PC400-7 Testing 2712

Technical Presentation Kit
Hydraulic Excavators
PC400-7/PC450-7
TESTING AND ADJUSTING
PC400/450-
PC400/450-7
Hydraulic Excavators
MN20031115
QUIT
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MEASURING ENGINE SPEED (1/3) Hydraulic Excavators
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1. Turn the starting switch ON and set the monitor panel to "Monitoring".
For the operating method, see "Special functions of monitor panel".
z 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.
KN20031115 PREV NEXT FIRST LAST MENU EXIT

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3. Measure the engine speed under each measurement condition.

1) Measuring low idling speed:
i) Start the engine and set the fuel control dial in the low idling position (MIN).
ii) Set the work equipment control, swing control, and travel levers in neutral and
measure the engine speed.
2) Measuring high idling speed:
i) Start the engine and set the fuel control dial in the high idling position (MAX).
ii) Set the working mode switch in the A-mode position.
iii) Turn the auto-decelerator switch OFF.
iv) Set the work equipment control, swing control, and travel levers in neutral.
3) Measuring 2-pump relief speed:
iii) Relieve the arm circuit by moving the arm in.

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4) 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.
5) Measuring auto-deceleration speed
1) Start the engine and set the fuel control dial in the high idling position (MAX).
2) Turn the auto-deceleration switch ON.
3) Set the work equipment control and swing control levers in neutral.
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.

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MEASURING INTAKE AIR PRESSURE Hydraulic Excavators
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(BOOST PRESSURE) (1/2)

Measuring instruments for intake air pressure (boost pressure)
When installing and removing the measuring instruments, take care not to touch a hot part
of the engine.
1. Open the engine hood and remove intake air pressure pick-
up plug (1).
2. Install nipple [1] of boost gauge kit A and connect gauge [2].

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MEASURING INTAKE AIR PRESSURE Hydraulic Excavators
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(BOOST PRESSURE) (2/2)

3. Run the engine at a medium or higher speed and drain the oil from the hose.
Insert the connecting parts of the gauge and hose about a half and open the self-seal on
the hose side repeatedly, and the oil will be drained.
If Pm kit A is available, you may drain the oil by using the air bleeding coupling (790-
261- 1130) in the kit.
If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil.
5. Set the working mode switch in the A-mode position.
6. While running the engine at high idling, relieve the boom

circuit by raising the boom and measure the intake air
pressure (boost pressure).
7. After finishing measurement, remove the measuring

instruments and return the removed parts.

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MEASURING EXHAUST TEMPERATURE Hydraulic Excavators
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(1/2)
Measuring instrument of exhaust gas temperature
¾ Install and remove the measuring instrument after the exhaust manifold is cooled.
1. Open the engine hood and remove exhaust temperature

pick-up plug (1).
2. Install sensor [1] of digital thermometer B and connect them

to meter [2].
Clamp the wiring harness of the digital thermometer so
that it will not touch a hot part.

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MEASURING EXHAUST TEMPERATURE Hydraulic Excavators
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(2/2)
4. Procedure for measuring maximum exhaust temperature for troubleshooting

Operate the machine actually and measure the maximum exhaust temperature.
Set the digital thermometer in the PEAK mode.
5. Procedure for measuring exhaust temperature periodically for

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


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MEASURING COMPRESSION PRESSURE Hydraulic Excavators
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(1/4)
Measuring instruments for compression pressure
¾ When measuring the compression pressure, take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating part.
1. Run the engine and warm up the engine oil temperature to 40 – 60°C.
2. Open the engine hood and remove cover (1) of the cylinder
head to be measured.
Remove all the intermediate clamps of the fuel high-
pressure tube and disconnect the sleeve nuts on the
common rail side and injector side, and you can remove
the cylinder head cover.
Use ring wrenches (on the market) for highpressure pipes
to disconnect and connect the fuel high-pressure tubes.
Remove the air intake connector, too, from the top of the
No. 1 cylinder head cover.
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(2/4)
3. Using puller E3, remove injector (2).
Loosen the nuts of the wiring harness alternately.
After removing the injector, tighten the sleeve nut
temporarily so that the fuel high-pressure tube will not
interfere with the rocker arm.
4. Install adapter E2 and connect it to compression gauge E1.

Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5. Adjust the valve clearance. For details, see ADJUSTING

VALVE CLEARANCE.

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(3/4)
6. Remove the engine undercover and disconnect engine intermediate connectors ER02 and
ER03.
¾ If the connectors are not disconnected, the engine starts during measurement, and that
is dangerous. Accordingly, be sure to disconnect the connectors.
¾ Cover the connectors on the controller side (chassis side) with a vinyl sheet, etc. to
prevent electric leakage and grounding fault.
7. Turn the starting switch ON and prepare the monitor panel for measuring the engine speed.
See MEASURING ENGINE SPEED.
8. Crank the engine with the starting motor and measure the compression pressure.
Measure the pressure when the pointer of the gauge is stabilized.
While measuring the compression pressure, measure the engine speed, too, and check
that it is in the measurement condition range.

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(4/4)
9. After finishing measurement, remove the measuring instruments and return the removed
parts.
Injector holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
After tightening the sleeve nuts permanently, tighten the clamp bolts of the fuel high-
pressure tubes permanently.
Fuel high-pressure tube sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
Fuel high-pressure tube clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
Air intake connector clamp:
9.8 ± 0.5 Nm {100 ± 5 kgcm}

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HANDLING OF FUEL SYSTEM DEVICES Hydraulic Excavators
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Precautions for testing and adjusting fuel system

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

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RELEASING RESIDUAL PRESSURE Hydraulic Excavators
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FROM FUEL SYSTEM

Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel
system while the engine is running.
Low-pressure circuit : Feed pump – Fuel filter – Fuel supply pump
High-pressure circuit : Fuel supply pump – Common rail – Fuel injector
The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is stopped.
Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel
circuit must be released completely. Accordingly, observe the following.
¾ Before testing the fuel system or removing its parts, wait at least 30 seconds after
stopping the engine until the residual pressure in the fuel circuit is released. (Do not
start the work just after stopping the engine since there is residual pressure.)

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MEASURING FUEL PRESSURE (1/2) Hydraulic Excavators
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Measuring instruments for fuel pressure
Measure only the fuel pressure in the low-pressure circuit from the feed pump to the fuel
filter and fuel supply pump.
¾ Since the pressure in the high-pressure circuit from the fuel supply pump to the common
rail and fuel injector is very high, it cannot be measured.
1. Open the engine hood and remove fuel pressure pick-up

plug (1).

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MEASURING FUEL PRESSURE (2/2) Hydraulic Excavators
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2. Install nipple [1] of hydraulic tester H1 and connect them to

hydraulic tester H2.
3. Run the engine at high idling and measure the fuel pressure.
If the fuel pressure is in the following range, it is normal.
0.15 – 0.3 MPa {1.5 – 3 kg/cm2}


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BLEEDING AIR FROM FUEL CIRCUIT Hydraulic Excavators
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(1/3)
If fuel is used up or if a fuel circuit device is removed and installed, bleed air from the fuel
circuit according to the following procedure.
Open the engine hood.

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(2/3)
1. Remove fuel filter (1) and fill it with fuel and install it again.
Fill the fuel filter with clean fuel and take care that dirt will
not enter it.
Add fuel through inlet ports (1a) (8 places) of the filter.
Since hole (1b) is the outlet port (clean side), do not add
fuel through it.
If clean fuel is not available, do not remove the filter but fill
it with the fuel from the fuel tank by operating the priming
pump.
2. Remove plug (2a) of the fuel filter and operate priming pump
(3).
Operate the priming pump until the fuel flows out of the
plug hole and install the plug.
Plug: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}

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(3/3)
3. Remove air bleed plug (2b) of the fuel filter and operate priming pump (3).
Operate the priming pump until the fuel flows out of the plug hole and install the plug.
Air bleed plug:7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Loosen air bleeder (4) of the fuel supply pump and operate priming pump (3) 90 – 100
times.
Operate the priming pump until the fuel flows out of the air bleeder and tighten the air
bleeder. Then, operate the priming pump several times more until it becomes heavy.
Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5. Start the engine with the starting motor.

The air in the high-pressure circuit is bled automatically if the engine is cranked.
If the engine does not start, there may be still air in the low-pressure circuit. In this case,
repeat the above procedure from step 2.

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INSPECTION OF FUEL CIRCUIT FOR Hydraulic Excavators
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LEAKAGE (1/2)
¾ Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks
while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing its parts, inspect it for fuel leakage according to
the following procedure.
Clean and degrease the engine and the parts around it in advance so that you can inspect
it easily for fuel leakage.
1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leakage.

Inspect around the high-pressure circuit parts coated with the color checker for fuel
leakage.
If any fuel leakage is detected, repair it and inspect again from step 2.
4. Run the engine at low idling.

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INSPECTION OF FUEL CIRCUIT FOR Hydraulic Excavators
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LEAKAGE (2/2)
leakage.
6. Run the engine at high idling.

leakage.
8. Run the engine at high idling and load it.

Relieve the oil by moving the arm in.

leakage.
If any fuel leakage is not detected, inspection is completed.
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TESTING AND ADJUSTING OIL Hydraulic Excavators
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PRESSURE IN WORK EQUIPMENT,

SWING, AND TRAVEL CIRCUITS (1/12)
Testing and adjusting instruments for oil pressure in work equipment, swing, and travel
circuits
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").
z Monitoring code: 01100 F Pump Pressure 01101 R Pump Pressure
z The pump oil pressure is displayed in 1 MPa {1 kg/cm2, 1 PSI}.

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Measuring
1. Preparation work
¾ 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) Open the pump room cover and remove oil pressure pick-
up plugs (1) and (2).
z (1): Front pump discharge pressure pickup plug
z (2): Rear pump discharge pressure pickup plug
2) Install nipple K2 and connect it to oil pressure gauge [1] of

hydraulic tester K1.
Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.

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3) Run the engine and raise the hydraulic oil temperature to

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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 attachment is installed to the service valve).
3. Measuring unload pressure

1) Start the engine.
2) Run the engine at high idling and set all the control levers
in neutral and measure the oil pressure.
The pressure measured when the unload valve is
unloaded is indicated.

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4. Measuring work equipment circuit relief pressure
1) Start the engine and move the cylinder to be measured to the stroke end.
2) Run the engine at high idling and relieve the cylinder and measure the oil pressure.
The pressure measured when the main relief valve is relieved is indicated.
If the one-touch power maximizing switch is released, the valve is relieved at low
pressure. If the former is pressed, the lower is relieved at high pressure.
If the swing lock switch is turned ON, the 2-stage relief valve is kept turned ON and the
valve is relieved at high pressure. Accordingly, keep the swing lock switch turned OFF.
5. Measuring swing circuit relief pressure

1) Start the engine and turn the swing lock switch ON.
2) Run the engine at high idling and relieve the swing circuit and measure the oil pressure.
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.

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6. Measuring travel circuit relief pressure
1) Start the engine and lock the travel mechanism.
¾ Set pin [2] between the sprocket and track frame to lock the travel mechanism
securely.
2) 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.

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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.
z (3): Front main relief valve
z (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.
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1) Disconnect pilot hose (5).
2) Fixing holder (6), loosen locknut (7).
3) Turn holder (6) to adjust the pressure.
If the holder is
z turned to the right, the pressure rises.
z turned to the left, the pressure lowers.
Quantity of adjustment per turn of holder:
Approx. 20.5 MPa {Approx. 209 kg/cm2}
4) Fixing holder (6), tighten locknut (7).
Locknut: 49.0 – 58.8 Nm {5 – 6 kgm}
5) Connect pilot hose (5).
6) After finishing adjustment, check again that the pressure
is normal according to the procedure for measurement
described above.

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2. Adjustment of boom LOWER relief pressure (High-pressure
setting side)
If the high relief pressure of the boom LOWER circuit is
abnormal, adjust the high pressure setting side of boom
LOWER safetysuction 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.
If the holder is
Locknut: 93 – 123 Nm {9.5 – 12.5 kgm}
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6) 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.

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If the holder is
Locknut: 78 – 93 Nm {8.0 – 9.5 kgm}
6) After finishing adjustment, check again that the pressure is normal according to the
procedure for measurement described above.

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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.
1) Fixing adjustment screw (15), loosen locknut (16).
2) Turn adjustment screw (15) to adjust the pressure.
If the adjustment screw is
Quantity of adjustment per turn of adjustment screw:
4.70 MPa {47.9 kg/cm2}
3) Fixing adjustment screw (15), tighten locknut (16).
Locknut: 147 – 196 Nm {15 – 20 kgm}
4) After finishing adjustment, check again that the pressure
is normal according to the procedure for measurement
described above.

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MEASURING BASIC PRESSURE IN Hydraulic Excavators
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CONTROL CIRCUIT (1/2)

Measuring instruments for basic pressure in control circuit
¾ 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.

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MEASURING BASIC PRESSURE IN Hydraulic Excavators
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CONTROL CIRCUIT (2/2)

2. Install nipple L2 and connect it to oil pressure gauge [1] of
hydraulic tester L1.
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.

The relief valve for the control circuit basic pressure is not
adjustable.

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PRESSURE IN PUMP PC CONTROL

CIRCUIT (1/10)
Testing and adjusting instruments for oil pressure in pump PC control circuit
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.

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CIRCUIT (2/10)
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.
1) Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (3), and (4).
z (3): Front PC valve output pressure pickup plug
z (4): Rear PC valve output pressure pickup plug

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CIRCUIT (3/10)
2) Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1.
z The figure shows the pump discharge pressure side.
z The figure shows the PC valve output pressure side.

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CIRCUIT (4/10)
4) Run the engine at high idling and measure the pump
discharge pressure and PC valve output pressure (servo
piston inlet pressure) at the same time under the following
condition.
z Working mode: A
z Swing lock switch: ON
(2-stage relief solenoid valve is turned ON and oil is
relieved at high pressure)
z 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.

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CIRCUIT (5/10)
If the PC valve or servo piston is abnormal, the PC valve output pressure (servo
piston output pressure) becomes "the same as the pump discharge pressure" or
"almost 0".
5) After finishing measurement, remove the measuring instruments and return the
removed parts.
2. Measuring PC-EPC valve output pressure

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

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CIRCUIT (6/10)
2) Install nipple M2 and connect it to oil pressure gauge [1] of
hydraulic tester M1.


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CIRCUIT (7/10)
4) 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.
removed parts.

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CIRCUIT (8/10)
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.
z When the working load is increased, the engine speed lowers largely.
z The engine speed is normal but the work equipment speed is low.
z (6): Front pump PC valve
z (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.

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CIRCUIT (9/10)
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.
z If the work equipment speed is low, turn the adjustment screw to the right (to
increase the pump absorption torque).
z 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.
z Counterclockwise: Max. 1 turn
z Clockwise: Max. 1 turn

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CIRCUIT (10/10)
3. Tighten locknut (8).
Locknut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
4. After finishing adjustment, check that the PC valve output pressure (servo piston inlet
pressure) is normal according to the procedure for measurement described above.

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PRESSURE IN PUMP LS CONTROL

CIRCUIT (1/11)
Testing and adjusting instruments for oil pressure in pump LS control circuit
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.

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CIRCUIT (2/11)
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) Open the pump room cover and remove oil pressure
pick-up plugs (1), (2), (3), and (4).
z (3): Front LS valve output pressure pickup plug
z (4): Rear LS valve output pressure pickup plug
2) Install nipple N2 and connect it to oil pressure gauge [1] of

hydraulic tester N1.

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CIRCUIT (3/11)
z The figure shows the LS valve output pressure side.
3) Run the engine and raise the hydraulic oil temperature to the operating range and push
up the track shoe on the side to be measured with the work equipment.
z When measuring front circuit: Left track shoe
z When measuring rear circuit: Right track shoe
¾ Since the track shoe pushed up will be driven idle for
measurement, secure sufficient work area.

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CIRCUIT (4/11)
4) Run the engine at high idling and measure the pump discharge pressure and LS valve
output pressure (servo piston inlet pressure) at the same time under the following
condition.
z Working mode: A
z 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.
removed parts.

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CIRCUIT (5/11)
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) Open the pump room cover and remove oil pressure pick-up plugs (1), (2), (5), and (6).
z (5): Front LS valve output pressure pickup plug

z (6): Rear LS valve output pressure pickup plug

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CIRCUIT (6/11)
2) 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 58.8 MPa {600 kg/cm2}.
Since the differential pressure is about 2.9 MPa {30 kg/cm2} at maximum, measure it
by installing the same gauge to the pick-up plugs alternately.

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CIRCUIT (7/11)
z The figure shows the LS valve output pressure side.

the operating range and push up the track shoe on the
side to be measured with the work equipment.
z When measuring front circuit:
Left track shoe
z When measuring rear circuit:
Right track shoe
¾ Since the track shoe pushed up will be driven idle for
measurement, secure sufficient work area.

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CIRCUIT (8/11)
4) Run the engine at high idling and measure the pump discharge pressure and LS
pressure (actuator load pressure) at the same time under the following condition.
z Working mode: A
z Travel speed: Hi
z 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.
removed parts.

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CIRCUIT (9/11)
3. Measuring LS-EPC valve output pressure
1) Open the pump room cover and remove LSEPC valve
output pressure pick-up plug (7).
2) Install nipple N2 and connect it to oil pressure gauge [1] of

hydraulic tester N1.

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CIRCUIT (10/11)
4) 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.
Note: Operate the travel lever to a degree that the PPC oil pressure switch is turned
ON (Stop before the machine starts traveling).
removed parts.
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CIRCUIT (11/11)
Adjusting
If the LS differential pressure is abnormal, adjust LS valves
(8) and (9) according to the following procedure.
z (8): Front pump LS valve
z (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
z turned to the right, the differential pressure rises.
z turned to the left, the differential pressure lowers.
Quantity of adjustment (LS differential pressure) per turn
of adjustment screw:
Approx. 1.3 MPa {Approx. 13.3 kg/cm2}
3. After finishing adjustment, check that the LS pressure is normal according to the procedure
for measurement described above.
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MEASURING PPC VALVE OUTPUT Hydraulic Excavators
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PRESSURE (1/4)
Measuring instruments for PPC valve output pressure
1. Remove the control valve top cover and operator's cab undercover.

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PRESSURE (2/4)
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.

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PRESSURE (3/4)
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.
The figure shows the measuring instruments installed to
the mounting part of the arm IN PPC pressure sensor.
4. Run the engine and raise the engine oil temperature to the
operating range.

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PRESSURE (4/4)
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.
6. After finishing measurement, remove the measuring instruments and return the removed
parts.

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TESTING PROCEDURE OF DIODE (1/3) Hydraulic Excavators
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Test an assembled-type diode or a diode unit according to

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.

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1. When using a digital tester

1) 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.
2) Apply the red (+) test pin to the anode (P) side of the diode and the black (–) test pin to
the cathode (N) side and read the indicated value.
3) Judge the condition of the diode from the indicated value.
z The indicated value does not change: There is not continuity (Defective).
z The indicated value changes: There is continuity (Normal) (Note).
Note: In the case of a silicon diode, the tester indicates a value of 460 – 600.

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2. When using an analog tester

1) Set the tester in the resistance range.
2) 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.
3) Judge the condition of the diode from movement of the pointer.
z 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)
z The pointer moves in both i) and ii): Defective (Internal short circuit)
z The pointer does not move in either of i) and ii): Defective (Internal disconnection)

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SPECIAL FUNCTIONS OF MONITOR Hydraulic Excavators
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PANEL (1/46)
[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
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PANEL (2/46)
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.

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PANEL (4/46)
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. Function of inputting and setting password

When the starting switch is turned ON, the screen to input a
password is displayed.
This screen is displayed only when the password function
is set.
2. Screen to display KOMATSU logo

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

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

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

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5. Function of displaying caution items
After the screen for check before starting is displayed, if any
check item is abnormal, the corresponding symbol mark is
displayed.
6. Function of checking working mode and travel speed

After the screen for check before starting is displayed, the
symbol marks of the working mode and travel speed are
displayed in large size for 2 seconds to urge the operator to
check the setting.

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PANEL (7/46)
7. 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
preheater is turned ON.
8. Function of adjusting brightness and contrast of display

The operator can adjust the brightness and contrast of the
display with the screen adjustment switches.

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9. Function of adjusting flow rate for breaker and attachments
(for machine with breaker or attachment)
The operator can adjust the pump flow rate for the breaker or
an attachment wit h the selector switch.
The symbol marks and description of the breaker and
attachment shown on the screen are partly different.
10.Function of checking maintenance information

The operator can check the detailed information about the
maintenance items (set time and elapsed time) and reset
them after checking with the maintenance switches.
The maintenance function is set and reset and the
maintenance time is set with the service menu.

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

On the password inputting screen or ordinary screen, the
operator can check the display LCD.
z 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.

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PANEL (10/46)
13.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.
14.Function of displaying user code

If the machine has any failure, the corresponding user code
is displayed to urge the operator to take a proper remedy,
depending on the degree of the failure.
If any switch is operated while the user code is displayed,
the service code and failure code screen appears (See
15).

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User codes and instructions given to operator

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PANEL (12/46)
15.Function of displaying error code and failure code
While a user code is displayed, if the following switches are
operated, the phone mark (if registered), phone No. (if
registered), error code, and failure code are displayed in
order.
z Operation of switch: [ ]
The following are displayed in order repeatedly as the
switch is operated.
(1) Phone mark
È
(2) Phone No.
È
(3) Error code and failure code

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PANEL (13/46)
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.

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Table for Error and Failure Code Nos.

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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.
z With E: The failure has not been repaired yet.
z 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.
1) Checking display
Check that the ordinary screen is displayed.
The service menu can be selected only while the ordinary
screen is displayed.
2) Operating switches
Operate the following switches.
z Operation of switches: [ ] Æ [1] Æ [2] Æ [3]
(While pressing [ ], press the numeral keys)

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3) Displaying menu screen
The initial screen of the service menu is displayed. Select a
menu which you will use.
4) Finishing menu and function

To finish the service menu screen or each menu screen,
perform one of the following operations.
(1) Press the [ ] switch (This operation is effective on all
screens).
(2) When the "Return" switch is displayed, press it.
(3) When the "Return" menu is displayed, select it and press
the [ ] switch.

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16.Function of monitoring [01]
The monitor panel monitors the signals from various
switches, sensors, and actuators installed to various parts of
the machine. The operator can display and check the
monitoring information in real time by the following operation.
1) Selecting menu
On the initial screen of the service menu, select "01
Monitoring" and press the [ ] switch.

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2) Setting monitoring items
Select and register monitoring items with the following
switches.
z [ ] switch: Select
z [ ] switch: Select
z [ ] 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.
z Hold the [ ] switch (for about 3 seconds).
z Select menu "99999" and press the [ ] switch.
If all of the settable 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.

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3) Operating for monitoring
After the monitoring infomation screen appears, operate the
machine to check the monitoring information.

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4) Function of holding monitoring information
If the [ ] switch is pressed during the monitoring operation,
all the monitoring information is held. If the [ ] switch is
pressed while the monitoring information is held, the
monitoring information is released.
5) Function of selecting machine setting mode To change

settings of the working mode, travel speed, or auto
deceleration during the monitoring operation, press the
switches for those items, and the mode checking screen
appears.
After checking the settings, press the [ ] switch, and the
monitoring screen appears again.
If the settings are changed during the monitoring
operation, the new settings are held even after monitoring
is finished and the service menu disappears and the
operator menu appears again.

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Monitoring items list

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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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17.Function of abnormality record [02]
The monitor panel classifies and records the past failures into
the electrical system group and mechanical system group.
The operator can display and check those failures by the
following operation.
1) Selecting menu
Abnormality Record" and press the [ ] switch.
2) Selecting sub-menu
On the abnormality record menu screen, select a sub-
menu and press the [ ] switch.

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

[1]: Record No.
[2]: Contents of failure
[3]: Failure code (Component: 4 characters, Trouble: 2
characters)
[4]: Total number of occurrences
[5]: Service meter reading at 1st occurrence
See "Error codes and failure codes table" in the
operator menu.

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5) 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

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i) While the electrical system abnormality record screen is
displayed, operate the following switches to display the
reset screen.
z Operation of switches: [ ] + [1] Æ [2] Æ [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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18.Function of maintenance record [03]
The monitor panel records the maintenance information
about the filters and oils. The operator can display and check
that information by the following operation.
1) Selecting menu
Maintenance Record" and press the [ ] switch.
2) Displayed information
(1) Names of oils and filters
(2) Number of replacement times up to now
(3) Service meter reading at previous replacement

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19.Function of maintenance mode change [04]
The condition for setting the operation of the maintenance
display function can be changed according to the following
procedure.
z Set the function effective or ineffective.
z Change the set replacement interval.
1) Selecting menu
Maintenance Mode Change" and press the [ ] switch.
2) Selecting item to be changed

On the screen of maintenance mode changing menu,
select an item to be changed.

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Menus "01" and "12" are used to set the whole maintenance mode and menus "02" –
"11" are used to set the items one by one.
3) Contents of setting of "maintenance mode On/Off"

z 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).
z Off: The function of displaying all the oil and filter items
becomes ineffective (This setting is applied, even if
On/Off is set for each item).
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4) Contents of setting of each item
(1) Default: Maintenance time set in monitor. (Value
recommended by manufacturer. Constant value.)
(2) Set value: Maintenance time which operation can set
freely. Monitor panel operates according to this value
in maintenance mode. (This value can be changed by
50 hours with [ ] and [ ] switches.)
(3) Off: Function of displaying this maintenance item
becomes ineffective.
(4) On: Function of displaying this maintenance item
becomes effective.
The lower limit of the set time is 50 h.
5) Contents of setting "Return all items to initial values"

If this menu is selected and the [ ] switch is pressed, all
the information items are changed to the initial values.

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20.Function of phone number entry [05]
The operator can input a phone No. and change it according
to the following procedure. Once the phone No. is input, it
and service code are displayed alternately when the user
code is displayed.
If a phone No. is not input, the phone No. screen is not
displayed.
1) Selecting menu
Phone Number Entry" and press the [ ] switch.
2) 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.

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3) Inputting and setting phone No.
On the phone No. input screen, input a phone No.
according to the following procedure (The phone No. is
input from the cursor at the left end automatically).
i) Input a No. with the numeral keys from the cursor at
the left end.
ii) After finishing inputting the No., press the [ ] switch.
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.

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21.Function of initial setting and default [06]
The operator can change the following items related to the
monitor panel and machine, if necessary.
z Working mode when starting switch is turned ON
z Language displayed on service menu
z Unit displayed in monitoring function mode
z With/Without attachment
1) Selecting menu
Function of initial setting and default" and press the [ ]
switch.
Select a sub-menu to change its setting and press the [ ]
switch.

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3) Function of selecting mode when key is ON
When the starting switch is turned ON, a working mode is
displayed on the monitor panel. The operator can change
this working mode.
z 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.
z 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.
z Initial value: If this mode is set, the machine is started
in the default mode set in the factory when the starting
switch is turned ON.
If the machine having an attachment is stopped in the
B-mode, it is started in the B-mode when the starting
switch is turned ON next time, regardless of this setting.

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4) 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.
5) Function of selecting unit

The operator can select 1 of the 3 unit systems as the unit
system used for the data displayed by the monitoring
function of the service menu.
The default unit system of the monitor panel is the SI
unit system.

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6) Function of selecting "with/without service circuit"
The operator can set "with/without service circuit".
z With service circuit: When attachment is installed
z 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.

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22.Function of adjustment [07]
The operator can adjust various items of the machine on the
monitor panel.
1) Selecting menu
Adjustment" and press the [ ] switch.
Select a sub-menu to change its setting and press the [ ]
switch.

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3) Function of pump absorption torque
The operator can adjust the pump absorption torque
within the ranges shown in the following table.
4) Function of adjustment of oil flow for attachment in

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

PC400/450-
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PANEL (43/46)
23.Function of cylinder cut out mode operation [09]
The operator can operate the machine in the cylinder cut out
mode with the monitor panel. Cylinder cut out mode
operation means to run the engine with 1 or more fuel
injectors disabled electrically to reduce the number of
effective cylinders. This operation is used to find out a
cylinder which does not output power normally (or,
combustion in it is abnormal).
1) Selecting menu
Cylinder cut out mode operation" and press the [ ] switch.
2) Setting cylinders to be disabled

Press switches [1] – [6] on the monitor panel
corresponding to the cylinder Nos. to be disabled.
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).
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PANEL (44/46)
Only one or more cylinders can be disabled for the
reduced cylinder mode operation.
3) Cancellation of disabled cylinders

Press switches [1] – [6] on the monitor panel
corresponding to the disabled cylinder Nos. to cancel
disabling of those cylinders.
After a switch is pressed, if the cylinder No.
corresponding to it on the monitor panel is displayed
black in a black frame, disabling of the cylinder is
cancelled.

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PANEL (45/46)
4) Function of holding engine speed
If the [ ] switch is pressed while the reduced cylinder
mode operation screen is used, the engine speed is held
and displayed on the lower line.
If the [ ] switch is pressed while the engine speed is held,
holding of the engine speed is cancelled and the engine
speed displayed on the lower line goes off.
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.
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PANEL (46/46)
(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.

PC400/450-
PC400/450-7
HANDLING OF HIGH-VOLTAGE Hydraulic Excavators
Page 110 -114

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CIRCUIT OF ENGINE CONTROLLER

¾ The engine controller has a high-voltage circuit (110 – 130 V)
(1/2)
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.
¾ 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.
z Engine controller connector: CB3
z Junction connector: ER03
z Injector connectors: CN1, CN2, CN3, CN4, CN5, CN6
z 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.

PC400/450-
PC400/450-7
HANDLING OF HIGH-VOLTAGE Hydraulic Excavators
Page 111 -114

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CIRCUIT OF ENGINE CONTROLLER

3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit
(2/2)
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.

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PC400/450-7
PREPARATION WORK FOR Hydraulic Excavators
Page 112 -114

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TROUBLESHOOTING FOR ELECTRICAL

EQUIPMENT SYSTEM (1/3)
When carrying out troubleshooting for an electric circuit related to the monitor panel, engine
controller, or pump controller, expose the related connectors according to the following
procedure.
1. Monitor panel
1) Remove cover (1).
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.
2) Remove the 3 mounting screws and disconnect monitor

panel (2) from the mount.
Take care not to drop the mounting screws in the
console.
3) Insert or connect T-adapters in or to connectors P01, P02,
P70 of the monitor panel.

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2. Engine controller
1) Open the right side cover and remove radiator sub tank
(3) and bracket together.
2) Remove the 4 mounting bolts and pull out engine

controller (4).
3) Insert or connect T-adapters in or to connectors CB1,
CB2, and CB3 of the engine controller.
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 {0.288 kgm}

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3. Pump controller
The pump controller is installed inside the cover at the rear of
the operator’s seat.
1) Remove the 3 mounting bolts and cover (5).
2) Insert or connect T-adapters in or to connectors C01, C02,

and C03 of the pump controller.
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 {0.288 kgm}

PC400-7 Testing 2712

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Technical Presentation Kit

TESTING AND ADJUSTING

MEASURING ENGINE SPEED (1/3) Hydraulic Excavators

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING ENGINE SPEED (2/3) Hydraulic Excavators

3. Measure the engine speed under each measurement condition.

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING ENGINE SPEED (3/3) Hydraulic Excavators

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING INTAKE AIR PRESSURE Hydraulic Excavators

(BOOST PRESSURE) (1/2)

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING INTAKE AIR PRESSURE Hydraulic Excavators

(BOOST PRESSURE) (2/2)

5. Set the working mode switch in the A-mode position.

6. While running the engine at high idling, relieve the boom

7. After finishing measurement, remove the measuring

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING EXHAUST TEMPERATURE Hydraulic Excavators

1. Open the engine hood and remove exhaust temperature

2. Install sensor [1] of digital thermometer B and connect them

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING EXHAUST TEMPERATURE Hydraulic Excavators

4. Procedure for measuring maximum exhaust temperature for troubleshooting

5. Procedure for measuring exhaust temperature periodically for

6. After finishing measurement, remove the measuring

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING COMPRESSION PRESSURE Hydraulic Excavators

MEASURING COMPRESSION PRESSURE Hydraulic Excavators

4. Install adapter E2 and connect it to compression gauge E1.

5. Adjust the valve clearance. For details, see ADJUSTING

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING COMPRESSION PRESSURE Hydraulic Excavators

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING COMPRESSION PRESSURE Hydraulic Excavators

KN20031115 PREV NEXT FIRST LAST MENU EXIT

HANDLING OF FUEL SYSTEM DEVICES Hydraulic Excavators

 Precautions for testing and adjusting fuel system

KN20031115 PREV NEXT FIRST LAST MENU EXIT

RELEASING RESIDUAL PRESSURE Hydraulic Excavators

FROM FUEL SYSTEM

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING FUEL PRESSURE (1/2) Hydraulic Excavators

 Measuring instruments for fuel pressure

1. Open the engine hood and remove fuel pressure pick-up

KN20031115 PREV NEXT FIRST LAST MENU EXIT

MEASURING FUEL PRESSURE (2/2) Hydraulic Excavators

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

4. After finishing measurement, remove the measuring

KN20031115 PREV NEXT FIRST LAST MENU EXIT

BLEEDING AIR FROM FUEL CIRCUIT Hydraulic Excavators

 Open the engine hood.

KN20031115 PREV NEXT FIRST LAST MENU EXIT

BLEEDING AIR FROM FUEL CIRCUIT Hydraulic Excavators

KN20031115 PREV NEXT FIRST LAST MENU EXIT

BLEEDING AIR FROM FUEL CIRCUIT Hydraulic Excavators

5. Start the engine with the starting motor.

KN20031115 PREV NEXT FIRST LAST MENU EXIT

INSPECTION OF FUEL CIRCUIT FOR Hydraulic Excavators

3. Inspect the fuel piping and devices for fuel leakage.

4. Run the engine at low idling.

KN20031115 PREV NEXT FIRST LAST MENU EXIT

INSPECTION OF FUEL CIRCUIT FOR Hydraulic Excavators

Precautions for testing and adjusting fuel system

Measuring instruments for fuel pressure

Open the engine hood.

The unload valve cannot be adjusted.