There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully.
1. If any abnormality returns to normal by itself.
2. If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned
to its original position when carrying out troubleshooting on the failure, and the service code is no longer displayed, or if
the monitor display returns to normal.
3. After completing troubleshooting, always erase the user code from memory.
USER CODE MEMORY RETENTION FUNCTION

When displaying the codes in the memory and carrying out troubleshooting, record the content of the display first, then erase
the display. After re-enacting the problem, carry out troubleshooting according to the failure codes that are now displayed.
There are cases where mistaken operation or abnormalities occur when a connector is disconnected. Erasing the data in this
way saves any wasted work.
PC400LC-7L 20-505 1
12
INFORMATION CONTAINED IN TESTING PROCEDURES
★ The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to
isolate each part of the circuit.
• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while
performing these tests.
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or actuator
Your
Resistance Ω Test procedure for component only. readings 1 information
A. What you are
or
testing Voltage Your
Test procedure for component only. readings 2
information
2. Diode test
• With ignition switch in the OFF position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm electrical
flow. Electrical flow should be one way only.
At a diode, between point (x) and (x) reverse meter lead Continuity one
A.Diode test Resistance Ω polarity each time to check diode. way only? 3 Yes or No
Your
Resistance Ω Test procedure for harness. (connector) to (connector) readings 4
A.Open or high information
or
resistance Voltage Your
Test procedure for harness. (connector) to (connector) readings 5
information
Your
B.Short to chas- Resistance Ω Test procedure for harness. (connector) to (connector) readings 6 information
sis ground or or
Voltage Your
within harness Test procedure for harness. (connector) to (connector) readings 7
information
4. Additional components to be tested
A.What you are Resistance Ω Your
or Test procedure for any additional components. readings 8
testing Voltage information
20-506 1 PC400LC-7L
12
Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC400LC-7L 20-507 1
TROUBLESHOOTING E-1
12
E-1
THE ENGINE DOES NOT CRANK
Failure information • The engine will not crank.
• Failure code none displayed.
Relative information • The engine starting circuit has the start lock mechanism of the safety lock lever type

Steps Circuit Diagnostic Procedures For Code [---] Specifications No. Readings
1. Battery
• Keep ignition switch to the OFF position for this test.
A. Battery test Voltage Battery voltage Min. 24V 1
Insufficient capacity --- Electrolyte specific gravity Min. 1.26 2
2. Fusible link A35
If circuit breaker is turned OFF or the fuse is broken, the circuit probably has a ground fault (See cause 9).
3. Fuse No. 3 or 17
4. Ignition switch
• Prepare with ignition switch in the OFF position.
• Disconnect H15 connector and install T-adapter.
A. Ignition switch test At H15, between (1) and (4) key OFF position Min. 1MΩ 2
Resistance Ω
Internal disconnection At H15, between (1) and (4) key START position Max. 1Ω 3
5. Safety lock switch
• Disconnect S14 connector and install T-adapter.
A. Safety lock switch test At S14, between (1) and (3), locked Min. 1MΩ 4
Resistance Ω
Internal short circuit At S14, between (1) and (3), unlocked Max. 1Ω 5
6. Starting motor cut-out relays
• Disconnect R11 and R13 connector and install T-adapter.
At R11, between (1) and (2) 100 - 500Ω 6
At R11, between (3) and (5) Min. 1MΩ 7
A. Starting motor cut-out
At R11, between (3) and (6) Max. 1Ω 8
relays Resistance Ω
Internal defect At R13, between (1) and (2) 100 - 500Ω 9
At R13, between (3) and (5) Min. 1MΩ 10
At R13, between (3) and (6) Max. 1Ω 11
7. Starting motor
• Turn ignition switch to START and carry out troubleshooting.
Starting motor, between terminal B
B - power supply 20 - 30V 12
and chassis ground
Starting motor, between ST (1) and
S - start 20 - 30V 13
A. Starting motor test chassis ground
Voltage
Internal defect Starting motor, between ST (2) and
R - charge Max. 1V 14
chassis ground
If the above voltage is normal and the starting motor does not crank, starting motor has a defect in it
or engine is defective.
8. Alternator
• Prepare with ignition switch OFF (with only wiring harness R disconnected).
• Turn ignition switch ON and carry out troubleshooting.
A. Alternator test
Voltage Alternator, between terminal R and chassis ground Max. 1V 15
Internal short circuit
20-508 1 PC400LC-7L
TROUBLESHOOTING E-1
• Disconnect A35, H15, R1, R13, S14 connectors from and install T-adapter.
• Carry out troubleshooting with ignition switch OFF.
★ Turn ignition switch ON during troubleshooting
Between battery relay terminal B and A35 (1) Max. 1Ω 16
Between A35 (2) and H15 (1) Max. 1Ω 17
A. Wiring harness Between H15 (4), J01 and R11 (5) Max. 1Ω 18
Disconnection in Between R11 (3) and ST (1) Max. 1Ω 19
Resistance Ω
harness or defective Between FB1 (3) and S14 (1) Max. 1Ω 20
contact in connector Between S14 (3) and R11 (1) Max. 1Ω 21
Between R11 (2) and R13 (6) Max. 1Ω 22
Between R13 (3), J04 and chassis ground Max. 1Ω 23
Resistance Ω Between A35 (2) and H15 (1) and chassis ground Min. 1MΩ 24
Between H15 (4), J01 and R11 (5) and other related
Min. 1MΩ 25
B. Wiring harness circuits and chassis ground
Short to chassis Between R11 (3) and ST (1) and chassis ground Min. 1MΩ 26
ground or within
Between FB1 (3) and S14 (1) and chassis ground Min. 1MΩ 27
harness
Contact with ground Between A14 (3) and R11 (1) and chassis ground Min. 1MΩ 28
circuit Between R11 (2) and R13 (6) and chassis ground Min. 1MΩ 29
Between R13 (2), J05, P02 (14 and other related circuits
Min. 1MΩ 30
and chassis ground
C. Wiring harness
★ Between ST(2), alternator terminal R, J02, D01 (6) Max. 1V 31
and P02 (11) and chassis ground
circuit
PC400LC-7L 20-509 1
TROUBLESHOOTING E-1
Electrical circuit diagram for engine preheating, starting, charging
20-510 1 PC400LC-7L
TROUBLESHOOTING E-2
12
E-2
PREHEATER DOES NOT OPERATE
PREHEATING MONITOR DOES NOT LIGHT
Failure information • The preheater does not operate. 1. When the starting switch is turned to the HEAT position, the preheating
monitor does not light up.
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about 30 seconds, it start
flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
• Input of the preheating signal (ON or OFF) can be checked in the monitoring function.
(Code No. 04500: Monitor input 1)

1. Ignition switch system
If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting
defective
2. Wiring harness
Disconnection or
Resistance Ω Between P02 (18) and J02 (7) Below 1Ω 1
connector
3. Monitor panel
• Hold ignition switch in OFF position or HEAT position during troubleshooting.
At P02, between Ignition switch - OFF Below 1V 2
(18) and ground Ignition switch - HEAT 20 - 30V 3
PC400LC-7L 20-511 1
TROUBLESHOOTING E-2
12
HEATER UNIT DOES NOT WARM
Failure information • The preheater does not operate. 2. When the starting switch is turned to the HEAT position, the heater
unit is not warmed.
• Check that the starting motor rotates normally.
• (If the starting motor does not rotate, carry out troubleshooting in “E-1 Engine does not crank”.)

1. Ignition switch
• Disconnect H15 and install T-adapter.
A. Ignition switch test At H15, between Ignition switch - OFF Above 1MΩ 1
Resistance Ω
Internal disconnection (1) and (3) Ignition switch - HEAT Below 1Ω 2
2. Heater relay
• Disconnect H15 and install T-adapter.
A. Heater relay test Ignition switch Heater relay ---
Internal disconnection Continuity and
OFF Between coil terminal and grounding Continued 3
Resistance Ω
HEAT Between contact terminals Below 1Ω 4
3. Intake air heater
A. Intake air heater test
Continuity Intake air heater, between terminals Continued 5
Internal disconnection
4. Wiring harness
A. Wiring harness test Between H15 (3), J02, and heater relay terminal Below 1Ω 6
Disconnection or Between starting motor terminal B and heater relay Below 1Ω 7
Resistance Ω
defective contact with Between heater relay and intake air heater Below 1Ω 8
connector Between air heater and engine Below 1Ω 9
20-512 1 PC400LC-7L
TROUBLESHOOTING E-2
12
Electrical circuit diagram for engine preheating, starting, charging
PC400LC-7L 20-513 1
TROUBLESHOOTING E-3
12
E-3
AUTO ENGINE WARM-UP DEVICE DOES NOT WORK
Failure information • The auto engine warm-up device does not work.
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C, and raise the engine
rotation up to 1,200 rpm.
• The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more than 3 seconds, when
the engine starting switch is in the ON position or after the engine is started.
• If the engine water temperature is below 10°C, the turbocharger protection function operates to keep the engine speed below
1,000 rpm for up to 5 seconds after the engine is started.

1. Engine cooling water temperature signal
• Turn the ignition switch ON for the trouble shooting
Compare the
monitor
Monitor code indication with
A. Engine cooling water Engine cooling water temperature (low temperature) 1
04107 the actual engine
temperature signal cooling water
fault
temperate
If the display on the monitor panel is abnormal, carry out troubleshooting in “Engine water thermometer does not dis-
play normally.
2. Engine controller If step1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting
A. Engine controller test cannot be carried out.)
20-514 1 PC400LC-7L
TROUBLESHOOTING E-4
12
E-4
AUTO-DECELERATOR DOES NOT OPERATE
Failure information • The auto-decelerator does not operate.
• Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above this level.
• Check the display on the monitor panel while the engine is running.
• If the display on the monitor panel is abnormal, carry out troubleshooting in “*** is not displayed normally in monitoring
function”.
--- Standard value and references for testing

Cause Monitoring code Item Normal display
01900 Lever operation: ON
1 Boom RAISE signal fault Boom RAISE
Pressure switch 1 Lever NEUTRAL: OFF
2 Boom LOWER signal fault Pressure switch 1 Boom LOWER Lever NEUTRAL: OFF
3 Arm RETRACT signal 01900 Arm RETRACT Lever operation: ON

Presumed cause and standard value
fault Pressure switch 1 Lever NEUTRAL: OFF

4 Arm EXTEND signal fault Arm EXTEND
5 Bucket CURL signal fault Pressure switch 2 Bucket CURL Lever NEUTRAL: OFF
Bucket DUMPING signal 01901 Lever operation: ON
6 fault Pressure switch 2 Bucket DUMPING Lever NEUTRAL: OFF
7 Swing signal fault 01900 Swing Lever operation: ON

8 Travel signal fault Travel
9 Service signal fault Pressure switch 2 Service Lever NEUTRAL: OFF
10 Pump controller defective As this is an internal failure, testing cannot be conducted. (If there is none of the causes listed in Item 1
through 9, the controller is judged as defective.
As this is an internal failure, testing cannot be conducted. (If there is none of the causes listed in Item 1
11 Engine controller defective
through 9, the controller is judged as defective.
PC400LC-7L 20-515 1
TROUBLESHOOTING E-5
12
E-5
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE
Failure information • All the work equipment, swing and travel do not move.

1. Fuse No. 9 fault If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 4B.
1. Safety lock switch
• Hold ignition switch in OFF position.
A. Safety lock switch test At S14, between Safety lock lever - Free Below 1Ω 1
Resistance Ω
Internal disconnection (1) and (2) Safety lock lever - Lock Above 1MΩ 2
2. PPC lock solenoid
A. PPC lock solenoid At V08, between (1) and (2) 20 - 60Ω 3
Internal disconnec-
Resistance Ω
tion, short circuit or At V08, between (1) and grounding Above 1MΩ 4
ground fault
3. Assembled type diode D01
A. Assembled type diode
Above 1MΩ
D01 Resistance Ω At D01, between (4) and (8) 5
(Νο Continuity)
Internal short
4. Wiring harness
A. Wiring harness test Between FB1 (3) outlet and S14 (1) Below 1Ω 6
Disconnection or Between S14 (2) and J02 - V01 (2) Below 1Ω 7
Resistance Ω
connector Between V08 (1) to J13 and ground Below 1Ω 8
B. Wiring harness test Between FB1 (3) outlet and S14 (1) and grounding Above 1MΩ 9
Contact with Resistance Ω Between S14 (2) to J02 - V01 (2) and grounding Above 1MΩ 10
grounding circuit Between S14 (2) and D01 (4) and grounding Above 1MΩ 11
20-516 1 PC400LC-7L
TROUBLESHOOTING E-5
12
Electrical circuit diagram for PPC lock solenoid
PC400LC-7L 20-517 1
TROUBLESHOOTING E-6
12
E-6
ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE
Failure information • One-touch power max. function does not operate
• If the one-touch power max. switch is pressed while the engine is running, the one-touch power max. monitor is displayed
on the monitor panel.
• Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in the monitoring
function. (Code No. 02200: Switch input 1)

1. One touch power max. switch
• Disconnect M23 and install T-adapter.
A. One touch power max. At M23, One touch pwr. max. sw. - released Min. 1MΩ 1
switch test Resistance Ω between (1) and
One touch pwr. max. sw. - Pressed Max. 1Ω 2
Internal disconnection (2)
2. Wiring harness
Disconnection or
Resistance Ω Between FB1 (9) outlet and M23 (1) Max. 1Ω 3
connector
B. Wiring harness test Between FB1 (9) outlet and M23 (1) and grounding Min. 1MΩ 4
Contact with Resistance Ω Between FB1 (9) outlet and other related circuit and
grounding circuit Min. 1MΩ 5
grounding
3. Pump controller
• Disconnect C01 and install T-adapter
• Keep ignition switch to the ON position for this test.
At C01, One touch pwr. max. sw. - released Max. 1V 6
A. Pump controller test Voltage Between (11)
and ground One touch pwr. max. sw. - Pressed 20 - 30V 7
20-518 1 PC400LC-7L
TROUBLESHOOTING E-6
12
Electrical circuit diagram related to one-touch power max. switch
PC400LC-7L 20-519 1
TROUBLESHOOTING E-7
12
E-7
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE
Failure Machine push-up function does not operate (1)The machine push-up function does not operate.
information normally.
Relative
When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
information

1. Machine push-up switch
A. Machine push-up At M38, Low pressure position Below 1Ω 1
High pressure position Above 1MΩ 2
2. Wiring harness
A. Wiring harness test Between M38 (2), J07 and V06 (2) and grounding Below 1V 3
Contact with Voltage
Between M38 (2) and D02 (3) and grounding Below 1V 4
24V grounding circuit
20-520 1 PC400LC-7L
TROUBLESHOOTING E-7
12
MACHINE PUSH-UP FUNCTION IS NOT TURNED OFF
Failure information • Machine push-up function does not operate normally. (2)The machine push-up function is not turned OFF.
Relative information • When the machine push-up function is set in the low pressure position, the solenoid is turned ON.

1. Machine push-up switch
A. Machine push-up At M38, Low pressure position Below 1Ω 1
High pressure position Above 1MΩ 2
2. Machine push-up solenoid
A. Machine push-up At V06, between (1) and (2) 20 - 60Ω 3
solenoid
Internal disconnec- Resistance Ω
At V06, between (2) and grounding Above 1MΩ 4
tion, short circuit or
ground fault
3. Assembled type diode D02
A. Assembled type diode
Above 1MΩ
D02 Resistance Ω At D02, between (3) and (7) 5
(Νο Continuity)
Internal short
4. Wiring harness
A. Wiring harness test Between FB1 (2) outlet and M38 (1) Below 1Ω 6
Disconnection or Between M38 (2) and J07 - V06 (2) Below 1Ω 7
Resistance Ω
connector Between V06 (1) and ground Below 1Ω 8
Between FB1 (2) outlet and M38 (1) and related circuits
B. Wiring harness test Above 1MΩ 9
and grounding
Between M38 (2) to J07 - V06 (2) and grounding Above 1MΩ 10
grounding circuit
Between M38 (2) and D02 (3) and grounding Above 1MΩ 11
PC400LC-7L 20-521 1
TROUBLESHOOTING E-7
12
Electrical circuit diagram related to machine push-up solenoid
20-522 1 PC400LC-7L
TROUBLESHOOTING E-7
12
MEMORANDUM
PC400LC-7L 20-523 1
TROUBLESHOOTING E-8
12-
E-8
ATTACHMENT CIRCUIT DOES NOT CHANGE
WHEN ATTACHMENT IS INSTALLED
(1)When working mode A or E is selected, attachment circuit is not switched to crusher

Failure information Attachment circuit does not change. circuit (reciprocation circuit).
(2)When working mode B is selected, attachment circuit is not switched to breaker circuit
(one-way circuit).
Relative information If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or disconnection), an error code is
displayed. A fault on the secondary side (contact side) cannot be detected, however.

1. Attachment return selection solenoid
A. Attachment return At V12, between (1) and (2) 20 - 60Ω 1
selection solenoid test Resistance Ω
At V12, between (2) and grounding Above 1MΩ 2
2. Attachment return selection relay
A. Attachment return At R20, between (3) and (5) Below 1Ω 3
selection relay
Internal Resistance Ω
At R20, between (3) and (6) Above 1MΩ 4
disconnection, short
circuit or ground fault
3. Wiring harness
★ Hold ignition switch in the ON position for this test
A. Wiring harness test Between J03 (8) and R20 (3) Below 1Ω 6
Disconnection or Between R20 (5) and V12 (2) Below 1Ω 7
Resistance Ω
connector Between C03 (3), (13), (23) and V12 (1) Below 1Ω 8
Contact with 24V Voltage ★ Between R20 (5) and V12 (2) and grounding Below 1V 9
grounding circuit
20-524 1 PC400LC-7L
TROUBLESHOOTING E-8
12
Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid
PC400LC-7L 20-525 1
TROUBLESHOOTING E-9
12
E-9
NO DISPLAY IN MONITOR PANEL AT ALL
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.

2. Wiring harness
A. Wiring harness test From P01 (1), (2) to J07 to FB1 (12) Below 1Ω 1
Disconnection or
Resistance Ω
defective contact with From P01 (6), (7) to J04 and grounding Below 1Ω 2
connector
Between P01 (1), (2) to J07 to FB1 (12) outlet or related
Contact with Resistance Ω Above 1MΩ 3
circuits and grounding
grounding circuit
3. Monitor panel
Starting Switch
Voltage At P01, between (1), (2) and ground 20 - 30V 4
ON
A. Monitor panel test
Starting switch
Resistance Ω At P01, between (6), (7) and ground Below 1Ω 5
OFF
20-526 1 PC400LC-7L
TROUBLESHOOTING E-9
12
Electrical Circuit Diagram for Power Source in Monitor Panel
PC400LC-7L 20-527 1
TROUBLESHOOTING E-10
12
E-10
PART OF DISPLAY ON MONITOR PANEL IS MISSING
Failure information • Part of display on monitor panel is missing Part of the display in the monitor panel is missing during starting switch in ON.
Cause Standard value in normalcy and references for troubleshooting

★ Turn the starting switch ON during the troubleshooting.
1 Monitor panel LCD fault If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen becomes totally white) by the
following switching operation, then the monitor panel is normal.
• Switching operation: [/] + [A] (push switches simultaneously.)
2 Monitor panel defective If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting
cannot be carried out.)
E-11
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL
Failure information • The monitor panels displays contents that have nothing to do with the model on which it is installed.

★ Turn the starting switch in ON during the troubleshooting (monitoring).
1. Model code signal fault Monitoring code Item Normal display
(Internal failure) 00200 Controller model code PC400-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217].
2. Monitor panel defective If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot
be carried out.)
20-528 1 PC400LC-7L
12
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)

1. Fuel level lowered
Check fuel level in fuel tank. If insufficient, refill fuel.
(system in normal condition)
2. Fuel level sensor
• Disconnect A60 and install T-adapter.
Fuel level
At A60, between Approximately
A. Fuel level sensor test FULL (Upper limit) 1
Resistance Ω (1) and 12Ω
grounding EMPTY (Lower limit) 85 - 110Ω 2
3. Wiring harness
Contact with Resistance Ω Between P02 (2) and A60 (1) Below 1Ω 3
grounding circuit
4. Monitor panel
Fuel level
At A60, between Approximately
FULL (Upper limit) 4
A. Monitor panel test Resistance Ω (2) and 12Ω
grounding EMPTY (Lower limit) 85 - 110Ω 5
Electrical Circuit Diagram for Fuel Level Sensor
PC400LC-7L 20-529 1
12
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).
Failure • Engine water temperature gauge does not display
information correctly
2. While the engine water temperature is stabilized normally, the
temperature gauge rises up to the red range (H).
• The signal of the engine water high temperature sensor for the water temperature gauge is received from the engine controller
through the communication line.
Relative • If the engine water high temperature sensor system becomes defective, error code [E934] may be displayed.
information • Input from the engine water high temperature sensor (voltage and temperature) can be checked in the monitoring function.
(Code No. 04106: Engine water sensor voltage Hi,
Code No. 04102: Engine water temperature (High temperature))

1. Engine water high temperature sensor
• Disconnect TWH and install T-adapter.
• Turn ignition switch ON or keep the engine running during troubleshooting.
A. Engine water high At TWH, between (1) and (2) 3.5k - 90kΩ 1
sensor test - Internal At TWH, between (1) and grounding Above 1MΩ 2
Resistance Ω
disconnection, short
circuit, ground fault At TWH, between (2) and grounding Above 1MΩ 3
2. Wiring harness
• Disconnect CB2 and install T-adapter.
★ Hold ignition switch in the ON position during troubleshooting.
A. Wiring harness test Between CB2 (27) and THW (1) Below 1Ω 4
Disconnection or Between CB2 (29) and THW (2) Below 1Ω 5
Resistance Ω
contact with
connector Between CB2 (39) and THW (2) Below 1Ω 6
Contact with Resistance Ω Between CB2 (27) and TWH (1) and ground Above 1MΩ 7
grounding circuit
C. Wiring harness test
Contact with 24V Voltage ★ Between CB2 (27) and TWH (1) and ground Below 1V 8
circuit
• Disconnect CB2 and install T-adapter.
4. Monitor panel If causes 1 - 3 are not detected, the monitor panel may be defective. (Since trouble is in the monitor panel,
troubleshooting cannot be carried out.)
20-530 1 PC400LC-7L
12
Electrical circuit diagram related to engine water high temperature sensor
PC400LC-7L 20-531 1
12
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)

1. Hydraulic oil temperature sensor
• Turn ignition switch OFF.
Engine cooling water
temperature
A. Hydraulic oil At A61, between (1) and (2) 90 - 3.5kΩ 1
temperature sensor test
- Internal Resistance Ω 10 - 100°C At A61, between (2) and
Above 1MΩ 2
disconnection, short grounding
circuit, ground fault
2. Wiring harness
Disconnection or
Resistance Ω
contact with Between P02 (13) and A61 (1) Below 1Ω 4
connector
Contact with Resistance Ω Between P02 (12) and A61 (2) and ground Above 1MΩ 5
grounding circuit
Contact with 24V Voltage ★ Between P02 (12) and A61 (2) and ground Below 1V 6
circuit
3. Monitor panel
Engine cooling water
temperature
At P02, between (12) and (13) 90 - 3.5kΩ 7
A. Monitor panel test Resistance Ω 10 - 100°C At P02, between (12) and
90 - 3.5kΩ 8
ground
20-532 1 PC400LC-7L
12
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC400LC-7L 20-533 1
12
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)

1. Fuel level sensor
• Turn ignition switch OFF during troubleshooting.
Fuel level
A. Fuel level sensor test - Approximately
Internal At A60, between (1) and 12Ω
Resistance Ω
disconnection, short grounding
EMPTY (Lower limit) 85 - 110Ω 2
2. Wiring harness
Disconnection or
Resistance Ω Between P02 (2) and A60 (1) Below 1Ω 3
contact with
connector
Contact with Resistance Ω Between P02 (2) and A60 (1) and ground Above 1MΩ 4
grounding circuit
Contact with 24V Voltage ★ Between P02 (2) and A60 (1) and ground Below 1V 5
circuit
3. Monitor panel
Fuel level
Approximately
A. Monitor panel test Resistance Ω At P01, between (2) and ground 12Ω
EMPTY (Lower limit) 85 - 110Ω 7
20-534 1 PC400LC-7L
12
Electrical Circuit Diagram for Fuel Level Sensor
PC400LC-7L 20-535 1
12
E-16
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY
1. Though the swing lock switch was turned ON, the swing lock monitor
does not light up.
• Swing lock monitor does not display cor-
Failure information
rectly
2. Though the swing lock switch was turned OFF, the swing lock monitor
lights up.
• Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.

1. Swing lock switch
• Disconnect X05 and install T-adapter.
Swing lock switch
A. Swing lock switch test OFF Above 1MΩ 1
Internal
Resistance Ω At X05, between (1) and (2)
disconnection, short ON Below 1Ω 2
2. Wiring harness
A. Wiring harness test From P02 (17) to J02 and X05and A60 (1) Below 1Ω 3
Disconnection or
Resistance Ω
contact with From X05 (2) to J05 and grounding Below 1Ω 4
connector
B. Wiring harness test From P02 (17) to J02 to X05 (1) and ground Above 1MΩ 5
From P02 (17) to C02 (38) and ground Above 1MΩ 6
grounding circuit
C. Wiring harness test ★ From P02 (17) to J02 and X05 (1) and ground Below 1V 7
circuit ★ From P02 (17) to C02 (38) and ground Below 1V 8
3. Monitor panel
Swing lock switch
OFF At P01, between (17) and 20 − 30ς 9
ON ground Below 1V 10
20-536 1 PC400LC-7L
12
Electrical circuit diagram related to swing holding brake solenoid
PC400LC-7L 20-537 1
12
E-17
WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED
Failure information When monitor switch is operated, nothing is (1) When mode selector switch is operated, working mode monitor is not
displayed. displayed.
Presumed cause and Cause Standard value in normalcy and references for troubleshooting
standard value in
normalcy Monitor panel defective As this is an internal failure, troubleshooting cannot be conducted.
When monitor switch is operated, nothing is (2) When LCD monitor adjustment switch is operated, mode selection screen is
Failure information displayed. not displayed.
standard value in
When monitor switch is operated, nothing is (3) When selector switch is operated, flow rate adjustment screen or flow rate
Failure information
displayed. selection screen is not displayed.
standard value in
When monitor switch is operated, nothing is

Failure information displayed. (4) When maintenance switch is operated, item selection screen is not displayed.

standard value in
When monitor switch is operated, nothing is (5) When automatic deceleration switch is operated, automatic deceleration
Failure information
displayed. monitor is not displayed.
Relative information When the automatic decelerator does not operate either, conduct the troubleshooting for E-4.
standard value in
Failure information When monitor switch is operated, nothing is (6) When travel speed selector switch is operated, travel speed monitor is not
displayed. displayed.
Relative information When the travel speed does not change either, conduct the troubleshooting for H-22.
standard value in
When monitor switch is operated, nothing is

Failure information displayed. (7) When wiper switch is operated, wiper monitor is not displayed.
Relative information When the wiper does not operate either, conduct the troubleshooting for E-18.
standard value in
20-538 1 PC400LC-7L
12
MEMORANDUM
PC400LC-7L 20-539 1
12
E-18
WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK
WINDSHIELD WIPER DOES NOT WORK
Failure information • Windshield wiper and window washer do not work. (1) The windshield wiper does not work.
• Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.

1. Window rear limit switch
• Disconnect W03 and install T-adapter.
Front window
A. Window rear limit When installed at front Above 1MΩ 1
switch test - Internal
Resistance Ω At W03, between (1) and (2)
disconnection, short When retracted at rear Below 1Ω 2
2. Windshield wiper motor
• Disconnect W03 and install T-adapter.
• Turn ignition switch OFF or keep the engine running during troubleshooting.
A. Windshield wiper Continuity
motor test - Internal and resis- At W04, between (3) and (1) Continued 3
disconnection tance value
3. Wiring harness
• Disconnect P01 and P02 and install T-adapter.
A. Wiring harness test From P01 (9) and W04 (3) Below 1Ω 4
Disconnection or
Resistance Ω
contact with From P01 (10) and W04 (1) Below 1Ω 5
connector
Contact with Resistance Ω From P02 (15) and W03 (2) Above 1MΩ 6
grounding circuit
4. Monitor panel (Window rear limit switch system)
Front window
A. Monitor panel When installed at front 20 - 30V 7
At P02, between (15) and
(Window rear limit Voltage
When retracted at rear ground Below 1V 8
switch system) test
5. Monitor panel (Windshield wiper motor system)
Windshield wiper switch
OFF Below 3V 9
A. Monitor panel At P01, between (9) and ground
(Windshield wiper Voltage At P01, between (10) and Below 3V ↔ 20 -
ON 30V (Constant 10
motor system) test ground
cycle)
20-540 1 PC400LC-7L
12
Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch
PC400LC-7L 20-541 1
12
WINDSHIELD WASHER DOES NOT OPERATE
Failure information Windshield wiper and window washer do not work. (2) Windshield washer does not operate.

1. Fuse No. 4 If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 3B.)
2. Windshield wiper motor
• Turn ignition switch OFF or keep the engine running during troubleshooting.
A. Windshield wiper At A50, between (1) and (2) 5 - 20Ω 1
motor test - Internal Resistance Ω
At A50, between (1) and ground Above 1MΩ 2
disconnection
3. Wiring harness
• Disconnect A50 and P01 and install T-adapter.
A. Wiring harness test From FB1 (4) to J03 to J06 and A50 (1) Below 1Ω 3
Disconnection or
Resistance Ω
contact with From FB1 (4) to J04 and P01 (3) Below 1Ω 4
connector
From FB1 (4) to J03 to J06 A50 (1) and grounding Above 1MΩ 5
B. Wiring harness test From FB1 (4) to D02 (4) and to other relative circuits and
Above 1MΩ 6
Contact with Resistance Ω grounding
grounding circuit From A50 (2) to J04 and P01 (3) and grounding Above 1MΩ 7
From A50 (2) to D02 (8) and grounding Above 1MΩ 8
4. Monitor panel
Windshield wiper switch
OFF 20 - 30V 9
A. Monitor panel test Voltage At P01, between (3) and ground
ON Below 1V 10
20-542 1 PC400LC-7L
12
Electrical Circuit Diagram for Window Washer Motor
PC400LC-7L 20-543 1
12
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.

1. Alarm buzzer stop switch
• Turn ignition switch OFF.
Alarm buzzer stop switch
A. Alarm buzzer stop Release Above 1MΩ 1
At P03, between (1) and
switch test - Internal Resistance Ω
(2) Depress Below 1Ω 2
disconnection
2. Wiring harness
• Disconnect P01, P02 and P03 and install T-adapter.
★ Have ignition switch ON for this test.
A. Wiring harness test At P02 (16) and P03 (1) Below 1Ω 3
Disconnection or
Resistance Ω
contact with From P03 (2) to J05 to grounding Below 1Ω 4
connector
Contact with Voltage ★ Between P02 (16) and P03 (1) and grounding Below 1V 5
grounding circuit
3. Monitor panel
Alarm buzzer stop switch
Release At P02, between (16) and 20 - 30V 6
Depress ground Below 1V 7
20-544 1 PC400LC-7L
12
Electrical circuit diagram related to alarm buzzer stop switch
PC400LC-7L 20-545 1
12
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.

1. Boom RAISE PPC hydraulic switch
RH work equipment control
lever
A. Boom RAISE PPC NEUTRAL Above 1MΩ 1
At S06, between (1) and
hydraulic switch test - Resistance Ω
(2) Boom RAISE Below 1Ω 2
2. Wiring harness
• Disconnect C03 and S06 and install T-adapter.
A. Wiring harness test Between C03 (10) and S06 (2) Below 1Ω 3
Disconnection or
Resistance Ω
contact with Between S06 (1) and grounding Below 1Ω 4
connector
Contact with Resistance Ω Between C03 (10) and S06 (2) and grounding Above 1MΩ 5
grounding circuit
Contact with 24V Voltage ★ Between C03 (10) and S06 (2) and grounding Below 1V 6
circuit
3. Pump controller
• Disconnect C03 and install T-adapter.
• Start the engine during troubleshooting.
RH work equipment
control lever
NEUTRAL At C03, between (10) and 20 - 30V 7
Boom RAISE ground Below 1V 8
20-546 1 PC400LC-7L
12
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC400LC-7L 20-547 1
12
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.

1. Boom LOWER PPC hydraulic switch
lever
A. Boom LOWER PPC NEUTRAL Above 1MΩ 1
(2) Boom LOWER Below 1Ω 2
2. Wiring harness
Disconnection or
Resistance Ω
connector
grounding circuit
circuit
3. Pump controller
• Start the engine during the troubleshooting.
RH work equipment
control lever
Boom LOWER ground Below 1V 8
20-548 1 PC400LC-7L
12
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
PC400LC-7L 20-549 1
12
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 (special
function. function) of monitor panel.

1. Arm IN PPC pressure sensor defective The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for error code [E247].
2. Pump controller defective If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot
be carried out since the defect is in the pump controller).
20-550 1 PC400LC-7L
12
E-23
“ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
• Arm DUMPING is not correctly displayed in monitor function
Failure information
• Arm DUMPING is not correctly displayed in the monitor function (special function) on the monitor panel.

1. Arm DUMPING PPC hydraulic switch
LH work equipment control
lever
A. Arm DUMPING PPC NEUTRAL Above 1MΩ 1
(2) Arm DUMPING Below 1Ω 2
2. Wiring harness
Disconnection or
Resistance Ω
connector
grounding circuit
circuit
3. Pump controller
LH work equipment
control lever
Arm DUMPING ground Below 1V 8
PC400LC-7L 20-551 1
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-552 1 PC400LC-7L
12
E-24
“BUCKET CURL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNC-
TION
Bucket CURL is not displayed normally in monitoring Bucket CURL is not displayed normally in monitoring function (special
Failure information function. function) of monitor panel.

1. Bucket CURL PPC pressure sensor
The bucket CURL PPC pressure sensor may be defective. Carry out troubleshooting for error code [E248].
defective
If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot be
2. Pump controller defective
carried out since the defect is in the pump controller).
PC400LC-7L 20-553 1
12
E-25
“BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNC-
TION
• Bucket DUMPING is not correctly displayed in monitor function.
Failure information
• Bucket DUMPING is not correctly displayed in the monitor function (special function) on the monitor panel.

1. Bucket DUMPING PPC hydraulic switch
lever
A. Bucket DUMPING NEUTRAL Above 1MΩ 1
PPC hydraulic switch At S05, between (1) and
Resistance Ω
test - Internal (2) Bucket DUMPING Below 1Ω 2
disconnection
2. Wiring harness
Disconnection or
Resistance Ω
connector
grounding circuit
circuit
3. Pump controller
RH work equipment
control lever
Bucket DUMPING ground Below 1V 8
20-554 1 PC400LC-7L
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
PC400LC-7L 20-555 1
12
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.

1. Swing left PPC hydraulic switch
LH work equipment control
lever
A. Swing left PPC NEUTRAL Min. 1MΩ 1
hydraulic switch test - At S07, between (1) and
Resistance Ω
Internal (2) Left swing position Max. 1Ω 2
disconnection
2. Swing right PPC hydraulic switch
lever
A. Swing right PPC NEUTRAL Min. 1MΩ 3
Resistance Ω
Internal (2) Right swing position Max. 1Ω 4
disconnection
3. Wiring harness
• Disconnect C03, S07 and S03 and install T-adapter.
A. Wiring harness test Between C03 (29) and S07 (2) Max. 1Ω 5
Disconnection or Between C03 (29) and S03 (2) Max. 1Ω 6
Resistance Ω
contact with Between S07(1) and grounding Max. 1Ω 7
connector Between S07(1) and grounding Max. 1Ω 8
B. Wiring harness test Between C03 (29) and S07 (2) and grounding Min. 1MΩ 9
grounding circuit Between C03 (29) and S07 (2) and grounding Min. 1MΩ 10
C. Wiring harness test ★ Between C03 (29) and S07 (2) and grounding Max. 1V 11
circuit ★ Between C03 (29) and S03 (2) and grounding Max. 1V 12
4. Pump controller
• Keep the engine running during the troubleshooting.
LH work equipment
control lever
NEUTRAL 20 - 30V 13
At C03, between (29) and
A. Pump controller test Voltage Left or right swing
ground Max. 1V 14
position
20-556 1 PC400LC-7L
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC400LC-7L 20-557 1
12
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.

1. Travel PPC hydraulic switch
Travel control lever
A. Travel PPC hydraulic NEUTRAL Above 1MΩ 1
switch test - Internal Resistance Ω
(2) Forward or reverse Below 1Ω 2
disconnection
2. Wiring harness
A. Wiring harness test From C03 (39) to J01 to S30 (2) Below 1Ω 3
Disconnection or
Resistance Ω
contact with From S30 (1) to J05 to grounding Below 1Ω 4
connector
B. Wiring harness test From C03 (39) to J01 to S30 (2) and grounding Above 1MΩ 5
grounding circuit From C03 (39) to A43 (2) and grounding Above 1MΩ 6
C. Wiring harness test ★ From C03 (39) to J01 to S30 (2) and grounding Below 1V 7
circuit ★ From C03 (39) and A43 (2) and grounding Below 1V 8
3. Pump controller
• Keep the engine running during the troubleshooting.
Forward or backward ground Below 1V 10
20-558 1 PC400LC-7L
12
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC400LC-7L 20-559 1
12
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.

1. Travel steering PPC hydraulic switch
A. Travel steering PPC NEUTRAL Above 1MΩ 1
Resistance Ω
Internal (2) One side of right or left only Below 1Ω 2
disconnection
2. Wiring harness
Disconnection or
Resistance Ω
contact with From S31 (1) to J05 to grounding Below 1Ω 4
connector
grounding circuit
Contact with 24V Voltage ★ From C02 (16) and S31 (2) and grounding Below 1V 6
circuit
3. Pump controller
NEUTRAL 20 - 30V 7
At C03, between (39) and
A. Pump controller test Voltage One side of right or left
ground Below 1V 8
only
20-560 1 PC400LC-7L
12
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC400LC-7L 20-561 1
12
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.

1. Service (front) PPC hydraulic switch
Service pedal
A. Service (front) PPC NEUTRAL Above 1MΩ 1
Resistance Ω
Internal (2) Operated to front Below 1Ω 2
disconnection
2. Service (rear) PPC hydraulic switch
Service pedal
A. Service (rear) PPC NEUTRAL Above 1MΩ 3
Resistance Ω
Internal (2) Operated to rear Below 1Ω 4
disconnection
3. Wiring harness
• Disconnect C02, S10 and S11 and install T-adapter.
Disconnection or
Resistance Ω Between C02 (35) and S11 (2) Below 1Ω 6
contact with
connector Between S10 (1) and grounding Below 1Ω 7
B. Wiring harness test Between C02 (35) and S10 (2) and grounding Above 1MΩ 8
Between C02 (35) and S11 (2) and grounding Above 1MΩ 9
grounding circuit
C. Wiring harness test ★ Between C02 (35) and S10 (2) and grounding Below 1V 10
circuit ★ Between C02 (35) and S11 (2) and grounding Below 1V 11
4. Pump controller
Service pedal
NEUTRAL At C02, between (35) and 20 - 30V
Operated to front or rear ground Below 1V
20-562 1 PC400LC-7L
12
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC400LC-7L 20-563 1
12
E-30
TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING
• Travel alarm does not sound or does not stop sounding.
Failure information 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.


1. Fuse No. 15 When fuse No. 15 is blown, there is a big possibility that ground fault occurred in the circuit. (See Step 3B.)
2. Travel signal
• Start the engine during troubleshooting (monitoring).
A. Travel signal test - Monitoring code Item Normal display
Internal Control lever operated: ON
01900 Travel
disconnection Control lever NEUTRAL: OFF
3. Wiring harness
A. Wiring harness test Between FB1 (15) outlet to J03 and A43 (1) Below 1Ω 1
Disconnection or
Resistance Ω
contact with Between A43 (2) and J01 (19) Below 1Ω 2
connector
B. Wiring harness test Between FB1 (15) outlet to J03 and A43 and grounding Above 1MΩ 3
Contact with Resistance Ω Between FB1 (15) outlet and other related circuit and
grounding circuit grounding Above 1MΩ 4
4. Travel alarm
This is an internal failure, troubleshooting cannot be conducted. (If none of the causes listed in item 1 through 4 above is
A. Travel alarm test
found, the travel alarm is judged as defective.)
20-564 1 PC400LC-7L
12
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
PC400LC-7L 20-565 1
12
E-32
TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM
TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM
★ The control panel of the air conditioner constantly monitors the sensors and other devices in the system.
When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially.
★ If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to the
procedure for “Troubleshooting by self-diagnosis notice”, and then;
• If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”.
• If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE

Self-diagnosis notice Failure mode
E-- No failures
E11 Disconnection in recirculated air sensor
E12 Short-circuit in recirculated air sensor
E15 Disconnection in water temperature sensor
E16 Short-circuit in water temperature sensor
E18 Short-circuit in daylight sensor
E43 Abnormality in air outlet damper
E44 Abnormality in air mix damper
E45 Abnormality in recirculated and fresh air damper
★ Check the “Self-diagnosis notice” on the control panel according to the following procedure.
• How to display “Self-diagnosis notice”
1. Turn the starting switch ON.
2. Press OFF switch (1) and check that anything is not displayed on
display monitor (2).
3. 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.
20-566 1 PC400LC-7L
12
E-32-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR
Self-diagnosis notice
Trouble Disconnection in recirculated air sensor
E11
Contents of trouble • 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.
Action of control panel
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> +
<Starting air conditioner>
Related information ---
1. Recirculated air sensor
• Prepare with the ignition switch OFF
• Disconnect THi connection and install T-adapter.
• Keep the ignition switch in the OFF position for troubleshooting.
A. Recirculation air
sensor test - Internal Resistance Ω At THi, between (1) and (2) 300Ω − 430kΩ 1
disconnection
2. Wiring harness
A. Wiring harness test Between M30 (12) and THi (2) Max. 1Ω 2
Disconnection or
Resistance Ω
contact with Between M29 (11) and THi (1) Max. 1Ω 3
connector
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
3. Air conditioner system
COMPENT, Shop Manual, “Air conditioner”.
E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE

Self-diagnosis
Trouble Short circuit in recirculated air sensor
E12
Contents of trouble • Short circuit in the recirculated air sensor system is detected.
• Fixes the recirculated air temperature for control.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
1. Recirculated air sensor
• Disconnect THi connection and install T-adapter.
A. Recirculation air
sensor test - Internal Resistance Ω At THi, between (1) and (2) 300Ω − 430kΩ 1
disconnection
2. Wiring harness
A. Wiring harness test Between M30 (12) and THi (2) Max. 1Ω 2
Disconnection or
Resistance Ω
contact with Between M29 (11) and THi (1) Max. 1Ω 3
connector
PC400LC-7L 20-567 1
12
E-32-E15 DISCONNECTION IN WATER TEMPERATURE SENSOR
Trouble Disconnection in water temperature sensor
E15
Contents of trouble • 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.
1. Water temperature sensor
• Disconnect THw connection and install T-adapter.
A. Water temperature
sensor test - Internal Resistance Ω At THw, between (1) and (2) 95Ω − 455kΩ 1
disconnection
2. Wiring harness
A. Wiring harness test Between M30 (14) and THw (2) Max. 1Ω 2
Disconnection or
Resistance Ω
contact with Between M29 (11) and THw (1) Max. 1Ω 3
connector
E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR

Trouble Short circuit in water temperature sensor
E16
Contents of trouble • 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.
1. Water temperature sensor
• Disconnect THw connection and install T-adapter.
A. Water temperature
sensor test - Internal Resistance Ω At THw, between (1) and (2) 95Ω − 455kΩ 1
disconnection
2. Wiring harness
A. Wiring harness test Between M30 (14) and THw (2) Max. 1Ω 2
Disconnection or
Resistance Ω
contact with Between M29 (11) and THw (1) Max. 1Ω 3
connector
20-568 1 PC400LC-7L
12
E-32-E18 SHORT IN DAYLIGHT SENSOR
Trouble Short circuit in daylight sensor
E18
Contents of trouble • Short circuit in the daylight sensor system is detected.
• Assumes that the daylight sensor is not installed for control.
1. Daylight sensor The daylight sensor may be defective. Check it directly
2. Wiring harness
A. Wiring harness test Between M30 (16) and P15 (2) Max. 1Ω 1
Disconnection or
Resistance Ω
contact with Between M30 (3) and P15 (1) Max. 1Ω 2
connector
E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER

Trouble Trouble Abnormality in air outlet damper
E43
Contents of trouble • Abnormality in air outlet servomotor system is detected.
• Stops the air outlet servomotor.
Related information
★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor out-
put shaft and break the motor coils.
1. Air outlet servo motor The air outlet servo motor may be defective. Check it directly
2. Wiring harness
• Disconnect Mv1, M29 and M30 and install T-adapter.
Between Mv1 (1) and M30 (3) Max. 1Ω 1
A. Wiring harness test Between Mv1 (3) and M29 (11) Max. 1Ω 2
Disconnection or
Resistance Ω Between Mv1 (5) and M30 (9) Max. 1Ω 3
contact with
connector Between Mv1 (6) and M29 (8) Max. 1Ω 4
Between Mv1 (7) and M29 (9) Max. 1Ω 5
PC400LC-7L 20-569 1
12
E-32-E44 ABNORMALITY IN AIR MIX DAMPER
Trouble Abnormality in air mix damper
E44
Contents of trouble • Abnormality in air mix servomotor system is detected.
• Stops the air mix servomotor.
Related information
★ 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.
1. Air mix servo motor The air mix servo motor may be defective. Check it directly
2. Wiring harness
• Disconnect Mam, M29 and M30 and install T-adapter.
Between Mam (1) and M29 (11) Max. 1Ω 1
A. Wiring harness test Between Mam (3) and M30 (3) Max. 1Ω 2
Disconnection or
Resistance Ω Between Mam (5) and M30 (2) Max. 1Ω 3
contact with
connector Between Mam (6) and M29 (4) Max. 1Ω 4
Between Mam (7) and M29 (5) Max. 1Ω 5
E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER

Trouble Abnormality in recirculated and fresh air damper
E45
Contents of trouble • Abnormality in recirculated and fresh air servomotor system is detected.
• Stops the recirculated and fresh air servomotor.
Related information
★ 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.
1. Recirculated and fresh air
The recirculated and fresh air servo motor may be defective. Check it directly
servo motor
2. Fuse (in unit) If the fuse (in unit) is broken, the circuit probably has a ground fault, etc. Check the related circuits.
3. Wiring harness
• Disconnect Mrf, M29 and M33 and install T-adapter.
A. Wiring harness test Between Mrf (1) and M29 (6) Max. 1Ω 1
Disconnection or
Resistance Ω Between Mrf (3) and M29 (7) Max. 1Ω 2
contact with
connector Between Mrf (7) and M33 (3) Max. 1Ω 3
20-570 1 PC400LC-7L
12
Electrical Circuit Diagram for Air Conditioner
PC400LC-7L 20-571 1
12
E-32 - TROUBLESHOOTING BY FAILURE PHENOMENON
Trouble • The air conditioner does not operate. 1. The air conditioner does not operate at all.
1. Fuse No. 11 If the fuse is broken, the circuit probably has a ground fault, etc. Refer to cause 3.
2. Wiring harness
• Disconnect M27, M29 and M30 and install T-adapter.
A. Wiring harness test Between fuse (11) and M33 (3) Max. 1Ω 1
Disconnection or Between M27 (14) and M30 (6) Max. 1Ω 2
Resistance Ω
contact with Between M33 (2) and chassis ground Max. 1Ω 3
connector Between M29 (12) and chassis ground Max. 1Ω 4
B. Wiring harness Between fuse (11) and M33 (3) and chassis ground Min. 1Ω 5
Contact with ground Resistance Ω
Between M27 (14) and M30 (6) and chassis ground Min. 1Ω 6
circuit
3. Air conditioner unit
• Turn ignition switch to the ON position for this test.
A. Air conditioner unit Voltage At M33, between (2) and (3) 20 - 30V 7
test If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective.
4. Control panel
• Disconnect M33 and M29 and install T-adapter.
• Turn ignition switch to the ON position for this test.
8
Voltage Between M30 (6) and M29 (12) 20 - 30V
A. Control panel test 9
If the above voltage is normal and the air conditioner does not operate, the control panel is defective.
20-572 1 PC400LC-7L
12
Trouble • The air conditioner does not operate. 2. Air does not come out (Air flow is insufficient).
Related information
1. Fuse (in unit) If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
2. Blower relay
• Prepare with ignition switch OFF.
• Disconnect connector R30 and install T-adapter.
• Keep ignition switch OFF.
A. Blower relay (on coil
side) test
3. Blower relay
A. Blower relay (on
Voltage At R30, between (4) and ground 20 - 30V 2
contact side) test
4. Power transistor
Operate in rang of Low, If air flow can be changed with fan switch, power
A. Power transistor test Fan switch 3
Medium and High transistor is normal.
5. Blower motor
• Disconnect connector NB and install T-adapter.
A. Blower motor test Fan switch
At MB, between (1) and (2) 20 - 30V 4
Voltage ON
If the above voltage is normal and the blower motor does not rotate, the blower motor is defective.
6. Wiring harness
• Disconnect R30, R31, Mb, Ptr, M27, M29 and M30 and install T-adapters.
Between fuse 11 outlet, fuse in unit, R30 (3), R31 (1) and
Max. 1Ω 5
M30 (6)
Between M29 (3) and R30 (1) Max. 1Ω 6
A. Wiring harness test Between M29 (12) and chassis ground Max. 1Ω 7
Disconnection or
Resistance Ω Between Mb (1) and R30 (4) Max. 1Ω 8
contact with
Between Mb (2) and Ptr (3) Max. 1Ω 9
connector
Between Ptr (1) and chassis ground Max. 1Ω 10
Between Ptr (2) and M30 (7) Max. 1Ω 11
Between Ptr (4) and M30 (8) Max. 1Ω 12
7. Air conditioner unit If none of Steps 1 - 6 is the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT,
Shop Manual, “Air conditioner”.
PC400LC-7L 20-573 1
12
Trouble • The air conditioner does not operate. 3. Air is not cooled (Cooling capacity is low).
Related information
1. Fuse (in unit) If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
2. Compressor relay
A. Compressor relay (on
coil side) test
3. Compressor relay
• Turn ignition switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position).
A. Compressor relay (on
Voltage At R31, between (4) and ground (Fan switch ON) 20 - 30V 2
contact side) test
4. Thermostat (Internal defect) The thermostat may be defective. Check it directly. 3
5. High/Low pressure switch
• Disconnect connector P17 and install T-adapter.
• Keep ignition switch OFF and carry out troubleshooting.
A. High/Low pressure
Resistance Ω At P17, between (1) and (2) Max. 1Ω 4
switch test
6. Compressor clutch The compressor clutch may be defective. Check it directly. 5
7. Compressor The compressor may be defective. Check it directly. 6
8. Wiring harness
• Disconnect M30, M29, P17, R31, ST1and install T-adapters.
Between M30 (4) and P17 (1) Max. 1Ω 7
Between P17 (2) and chassis ground Max. 1Ω 8
A. Wiring harness test Between fuse 11 outlet, R31 (2), fuse in unit, R31 (1) and
Max. 1Ω 9
Disconnection or M30 (6)
Resistance Ω
contact with Between ST1 (1) and R31 (3) Max. 1Ω 10
connector Between M29 (2) and ST1 (2) Max. 1Ω 11
Between M29 (12) and chassis ground Max. 1Ω 12
Between R31 (4) and M34 (1) Max. 1Ω 13
9. Air conditioner unit If none of Steps 1 - 8 is the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT,
Shop Manual, “Air conditioner”.
20-574 1 PC400LC-7L
12
Electrical Circuit Diagram for Air Conditioner
PC400LC-7L 20-575 1
12
MEMORANDUM
20-576 1 PC400LC-7L
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H MODE)
12
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-605
H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW . . . . . 20-606
H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
NO WORK EQUIPMENT, TRAVEL OR SWING MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . 20-608
H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
AUTO-DECELERATOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
FINE CONTROL MODE DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
BOOM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
H-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
ARM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
H-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
BUCKET MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
H-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 20-612
H-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
WORK EQUIPMENT HAS BIG TIME LAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT . . . . . . . . . . . . . . . . . 20-614
H-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
MACHINE PUSH-UP FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
H-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY . . 20-615
H-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
H-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
H-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
MACHINE SWERVES IN TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
H-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
MACHINE TRAVELS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
MACHINE CANNOT BE EASILY STEERED OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED. . . . 20-620
H-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
PC400LC-7L 20-601 1
TESTING AND ADJUSTING TABLE OF CONTENTS
TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
H-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
MACHINE DOES NOT SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
H-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
EXCESSIVE OVERRUN WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
THERE IS BIG SHOCK WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
H-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . 20-624
H-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625
SWING NATURAL DRIFT IS TOO BIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625
H-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
ATTACHMENT CIRCUIT DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
H-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . 20-626
20-602 1 PC400LC-7L
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
12
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
PC400LC-7L 20-603 1
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
12
★ This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart (See Section 90
FOLDOUTs for complete hydraulic schematic). Use it as a reference material when troubleshooting the hydraulic and
mechanical systems.
20-604 1 PC400LC-7L
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
12
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
★ Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure information Phenomena occurring on machine
Relative information Information on occurred failures and troubleshooting

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

3 attached No. for filing and • The standard values in normalcy by which to judge “good” or “no good” about presumed causes.
reference purpose only. It does
not stand for any priority) • References for making judgement of “good” or “no good”.
4
PC400LC-7L 20-605 1
TROUBLESHOOTING H-1
12
H-1
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS
ARE SLOW
Failure information All the work equipment lack power, or their travel and swing speeds are slow.
Relative information Set the working mode at A mode for troubleshooting.

★ Stop engine for preparations. Start troubleshooting at engine high idling.
Control lever Unload pressure
Malfunctioning of
1
unload valve
All control levers in NEUTRAL 4.12±1.0 MPa {42±10 kgf/cm2}(597±142 psi)
Control lever Main relief pressure
Arm, DIGGING 33.34 - 36.77 MPa {340 - 375kgf/cm2}

Improper adjustment or (4836 - 5333 psi)
2 malfunctioning of main
relief valve If the pressure does not return to normalcy even after the adjustment, malfunctioning of main relief valve or its internal
failure is suspected. In that case, check the valve itself.
Malfunctioning of self Control lever Control circuit source pressure
3 pressure decompression
valve
Presumed cause andstandard value in normalcy
All control levers in NEUTRAL 2.84 - 3.43MPa {29 - 35kgf/cm2}

(412 - 497 psi)
Oil pressure to be measured Measurement condition Oil pressure ratio
Improper adjustment or
4 malfunctioning of PC Pump delivery pressure Swing lock: ON 1
valve PC valve output pressure Arm: Digging relief 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
Travel speed Travel control lever LS-EPC output pressure
5 Malfunctioning of LS-
EPC valve Lo NEUTRAL Approx. 1.37MPa {Approx. 14 kgf/cm2}
(199 psi)
Hi OPERATED 0 MPa {0 kgf/cm2}
Oil pressure ratio
Oil pressure to be measured All control levers in Travel without load (control lever held at half
Improper adjustment or NEUTRAL stroke)
6 malfunctioning of LS
valve Pump delivery pressure 1
Nearly equal pressure
LS valve output 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
7 Malfunctioning of servo Malfunctioning of servo piston is suspected. Check the piston itself.
piston
If none of the above listed causes is detected, the piston pump is suspected of deteriorated performance,
8 Piston pump defective
malfunctioning or internal failure.
20-606 1 PC400LC-7L
TROUBLESHOOTING H-2
12
H-2
ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS
Failure information The engine speed sharply drops or the engine stalls.
Relative information Relative Information

Control lever Main relief pressure
1 malfunctioning of main relief Arm, DIGGING 33.34 - 36.77 MPa {340 - 375 kgf/cm2}
valve (4835 - 5333 psi)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the main relief valve
or its internal failure is suspected. In that case, check the valve itself.
Presumed cause and standard value in normalcy

Oil pressure to be measured Measurement condition Oil pressure ratio
Improper adjustment or Pump delivery pressure 1
2 malfunctioning of PC valve Swing lock: ON
PC valve output pressure Arm: Digging relief 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.
Oil pressure ratio
Improper adjustment or NEUTRAL stroke)
3
malfunctioning of LS valve
Pump delivery pressure 1
Nearly equal pressure
LS valve output 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.
Orifice or filter in servo
4 equipment clogged The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself.
5 Malfunction of servo The servo piston is suspected of malfunction. Check the piston itself.
piston
PC400LC-7L 20-607 1
TROUBLESHOOTING H-3
12
H-3
NO WORK EQUIPMENT, TRAVEL OR SWING MOVE
Failure information No work equipment nor travel and swing functions can be set in motion.
Relative information Set the working mode at A mode for the troubleshooting.


Safety lock lever Solenoid output pressure
Malfunctioning of PPC lock
1
solenoid valve Locked 0 MPa {0 kgf/cm2} (0 psi)
Released 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
2 Malfunctioning of self Control lever Control circuit source pressure
pressure decompression valve
All control levers in NEUTRAL position 2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the following manner.
3 Piston pump defective • Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal
condition.
It is presumed that the pump shaft does not rotate due to some internal failure of the damper. Check the damper
4 Damper defective
itself.
H-4
ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP
Failure information An abnormal noise is heard from around the hydraulic pump.

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

value in normalcy
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
3 Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside
clogged the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
20-608 1 PC400LC-7L
TROUBLESHOOTING H-5
12
H-5
AUTO-DECELERATOR DOES NOT WORK
Failure information The auto-decelerator does not work.
Relative information • This troubleshooting mode is applied when the auto-decelerator does not work, while operating the travel control
lever. (A shuttle valve is provided between PPC valve and the hydraulic switch only in the travel circuit -actually
located inside PPC valve)
• Set the working mode at A mode for the troubleshooting.

standard value in normalcy
Presumed cause and

Travel control lever PPC valve output pressure
Malfunctioning of travel PPC NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
1
valve (shuttle valve)
Operation Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
H-6
FINE CONTROL MODE DOES NOT FUNCTION
Failure information The fine control mode poorly functions or its response is slow.

Travel speed Travel control lever LS-EPC valve output pressure
Malfunctioning of LS- EPC
1 valve Approx. 1.37 MPa {Approx. 14 kgf/cm2}

Lo NEUTRAL
(Approx. 199 psi)
Hi OPERATED 0 MPa {0 kgf/cm2} (0 psi)
2 Orifice in LS circuit clogged The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
Oil pressure ratio
NEUTRAL stroke)
3 Improper adjustment or
malfunctioning of LS valve Pump delivery pressure 1
Nearly equal oil pressure
PC valve output 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
4 Malfunctioning of servo Malfunctioning of the servo piston is suspected. Check the piston itself.
piston
PC400LC-7L 20-609 1
TROUBLESHOOTING H-7
12
H-7
BOOM MOVES SLOWLY OR LACKS POWER
Failure information The boom moves slowly or lacks power

R.H. work equipment control lever PPC valve output pressure
Malfunctioning of right PPC
1
valve (in boom circuit) NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Boom RAISE
Boom LOWER Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Travel lever Solenoid output pressure
Malfunction of merge/ divide
2 solenoid valve Neutral 0 MPa {0 kgf/cm2} (0 psi)
Operated (Note) 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
Malfunctioning of merge/
3 divide valve (main and LS The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve
itself.
valves)
Malfunctioning of boom
4 control valve (spool) The spool in the boom control valve (Lo - Hi) is presumed to malfunction. Check the valve itself.
5 control valve (pressure The pressure compensation valve in the boom control valve (Lo ïHi) is presumed to malfunction. Check the
valve itself.
compensation valve)
6 control valve (regeneration The regeneration valve in the boom control valve (Lo) or the seal is presumed to malfunction. Check the valve
itself.
valve)
7 control valve (lock valve) The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the valve itself.
8 Malfunction of boom control The check valve in the boom control valve (Hi) is presumed to malfunction. Check the valve itself.
valve (check valve)
Malfunctioning of safety
The safety valve for the lock valve is presumed to malfunction, or the seal is suspected to be defective. Check
9 valve for lock valve or the valve itself.
seal defective
The suction valve (bottom side) in the boom control valve (Lo) is presumed to malfunction, or the seal is
10 control valve (suction valve) or suspected to be defective.
seal defective
The safety and suction valves (head side) in the boom control valve (Lo) are presumed to malfunction, or the
11 control valve (safety and seal is suspected to be defective. Check those valves themselves.
suction valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the left travel control valve, bucket control valve and service control valve are presumed to
12 valve (left travel, bucket and malfunction. Check those valves themselves.
service valves)
13 Boom cylinder defective Boom cylinder Amount oil leakage from cylinder
Raise relief 20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
20-610 1 PC400LC-7L
TROUBLESHOOTING H-8
12
H-8
ARM MOVES SLOWLY OR LACKS POWER
Failure information The arm moves slowly, or lacks power.

L.H. work equipment control lever PPC valve output pressure
Malfunctioning of left PPC
1
valve (arm circuit) NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Arm DIGGING
Arm DUMPING Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Travel lever Solenoid output pressure
2 divide solenoid valve
0 MPa {0 kgf/cm2} (0 psi)
Neutral
Operated (Note) 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
3 divide valve (main and LS The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself.
valves)
Malfunctioning of arm control
4 valve (spool) The spool in the arm control valve (Lo•Hi) is presumed to malfunction. Check the valve itself.
Malfunctioning of arm control

5 valve (pressure compensation The pressure compensation valve in the arm control valve (Lo•Hi) is presumed to malfunction. Check the valve
itself.
valve)
Malfunctioning of arm control The generation valve in the arm control valve (Lo) is presumed to malfunction, or the seal is suspected to be
6 valve (regeneration valve) defective. Check the valve itself.
Malfunctioning of arm control The safety and suction valves in the arm control valve (Lo•Hi) are presumed to malfunction, or the seal is
7 valve (safety and suction
valves) or seal defective suspected of defect. Check those valves themselves.
8 Malfunction of arm control The quick return valve in the arm control valve (Hi) is presumed to malfunction. Check the valve itself.
valve (quick return valve)
9 valve (right travel, boom, left LS shuttle valves in the right travel control valve, boom control valve, left travel control valve, bucket control
travel, bucket and service valve and service valve are presumed to malfunction. Check those valves themselves.
valves)
10 Arm cylinder defective Arm cylinder Amount oil leakage from cylinder
Digging relief 20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
PC400LC-7L 20-611 1
TROUBLESHOOTING H-9
12
H-9
BUCKET MOVES SLOWLY OR LACKS POWER
Failure information The bucket moves slowly, or lacks power.

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

1 (bucket circuit) NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Bucket DIGGING Above 2.75MPa {Above 28 kgf/cm2}
Bucket DUMPING (Above 398 psi)
Malfunctioning of bucket control
2 valve (spool) The spool in the bucket control valve is presumed to malfunction. Check the valve itself.
3 Malfunctioning of bucket control The pressure compensation valve in the bucket control valve is presumed to malfunction. Check the valve
valve (pressure compensation valve) itself.
Malfunctioning of bucket control
The safety and suction valves in the bucket control valve are presumed to malfunction, or the seal is
4 valve (safety and suction valves) or suspected to be defective. Check those valves themselves.
seal defective
Malfunction of LS shuttle valve
5 The LS shuttle valve in the service control valve is presumed to malfunction. Check the valve itself.
(service valve)
6 Bucket cylinder defective Bucket cylinder Amount oil leakage from cylinder
H-10
WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION
Work equipment does not move in its single operation
(1) The boom does not move when operated independently.
Failure information
(2) The arm does not move when operated independently.
(3) The bucket does not move when operated independently.


value in normalcy
Work equipment control lever PPC valve output pressure

1 Malfunctioning of PPC valve
NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Operated Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
Malfunctioning of work
2 equipment control valve The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
(spool)
20-612 1 PC400LC-7L
TROUBLESHOOTING H-11
12
H-11
WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST
Failure information Work equipment has a bit too fast hydraulic drift
(1) Hydraulic drift of the boom is a bit too fast.


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

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


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

4 compensation The seal for pressure compensation valve (bottom side) in the arm control valve
(Lo•Hi) is suspected to be defective. Check the seal itself.
valve) seal defective
Work equipment has a bit too fast hydraulic drift

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


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

4 (pressure compensation The seal for pressure compensation valve (bottom side) in the bucket control valve is suspected to be
defective. Check the seal itself.
valve) seal defective
PC400LC-7L 20-613 1
12
H-12
WORK EQUIPMENT HAS BIG TIME LAG
Failure information The work equipment has a big time lag.


Malfunctioning of LS-EPC
1
valve Lo NEUTRAL Approx. 1.37 MPa {14 kgf/cm2}(199 psi)
Hi Operation 0 MPa {0 kgf/cm2} (0 psi)
Malfunctioning of control valve
2 (regeneration valve) - with The regeneration valve in the control valve is presumed to malfunction. Check the valve itself.
boom and arm only
Malfunctioning of control The safety and suction valves (boom : head side, arm and bucket : bottom side) of the control valve are presumed
3 to malfunction. Check those valves themselves directly.
valves (safety & suction valve) (Whether they are defective or not may well be determined by changing them for other safety and suction valves.)
Malfunctioning of control valve
4 (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
Failure information Other work equipment moves when relieving the single circuit of specific work equipment.

value in normalcy
Control valve (pressure The seal for pressure compression valve in the control valve is suspected to be defective. Check the seal
1 compensation valve) seal defective itself.
H-14
ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK
Failure information One-touch power max. function does not work.


value in normalcy
Swing lock switch Solenoid valve output pressure

Malfunctioning of 2-stage
1 solenoid valve OFF 0 MPa {0 kgf/cm2} (0 psi)
ON 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
Malfunctioning of main
2 The main relief valve of control valve is presumed to malfunction. Check the valve itself.
relief valve
20-614 1 PC400LC-7L
12
H-15
MACHINE PUSH-UP FUNCTION DOES NOT WORK
Failure information The machine push-up function does not work
Relative information When carrying out troubleshooting, set the working mode in A-mode.

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

Malfunction of machine push-up
1
solenoid valve OFF Min. 2.75 MPa {Min. 28 kgf/cm2} (Min. 398 psi)
ON 0 MPa {0 kgf/cm2}
2 Malfunction of boom 2 control The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting side on the head
valve (safety-suction valve) side) may be malfunctioning. Check it directly.
H-16
IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD
MOVES SLOWLY
Failure information In a compound operation, work equipment with larger load tends to move slowly.

The pressure compensation valve for the work equipment with larger load is presumed to malfunction.
Check the valve itself.
Work equipment with
Combination of compound operation Work equipment with larger load
smaller load
Boom RAISE +
arm DIGGING Boom Arm
Malfunctioning of pressure
1 compensation valve for work Boom RAISE + Arm Boom
arm DUMPING
equipment with larger load
Boom RAISE +
Boom Bucket
bucket DIGGING
Arm DUMPING +
bucket DIGGING Arm Bucket
Boom LOWER + Arm Boom

arm DUMPING
PC400LC-7L 20-615 1
12
H-17
IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY
Failure information In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.

value in normalcy
1 Malfunctioning of LS select valve The LS select valve of control valve is presumed to malfunction, or the seal is suspected to be defective.
or seal defective Check the valve and seal themselves.
H-18
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY
Failure information In a compound operation of swing + travel, the travel speed drops sharply.
Relative information If the travel speed is slow in the single operation of travel, carry out the H-20 check first.

value in normalcy
Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing control valve is presumed to malfunction.
1
valve (left travel and swing) Check both of them directly.
20-616 1 PC400LC-7L
12
H-19
MACHINE SWERVES IN TRAVEL
Failure information The machine tends to swerve while traveling.

Malfunctioning of travel PPC
1 Operated to Forward
valve
Operated to Reverse Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
Differential output between right and

left sides 0.4 MPa {4 kgf/cm2} (56 psi)

Malfunctioning of self-pressure Control lever Control circuit source pressure
2
decompression valve
All control levers in NEUTRAL 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Oil Pressure ratio
Oil pressure to be measured All control levers in Travel without load (control lever held at
3 malfunctioning of LS valve NEUTRAL half stroke)
Pump delivery pressure 1
Nearly equal pressure Approx. 0.6
LS valve output pressure (Approx. 3/5)
Malfunctioning of travel
4
interlocking solenoid valve NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Operating one side only 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
5 Malfunctioning of travel The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
interlocking valve
Malfunctioning of travel control
6 The spool in the travel interlocking valve is presumed to malfunction. Check the spool itself.
valve (spool)
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
Travel relief 40 l/min (10.56 gal/min)
The final drive is suspected of an internal failure. Check the inside of the final drive directly.
8 Final drive defective (An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat
or metal chip or dust contained in the drained oil.)
PC400LC-7L 20-617 1
12
H-20
MACHINE TRAVELS SLOWLY
Failure information The machine's travel speed is slow.

1 Malfunctioning of travel PPC Operated to Forward

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
valve Operated to Reverse
Output differential between right
and left Below 0.4 MPa {Below 4 kgf/cm2} (56 psi)
or front and rear
Malfunctioning of
2 self-pressure decompression Control lever Control circuit source pressure
valve
All control levers in NEUTRAL 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
3 Malfunctioning of LS-EPC
valve Lo NEUTRAL Approx. 1.37 MPa {Approx. 14 kgf/cm2}
(0.0199 psi)
Hi Operated 0 MPa {0 kgf/cm2} (0 psi)
4 Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool itself.
valve (spool)
5 control valve (pressure The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
compensation valve)
6 The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
control valve (suction valve)
7 valve (bucket) The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.

7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
8 Final drive defective (An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or
metal chip or dust contained in the drained oil.)
20-618 1 PC400LC-7L
12
H-21
MACHINE CANNOT BE EASILY STEERED OR LACKS POWER
Failure information The machine cannot be easily steered.

Travel control lever PPC valve output pressure (steering)
Malfunctioning of travel PPC valve
1
(steering spool) NEUTRAL on both sides 0 MPa {0 kgf/cm2} (0 psi)
Operating one side only Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
Travel control lever Solenoid valve output pressure
Malfunctioning of travel interlocking
2 solenoid valve NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Operating one side only 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
Malfunctioning of travel interlocking

3 The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
valve
Travel control lever Solenoid valve output pressure
4 Malfunctioning of merge/ divide
solenoid valve NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
OPERATED 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
Malfunctioning of merge/ divide
5 valve The merge/divide valve of control valve is presumed to malfunction. Check the valve itself.
6 Malfunction of travel The spool in the travel control valve is presumed to malfunction. Check the spool itself.
control valve (spool)
Malfunctioning of travel control The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve
7
valve (pressure compensation valve) itself.
Malfunctioning of travel control
8 valve (suction valve) The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
9 Malfunctioning of LS shuttle valve The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
(bucket)
Check valve seal defective at LS oil The seal in the check valve of LS oil pressure pick-up port is suspected to be defective. Check the seal
10
pressure pick-up port itself.
The seal in the check valve of the travel motor is suspected to be defective. Check the seal itself.
11 Malfunctioning of travel motor (Whether the seal is defective or not may well be determined by swapping the motors between forward
(safety valve)
and reverse, or right and left.)
The seal in the check valve of the travel motor is suspected of defect. Check the seal itself.
12 Malfunctioning of travel motor (Whether the seal is defective or not may well be determined by swapping the motors between forward
(check valve)
and reverse, or right and left.)
PC400LC-7L 20-619 1
12
H-22
TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN
PRESET SPEED.
Failure information Travel speed does not shift, or it is slower or faster than preset speed.

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

Approx.
Lo NEUTRAL
1.37 MPa {14 kgf/cm2}(0.0199 psi)
Hi Operation 0 MPa {0 kgf/cm2} (0 psi)
Travel speed Travel control lever Solenoid output pressure
2 Malfunctioning of travel
speed solenoid valve Lo NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Hi Operation 2.84 - 3.43 MPa {29 - 35 kgf/cm2}

(412 - 497 psi)
Malfunctioning of travel motor
3 The travel motor is presumed to malfunction when shifting speed. Check the speed shifting portion directly.
(speed shifting)
H-23
TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)
Failure information A track shoe does not turn (only on one side).

Travel control valve (suction valve) seat

1 defective The suction valve seat in the travel control valve is suspected of defect. Check the seat itself.
2 Travel motor (safety valve) seat defective The safety valve seat in the travel motor is suspected of defect. Check the seat itself.
3 Travel motor (check valve) seat defective The check valve seat in the travel motor is suspected of defect. Check the seat itself.
4 Travel Motor speed Travel control lever Amount of oil leakage from travel motor
5 Final drive defective (A failure inside the final drive may well be determined by an abnormal noise from within,
abnormal heat generated or metal dust or chips contained in the drained oil.)
20-620 1 PC400LC-7L
12
H-24
MACHINE DOES NOT SWING
Failure information Machine does not swing
(1) The machine swings neither to the right nor to the left.

R.H. work equipment control lever Solenoid valve output pressure
1 Malfunctioning of swing
holding brake solenoid valve NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Swing operated 2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)

Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
2 (holding brake) Check it directly.
L.H. work equipment
Swing lock switch Swing relief pressure
Improper adjustment or control lever
3 malfunctioning of swing motor
(safety valve) ON Swing relief 27.95 - 32.85 MPa {285 - 335 kgf/cm2}
(4,053 - 4,764 psi)
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to mal-
function, or suspected of an internal failure. Check the valve itself.
4 Swing motor defective L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Below 11 l/min (2.9 gal/min)
The swing machinery is suspected of an internal failure. Check the inside of the swing machinery directly.
5 Swing machinery defective (A failure inside the swing machinery may well be determined by an abnormal noise from within, abnormal
heat generated or metal dust or chips contained in the drained oil.)
Failure information Machine does not swing

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


1 Malfunctioning of swing PPC
valve NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Swing operated Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
2 Malfunctioning of swing con- The spool in the swing control valve is presumed to malfunction. Check the spool itself.
trol valve (spool)
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
Swing motor (suction valve)
3 seal defective (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
watching if there is any change.)
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
4 Swing motor (check valve) seal (Whether the seal is defective or not may well be determined by swapping the right and left check valves and
defective
watching the result.)
PC400LC-7L 20-621 1
12
H-25
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW
Failure information Swing acceleration is poor, or swing speed is slow
(1) Swing acceleration is poor, or swing speed is slow.

Malfunctioning of LS shuttle valve
1 (all LS shuttles) The LS shuttle valves for all the control valves are presumed to malfunction. Check them directly.
2 Malfunctioning of swing The swing holding brake portion of the swing motor is presumed to malfunction.
Swing lock switch L.H. work equipment Swing relief pressure
(4,053 - 4,764 psi)
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to
malfunction, or suspected of an internal failure. Check the valve itself.
4 Swing motor defective L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Below11 l/min (2.9 gal/min)
Inside of the swing machinery is presumed to malfunction. Check itself.
5 Swing machinery defective (Whether it is defective or not may well be determined by abnormal noise, abnormal generation of heat and
the mixture of the metal particles in drain oil.)
Swing acceleration is poor, or swing speed is slow.

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


Malfunctioning of swing PPC
1 valve NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Malfunctioning of swing The spool in the swing control valve is presumed to malfunction. Check the valve itself.
2
control valve (spool)
Malfunctioning of swing
3 control valve (pressure The pressure compensation valve in the swing motor is presumed to malfunction.
Check the valve itself.
compensation valve)
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
4 Swing motor (suction valve) (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
seal defective
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
5 Swing motor (check valve) seal (Whether the seal is defective or not may well be determined by swapping the right and left check valves and
defective
20-622 1 PC400LC-7L
12
H-26
EXCESSIVE OVERRUN WHEN STOPPING SWING
Failure information Excessive overrun when stopping swing.
(1) The work equipment overruns excessively when stopping swing.


Swing lock switch L.H. work equipment Swing relief pressure
(4,053 - 4,764 psi)
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to mal-
function, or suspected of an internal failure. Check the valve itself.
L.H. work equipment control
2 Swing motor defective lever Amount of oil leakage from swing motor
Swing relief Below11 l/min (2.9 gal/min)
Excessive overrun when stopping swing

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


1 Malfunctioning of swing PPC
valve NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Swing operated Above2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)
The PPC slow return valve is suspected of clogging. Check the valve itself.
2 Swing PPC slow return valve (Whether the valve is clogged or not may well be determined by swapping the right and left valves and watching
clogged
the result.)
Malfunctioning of swing
3 control valve (spool) The spool in the swing control valve is resumed to malfunction. Check the valve itself.
Swing motor (suction The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
4 (Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
valve) seal defective watching the result.)
Swing motor (check The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
5 (Whether the seal is defective or not may well be determined by swapping the right and left check valves and
valve) seal defective watching the result.)
PC400LC-7L 20-623 1
12
H-27
THERE IS BIG SHOCK WHEN STOPPING SWING
Failure information There is a big shock caused when stopping a swing motion.


Malfunctioning of swing PPC
1
valve NEUTRAL 0 MPa {0 kgf/cm2}(0 psi)
Malfunctioning of swing PPC The swing PPC slow return valve is presumed to malfunction. Check the valve itself.
2 (Whether the valve malfunctions or not may well be determined by swapping the right and left valves and
slow return valve watching the result.)
Malfunctioning of swing motor

3 (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.

Malfunctioning of
1 backpressure valve The backpressure valve is presumed to malfunction. Check the valve itself.
2 Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the valve itself.
(safety valve)
The seal in suction valve of the swing motor is suspected of defect. Check the seal itself.
Malfunction of swing motor
3 (suction valve) (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.
4 Swing machinery defective (A failure inside the swing machinery may well be determined by monitoring abnormal noise, abnormal heat
generated or metal dust or chips contained in the drained oil.)
20-624 1 PC400LC-7L
12
H-29
SWING NATURAL DRIFT IS TOO BIG
Failure information Swing natural drift is too big.
(1) When the swing holding brake is activated.
• When the swing lock switch is ON position, or the swing holding brake release switch is in the normal position, the
Relative information swing brake is activated and the swing is fixed with a disc brake.
• Set the working mode in A mode for troubleshooting.


value in normalcy
R.H. work equipment control lever Solenoid valve output pressure

1 Swing and holding brake solenoid
valve malfunctioned NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
Swing operated 2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)
Swing motor (parking brake The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that
2 portion) malfunctioned portion directly.
Swing natural drift is too big.

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

1 Swing control valve (spool) The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly.
malfunctioned
Swing control valve (pressure
The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself
2 compensation valve) directly.
malfunctioned
Swing motor (safety valve)
3 The safety valve seal in the swing motor is suspected of defect. Check the valve itself directly.
defective
Swing motor (suction valve)
4 defective The suction valve seal in the swing motor is suspected of defect. Check the valve itself directly.
5 Swing motor (check valve) The check valve seal in the swing motor is suspected of defect. Check the valve itself directly.
defective
Swing motor (shockless valve) The shockless valve in the swing motor is suspected of malfunction or the seal is suspected of defect. Check the
6
malfunctioned or seal defective valve or seal itself directly.
PC400LC-7L 20-625 1
12
H-30
ATTACHMENT CIRCUIT DOES NOT CHANGE
When attachment is installed
Failure information The return circuit of the attachment circuit does not change.
• If an attachment is installed, the service circuit changes according to the selected working mode as shown below.
1) In mode A or E: The double acting circuit is selected and the safety valve is set to the low pressure.
Relative information 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.

★ Keep the engine stopped for the preparations, and keep it running at high idling during the trou-
bleshooting.
value in normalcy
Malfunction of attachment return Working mode Solenoid valve output pressure

1 selector solenoid valve
Mode E or A 0 MPa {0 kgf/cm2} (0 psi)
Mode B 2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)
2 Malfunction of 2 attachment return The attachment return selector valve may have a malfunction. Check it directly.
selector valve
Malfunction of service 3 control valve The safety valve of the service control valve (on port B side) may have a
3
(safety valve) 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.

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

Malfunction of attachment flow

1 The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly.
rate adjustment EPC valve
value in normalcy
★ Keep the engine stopped for the preparations, and keep it running at high idling during the trouble-
shooting.
Wiring harness connector Service pedal PPC valve output pressure
2 Malfunction of service PPC valve
Disconnect connector V30 of
In NEUTRAL 0 MPa {0 kgf/cm2} (0 psi)
attachment flow rate adjustment
EPC valve. Operated Above 2.75 MPa {Above 28 kgf/cm2}
(Above 398 psi)
20-626 1 PC400LC-7L
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

REMOVAL AND INSTALLATION OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
STRIPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
STRIPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ENGINE REAR SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
ENGINE AND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
SWING MOTOR AND SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
PC400LC-7L 30-1 2
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
TRAVEL MOTOR AND FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71
EXPANSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
REVOLVING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
30-2 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL . . . . . . . . . . . . . . 30-96
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
OPERATOR’S CAB GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
FRONT WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
PC400LC-7L 30-3 2
DISASSEMBLY AND ASSEMBLY
12
MEMORANDUM
30-4 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

SPECIAL TOOLS
● Special tools that are deemed necessary for removal or installation of parts are listed.
● List of the special tools contains the following kind of information.
1. Necessity:
■: Special tools which cannot be substituted, should always be used.
●:Special tools which are very useful if available, can be substituted with commercially available tools.
2. Distinction of new and existing special tools:

N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from already available tools for other models.
Blank: Tools already available for other models, used without any modification.
3.Circle mark (❍) in sketch column:

A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
★ Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with
those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
● The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained.
● Various symbols used in the REMOVAL Section are explained and listed below.
WARNING! This mark indicates safety-related precautions which must be followed when doing the
work.
★ This mark gives guidance or precautions when doing the procedure.

[*1] This mark shows that there are instructions or precautions for installing parts.
This mark shows oil or water to be drained.
INSTALLATION OF PARTS
● Except where otherwise instructed, install parts is the reverse order of removal.
● Instructions and precautions for installing parts are shown with [*1] mark in the INSTALLATION Section, identifying
which step the instructions are intended for.
● Marks shown in the INSTALLATION Section stand for the following.
WARNING! This mark indicates safety-related precautions which must be followed when doing the
work.
PC400LC-7L 30-5 2
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
★ This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil or water to be added.
SKETCHES OF SPECIAL TOOLS
● Various special tools are illustrated for the convenience of local manufacture.
30-6 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS DURING OPERATION
★ Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or
assembly) of units.
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK

● If the coolant contains antifreeze, dispose of it correctly.
● After disconnecting hoses or tubes, over them or fit blind plugs to prevent dirt or dust from entering.
● When draining oil, prepare a container of adequate size to catch the oil.
● Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
● To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the
connectors.
● Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
● Check the number and thickness of the shims, and keep in a safe place.
● When raising components, be sure to use lifting equipment of ample strength.
● When using forcing screws to remove any components, tighten the forcing screws alternately.
● Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
★ Precautions when handling piping during disassembling
● Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1. Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end) Use the two items

Plug (nut end)
number below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2. Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
PC400LC-7L 30-7 2
3. If the part is not under hydraulic pressure, the following corks can be
used:
Dimensions
Nominal
Part Number
number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

● Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
● Install the hoses without twisting or interference.
● Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
● Bend the cotter pin or lock plate securely.
● When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
drops of adhesive.
● When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage,
then coat uniformly with gasket sealant.
● Clean all parts, and correct any damage, dents, burrs, or rust.
● Coat rotating parts and sliding parts with engine oil.
● When press-fitting parts, coat the surface with anti-friction compound (LM-P).
● After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
● When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
● When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of
the hook.
● When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
30-8 2 PC400LC-7L
12
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
● If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate
the coolant through the system. Then check the coolant level again.
● If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
● If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
● Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
OTHER PRECAUTIONS
● To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
● To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when
disassembling or assembling.
● Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
● Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
● Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
● When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
● Do not use seal tape for the thread of the plug mounts or connections.
● If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
● When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air
from piston pump.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.
B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
C. Raise the engine speed and repeat Step B to bleed the air. Repeat this procedure until no more air comes out from the
plugs.
D. After completing bleeding the air, tighten the plugs.
Plug: 11.3 ± 1.5 Nm (8.33 ± 1.10 lbf ft)
E. After repair or long storage, follow the same procedure.
PC400LC-7L 30-9 2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

12
Remark
Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
Remark
Necessity: ■:............... Cannot be substituted, should always be installed (used)
●:................Extremely useful if available, can be substituted with commercially available part
Remark
New/remodel: N:..........Tools with new part numbers, newly developed for this model
R:..........Tools with upgraded part numbers, remodeled from items already available for
other models
Blank:.... Tools already available for other models, used without any modification
Remark
Tools marked O in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
Removal, installation of nozzle holder

1 795-799-1170 Puller ■ 1
assembly
2 790-331-1110 Wrench ● 1 Tightening of cylinder head bolt
3 795-931-1100 Seal puller ■ 1 Removal of engine seal
795-931-1210 Push tool ■ 1
4 ● 01050-31625 ● Bolt ■ 3
● 01050-31645 ● Bolt ■ 3 Press fitting of engine rear seal
795-931-1220 Push tool ■ 1
5
● 01050-31645 ● Bolt ■ 3
795T-521-1140 Push tool ■ 1 O
Engine assembly A ● 790-101-5221 ● Grip ■ 1
6 Press fitting of engine front seal
● 01010-81225 ● Bolt ■ 1
● 01050-31640 ● Bolt ■ 3
795-471-1800 Remover ■ 1 N
● 795-471-1810 ● Plate ■ 1
● 795-471-1820 ● Bolt ■ 1
7 Removal of fuel supply pump
● 795-471-1830 ● Bracket ■ 1
● 01435-01035 ● Bolt ■ 3
● 01435-01025 ● Bolt ■ 1
8 795T-471-1550 Wrench ■ 1 O Removal, installation of nozzle tip
B 796-601-1110 Stopper ■ 1 N Removal, installation of engine mount bolt
Engine and
hydraulic pump 796-460-1210 Oil stopper ● 1
assembly C Stopping of oil
796-770-1320 Adapter ● 1
30-10 2 PC400LC-7L
12
New/remodel
Necessity
Symbol
Sketch
Q'ty
1 796T-627-1630 Push tool ● 1 Removal of shaft

2 790-201-2350 Push tool ■ 1 Removal of bearing
3 790-201-2510 Push tool ■ 1 Press fitting of bearing
790-101-5401 Push tool kit ■ 1
Swing motor and swing ● 790-101-5531 ● Plate 1

machinery assembly D 4 Press fitting of oil seal
● 790-101-5421 ● Grip 1
● 01010-51240 ● Bolt 1
5 790-201-2870 Push tool ■ Press fitting of bearing inner race
6 790-201-2770 Push tool ■ 1 Press fitting of bearing inner race
7 796T-626-1110 Push tool ■ 1 O Press fitting of bearing
796-627-1210 Wrench assembly ■ 1
● 796-627-1220 ● Wrench 1
1 Removal, installation of round nut
● 796-427-1140 ● Pin 3
● 01314-20612 ● Screw 3
796T-627-1230 Push tool ■ 1 O
790-101-2510 Block ● 1
791-122-1130 Plate ● 1
Final drive assembly E
790-101-2550 Leg ● 2
2 790-101-2740 Adapter ● 2 Pressing of bearing inner race
790-101-2570 Plate ● 4
790-101-2560 Nut ● 2
790-101-2102 Puller (294 kN {30 t}) ■ 1
790-101-1102 Pump ■ 1
3 796-627-1020 Installer ■ 1 Installation of floating seal
791-430-3230 Installer ■ 1
Carrier roller assembly F
791-601-1000 Oil pump ■ 1
791-630-1780 Installer ■ 1
Track roller assembly G Supply of oil
791-601-1000 Oil pump ■ 1
791-575-1520 Installer ■ 1
Idler assembly H
791-601-1000 Oil pump ■ 1
791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1 Disassembly, assembly of recoil spring
1
790-101-1600 Cylinder (686 kN {70 t}) ■ assembly
790-101-1102 Pump ■
Recoil spring assembly J
790-201-1500 Push tool kit ■ 1
● 790-201-1660 ● Plate 1
2 Installation of dust seal
● 790-101-5021 ● Grip 1
● 01010-50816 ● Bolt 1
PC400LC-7L 30-11 2
12
New/remodel
Necessity
Symbol
Sketch
Q'ty
Remover and
791-650-3000 ■ 1
installer
Track shoe assembly K Cylinder Pulling out of master pin
790-101-1300 (980 kN {100 t}) ■ 1
790-101-1102 Pump ■ 1
796-946-1310 Guide ∅21.8
1
(For 723-46-40100, 723-46-40601)
1 796-946-2110 Guide ∅20.9
1
(For 723-46-44100)
796-946-2210 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 Guide ∅21.6
1
(For 723-46-42800)
2
796-946-2120 Guide
Control valve assembly L 1 Replacement of pressure compensation valve seal
(For 723-46-44100)
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500)
796-946-1330 Sleeve
1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve
1
(For 723-46-42800)
3 796-946-2130 Sleeve
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
790-101-2501 Push puller ■ 1
● 790-101-2510 ● Block 1
● 790-101-2520 ● Screw 1
● 791-112-1180 ● Nut 1
Center swivel joint ● 790-101-2540 ● Washer 1 Disassembly, assembly of center swivel joint
assembly M assembly
● 790-101-2630 ● Leg 2
● 790-101-2570 ● Plate 4
● 790-101-2560 ● Nut 2
● 790-101-2650 ● Adapter 2
30-12 2 PC400LC-7L
12
New/remodel
Necessity
Symbol
Sketch
Q'ty
1 790-502-1003 Cylinder repair stand ■ 1 Disassembly, assembly of hydraulic cylinder

assembly
2 Removal, installation of piston assembly
790-102-4310 Pin ■ 2
3 790-720-1000 Expander ● 1
796-720-1680 Ring (For boom and bucket) ● 1
07281-01589 Clamp (For boom and ● 1 Installation of piston ring

4 bucket)
796-720-1690 Ring (For arm) ● 1
07281-01919 Clamp (For arm) ● 1
790-201-1702 Push tool kit ■ 1
Hydraulic cylinder
N
assembly ● 790-201-1851 ● Push tool (For bucket) 1
5 ● 790-201-1861 ● Push tool (For boom) 1 Press fitting of bushing
● 790-101-5021 ● Grip 1
● 01010-50816 ● Bolt 1
790-201-1500 Push tool kit ■ 1
● 790-101-5021 ● Grip 1
● 01010-50816 ● Bolt 1
6 Press fitting of dust seal
● 790-201-1660 Plate (For bucket) 1
● 790-201-1670 ● Plate (For boom) 1
● 790-201-1680 ● Plate (For arm) 1
796-670-1100 Remover ● 1
● 796-670-1110 ● Sleeve 1
● 796-670-1120 ● Plate 1
● 796-670-1130 ● Screw 1
Work equipment P Removal of foot pin
assembly ● 796-870-1110 ● Adapter 1
● 01643-33080 ● Washer 1
● 01803-13034 ● Nut 1
790-101-4000 Puller (490 kN {50t}, long) ● 1
790-101-1102 Pump (294 kN {30t}) ● 1
PC400LC-7L 30-13 2
12
New/remodel
Necessity
Symbol
Sketch
Q'ty
799-703-1200 Service tool kit ■ 1

799-703-1100 Vacuum pump (100V) ■ 1
Air conditioner assembly Q 799-703-1110 Vacuum pump (220V) ■ 1 Collection and supply of air conditioner
refrigerant
799-703-1120 Vacuum pump (240V) ■ 1
799-703-1400 Gas leak tester ■ 1
1 793-498-1210 Lifter (Suction cup) ■ 2 Removal and Installation of operatorís
Operatorís cab glass Y
2 20Y-54-13180 Adapter ■ 2 cab glass
30-14 2 PC400LC-7L
12
SKETCHES OF SPECIAL TOOLS
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A6. Push tool
A8. Wrench
PC400LC-7L 30-15 2
D7. Push tool
E2. Push tool
30-16 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
CONTACT TERMINAL REMOVAL (HD30 TYPE)
1. Obtain the correct removal tool according to the wire size used in
the connector.
2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will hinder wire
removal and may damage the connector or removal tool. Always
use the correct removal tool size for the wire gauge you are
servicing.
3. In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting removal tool
into the grommet. Damage to the tool or connector may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
PC400LC-7L 30-17 2
12
STRIPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 -.218)

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

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

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

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

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 -.492)
Using wire insulation stripers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
30-18 2 PC400LC-7L
12
CRIMPING CONTACT TERMINAL (HD30 TYPE)
1. After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
PC400LC-7L 30-19 2
12
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
1. Grasp contact terminal approximately 25.2mm (1in) behind the
crimped barrel.
2. Holding connector with rear grommet facing you.
3. Insert completed contact terminal straight into connector grommet

until a positive stop is felt.
4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.
5. For unused wire cavities, insert sealing plugs for full environmental
sealing.
30-20 2 PC400LC-7L
12
CONTACT TERMINAL REMOVAL (DT TYPE)
1. Remove the wedge lock using needle nose pliers or a hooked
shaped
wire.
2. Pull the wedge lock straight out and save for reinstallation.
3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
PC400LC-7L 30-21 2
12
STRIPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 -.218)

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

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

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

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

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 -.492)
Using wire insulation stripers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
30-22 2 PC400LC-7L
12
CRIMPING CONTACT TERMINAL (DT TYPE)
1. After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
PC400LC-7L 30-23 2
12
INSERTION OF CONTACT TERMINAL (DT TYPE)
1. Grasp the crimped contact terminal approximately 25.2mm (1in)
behind the crimped barrel.
2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.
3. Push the contact terminal straight into the connector until a “click”
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.
4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not
oriented and may fit either way.
Remark
As the connector receptacle is shown - use the same procedures for
a plug.
30-24 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY ENGINE
12
ENGINE
Remark
Removal, installation, disassembly and assembly of the following components, see the ENGINE SHOP
MANUAL.
AFTERCOOLER
ALTERNATOR
CYLINDER HEAD
ENGINE FRONT SEAL
ENGINE OIL COOLER
ENGINE REAR SEAL
FUEL INJECTION PUMP
NOZZLE HOLDER
NOZZLE TIP
STARTING MOTOR
THERMOSTAT
TURBOCHARGER
WATER PUMP
PC400LC-7L 30-25 2
DISASSEMBLY AND ASSEMBLY RADIATOR
12
RADIATOR
REMOVAL
1. Remove cover (1).
2. Drain the coolant.
Coolant: Approximately 35 L (9.25 gal)
3. Erect the engine hood according to the following procedure.
A. Open engine hood (2) and sling it temporarily.

★ When slinging the engine hood, take care not to damage the
rubber seal.
B. Prepare M10 bolt [1].

● When removing the radiator, L = 50 or longer.
● When removing the oil cooler, L = 70 or longer.
C. Remove bolt (4).
D. Remove pin (5) from the lower part of stay (3).
E. Adjust the engine hood so that center hole A of stay (3) will be at
the bolt (4).
F. Install stay (3) with bolt [1] and fix engine hood (2) vertically.
4. Disconnect reservoir tank hose (6).

★ Disconnect the hose from the radiator.
5. Disconnect radiator hoses (7), (8), and (9). [*1]
6. Remove covers (10) and (11).
30-26 2 PC400LC-7L
12
8. Disconnect radiator hose (13). [*1]
9. Remove 2 mount bolts (14).
10. Lift off radiator assembly (15).
Radiator assembly: 30 kg (66.13 lb)
PC400LC-7L 30-27 2
12
INSTALLATION
● Carry out installation in the reverse order to removal.
● Refilling with coolant
Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.
[*1]
Radiator hose clamps

(7): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm} (2.4 ± 0.36 lbf ft)
(8): 4.4 ± 0.49 Nm {0.49 ± 0.05 kgm} (3.2 ± 0.36 lbf ft)
(9), (13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} (6.4 ± 0.3 lbf ft)
30-28 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
12
HYDRAULIC OIL COOLER
REMOVAL
2. Remove plug (2) of the hydraulic oil cooler drain hose to drain the
hydraulic oil.
★ Before draining, open the hydraulic tank cap to release the
pressure in the tank. Then, drain the oil through the cooler hose.

rubber seal.
C. Remove bolt (102).
E. Adjust the engine hood so that center hole A of stay (101) will be
at the bolt (102).
F. Install stay (101) with bolt [1] and fix engine hood (100) vertically.
PC400LC-7L 30-29 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
12
5. Remove hydraulic oil cooler tube mount bolts (5) and (6).
6. Remove right and left hydraulic oil cooler mount bolts (7).
7. Remove 3 hydraulic oil cooler-side mount bolts (8).

★ When removing 1 of the 3 bolts which is hidden behind cover B,
pull cover B lightly.
★ Bolt [1] is used to fix the engine hood vertically.
8. Remove the net on the outside of the hydraulic oil cooler.
9. Lift off hydraulic oil cooler assembly (9).
Hydraulic oil cooler: 50 kg (110 lb)
INSTALLATION
● Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the
oil level again.
30-30 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
12
ENGINE AND HYDRAULIC PUMP
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Qíty
B 796-601-1110 Stopper ■ 1 N
796-460-1210 Oil stopper ■ 1
C
796-770-1320 Adapter ■ 1
REMOVAL
WARNING! Disconnect the cable from the negative

(–) terminal of the battery.
WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal pressure of the hydraulic tank.
★ Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.
1. Remove the 4 engine undercovers.
2. Remove the hydraulic tank strainer. Using tool C, stop the oil.
★ When not using tool C, remove the drain plug to drain the oil from
the hydraulic tank and piping.
Hydraulic tank: Approximately 335 L (88.5 gal)
3. Drain the coolant.
4. Close the fuel stop valve of the fuel tank.

rubber seal.
C. Remove bolt (102).
PC400LC-7L 30-31 2
E. Adjust the engine hood so that center hole A of stay (101) will be
at the bolt (102).
F. Install stay (101) with bolt [1] and fix engine hood (100)
vertically.
6. Remove tube (1). [*1]

★ Remove the tube and bracket together.
7. Disconnect clamp (2) and pipe (3). [*2]

★ Remove the clamp, pipe, and bracket (4) together.
8. Disconnect fuel inlet hose (5) and fuel return hoses (6) and (7). [*3]
9. Disconnect clamp (8) and radiator hoses (9), (10), and (11). [*4]
11. Remove fan guard (14).

★ Bolt [1] is used to fix the engine hood vertically.
30-32 2 PC400LC-7L
12
12. Loosen adjustment bolt (15) and remove belt (16). [*5]
13. Remove air conditioner compressor assembly (17).

★ Move the air conditioner compressor assembly toward the control
valve top cover.
14. Disconnect fan (18).

★ Insert your hand through clearance A between the fan and the
radiator and remove the 6 fan mount bolts in order, turning the fan
with your foot.
15. Disconnect aftercooler hose (21) and heater hose (22). [*6]
17. Disconnect radiator hose (24). [*4]
18. Disconnect heater hose (25).
PC400LC-7L 30-33 2
12
19. Disconnect the following 2 wiring connectors.
● (26): ERO2 (Various sensors)
● (27): ERO3 (Each injector and fuel supply pump)
20. Remove mount bolts (28) and bracket (29).
21. Open the main pump side cover.
22. Lift off covers (30) and (31) together.
23. Remove cover (32) and stay (33).
24. Disconnect the following 2 pump wiring connectors.

● (34): V22 (PC-EPC solenoid valve) Band color: Red
● (35): V21 (LS-EPC solenoid valve) Band color: White
25. Disconnect the following 10 hoses and 1 tube.

● (36): EPC basic pressure port hose (Band color: Yellow)
● (37): Rear pressure port hose (Band color: Yellow)
● (38): Rear pump discharge port hose
● (39): Front pump discharge port hose
30-34 2 PC400LC-7L
12 ● (40): Drain port hose
● (41): Front load pressure input port hose
● (42): Rear load pressure input port hose (Band color: Red)
● (43): Front pressure input port hose
● (44): Pump suction port tube
26. Disconnect engine ground cable (46) from the rear of the hydraulic
pump.
27. Using tool B, remove 4 front and rear engine mount bolts (47). [*7]
28. Lift off engine and hydraulic pump assembly (48).

★ Check that all the wires and pipes have been disconnected.
Engine and hydraulic pump assembly:

1,700 kg (3,748 lb)
PC400LC-7L 30-35 2
12
INSTALLATION
[*1]
Hose clamp: 9.8 ± 0.5 Nm {0.1 ± 0.05 kgm} (7.2 ± 0.36 lbf ft)
[*2]
Clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} (7.7 ± 0.36 lbf ft)
[*3]
Fuel hoses (5), (6), and (7): 14.8 - 19.6 Nm {1.5 - 2.0 kgm} (10.9 - 14.4 lbf ft)
[*4]
Radiator hoses:
(9): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}(2.4 ± 0.36 lbf ft)
(10): 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}(3.2 ± 0.36 lbf ft)
(11), (24):8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} (6.4 ± 0.36 lbf ft)
[*5]
★ See TESTING AND ADJUSTING, Testing and adjusting air conditioner compressor belt tension or REMOVAL
AND INSTALLATION OF ENGINE FRONT SEAL in engine manual.
[*6]
Air aftercooler hose clamp: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} (7.9 ± 0.73 lbf ft)
[*7]
Engine mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (607 - 759.6 lbf ft)
● Refilling with coolant

Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.

oil level again.
Hydraulic oil: Approximately 335 L (88.4 gal)
● Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.
30-36 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
12
SWING CIRCLE
REMOVAL
1. Remove the revolving frame assembly. For details, see REMOVAL
OF REVOLVING FRAME ASSEMBLY.
2. Sling swing circle assembly (1) by 3 points temporarily, remove 40

mount bolts, and lift off the swing circle assembly. [*1]
Swing circle assembly: 600 kg (1,323 lb)
INSTALLATION
[*1]
Mating face of swing circle: Gasket sealant (LG-6)
Threads of swing circle mount bolt: Adhesive (LT-2)
Swing circle mount bolt: 824 - 1,030 Nm {84 - 105 kgm}

(608 - 759 lbf ft)
Target: 927 Nm {94.5 kgm} (683.7 lbf ft)
★ When installing the swing circle to the track frame, bring soft zone mark S of the inner race and soft zone mark P of the
outer race to the right side of the chassis as shown below.
Quantity of grease in grease bath: Grease (G2-LI), 33 L (8.7 gal)

(Use GLT2-LI for 50°C (138.2°F) specification)
PC400LC-7L 30-37 2
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
SWING MOTOR AND SWING MACHINERY
REMOVAL
WARNING! Release the residual pressure in the hydraulic circuit. Refer to the Releasing of Residual
Pressure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this
manual.
WARNING! Lower the work equipment to the ground for oil filler cap on the fuel tank to release the
residual pressure inside the tank and move the safety lock lever to the LOCK position.
1. Disconnect five swing motor hoses (1) through (5).

● (1): Between swing motor and control valve (MA port)
● (2): Between swing motor and control valve (MB port)
● (3): Suction hose (S port)
● (4): Drain hose (T port)
● (5): Swing brake releasing pilot hose (B port)
2. Detach the swing motor and swing machinery assembly (6), using
forcing screw [1] after removing the mount bolts. [*1]
3. Lift and remove swing motor and swing machinery assembly (6).
★ When lifting the swing motor and swing machinery assembly for
removal, do so slowly so that the hoses and other parts will not be
damaged.
★ Take good care, when lifting the assembly, until the spigot
joint portion is pulled out.
Swing motor and swing machinery assembly: 550 kg

(1,212 lb)
30-38 2 PC400LC-7L
12
INSTALLATION
● Install in reverse order of removal.
[*1]
Mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (608 - 759 lbf ft)
● Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
● Air bleeding
Refer to the Air Bleeding of Various Parts section in the TESTING AND ADJUSTING chapter of this manual.
PC400LC-7L 30-39 2
12
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qíty
Part No. Part Name
1 796T-627-1630 Push tool ● 1

2 790-201-2350 Push tool ■ 1
3 790-201-2510 Push tool ■ 1
790-101-5401 Push tool kit ■ 1
● 790-101-5531 ● Plate 1
D 4
● 790-101-5421 ● Grip 1
● 01010-51240 ● Bolt 1 N
5 790-201-2870 Push tool ■ 1
6 790-201-2770 Push tool ■ 1
7 796T-626-1110 Push tool ■ 1 O
DISASSEMBLY
1. Draining oil
Loosen the drain plug and drain the oil from the swing machinery
case.
Swing machinery case: Approximately 21 L (5.5 gal)
2. Swing motor assembly
A. Set the swing motor and swing machinery assembly on block [1].
B. Remove 10 mount bolts and lift off swing motor assembly (1).
Swing motor assembly: 115 kg (254 lb)
3. No. 1 sun gear

Remove No. 1 sun gear (2).
30-40 2 PC400LC-7L
12
4. No. 1 carrier assembly
A. Remove No. 1 carrier assembly (3).
B. Disassemble the No. 1 carrier assembly according to the

following procedure. Remove snap ring (4), and then remove
shaft (5), gear (6), bearing (7), thrust washer (8), and plate (9).
5. Ring gear
Remove the mount bolts and ring gear (10).
6. No. 2 sun gear

Remove No. 2 sun gear (11).
PC400LC-7L 30-41 2
12
7. Bolt
Remove holder mount bolt (12).
A. Lift of No. 2 carrier assembly (13).

i. Push in pin (14) and drive out shaft (15) from carrier (16).
★ After removing the shaft, remove pin (14).
ii. Remove thrust washer (17), gear (18), bearing (19), and
thrust washer (20).
iii. Remove plate (21).
9. Shaft assembly
A. Turn over case and pinion assembly (24) and remove 12 mount
bolts (23) of cover assembly (22).
30-42 2 PC400LC-7L
12
B. Turn over case and pinion assembly (24) and set it on the press
stand. Using push tool [2], D1 and the press, pull out pinion shaft
assembly (25).
★ Set a wood block under the press so that the pinion shaft will
not be damaged when it comes off.
★ A rough standard pressing force is 20 odd tons.
10. Disassemble the pinion shaft assembly (25) according to the following
procedure.
A. Using the push tool, remove cover assembly (22) and bearing (26)
from shaft (27).
★ A rough standard pressing force is 30 tons.
B. Remove oil seal (28) from cover (29).
11. Bearing
Using multiple push tools [3], remove bearing (30) from case (31).
★ Push tool to be set contact with bearing: D2
PC400LC-7L 30-43 2
12
ASSEMBLY
★ Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing.
1. Bearing
Using push tool D3 and [4], press fit bearing (26) to case (31).
★ A rough standard pressing force is several tons.
2. Cover assembly
A. Using push tool D4, press fit oil seal (28) to cover (29).
Periphery of oil seal: Gasket sealant (LG-6)
★ Take care that the gasket sealant (LG-6) will not stick to the
oil seal lip and shaft assembly (22).
B. Install cover assembly (22) to case (31) and tighten mount bolts
(23).
★ Match the oil path of cover (22) to the drilled hole of case
(31).
Cover fitting face: Gasket sealant (LG-6)
Mount bolt: 98 - 123 Nm {10 - 12.5 kgm} (73 - 90 lbf ft)
Oil seal lip: Grease (G2-LI)
30-44 2 PC400LC-7L
3. Case assembly
A. Turn over case assembly (32) and set it to shaft (27). Using push
tools D5 and D6 [5], press fit the bearing inner race.
★ When setting the case assembly to the shaft, take care
extremely not to damage the oil seal.
★ A rough standard pressing force is 30 tons.
B. Bearing
Using too D7, press fit bearing (30).
★ Press both inner race and outer race of the bearing
simultaneously. Do not press only the inner race.
★ A rough standard pressing force is 20 odd tons.
★ After press fitting the bearing, check that the case turns
smoothly.
A. Assemble the No. 2 carrier assembly according to the following

procedure.
★ There is a caulking mark made when the pin was inserted at
the end of carrier side hole “a” and the inside wall of the hole
is swelled at that mark. Flatten the swelled part in advance.
i. Install plate (21) to carrier (16).
ii. Install bearing (19) to gear (18) and fit top and bottom thrust
washers (17) and (20), and then set the gear assembly to
carrier (16).
iii. Aligning the pin holes of shaft (15) and carrier, lightly hit the
shaft with a plastic hammer, etc. to install.
★ When installing the shaft, revolve the planetary gear and take
care not to damage the thrust washers.
iv. Insert pin (14).
PC400LC-7L 30-45 2
12 ★ When inserting the pin, do not set the 3 claws (parts “a”) on
the periphery to the thin part of the carrier (part “b”). The thin
part may be on the opposite side, however. Check each carrier
and avoid setting a claw to the thin part.
★ After inserting the pin, caulk the pin part of the carrier.
B. Install No. 2 carrier assembly (13).
5. Bolt and O-ring
A. Tighten bolt (12).
Threads of mount bolt: Adhesive (LT-2)
Mount bolt:
343 - 427 Nm {34 - 43.5 kgm} (253 - 314 lbf ft)
B. Fit the O-ring to case (31).
6. No. 2 sun gear

Install No. 2 sun gear (11).
7. Ring gear
Using the eyebolt (M12 x 1.75), install ring gear (10).
30-46 2 PC400LC-7L
12 ★ When installing ring gear (10), set its match mark (part “d”) and
the projection of the case flange (part “c”) as shown in the at right
figure.
★ Degrease the mating faces of ring gear (10) and case.

★ Never stick gasket sealant to the mating faces of ring gear (10)
and case.
Mount bolt:
245 - 309 Nm {25 - 31.5 kgm} (181 - 227 lbf ft)
★ Add engine oil (EO30-CD) at this time.

procedure.
i. Press fit shaft (5) to the carrier in the direction of the arrow
until the snap ring groove is seen.
ii. After installing snap ring (4), press back the shaft from the
opposite side until the snap ring is fitted to face P of the
carrier. At this time, take care not to press back too much.
iii. After installing plate (9), install thrust washer (8), bearing (7),
gear (6), and snap ring (4).
PC400LC-7L 30-47 2
12
9. No. 1 sun gear assembly

Install No. 1 sun gear (2).
★ Take care not to install the No. 1 sun gear upside down.
★ Install the No. 1 sun gear with the tooth (part “e”) down.
10. Swing motor assembly

Install swing motor assembly (1) to ring gear (10).
★ When installing the swing motor assembly, set the relief valve
(part f) and the projection of the case (part c) as shown in the
following figure.
★ Degrease the mating faces of swing motor assembly (1) and ring
gear (10).
Mating faces of swing motor assembly (1) and ring gear

(10): Gasket sealant (LG-6)
Swing motor assembly: 115 kg (254 lb)
30-48 2 PC400LC-7L
● Refilling with oil
Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-30K for extremely cold district) through the oil filler to
the specified level.
Swing machinery case: Approximately 21 L (5.5 gal)
PC400LC-7L 30-49 2
DISASSEMBLY AND ASSEMBLY SPROCKET
12
SPROCKET
REMOVAL
1. Remove track shoe assembly. For details, see REMOVAL OF TRACK
SHOE ASSEMBLY.
2. Swing work equipment 90°, push up chassis with work equipment and
place block [1] between track frame and track shoe.
3. Remove mount bolts and lift off sprocket (1). [*1]
Sprocket: 70 kg (154.3 lb)
INSTALLATION
[*1]
Thread of sprocket mount bolt:

Gasket sealant (LG-6)
Sprocket mount bolt:

640 - 785 Nm {65 - 80 kgm} (472 - 578 lbf ft)
30-50 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE
12
TRAVEL MOTOR AND FINAL DRIVE
REMOVAL
1. Remove the sprocket. For details, see Removal of sprocket.

and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
3. Disconnect drain hose (2), travel speed selector hose (3), and motor
hoses (4) and (5).
★ Remove the nipples, too.
4. Remove the 24 mount bolts and lift off the final drive assembly (6).
[*1]
★ Take care extremely not to damage the nipple sealing faces of the
hose joints.
★ When slinging the final drive assembly, do not use the tap hole for
the cover.
Final drive assembly: 700 kg (1544 lb)
INSTALLATION
[*1]
Mount bolt: 490 - 608 Nm {50 - 62 kgm} (362 - 448 lbf ft)

oil level again.
● Bleeding air
PC400LC-7L 30-51 2
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qíty
Part No. Part Name

● 796-627-1220 ● Wrench 1
1
● 796-427-1140 ● Pin 3
● 01314-20612 ● Screw 3
796T-627-1230 Push tool ■ 1 O
790-101-2510 Block ● 1
791-122-1130 Plate ● 1
E
790-101-2550 Leg ● 2
2 790-101-2740 Adapter ● 2
790-101-2570 Plate ● 4
790-101-2560 Nut ● 2
790-101-2102 Puller (30 tons) ■ 1
790-101-1102 Pump ■ 1
3 796-627-1020 Installer ■ 1
DISASSEMBLY
1. Draining oil
Remove the drain plug to drain the oil from the final drive case.
Final drive case: Approximately 11L (3 gal)
2. Cover
A. Place the final drive on block [1] and remove the mount bolts and
cover (1).
B. Using eyebolt [2], remove cover (1).
30-52 2 PC400LC-7L
12
3. Spacer
Remove spacer (2).
A. Remove No. 1 carrier assembly (3).

i. Push in pin (5) to drive out shaft (6) from carrier (7).
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).
PC400LC-7L 30-53 2
12
6. Thrust washer
Remove thrust washer (14).
A. Sling No. 2 carrier assembly (15) with wires, etc. and remove it.
B. Disassemble No. 2 carrier assembly according to the following

procedure.
i. Push in pin (16) to drive out shaft (17) from carrier (18).
ii. Remove thrust washer (19), gear (20), bearing (21), and
thrust washer (22).
8. Nut
A. Remove lock plate (23).
30-54 2 PC400LC-7L
12
B. Using tool E1, remove nut (24).
9. Hub assembly
A. Using eyebolts [3], remove hub assembly (25) from the travel
motor.
B. Disassemble hub assembly (25) according to the following

procedure.
i. Remove bearing (26) from hub (32).
ii. Remove floating seal (27) from hub (32).
PC400LC-7L 30-55 2
12
iii. Remove bearings (28) and (29) from hub (32).
C. Remove floating seal (30) from travel motor (31).
D. Using puller [4], remove bearing (34) and collar (33) together.
★ You can remove bearing (34) and collar (33) without using
puller [4] in some cases.
30-56 2 PC400LC-7L
12
ASSEMBLY
★ Clean the all parts and check them for dirt or damage. Coat their
sliding surfaces with engine oil before installing.
1. Hub assembly
A. Using the push tool, press fit bearings (28) and (29) to hub (32).
B. Using tool E3, install floating seal (27) to hub (32).

★ Thoroughly degrease and dry the O-ring and O-ring fitting
surface of the floating seal before installing.
★ After installing the floating seal, check that its slant is less
than 1 mm.
★ After installing the floating seal, thinly apply engine oil to the
sliding surfaces.
C. Install collar (33) and bearing (34) to travel motor (31).
D. Using tool E3, install floating seal (30) (which is hidden and not
seen behind tool E3) to travel motor (31).
★ Thoroughly degrease and dry the O-ring and O-ring fitting
surface of the floating seal before installing.
★ After installing the floating seal, check that its slant is less
than 1 mm.
★ After installing the floating seal, thinly apply engine oil to the
sliding surfaces.
PC400LC-7L 30-57 2
12
E. Using eyebolts [3], set hub assembly (25) to the travel motor.
Using the push tool, lightly hit the bearing to press fit it.
2. Nut
Install the nut according to the following procedure.
A. Rotate the hub 2 - 3 turns.
B. Using tool E2, press the bearing inner race.

★ Pressing force: 29.4 - 38.3 kN {3.0 - 3.9 tons}
C. While the bearing is pressed, rotate the hub at least 5 turns in 1

direction.
D. Release the pressing force.
E. Press the bearing again.

★ Pressing force: 14.7 - 18.6 kN {1.5 - 1.9 tons}
F. Under the condition in E above, measure dimension “a”.
G. Measure thickness “b” of nut (24).
H. Obtain a - b = c.
I. Using tool D1, tighten nut (24) until dimension “c” is as follows.
★ Dimension “c”: c +0.07
-0.03 mm
30-58 2 PC400LC-7L
12
J. Using push-pull gauge [5], measure the rotating force of the hub
in its revolving direction on the motor case.
★ Rotating force: Max. 765 N {78 kg} (171.9 lbf)
★ The rotating force means the maximum force at the tangent to
the bolt circle at the beginning of rotation.
K. Install lock plate (23), fitting it to the motor spline.
Mount bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} (48.8 ± 5.4 lbf ft)

procedure.
the end of carrier side hole “h” and the inside wall of the hole
i. Install bearing (21) to gear (20) and fit top and bottom thrust
washers (19) and (22), and then set the gear assembly to
carrier (18).
ii. Aligning the pin holes of shaft (17) and carrier, lightly hit the
★ When installing the shaft, revolve the planetary gear
and take care not to damage the thrust washers.
iii. Insert pin (16).

★ After assembling the carrier assembly, check that the gear
(20) turns smoothly.
PC400LC-7L 30-59 2
12
★ Install No. 2 carrier assembly (15) so that the 4 gear shaft
ends will be in the 4 hollows at the motor case end.
4. Thrust washer
Install thrust washer (14).
5. No. 2 sun gear

Install spacer (4) and No. 2 sun gear (13).

procedure.
the end of carrier side hole “h” and the inside wall of the hole
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).
30-60 2 PC400LC-7L
12
ii. Aligning the pin holes of shaft (6) and carrier, lightly hit the
★ When installing the shaft, revolve the planetary gear
and take care not to damage the thrust washers.
iii. Insert pin (5).

★ After assembling the carrier assembly, check that the gear (9)
turns smoothly.
7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (12).
8. Spacer
Install spacer (2).
9. Cover
Using eyebolts [2], install cover (1) and tighten the mount bolts.
Cover mount face: Gasket sealant (LG-6)

★ Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-
30K for extremely cold district) through the oil filler.
Final drive case: Approximately 11 L (2.9 gal)
★ After installing the final drive assembly to the chassis, check the oil level again at the specified position.
PC400LC-7L 30-61 2
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
12
CARRIER ROLLER
★ Only precautions for assembling the carrier roller assembly are
explained below.
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qíty
Part No. Part Name
1 791-430-3230 Installer ■ 1
F
2 791-601-1000 Oil pump ■ 1
Carrier roller assembly: 35 kg (78 lb)
ASSEMBLY
● Press fitting of support (2)
A. The threads of shaft (1) must be in the range of the following figure.
B. Press fitting dimension of shaft: (Shown in the following figure)
C. Using push tool [1], press fit support (2) to shaft (1).
At this time, apply press fitting force of at least 79 kN {8.1 tons}.
● Floating seal
★ When installing the floating seal, thoroughly clean, degrease, and
dry the contact surfaces of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the floating seal contact
surfaces.
★ Be sure to use the installer F to insert the floating seal assembly in
the housing.
★ After installing the floating seal, check that its slant is less than 1
mm and its projection “a” is 5 - 7 mm.
● Carrier roller
★ Using tool F, apply the standard pressure to the oil filler to check
the seal for air leakage.
★ Keep the following standard pressure for 10 seconds and check
that the pointer of the gauge does not lower.
Standard pressure:. . . . . . 0.1 MPa {1 kg/cm2} (14.2 psi)
30-62 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
12
★ Using tool F, fill the carrier roller assembly with oil and tighten the
plug.
Carrier roller: 170 - 180 cc (EO30-CD)
PC400LC-7L 30-63 2
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
12
TRACK ROLLER
★ Only precautions for assembling the track roller assembly are explained below.
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qíty
Part No. Part Name
1 791-630-1780 Installer ■ 1
G
2 791-601-1000 Oil pump ■ 1
Track roller assembly: 80 kg (176 lb)
ASSEMBLY
● Floating seal
★ When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating
seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces.
★ Be sure to use the installer G to insert the floating seal assembly in the housing.
★ After installing the floating seal, check that its slant is less than 1 mm and its projection “a” is 5 - 7 mm.
● Track roller
★ Using tool G, apply the standard pressure to the oil filler to check
the seal for air leakage.
★ Keep the following standard pressure for 10 seconds and check
that the pointer of the gauge does not lower.
Standard pressure:. . . . . . 0.1 MPa {1 kg/cm2} (14.2 psi)
★ Using tool G, fill the track roller assembly with oil and tighten the
plug.
Track roller: 280 - 310 cc (EO30-CD)
Plug: 10 - 20 Nm {1 - 2 kgm} (7.37 - 14.7 lbf ft)
30-64 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY IDLER
12
IDLER
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qíty
Part No. Part Name
791-575-1520 Installer ■ 1
H
791-601-1000 Oil pump ■ 1
DISASSEMBLY
1. Remove nut (1) and pull out bolt (2) to remove support (3).
2. Remove floating seal (4) from support (3) and idler (5).
3. Pull out idler (5) from shaft and support assembly (6).
★ Idler is filled with oil of 345 ± 10 cc. Drain it or spread cloths to
soak it at this time.
4. Remove floating seal (7) on the opposite side from idler (5) and shaft
and support assembly (6).
5. Remove nut (8), pull out bolt (9), and then remove support (10) from
shaft (11).
PC400LC-7L 30-65 2
12
6. Remove bushing (12) from idler (5).
ASSEMBLY
1. Press fit bushings (12) (on both sides) to idler (5).
2. Fit the O-ring and install support (10) to shaft (11) with bolt (9) and
tighten nut (8).
★ Install the shaft with the UP mark up.
3. Using tool H, install floating seal (7) to idler (5) and shaft and support
assembly (6).
30-66 2 PC400LC-7L
12 ★ When installing the floating seal, thoroughly clean, degrease, and
dry the contact surfaces of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the floating seal contact
surfaces.
★ Be sure to use the installer H to insert the floating seal assembly
in the housing.
★ After installing the floating seal, check that its slant is less than 1
mm and its projection “a” is 9 - 11 mm.
4. Install shaft and support assembly (6) to idler (5).
5. Similarly, using too H, install floating seal (4) to idler (5) and support
(3).
PC400LC-7L 30-67 2
12 ★ Coat the sliding surface of the floating seal with oil and take care
that dirt will not stick to it.
★ Degrease the floating seal and the O-ring contact surfaces.
6. Fit the O-ring, set support (3), install bolt (2), and tighten nut (1).
7. Add oil and tighten the plug.
Quantity of oil: Approximately 345 ± 10 cc (EO-30CD)
Plug: 130 - 180 Nm {13 - 18 kgm} (96 - 132 lbf ft)
30-68 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
RECOIL SPRING
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Qíty
791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
1 Cylinder
790-101-1600 ■ 3
(686 kN {70 t})
790-101-1102 Pump ■ 3
j
790-201-1500 Push tool kit 1
● 790-201-1660 ● Plate
2
● 790-101-5021 ● Grip
● 01010-50816 ● Bolt
Recoil spring (Excluding idler): 900 kg (1985 lb)
DISASSEMBLY
1. Remove piston assembly (2) from recoil spring assembly (1).
2. Disassembly of recoil spring assembly
A. Set tool J1 to recoil spring assembly (1).
WARNING! Since the installed load of the spring is

large and dangerous, set the tool
securely.
Installed load of spring: 239.037 kN {24,375 kg} (53,738 lbf)
B. Apply oil pressure gradually to compress the spring and remove

lock plate (3) and nut (4).
★ Compress the spring to a degree that you can loosen the nut.
★ Release the oil pressure gradually to reduce the spring tension
to 0 (zero).
★ Free length of spring: 845.3 mm (33.2 in)
C. Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from
spring (5).
3. Disassembly of piston assembly
A. Remove lock plate (11) from piston (10), and then remove valve (12).
B. Remove snap ring (13), U-packing (14), and ring (15).
PC400LC-7L 30-69 2
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
ASSEMBLY
1. Assembly of piston assembly
A. Install ring (15) and U-packing (14) to piston (10) and secure
them with snap ring (13).
B. Tighten valve (12) temporarily and secure it with lock plate (11).
2. Assembly of recoil spring assembly
A. Using tool J2, install dust seal (9) to cylinder (7).
B. Install cylinder (7), collar (8), and yoke (6) to spring (5), and then
set them to tool J1.
Sliding parts of cylinder: Grease (G2-LI)
C. Apply oil pressure gradually to compress the spring and tighten

nut (4) so that installed length of the spring will be “a”, and then
secure it with lock plate (3).
★ Installed length of spring “a”: Approximately 690 mm
D. Remove recoil spring assembly (1) from tool J1.
3. Install piston assembly (2) to recoil spring assembly (1).
Sliding parts of piston: Grease (G2-LI)
Wear ring: Grease (G2-LI)
★ Install the piston assembly so that the position of the valve will be on outside.
★ Supply 320 cc of grease (G2-LI) to the cylinder, bleed air, and check that the grease flows out of the grease hole.
30-70 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY TRACK SHOE
12
TRACK SHOE
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qíty
Part No. Part Name
Remover and
791-650-3000 installer ■
K 790-101-1300 Cylinder (980 kN ■

{100 t})
790-101-1102 Pump ■
EXPANSION
1. Start the engine and set the master pin to above the idler.
2. Remove track shoes (2) on the right and left sides of master pin (1).
[*1]
3. Lower the work equipment to the ground and loosen lubricator (3) to
slacken the track shoe. [*2]
WARNING! Since the internal pressure of the

adjustment cylinder is very high, do not
loosen the lubricator more than 1 turn. If
the grease does not come out sufficiently,
move the machine forward and in
reverse.
4. Using tool K, remove master pin (1). [*3]
5. Move the master pin forward and set block [1] under the track shoe in
front of the idler.
6. Pull out pusher K.
7. Move the machine in reverse slowly to expand the track shoe. [*4]
PC400LC-7L 30-71 2
DISASSEMBLY AND ASSEMBLY TRACK SHOE
12
INSTALLATION
● Carry out installation in the reverse order to expansion.
[*1]
Mount bolt: Anti-seizure compound (MARUZEN MOLYMAX No. 2 or equivalent)
Mount bolt: Tighten the 4 bolts first to 392 ± 39 Nm {40 ± 4 kgm} (289 ± 28 lbf ft). Check that the
mating faces are fitted, then retighten each bolt by 120° ± 10°.
[*2]
★ Adjust the tension of the track shoe. For detail, see TESTING
AND ADJUSTING, Testing and adjusting track shoe tension.
Lubricator: 58.8 - 88.3 Nm {6 - 9 kgm} (43.3 - 65.1 lbf ft)
[*3]
★ Using the tool, press fit the master pin so that its projection “a”
will be as follows.
● Dimension “a”: 4.4 ± 2 mm
Supply grease to the space between the bushing and

pin so that filling rate will be 100%. Grease: NIGUTAITE
LYK-2 manufactured by NIPPON GREASE CO., LTD.
or equivalent
Apply grease to the contact faces of dust seal (5) and

bushing (4) (all over the end face of the dust seal or
bushing) (parts marked Q). Do not apply grease to the
pars marked X, however.
R: Detail of regular pin position
M: Detail of master pin position
(Pins are not inserted, however)
[*4]
Set the track shoe and sprocket (4) as shown in the following figure
(on both right and left sides).
30-72 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
12
AIR CONDITIONER UNIT
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Qíty
Part No. Part Name
799-703-1200 Service tool kit ■ 1

799-703-1100 Vacuum pump (100V) ■ 1
Q 799-703-1110 Vacuum pump (220V) ■ 1
799-703-1120 Vacuum pump (240V) ■ 1
799-703-1400 Gas leak tester ■ 1
REMOVAL

1. Swing the upper structure by 90°.
2. Open the engine hood.
3. Connect tool Q to cap [1] and collect the air conditioner refrigerant.
4. Remove rear covers (1), (2), (3), and (4).
5. Remove duct (5), cover (6), and plate (7).
6. Remove plate (8) and duct (9).

★ Remove the duct lock clip.
7. Remove ducts (10) and (11).
PC400LC-7L 30-73 2
12
8. Disconnect connectors D01 (12), D02 (13), C09 (14), R22 (15), R20
(16), and K19 (17).
9. Remove and sling controller (18).
10. Remove plate (19).
11. Disconnect air conditioner unit connectors M27 (20) and M33 (21).
12. Remove the air conditioner unit undercover.

★ Part A
13. Remove mount bolt (24) and connector (25). [*1]
14. Disconnect heater hoses (22) and (23) and air conditioner tube (26).
[*1]
★ Put tags to the disconnected hoses and tubes to prevent a mistake
in re-connecting them.
15. Remove the 7 mount bolts and air conditioner unit assembly (27).
30-74 2 PC400LC-7L
12
INSTALLATION
★ When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them.
★ When connecting each air conditioner hose, check that the O-ring is fitted to the joint.
★ Check that each O-ring is free from flaw and deterioration.
[*1]
★ Apply compressor oil (ND-OIL8) to the threads of the refrigerant pipe joints and tighten each nut with double
spanner.
Hose clamp (M6 bolt): 8 - 12 Nm {0.8 - 1.2 kgm} (5.9 - 8.8 lbf ft)
Hose screw of M16 x 1.5: 12 - 15 Nm {1.2 - 1.5 kgm} (8.8 - 11.0 lbf ft)
Hose screw of M22 x 1.5: 20 – 25 Nm {2.0 – 2.5 kgm} (14.7 - 18.4 lbf ft)
Hose screw of M24 x 1.5: 30 – 35 Nm {3.0 – 3.5 kgm} (22.1 - 25.8 lbf ft)
● Charging air conditioner with refrigerant gas

Using tool Q, charge the air conditioner circuit with refrigerant (HFC R134a) from the compressor.
★ Quantity of refrigerant: 950 ± 50 g
PC400LC-7L 30-75 2
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
12
OPERATOR’S CAB
REMOVAL

1. Remove rear covers (1), (2), (3), and (4).
2. Remove duct (5), cover (6), and plate (7).
3. 3. Remove plate (8), duct (9) and the element.

★ Remove the duct lock clip.
4. Remove clip (10) and disconnect cab wiring connectors M45 (11),
H08 (12), and H09 (13).
5. Remove air conditioner connector plate (14).
6. Disconnect connectors M71 (15), H10 (16), H11 (17), and H12 (18).
7. Disconnect upper and lower duct joints (19) and (20).
8. Remove controller sub-plate (21) and incline it against the air condi-
tioner.
30-76 2 PC400LC-7L
12
9. Remove cover (22) and floor mat (23).
10. Move right console (24) into the cab.
11. Remove monitor panel undercover (25).
12. Disconnect cab wiring connector W04 (26) (Wiper motor).
13. Remove ducts (27) and (28).

★ Both (27) and (28) are two in number.
★ Cut the tie-wrap on the monitor wiring harness.
14. Remove cover (29) and monitor assembly (30).
15. Disconnect radio antenna (31).
16. Remove clip (32) and take wiring harness (33) out of grommet (34).
PC400LC-7L 30-77 2
12
17. Take grommet (35) out of the right front of the cab.
18. Disconnect the windshield washer hose from (36).
19. Remove 4 mount bolts (37) and 5 mount bolts (38).

★ Check the types of the bolts.
★ In the initial period, 7 mount bolts (38) are used.
20. Using lever block [1], lift off operator's cab assembly (39).
Operator's cab assembly: 300 kg (662 lb)
21. When starting the engine while the operator's cab is removed (for
transportation, etc.), use the following brackets.
A. Bracket (41) for controller (40), Part No.: 208-53-13920
B. Bracket (42) for monitor panel assembly (30)

Part No.: 208-53-13910
INSTALLATION
30-78 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY MONITOR
12
MONITOR
REMOVAL

1. Remove cover (1) and disconnect wiring connector P15 of air

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

★ Disconnect monitor panel wiring connectors P01, P02, and P70
before removing the monitor assembly.
INSTALLATION
PC400LC-7L 30-79 2
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
12
PUMP CONTROLLER
REMOVAL

1. Remove covers (1), (2), and (3).
2. Disconnect pump controller wiring connectors C01 (4), C02 (5), and
C03 (6).
3. Remove the 4 mount bolts and pump controller assembly (7).
INSTALLATION
30-80 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY ENGINE CONTROLLER
12
ENGINE CONTROLLER
REMOVAL

1. Open the right side cover (cooler).
2. Remove bracket (1).
3. Remove the 4 mount bolts and engine controller assembly (2).
4. Disconnect engine controller wiring connectors CB1 (3), CB2 (4), and
CB3 (5).
INSTALLATION
PC400LC-7L 30-81 2
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
12
REVOLVING FRAME
REMOVAL
WARNING! Extend the arm and bucket fully, lower the work equipment to the ground, and set the
safety lock lever to the LOCK position.
1. Remove the work equipment assembly. For details, see WORK

EQUIPMENT.
2. Remove the counterweight assembly. For details, see

COUNTERWEIGHT.
3. Disconnect 4 boom cylinder hoses (1).

★ Plug the hoses to stop oil.
4. Sling boom cylinder assembly (2) temporarily.
5. Remove plate (3) and pin (4) and lift off boom cylinder assembly (2).
★ Remove the boom cylinder on the opposite side similarly.
Boom cylinder assembly: 360 kg (794 lb)
30-82 2 PC400LC-7L
12
6. Disconnect 7 hoses (5) – (11).
● (5): Center swivel joint (Port D) – Swing motor (Port T)
● (6): Center swivel joint (Port D) – Hydraulic tank
● (7): Center swivel joint (Port E) – Solenoid valve
● (8): Center swivel joint (Port B) – Control
valve left travel (Port B2)
● (9): Center swivel joint (Port D) – Control
valve right travel (Port B5)
● (10): Center swivel joint (Port A) – Control
valve left travel (Port A2)
● (11):Center swivel joint (Port C) – Control
valve right travel (Port A5)
7. Pull out pin (12) on the center swivel joint side and disconnect the lock
plate from the center swivel joint.
8. Remove 29 mount bolts (13), leaving 3 each at the front and rear sides.
9. Using a lever block, sling the revolving frame assembly temporarily,

balancing it in each direction.
★ Put wood liners to the rear side of the frame.
● Rough standard length of sling:
Front: 8 m in total
Rear: 6 m
● If the engine hood interferes with the sling, erect the engine
hood, referring to RADIATOR.
10. Remove the remaining 6 bolts and lift off revolving frame assembly
(14). [*1]
WARNING! When removing the revolving frame

assembly, take care that it will not inter-
fere with the center swivel joint assembly.
Revolving frame assembly: 10,000 kg (22,047 lb)
PC400LC-7L 30-83 2
12
INSTALLATION
[*1]
● Match the soft zone point (P) of the outer race and the soft zone point (S) of the inner race.
Mating face of swing circle: Gasket sealant (LG-6)
Threads of revolving frame mount bolt: Adhesive (LT-2)
Revolving frame mount bolt

1. Tighten the bolts marked with A (at 4 places) according to the following steps 1) – 3).
1) Tighten each bolt to 392 Nm {40 kgm} (289 lbf ft) first.
2) Then, tighten the bolt by 90° ± 5°.
• Make a mark on the bolt head with a marker pen (to check the angle).
3) The tightening torque of the bolt tighten in 2) above must be 1,176 Nm {120 kgm} (867 lbf ft)
or larger.
2. Tighten each bolt 208-25-71230 which is not marked with A according to above steps 1) – 3).
If the tightening torque reaches 2,254 Nm {230 kgm} (1662 lbf ft) before completing the above
steps and the tightening angle is 35° – 95°, however, stop tightening.
★ Marks P and S are the soft zone points.

oil level again.
● Bleeding air
Bleed air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.
30-84 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
COUNTERWEIGHT
REMOVAL
1. Set eyebolt [1] to counterweight assembly (1).
2. Remove 4 mount bolts (2). [*1]

★ Check where shims have been used.
3. Lift off counterweight assembly (1). [*2]

★ When lifting off the counterweight, take care not to strike it
against the engine, radiator and cooler assembly, etc.
Counterweight assembly: 9,500 kg (20,944 lb)
INSTALLATION
★ If heat insulation cover (3) of the engine compartment is flattened,
replace it.
[*1]
Mount bolt:
3,430 - 4,212 Nm {350 - 430 kgm} (2,530 - 3106 lbf ft)
[*2]
★ Installation and adjustment of counterweight
1) Adjust the level difference from the exterior parts (horizontal clearance) with shims.
● Kinds of shim thickness: 0.5 mm, 1 mm
2) Insert the shims so that the clearance between the door and counterweight and that between the revolving frame
and counterweight will be 10 ± 5 mm evenly.
PC400LC-7L 30-85 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
HYDRAULIC TANK
REMOVAL
1. Remove 3 lower covers (1).
2. Drain the oil from the hydraulic tank.
Capacity of hydraulic tank:

Approximately 335 L (88.5 gal)
3. Open engine hood (2) and remove control valve top cover (3).
5. Disconnect drain hoses (5) and (6).
6. Disconnect block (7).
7. Disconnect drain hoses (8), (9), and (10).
8. Disconnect 2 clamps (11).
9. Remove side cover (12).
30-86 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
10. Remove sensor (13).
11. Disconnect suction tube (14).
12. Sling the hydraulic tank assembly temporarily and remove 6 mount
bolts (15).
13. Lift off hydraulic tank assembly (16).
Hydraulic tank assembly: 200 kg (441 lb)
INSTALLATION
oil level again.
Capacity of hydraulic tank: Approximately 335 L (88.5 gal)

Quantity of oil in tank (Center of oil level gauge): 248 L (65.5 gal)
● Bleeding air
PC400LC-7L 30-87 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
HYDRAULIC PUMP
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
796-460-1210 Oil stopper ● 1

C
796-770-1320 Adapter ● 1
REMOVAL


internal pressure of the hydraulic tank.
★ Put tags to the disconnected hoses and tubes to prevent a mistake in

re-connecting them.
1. Remove 2 lower covers (1).
2. Remove the hydraulic tank strainer. Using tool C, stop the oil.
★ When not using tool C, remove the drain plug to drain the oil from
the hydraulic tank and piping.
Capacity of hydraulic tank:

Approximately 335 L (88.5 gal)
3. Drain the oil from the flywheel housing.
4. Open the main pump side cover.
5. Open the engine hood.
6. Lift off covers (2) and (3) together.
8. Remove stay (5).
30-88 2 PC400LC-7L
12
9. Disconnect the following 2 pump wiring connectors.
● (6): V22 (PC-EPC solenoid valve) Band color: Red
● (7): V21 (LS-EPC solenoid valve) Band color: White
10. Disconnect the following 10 hoses and 1 tube.

● (8): EPC basic pressure port hose (Band color: Yellow)
● (9): Rear pump pressure input port hose (Band color: Red)
● (10): Rear pump discharge port hose
● (11): Front pump discharge port hose
● (12): Drain port hose
● (13): Front load pressure input port hose
● (14): Rear load pressure input port hose (Band color: Red)
● (15): Front pump pressure input port hose
● (16): Pump suction port tube
11. Sling hydraulic pump assembly (18) temporarily and remove 12

mount bolts (17).
12. Lift off hydraulic pump assembly (18). [*1]
Hydraulic pump assembly: 255 kg (563 lb)
PC400LC-7L 30-89 2
12
INSTALLATION
[*1]
Hydraulic pump involute spline: Anti-friction compound (LM-G)
Mating face of hydraulic pump case: Gasket sealant (LG-6)
Flywheel housing drain plug: 42.1 - 70.6 Nm {4.3 - 7.2 kgm} (31 - 52 lbf ft)
Add oil through the oil filler to the specified level.

oil level again.
Capacity of hydraulic tank: Approximately 335 L (88.5 gal)

Quantity of oil in tank (Center of oil level gauge): 248 L (65.5 gal)
● Bleeding air
30-90 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
12
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
REMOVAL
1. Remove the hydraulic pump assembly. Refer to the HYDRAULIC
PUMP section.
2. Remove snap ring (1) and then remove spacer (2).
3. Pry off oil seal (3) with a screwdriver. [*1]

★ When attempting to pry off the seal, do not damage the shaft.
INSTALLATION
[*1]
Oil seal lip portion: Grease (G2-LI)
Oil seal outer circumference: Grease (G2-LI)
★ Coat the oil seal outer circumference thinly with grease.

★ Press-fit oil seal (3), using tool.
PC400LC-7L 30-91 2
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
CONTROL VALVE
REMOVAL

internal pressure of the hydraulic tank and
set the safety lock lever to the LOCK
position.
★ Put tags to the disconnected hoses and tubes to prevent a mistake in re-
connecting them.
1. Open engine hood (1).
2. Remove control valve top cover (2).
3. Remove partition covers (3), (4), and (5) between the engine and
control valve.
4. Remove the control valve bottom cover.
5. Disconnect the 2 wiring connectors and 8 hoses.

● (6): A51 (Front pump pressure sensor)
● (7): A52 (Rear pump pressure sensor)
● (8): Port PS hose (Hose band: Yellow-Blue)
● (9): Port PST hose (Hose band: Brown)
● (10): Port PPS2 hose (Rear pump, red)
● (11): Port PR hose (Solenoid)
● (12): Port PR hose (Pump, yellow)
● (13): Port PP1 hose (Front pump)
● (14): Port PP2 hose (Rear pump)
● (15): Port T hose (Oil cooler)
6. Disconnect the following 4 control valve hoses:

● (16): Port PPS1 hose (Front pump)
● (17): Port PLS2 hose (Hose band: Red)
● (18): Port PLS1 hose
● (19): Port PX1 hose (Hose band: Blue)
7. Remove relay bracket (20) and clamp (21).
8. Disconnect drain hose (22). (To tank)
9. Disconnect the following 6 left PPC hoses.

● (23): In order from top
Bucket CURL (Hose band: White)
Left travel REVERSE
Boom RAISE (Hose band: Green)
Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm DUMP (Hose band: Yellow)
30-92 2 PC400LC-7L
10. Disconnect 4 boom hoses (24).
11. Remove boom tube clamps (25) and (26).
12. Disconnect port TSW hose (27) (Swing motor port S).
13. (28): In order from top

Remove port A-1 tube (Boom Hi bottom side).
Remove port A1 tube (Bucket bottom side).
Disconnect port A2 hose (Swivel joint port A).
After removing the hoses from ports B, remove port A3 tube (Boom
bottom side).
Remove port A4 hose (Swing motor port MB).
Disconnect port A5 hose (Swivel joint port C).
Remove port A6 tube (Arm head side).
14. (29): In order from top

Disconnect port B-1 hose (Arm Hi bottom side).
Disconnect port B1 hose (Bucket head side).
Disconnect port B2 hose (Swivel joint port B).
Remove port B3 tube (Boom head side).
Remove port B4 hose (Swing motor port MA).
Disconnect port B5 hose (Swivel joint port D).
Remove port B6 tube (Arm bottom side).
15. Disconnect the following 6 right PPC hoses.

● (30): Bucket DUMP (Hose band: Black)
● (31): Left travel FORWARD (Hose band: Red)
● (32): Boom LOWER (Hose band: Brown)
● (33): Right SWING
● (34): Right travel FORWARD (Hose band: Green)
● (35): Arm IN (Hose band: Blue)
PC400LC-7L 30-93 2
12
16. Disconnect the following 3 control valve hoses.
★ Do not disconnect hose C.
● (36): Port BP5 hose (To solenoid)
● (37): Port PX2 hose
● (38): Port TS hose
17. Sling control valve assembly (40) temporarily and remove 3 mount
bolts (39).
18. Lift off control valve assembly (40).
Control valve assembly: 250 kg (552 lb)
30-94 2 PC400LC-7L
12
INSTALLATION
oil level again.
● Bleeding air
PC400LC-7L 30-95 2
12
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE
SEAL
Remark
Only precautions for assembling the pressure compensation valve assembly and control valve assembly
are explained below.
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
796-946-1310 Guide ➆21.8

1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide ➆20.9
1 1
(For 723-46-44100)
796-946-2210 Guide ➆20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide 21.6
1
(For 723-46-42800)
2
796-946-2120 Guide
L 1
(For 723-46-44100)
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500)
796-946-1330 Sleeve
1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve
1
(For 723-46-42800)
3
796-946-2130 Sleeve
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
30-96 2 PC400LC-7L
12
★ Since there many types of the pressure compensation valves, make a mark on each valve to indicate from where it was
removed.
1. Remove piston (2), plug (3), and spring (4) from pressure
compensation valve (1).
2. Remove seal (5) and O-ring (6) from piston (2).

★ There many types of the pistons.
★ Clean the pressure compensation valve thoroughly. Then, using
the tool, install seals as shown in the figure.
3. Fit O-ring (6) to piston (2).
4. Set tool L1 to piston (2) and push it in with your hand slowly so that
seal (5) will expand evenly.
★ You may push in the seal to the flat part of the tool first, and then
install the tool to the piston and push in the seal further.
5. Set tool L2 to piston (1) for other seal (3) and push it in with your hand
slowly so that seal (3) will expand evenly.
★ You may push in the seal to the flat part of the tool first, and then
install the tool to the piston and push in the seal further.
6. Install correcting tool L3 to piston (1) for about 1 minute to fit seals
(2) and (3).
★ Check that the seal are not projected or broken.
7. Fit plug (3) and spring (4) to piston (2) and assemble pressure
compensation valve (1).
★ If these parts are difficult to install, do not push them in forcibly,
but install them to correcting tool L3 to fit the seals, and then
install them to the piston.
★ After assembling, push the piston with your hand and check that it
is returned by only the spring force.
PC400LC-7L 30-97 2
12
ASSEMBLY
● Apply engine oil to the sliding surfaces of the parts before installing.
● When installing spools (7) and (10) in the valve chamber, direct drilled
holes (8) and (11) toward cylinder ports (9) and (12).
● Install filters (13) to the bottom of ports PLS1 and PLS2 as shown at
right.
30-98 2 PC400LC-7L
12
● Control valve top and bottom covers
Mating faces of control valve top and bottom covers:

SEALEND 242 or equivalent
★ Use 2 washers (W2) each for only 2 places of the control valve
top cover.
● Tighten the mount bolts of the control valve top and bottom covers in
the following order.
(A → D → C → B)
Mount bolt of control valve top and bottom covers:

156.9 - 176.5 Nm {16 - 18 kgm} (115.7 - 130.1 lbf ft)
● Merge-divider valve
Mating face of merge-divider valve: SEALEND 242 or

equivalent
● Tighten the mount bolts of the merge-divider valve similarly to those of the control valve covers.
Mount bolt of merge-divider valve:

156.9 - 176.5 Nm {16 - 18 kgm} (115.7 - 130.1 lbf ft)
● Tighten the mount bolts of the boom Hi check valve, quick return valve, lock valve, and arm plate similarly to those of the
control valve covers.
Mount bolt of boom Hi check valve, quick return valve,

lock valve, and arm plate:
58.8 - 73.6 Nm {6 - 7.5 kgm} (43.3 - 54.2 lbf ft)
PC400LC-7L 30-99 2
12
Mount bolts of back-pressure valve, boom Hi check

valve, quick return valve, lock valve and arm plate: 58.8
- 73.6 Nm {6 - 7.5 kgm} (43.3 - 54.2 lbf ft)
● Pressure compensation valve

★ When installing each pressure compensation valve, check the
mark made when it was removed.
● Main relief valve assembly
After installing the main relief valve to the control valve, see TEST-
ING AND ADJUSTING, Testing and adjusting oil pressures in work
equipment, swing, and travel circuits.
30-100 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
REMOVAL
WARNING! Replace the remaining pressure in the

hydraulic circuit. For details, see TESTING
AND ADJUSTING, release of remaining
pressure in hydraulic circuit.
★ Mark all the piping with tags to prevent mistakes in the mount
position when installing.
1. Disconnect six hoses (1) through (6) between travel motor and center
swivel joint.
● (1): Center swivel joint (T port) – Left travel motor (T port)
● (2): Center swivel joint (T port) – Right travel motor (T port)
● (3): Center swivel joint (B port) – Left travel motor (PA port)
● (4): Center swivel joint (D port) – Right travel motor (PB port)
● (5): Center swivel joint (A port) – Left travel motor (PB port)
● (6): Center swivel joint (C port) – Right travel motor (PA port)
2. Disconnect nine hoses (7) through (15).

● (7): Center swivel joint (E port) – Left travel motor (P port)
● (8): Center swivel joint (E port) – Right travel motor (P port)
● (9): Center swivel joint (D port) – swing motor (T port)
● (10): Center swivel joint (D port) – Hydraulic tank
● (11): Center swivel joint (E port) – solenoid valve
● (12): Center swivel joint (B port) – Left travel control valve (B2
port)
● (13): Center swivel joint (D port) – Right travel control valve (B5
port)
● (14): Center swivel joint (A port) – Left travel control valve (A2
port)
● (15): Center swivel joint (C port) – Right travel control valve (A5
port)
3. Pull out pin (16) on the side of center swivel joint and remove the jam
plate from the center swivel joint.
4. Remove four mount bolts (17).
5. Remove center swivel joint assembly (18). [*1]
Center swivel joint assembly: 40 kg (89 lb)
PC400LC-7L 30-101 2
12
INSTALLATION
[*1]
Install the center swivel joint facing in the direction shown in the dia-
gram.
(The diagram shows the machine as seen from above)
● Refilling with oil (hydraulic tank)
Add oil through the oil filler to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
● Bleeding air
Bleed the air from the travel motor. For details see TESTING AND
ADUSTING, Air Bleeding of Various Parts.
30-102 2 PC400LC-7L
12
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
790-101-2501 Push puller ● 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
DISASSEMBLY
2. Remove snap ring (2).
3. Using tool M, pull out swivel rotor (4) and ring (3) from swivel shaft
(5).
4. Remove seal (6) from swivel shaft (5).
5. Remove O-ring (7) and slipper seal (8) from swivel rotor (4).
ASSEMBLY
1. Assemble slipper seal (8) and O-ring (7) to swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5).
3. Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install.
Contact surface of rotor, shaft: Grease (G0-LI or G2-LI)
● When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring.
4. Install ring (3) and secure with snap ring (2).
5. Install O-ring and cover (1).
Mount bolt: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
PC400LC-7L 30-103 2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
12
WORK EQUIPMENT PPC VALVE
★ Only precautions for assembling the work equipment PPC valve
assembly are explained below.
ASSEMBLY
● Work equipment PPC valve assembly
★ Install springs (11❈) with the small-diameter (inside diameter)
end on the shim (12) side.
★ Springs (10❈) having different number of turns are used for the
following hydraulic ports. Take care when installing them.
Installed height: 31.9 mm (Common to all springs)
Installed load:
P1, P2: 35.3 N {3.6 kg} (7.9 lbf)
P3, P4: 21.6 N {2.2 kg} (4.85 lbf)
★ The position of each port is stamped on the underside of valve
body.
Piston (8): Grease (G2-LI)
★ When installing pistons (8), apply grease to their outside and the
inside of the valve body holes.
Mount bolt of plate (5):

11.8 - 14.7 Nm {1.2 - 1.5 kgm} (8.7 - 10.8 lbf ft)
Sliding parts of joint (4): 2 - 4 cc of Grease (G2-LI)
Female threads of body (A): Adhesive (LT-2)
★ Apply a drop (about 0.02 g) of LOCTITE to each of the 2 threaded parts of the body as shown in the figure, and then
tighten joint (4).
Joint (4): 39 - 49 Nm {4 - 5 kgm} (28.7 - 36.1 lbf ft)
★ Observe the tightening torque of the joint.
Contact parts of piston and disc (2): Grease 0.3 - 0.8 cc

(G2-LI)
Nut (1): 69 - 88 Nm {7 - 9 kgm} (51.8 - 64.9 lbf ft)
★ When installing disc (2), adjust the play to 0.5 - 3mm at 200 mm
from the turning center of the lever.
30-104 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
12
TRAVEL PPC VALVE
DISASSEMBLY
★ Only precautions for assembling the travel PPC valve assembly are explained below.
ASSEMBLY
● Travel PPC valve assembly
★ Insert shim (3) of the thickness and quantity checked when disassembled.
Standard shim thickness: 0.3 mm
★ Since spring (4) is not symmetric vertically, install it with the small-diameter (inside diameter) end on the shim side.
Periphery of piston (7) and inside of hole of body (1): Grease (G2-LI)
Sliding part of shaft (13) (4 – 8 cc), contact parts of lever (12) and piston (7), and contact part of pin of
lever (26) and plate (24) (0.3 – 0.8 cc): Grease (G2-LI)
★ Use the inserting jig described in KES.D.07177 to insert bushing (19).

★ Use the inserting jig described in KES.D.04025 to insert spring pin (25).
PC400LC-7L 30-105 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Qíty
1 790-502-1003 Cylinder repair stand ■ 1

2
790-102-4310 Pin ■ 2
3 790-720-1000 Expander ● 1
796-720-1680 Ring (For boom and bucket) ● 1
07281-01589 Clamp (For boom and bucket) ● 1
4
796-720-1690 Ring (For arm) ● 1
07281-01919 Clamp (For arm) ● 1
790-201-1702 Push tool kit ■ 1
● 790-201-1851 ● Push tool (For bucket) 1
N ● 790-201-1861 ● Push tool (For boom) 1
5
● 790-201-1871 ● ï Push tool (For arm) 1
● 790-101-5021 ● Grip 1
● 01010-50816 ● Bolt 1
790-201-1500 Push tool kit 1
● 790-101-5021 ● Grip 1
● 01010-50816 ● Bolt 1
6
● 790-201-1660 ● Plate (For bucket) 1
● 790-201-1670 ● Plate (For boom) 1
● 790-201-1680 ● Plate (For arm) 1
DISASSEMBLY
1. Piston rod assembly
A. Remove the piping from the cylinder assembly.
B. Remove the mount bolts and disconnect cylinder head

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

★ Put a container under the cylinder to receive oil.
30-106 2 PC400LC-7L
12
D. Disassemble the piston rod assembly according to the following
procedure.
i. Set piston rod assembly (2) to tool N1.
ii. Remove piston assembly lock screw (3).

★ This work is common to the boom, arm, and bucket cylinders.
Screw size: M12 x Pitch 1.75
★ If screw (3) is so caulked that you cannot remove it, tighten it

temporarily and tap the threads on it, and then remove it.
iii. Using tool N2, remove piston assembly (4).

● When not using tool N2, loosen the piston assembly
by using the drilled holes (Ø10: 2 places) (in which the
pins of N2 are inserted in the figure at right).
PC400LC-7L 30-107 2
12
iv. Remove plunger (5).
● Perform this work for only the boom and arm cylin-
der.
v. Remove collar (6).

der.
vi. Remove head assembly (7).
vii. Remove cap (8), 11 balls (9), and plunger (10).

● Perform this work for only the arm cylinder.
★ Since cap (8) is made of nylon, tighten a screw into it
and pull it with pliers.
2. Disassembly of piston assembly
A. Remove rings (11).
B. Remove wear rings (12).
C. Remove piston ring (13).
D. Remove the O-ring and backup rings (14).
3. Disassembly of cylinder head assembly
A. Remove the O-ring and backup ring (15).
B. Remove snap ring (16) and dust seal (17).
C. Remove rod packing (18).
D. Remove buffer ring (19).
E. Remove snap ring (21).
F. Remove bushing (20).
30-108 2 PC400LC-7L
12
ASSEMBLY
★ Take care not to damage the packings, dust seals, O-rings, etc.
★ Clean the all parts. After installing them, cover the piping ports and
pin holes to prevent dirt from entering.
★ Do not insert each backup ring forcibly, but warm it in water at 50 -
60°C (122 - 140°F) and then insert it.
1. Assembly of cylinder head assembly
A. Using tool N5, press fit bushing (20).
B. Install buffer ring (19).
C. Install rod packing (18).
D. Using tool N6, install dust seal (17) and secure it with snap ring
(16).
E. Install backup ring and O-ring (15).
F. Install snap ring (21).
2. Assembly of piston assembly
A. Using tool N3, expand piston ring (13).

★ Set piston ring (13) to tool N3 and turn the handle 8 - 10
times to expand the piston ring.
B. Set tool N4 and contract piston ring (13).
C. Install backup ring and O-ring (14).
D. Install wear ring (12).
E. Install ring (11).

★ Do not increase the closed gap of the ring too much.
Ring groove: Grease (G2-LI)
PC400LC-7L 30-109 2
12
3. Piston rod assembly
A. Set the piston rod to tool N1.
B. Install cylinder head assembly (7) to the piston rod.
C. Fit the O-ring and backup ring to collar (6), and then install them.
● Perform this work for only the boom and arm cylinders.
D. Install plunger (5).

● Perform this work for only the boom and arm cylinders.
E. Set plunger (10) to the piston rod. Install 11 balls (9) and secure
them with cap (8).
★ After installing the plunger, check that it has a little play at its
end.
F. Assemble piston assembly (4) according to the following

procedure.
● When reusing the rod and piston assembly (4).
i.Tighten piston assembly (4). Then, using tool N2, tighten pis-
ton assembly (4) until the screw holes are aligned.
★ Remove the burrs from the threads with a file.
Go to D.
● When replacing either or both of the rod and piston assembly
(4) with new ones.
★ Make a mark of the cushion plug position on the end of the
rod having the bottom cushion.
ii. Using the tool, tighten piston assembly (4) until it reaches the
end of the rod.
Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm} (216 ± 21.6 lbf ft)
★ After tightening the piston, check that plunger (5) has

some play.
ders.
30-110 2 PC400LC-7L
12
iii. Make a screw hole to install screw (3).
★ Apply a drill to the V-groove of the threaded parts of piston (4) and rod (2) and make a hole.
★ When making a hole on the cylinder (arm cylinder) having the bottom cushion, make it around the cushion
plug.
● • Dimensions of screw hole (mm)
Tap drill diameter Tap to be used
10.3 12 x 1.75
Tap drill hole Tapping

depth depth
Bucket/Boom 27 20
Arm 36 29
iv. Tighten screw (3).

★ Clean the parts thoroughly and remove metal chips, dirt, etc.
Threads of screw: Adhesive (LOCTITE No. 262)
Screw: 58.9 - 73.6 Nm {6 - 7.5 kgm} (43.4 - 54.2 lbf ft)
v. Caulk the threaded part by 4 places with a punch.
G. Install piston rod assembly (2).

★ Set the abutment joint of the ring at a side and insert the
piston rod, aligning it with the cylinder tube.
★ After inserting the piston rod, check that the ring is not
broken or removed, and then insert to the end.
PC400LC-7L 30-111 2
12
H. Tighten the mount bolts of cylinder head assembly (7).
Mount bolt:
Bucket: 530 ± 78.5 Nm {54.0 ± 8 kgm} (390 ± 57.8 lbf ft)
Arm: 892 ± 137 Nm {91.0 ± 14 kgm}(657 ± 101 lbf ft)
Boom: 530 ± 78.5 Nm {54.0 ± 8 kgm} (390 ± 57.8 lbf ft)
I. Install the piping.
30-112 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
WORK EQUIPMENT
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
796-670-1100 Remover ● 1
● 796-670-1110 ● Sleeve 1
● 796-670-1120 ● Plate 1
● 796-670-1130 ● Screw 1
P ● 796-870-1110 ● Adapter 1
● 01643-33080 ● Washer 1
● 01803-13034 ● Nut 1
790-101-4000 Puller (490 kN {50t}, long) ● 1
790-101-1102 Pump (294 kN {30t}) l 1
REMOVAL
WARNING! Extend the arm and bucket fully, lower the

work equipment to the ground, and set
the safety lock lever to the LOCK position.
WARNING! See TESTING AND ADJUSTING,

Releasing residual pressure in hydraulic
circuit.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2) temporarily and remove lock bolt and nut (3). [*1]
3. Remove plate (4) and head pin (5). [*2]

★ Check the quantity and positions of the inserted shims.
4. Start the engine and retract the piston rod.

★ Bind the rod with wires, etc. so that it will not be extracted and lower it onto a stand or put a wood block to the bottom
side so that the cylinder will not lower. When putting the wood block, remove the grease fitting on the bottom side.
★ Disconnect the boom cylinder on the opposite side similarly.
★ When slinging the boom cylinder, if the sling interferes with the work equipment lamp, remove the work equipment
lamp.
PC400LC-7L 30-113 2
5. Disconnect intermediate connector A42 (6) for the work equipment
lamp.
6. Disconnect 3 arm cylinder hoses (7) and 2 bucket cylinder hoses (8).
★ Put oil stopper plugs and secure the hoses to the valve side with
ropes.
7. Sling work equipment assembly (12) temporarily.
8. Remove cover (9), plate (10), and foot pin (11) to disconnect work
equipment assembly (12). [*3]
● When removing with tool P

Remove plate (10). Sling and set tool P and remove foot pin (11)
to disconnect work equipment assembly (12).
★ Check the quantity and positions of the inserted shims.
9. Move the machine in reverse to remove work equipment assembly

(12).
Work equipment assembly: 7,400 kg (16,315 lb)
30-114 2 PC400LC-7L
12
INSTALLATION
[*1]
★ Tighten the locknut so that clearance “a” between the plate and
nut will be 0.5 - 1.5 mm.
[*2]
Inside wall of bushing before assembling pin:

Anti-friction composition (LM-P)
Greasing after assembling pin: Grease (LM-G)
WARNING! When aligning the pin holes, never insert

your fingers in them.
★ Adjust the shim thickness so that clearance “b” between cylinder

rod (12) and plate (4) will be 1.5 mm or less.
Standard shim: 1.0, 2.0 mm
[*3]
Inside wall of bushing before assembling pin:

Anti-friction composition (LM-P)
Greasing after assembling pin: Grease (LM-G)
WARNING! When aligning the pin holes, never insert

your fingers in them.
★ Adjust the shim thickness so that clearance “c” between boom

(13) and bracket (14) will be 1 mm or less.
Standard shim: 2.0, 2.5, 3.0, 3.5 mm
● Bleeding air
oil level again.
PC400LC-7L 30-115 2
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS
12
OPERATOR’S CAB GLASS
1. Right side window glass 4. Front window glass 7. Center trim seal
5. Front window assembly (Front window

2. Left side rear window glass
glass + Front frame)
3. Door lower window glass 6. Both-sided adhesive tape
★ Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) – (4) are stuck. In this section, the
procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window
assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the
operator's cab.)
For the procedure for replacing the front window assembly, see FRONT WINDOW.
30-116 2 PC400LC-7L
12
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 793-498-1210 Lifter (Suction cup) ■ 2

Y
2 20Y-54-13180 Adapter ■ 2
Part No. Part name Remarks

Yokohama M-300 Metal primer
Yokohama G-200 Glass primer
20Y-54-39850 Sikaflex 256HV Adhesive
20Y-54-51531 Two-sided tape (DAM)
REMOVAL
★ Remove the window glass to be replaced according to the following
procedure.
1. Using seal cutter [1], cut the adhesive between broken window glass
(7) and operator's cab (metal sheet) (8).
★ If a seal cutter is not available, make holes on the adhesive and

both-sided adhesive tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes.
Grip the both ends of the wire with priors [3], etc. (or hold them
by winding them onto something) and move the wire to the right
and left to cut the adhesive and both-sided adhesive tape.
Since the wire may be broken by the frictional heat, apply
lubricant to it.
(The figure to the right shows the operator's cab of a wheel
loader.)
★ If the window glass is broken finely, it may be removed with knife
[4] and a screwdriver.
★ Widening the cut with a screwdriver, cut the adhesive and both-
sided adhesive tape with knife [4].
loader.)
2. Remove the window glass.
PC400LC-7L 30-117 2
12
INSTALLATION
1. Using a knife and scraper [5], remove the remaining adhesive and
both-sided adhesive tape from the metal sheets (glass sticking
surfaces) of the operator's cab.
★ Remove the adhesive and both-sided adhesive tape to a degree
that they will not affect adhesion of the new adhesive. Take care
not to scratch the painted surfaces. (If the painted surfaces are
scratched, adhesion will be lowered.)
loader.)
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and
window glass (9) with white gasoline.
★ If the sticking surfaces are not cleaned well, the glass may not be
stuck perfectly.
★ Clean the all black part on the back side of the window glass.
★ After cleaning the sticking surfaces, leave them for at least 5
minutes to dry.
loader.)
3. Apply primer (10).

★ The using limit of primer (10) is 4 months after the date of
manufacture. Do not use primer (10) after this limit.
★ Use the primer within 2 hours after unpacking it.
★ Even if the primer is packed again just after it is unpacked, use it
within 24 hours after it is unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
A. Stir the primers for paint and glass sufficiently before using them.
★ If the primer has been stored in a refrigerator, leave it at the
room temperature for at least half a day before stirring it. (If
the primer is unpacked just after taken out of the refrigerator,
water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.)
B. When reusing primer brush (11), wash it in white gasoline.

★ After washing the brush, check it again for dirt and foreign matter.
★ Prepare respective brushes for the paint primer glass primer.
30-118 2 PC400LC-7L
12
C. Evenly apply paint primer to the surfaces to stick both-sided
adhesive tapes and the surfaces out of those surfaces on operator's
cab (8) which will be coated with the adhesive.
Paint primer: Yokohama M-300 or equivalent
★ Do not apply the primer more than 2 times. (If it is applied

more than 2 times, its performance will be lowered.)
★ Parts to be coated with primer: Apply the primer all over

dimension (a).
● Dimension to apply primer (a): 25 mm
★ In addition to the above parts, apply the primer to right side

window glass (1) and door lower window glass (3).
● Range to apply primer additionally for right side window
glass (1): (b)
● Range to apply primer additionally for door lower window
glass (3): (c)
★ After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.
Remark
Never apply wrong primer. If the glass primer is applied by
mistake, wipe it off with white gasoline.
PC400LC-7L 30-119 2
12
D. Evenly apply glass primer to the sticking surfaces of window
glass (9).
Glass primer: Yokohama G-200 or equivalent
★ Do not apply the primer more than 2 times. (If it is applied

more than 2 times, its performance will be lowered.)
★ Parts to be coated with primer:

Apply the primer to the sticking surfaces of window glass (9)
and all over dimension (d) which will be on both-sided
adhesive tape (6) and operator's cab (8).
★ Do not apply the primer to the boarder about 5 mm wide
between the black part and transparent part of the glass.
★ After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.
Remark
Never apply wrong primer. If the glass primer is applied by
mistake, wipe it off with white gasoline.
4. Stick both-sided adhesive tape (P/N 20Y-54-51531) (6) along the

inside edge of the glass sticking section.
★ Do not remove the release tape of the both-sided adhesive tape on
the glass sticking side before sticking the glass.
★ When sticking the both-sided adhesive tape, do not touch the
cleaned surface as long as possible.
★ Take that the both-sided adhesive tape will not float at each corner
of the window frame.
★ When sticking both-sided adhesive tape (6) around a frame, do
not lap its finishing end over the starting end but make clearance e
of about 5 mm between them.
A. Stick both-sided adhesive tape (6) for right side window glass (1).
30-120 2 PC400LC-7L
12 ★ Stick both-sided adhesive tape (6a) additionally for right side
window glass (1).
● Positions to stick additional both-sided adhesive tape for right
side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
B. Stick both-sided adhesive tape (6) for left side rear window glass
(2) as shown in the figure.
C. Stick both-sided adhesive tape (6) for door lower window glass
(3) as shown in the figure.
★ Stick both-sided adhesive tape (6b) additionally for door

lower window glass (3).
★ Positions to stick additional both-sided adhesive tape for door
lower window glass:
(j): 110 mm
(k): 90 mm
(m): 200 mm
PC400LC-7L 30-121 2
12
D. Stick both-sided adhesive tape (6) for front window glass (4) as
shown in the figure.
★ Stick both-sided adhesive tape (6c) of the lower side of the

front window glass along the outside edge of the lower line,
differently from other both-sided adhesive tapes (6). (If it is
stuck along the inside, it will be seen through the transparent
part of the glass.)
5. Position the new window glass.
A. Check the clearance between the window glass and the operator's
cab on the right, left, upper, and lower sides, and then adjust it
evenly.
B. Stick tapes [6] between window glass (9) and operator's cab (8)
and draw positioning line n.
★ Stick tapes [6] to the right, left, and lower parts of the right
side window glass, left side rear window glass, and door
lower window glass for accurate positioning.
C. Cut the tape between window glass (9) and operator's cab (8) with
a knife, and then remove the window glass.
★ Do not remove the tapes left on the window glass and
operator's cab before installing the window glass.
30-122 2 PC400LC-7L
12 ★ 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.
★ Use Sikaflex 256HV adhesive
★ The using limit of the adhesive is 4 months after the date of
manufacture. Do not use the adhesive after this limit.
★ Keep the adhesive in a dark place where the temperature is below 25°C (77°F).
★ Never heat the adhesive higher than 30°C (86°F).
★ When reusing the adhesive, remove the all hardened part from the nozzle tip.
A. Break aluminum seal of the outlet of adhesive cartridge and install the nozzle.
B. Cut the tip of the adhesive nozzle (14) so that dimensions (q) and
(r) will be as follows.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
C. Set adhesive cartridge (12) to caulking gun [7].

★ An electric caulking gun is more efficient.
PC400LC-7L 30-123 2
12
D. Remove the release tape of the both-sided adhesive tape on the
glass side.
E. Apply adhesive (15) to the outside of both-sided adhesive tape (6)

of the operator's cab.
★ Apply adhesive (15) to dimensions (s) and (t) of both-sided

adhesive tape (6) of operator's cab (8).
• Dimension (s): 10 mm
• Dimension (t): 15 mm
★ Apply adhesive (15) higher than both-sided adhesive tape (6).
★ Apply the adhesive evenly.
★ Apply adhesive (15) additionally for additional both-sided

adhesive tape (6a) of the right side window glass and
additional both-sided adhesive tape (6b) of door lower
window glass.
30-124 2 PC400LC-7L
12
7. Install the window glass.
A. Install window glass (9), matching it to the lines of the positioning

tapes drawn in step 5.
★ Since the window glass cannot be removed and stuck again,
stick it very carefully.
★ Stick the glass within 5 minutes after applying the adhesive.
B. After sticking window glass (9), press all around it until it is stuck
to the both-sided adhesive tape.
★ Press the corners of the window glass firmly.
★ You can perform this work efficiently by pulling window

glass (9) from inside of the operator's cab with suction cup
Y1.
★ After installing front window glass (4), fill the clearances

between it and center trim seal (16) with caulking material in
range (s) to dimensions (t) and (u). After applying the primer
to glass (4) of section A – A, apply adhesive as caulking
material.
• Caulking dimension (t): 2 mm
• Caulking dimension (u): 5 mm
★ When caulking, mask the glass side and form the adhesive
with a rubber spatula as shown in the figure.
★ Wipe off projected adhesive.
Glass primer: Yokohama G-200
Adhesive: Sikaflex 256HV
PC400LC-7L 30-125 2
12
8. Fix the window glass.
A. After installing right window glass (1) to the operator's cab, insert
stopper rubbers Y2 to 2 places (v) at the bottom of the glass to fix
the glass.
B. Using styrene foam blocks [9] and rubber bands [10], fix the
window glass and both-sided adhesive tape to fit them completely.
9. After installing the window glass, remove the primer and adhesive
from the operator's cab and window glass.
★ Using white gasoline, wipe off the adhesive before it is dried up.
★ When cleaning the glass, do not give an impact to it.
10. Protect the stuck window glass.
A. Keep the stopper rubbers, styrene foam blocks, and rubber bands
installed for 10 hours (at temperature of 20°C (68°F) and
humidity of 60%).
B. After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in
total, before operating the machine actually.
30-126 2 PC400LC-7L
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
FRONT WINDOW

and stop the engine.
★ To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure
for removing and installing the front window assembly (front frame and front window glass) is explained below.
REMOVAL
1. Raise the front window assembly to the ceiling and fix it with the rear
locks (on both sides).
2. Remove left corner blocks (1) and (2) and right corner block (3). [*1]
3. Remove left striker bolt (4), right striker bolt (5), left corner block
bracket, and right corner block bracket (7). [*2]
4. Install left striker bolt (4) to the operator's cab again and tighten it
lightly.
★ This bolt will be used to hang the pull-up assist cable in step 8.
5. Release the rear locks.
6. Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the both sides of the front window
through the portion from which the corner blocks were removed in step 3 (the portion where the rail is open) and hold
them.
7. Remove rollers (8) and (9) under the both sides of the front window.
PC400LC-7L 30-127 2
12
8. Remove left lower pin (10). [*3]
★ If left lower pin (10) is removed, plate (12) at the end of pull-up
assist cable (11) comes off.
★ Hang plate (12) on the left striker bolt.
WARNING! The return load of 58.8 N {6 kg} (13.2 lbf)

is applied to the rear of the operator's cab.
Accordingly, take care when removing left
lower pin (10) to disconnect pull-up assist
cable (11).
9. Put out the bottom of front window assembly (13) through the rail
opening portion and lower it gradually.
10. Lower front window assembly (13) completely.

★ Do not let the front window assembly touch the monitor.
30-128 2 PC400LC-7L
12
11. Twist front window assembly (13) to the right and left to remove both
upper rollers (14) and (15) from the rails, and then remove front
window assembly (13).
PC400LC-7L 30-129 2
12
INSTALLATION
[*1] [*2]
● Adjust opening and closing of the front window assembly according to
the following procedure.
1. Open and close the front window to check that it does not interfere
with the rails and the rollers are not hitch.
2. If there is any problem in opening or closing of the front window,

loosen the mount bolts of roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and then tighten the mount
bolts again.
Mount bolt: 98 Nm {1.0 kgm} (72.2 lbf ft)
30-130 2 PC400LC-7L
12
3. Raise the front window assembly and fix it with the rear locks (on both
sides).
★ Check that the locks in the rear of the operator's cab are applied
securely.
4. Install right corner block (3) and fix right corner block bracket (7) with
right striker bolt (5).
★ Tighten the striker bolt securely after adjusting it in step 6.
★ Install the right corner block so that there will be no level
difference at part (a).
★ Install the right corner block so that level difference (b) between
the rail and right corner block (3) at part PF will be 0 - 1.0 mm.
Check that the right corner block is not projected from the rail at
the rolling surface of the roller.
★ Secure roller clearance (c) at part PJ.
PC400LC-7L 30-131 2
12
5. Install left corner blocks (1) and (2) and secure left corner bracket (6)
with left striker bolt (4).
★ Tighten the striker bolt securely after adjusting it in step 6.
★ Install the left corner blocks so that there will be no level
difference at 2 part (d).
★ Secure roller clearance (e).
6. Tighten left striker bolt (4) and right striker bolt (5) at roughly right
positions so that front window glass (18) will be fitted to cab-side trim
seal (19).
30-132 2 PC400LC-7L
12
7. Open and close the front window assembly and check the working
condition of both locks (20) and (21).
A. If both locks do not work normally, move the striker bolts toward
the rear of the cab and tighten them again.
B. After moving the striker bolts, check the fitness of the front
window glass and cab-side trim seal which was checked in step 6.
C. Repeat the work in 1) and 2) until the fitness of the front window
and the working condition of both locks (20) and (21) are
acceptable, and then tighten the striker bolts.
8. After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak
into the cab.
9. Adjust the “opening” lock of the front window assembly.
A. After adjusting the “closing” lock of the front window in steps 6

and 7, raise the front window assembly to the ceiling.
B. Check the working condition of both front window assembly

“opening” locks in the rear of the operator's cab.
C. If the locks do not work normally, move both striker plates (22) in
the rear of the operator's cab forward and in reverse and fix them
at places where the locks work normally.
PC400LC-7L 30-133 2
12
10. Adjust the front window stoppers.
A. After adjusting “closing” lock of the front window assembly in

step 9, check the contact of both front window stoppers (23).
B. If both stoppers (23) do not contact normally, adjust and fix them
at places where they contact normally.
11. Check the latching effort of the front window assembly.
A. After finishing steps 6 - 10, check that latching efforts of both

locks (20) and (21) are even.
★ Check the latching efforts on both “closing” side (in the front
of the operator's cab) and “opening” side (in the rear of the
operator's cab).
[*3]
Left lower pin:

27 - 34 Nm {2.75 - 3.47 kgm} (20 - 25 lbf ft)
Mount bolt: Adhesive (LT-2)
30-134 2 PC400LC-7L
90 OTHERS
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
HYDRAULIC DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17 . . . . . . . . . . . . 90-35
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18 . . . . . . . . . . . . 90-37
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19 . . . . . . . . . . . . 90-39
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20 . . . . . . . . . . . . 90-41
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21 . . . . . . . . . . 90-43
PC400LC-7L 90-1
OTHERS
12
MEMORANDUM
90-2 PC400LC-7L
OTHERS HYDRAULIC
12
HYDRAULIC
HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1
PC400LC-7L 90-3
OTHERS HYDRAULIC
MEMORANDUM
90-4 PC400LC-7L
OTHERS HYDRAULIC
12
PC400LC-7L 90-5
OTHERS HYDRAULIC
MEMORANDUM
90-6 PC400LC-7L
OTHERS HYDRAULIC
12
PC400LC-7L 90-7
OTHERS HYDRAULIC
MEMORANDUM
90-8 PC400LC-7L
OTHERS HYDRAULIC
12
PC400LC-7L 90-9
OTHERS HYDRAULIC
MEMORANDUM
90-10 PC400LC-7L
OTHERS HYDRAULIC
12
PC400LC-7L 90-11
OTHERS HYDRAULIC
MEMORANDUM
90-12 PC400LC-7L
OTHERS HYDRAULIC
12
PC400LC-7L 90-13
OTHERS HYDRAULIC
MEMORANDUM
90-14 PC400LC-7L
OTHERS HYDRAULIC
12
PC400LC-7L 90-15
OTHERS HYDRAULIC
MEMORANDUM
90-16 PC400LC-7L
OTHERS HYDRAULIC
12
PC400LC-7L 90-17
OTHERS HYDRAULIC
MEMORANDUM
90-18 PC400LC-7L
OTHERS ELECTRICAL
12
ELECTRICAL
ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9
PC400LC-7L 90-19
OTHERS ELECTRICAL
MEMORANDUM
90-20 PC400LC-7L
OTHERS ELECTRICAL
PC400LC-7L 90-21
OTHERS ELECTRICAL
MEMORANDUM
90-22 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-23
OTHERS ELECTRICAL
MEMORANDUM
90-24 PC400LC-7L
OTHERS ELECTRICAL
PC400LC-7L 90-25
OTHERS ELECTRICAL
MEMORANDUM
90-26 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-27
OTHERS ELECTRICAL
MEMORANDUM
90-28 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-29
OTHERS ELECTRICAL
MEMORANDUM
90-30 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-31
OTHERS ELECTRICAL
MEMORANDUM
90-32 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-33
OTHERS ELECTRICAL
MEMORANDUM
90-34 PC400LC-7L
OTHERS ELECTRICAL
12
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17
PC400LC-7L 90-35
OTHERS ELECTRICAL
MEMORANDUM
90-36 PC400LC-7L
OTHERS ELECTRICAL
12
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18
PC400LC-7L 90-37
OTHERS ELECTRICAL
MEMORANDUM
90-38 PC400LC-7L
OTHERS ELECTRICAL
12
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19
PC400LC-7L 90-39
OTHERS ELECTRICAL
MEMORANDUM
90-40 PC400LC-7L
OTHERS ELECTRICAL
12
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20
PC400LC-7L 90-41
OTHERS ELECTRICAL
MEMORANDUM
90-42 PC400LC-7L
OTHERS ELECTRICAL
12
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21
PC400LC-7L 90-43
OTHERS ELECTRICAL
MEMORANDUM
90-44 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-45
OTHERS ELECTRICAL
MEMORANDUM
90-46 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-47
OTHERS ELECTRICAL
MEMORANDUM
90-48 PC400LC-7L
OTHERS ELECTRICAL
12
PC400LC-7L 90-49
OTHERS ELECTRICAL
MEMORANDUM
90-50 PC400LC-7L

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CEBM012502

SERIAL NUMBERS PC400LC-7L A86001 and UP

May 2004 Copyright 2004 Komatsu

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

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

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

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

OPERATION AND MAINTENANCE MANUAL:

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE03-2

PC400LC-7L R02 pubinfok.fm 5/19/04

COMPLETE FORM DataKom Publications and Training Division

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91E 071403 CURRENT PRICES WILL BE CHARGED

● Page to be replaced Replace

( ) Page to be deleted Discard

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