PC450 (LC, HD) - 8 UEN02644-00 Testing & Adjusting

UEN02644-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8
Machine model Serial number

PC450-8 K50001 and up
PC450LC-8 K50001 and up
PC450LCD-8 K50001 and up
PC450LCHD-8 K50001 and up
30 Testing and adjusting 1

Testing and adjusting, part 1
Tools for testing, adjusting and troubleshooting .............................................................................................. 3
Measuring engine speed................................................................................................................................. 7
Measuring air boost pressure ......................................................................................................................... 8
Measuring exhaust temperature ..................................................................................................................... 9
Measuring exhaust gas color ........................................................................................................................ 10
Adjusting valve clearance ..............................................................................................................................11
Measuring compression pressure................................................................................................................. 13
Measuring blow-by pressure......................................................................................................................... 15
Measuring engine oil pressure ...................................................................................................................... 16
Handling fuel system parts............................................................................................................................ 17
Releasing residual pressure from fuel system .............................................................................................. 17
Measuring fuel pressure ............................................................................................................................... 18
Handling during cylinder cut-out operation ................................................................................................... 19
Handling during no injection cranking operation ........................................................................................... 19
Measuring fuel return rate and leakage ........................................................................................................ 20
Bleeding air from fuel circuit.......................................................................................................................... 23
PC450/LC/LCD/LCHD-8 1
UEN02644-00 30 Testing and adjusting
Checking fuel circuit for leakage ........................................................................................................ 24

Checking and adjusting fan belt and alternator belt ........................................................................... 25
Checking and adjusting air conditioner compressor belt tension ....................................................... 26
Measuring swing circle bearing clearance ......................................................................................... 27
Checking and adjusting track shoe tension........................................................................................ 28
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits ......................... 29
Measuring control circuit basic pressure ............................................................................................ 33
Checking and adjusting pump PC control circuit oil pressure ............................................................ 34
Checking and adjusting pump LS control circuit oil pressure............................................................. 37
Measuring solenoid valve output pressure......................................................................................... 42
Measuring PPC valve output pressure............................................................................................... 45
Adjusting play of work equipment and swing PPC valves.................................................................. 46
Inspecting locations of hydraulic drift of work equipment ................................................................... 47
Releasing residual pressure from hydraulic circuit............................................................................. 49
Measuring oil leakage amount ........................................................................................................... 50
Bleeding air from various parts........................................................................................................... 53
2 PC450/LC/LCD/LCHD-8
30 Testing and adjusting UEN02644-00
Tools for testing, adjusting and troubleshooting 1
Testing and adjusting Sym-

Part No. Part name Q'ty Remarks
item bol
–101 – 200 kPa {–760 – 1,500
Measuring intake air pres- 799-201-2202 Boost gauge kit 1
A mmHg}
sure (boost pressure)
799-401-2220 Hose 1
Measuring exhaust temper-
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
C Commercially
color 2 Smoke meter 1
available
Commercially
Adjusting valve clearance D Clearance gauge 1 (Intake: 35 mm, Exhaust: 57 mm)
available
1 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
Measuring compression
E 795-471-1420 Adapter 1
pressure 2
6217-71-6112 Gasket 1
Measuring blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5.0 kPa {0 – 500 mmH2O}
Pressure gauge: 2.5, 6.0, 40, 60
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
Measuring engine oil pres- Pressure gauge: 60 MPa {600 kg/
G 790-261-1204 Digital hydraulic tester 1
sure cm2}
Pressure gauge: 1.0 MPa {10 kg/
2 799-401-2320 Gauge 1
cm2}
Pressure gauge: 2.5, 6.0, 40, 60
MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600 kg/
790-261-1204 Digital hydraulic tester 1
cm2}
Measuring fuel pressure H
Pressure gauge: 1.0 MPa {10 kg/
2 799-401-2320 Gauge 1
cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Seal washer 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Joint inside diameter: 10 mm
Commercially
3 Hose 1 Ø5 mm × 2 – 3 m
available
Measuring fuel return rate Commercially
J 4 Hose 1 Ø15 mm × 2 – 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring swing circle Commercially
K Dial gauge 1 With magnet
bearing clearance available
Measuring and adjusting oil 1 * Common with G1
pressure in work equipment, L
swing, and travel circuits 799-101-5220 Nipple 2
2 Size: 10 × 1.25 mm
07002-11023 O-ring 2

item bol
1 * Common with G1
Measuring and adjusting 790-261-1204 Digital hydraulic tester 1
M
control circuit voltage 799-101-5220 Nipple 2
2 * Common with K2
07002-11023 O-ring 2
Measuring and adjusting oil 1 * Common with G1
pressure in pump PC con- N
trol circuit 799-101-5220 Nipple 4
2
07002-11023 O-ring 4
1 * Common with G1
Measuring and adjusting oil
799-101-5220 Nipple 4
pressure in pump LS control O 2 * Common with M2
circuit 07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1
gauge
1 * Common with G1
Measuring solenoid valve 799-401-3100 Adapter 1 Size: 02
P 2
output pressure 02896-11008 O-ring 1
799-401-3200 Adapter 1 Size: 03
3
02896-11009 O-ring 1
Measuring PPC valve out- 1 * Common with G1
Q 790-261-1204 Digital hydraulic tester 1
put pressure
2 799-301-1740 Joint 1 Size: PF1/4 + PT1/4
Commercially
Measuring oil leakage R Measuring cylinder 1
available
799-601-4100
or T-adapter assembly 1
799-601-4200
799-601-4130 • T-adapter 1 For Ne sensor
799-601-4150 • T-adapter 1 For oil pressure sensor
799-601-4180 • T-adapter 1 For EGR gas sensor
799-601-4211 • T-adapter 1 For controller (50-pole)
799-601-4220 • T-adapter 1 For controller (60-pole)
799-601-4240 • Socket 1 For ambient pressure sensor
799-601-4250 • Socket 1 For Bkup sensor
Troubleshooting for/engine
S 799-601-4260 • T-adapter 1 For controller (4-pole)
controller/sensors/actuators
799-601-4330 • Socket 1 For Bkup sensor
799-601-4350 • T-box 1 For 60-pole type
For coolant temperature sensor
795-799-5530 • T-adapter 1
For fuel temperature sensor
795-799-5540 • T-adapter 1 For boost temperature sensor
For EGR valve solenoid
799-601-9020 • T-adapter 1 For bypass valve solenoid
For injector
For EGR valve solenoid
799-601-9030 • T-adapter 1
For bypass valve stroke sensor

item bol
799-601-9420 • T-adapter 1 For common rail pressure sensor
799-601-9430 • T-adapter 1 For supply pump PCV
799-601-9000
or
Troubleshooting for/engine
S 799-601-9100 T-adapter assembly 1
controller/sensors/actuators
or
799-601-9300
799-601-9310 • Plate 1
For 24-pole type
799-601-9320 • T-box 1
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter assembly 1
or
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600 • T-adapter box 1
799-601-2740 • Adapter for MIC 1
799-601-4100
or
799-601-4200
799-601-9000
or
799-601-9200
Troubleshooting for chassis/ 799-601-9020 • Adapter for DT 1

T
sensors/wiring harnesses 799-601-9030 • Adapter for DT 1
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7010 • Adapter for X 1
799-601-7020 • Adapter for X 1
799-601-7040 • Adapter for X 1
799-601-7050 • Adapter for SWP 1
799-601-7080 • Adapter for M 1
799-601-7090 • Adapter for M 1
799-601-7110 • Adapter for M 1
799-601-7120 • Adapter for M 1
799-601-7130 • Adapter for M 1
799-601-7140 • Adapter for S 1

item bol
799-601-7160 • Adapter for S 1
799-601-7170 • Adapter for S 1
799-601-7210 • Adapter for AMP040 1
799-601-7220 • Adapter for AMP040 1
799-601-7340 • Adapter for M 1
799-601-7360 • Adapter for relay 1
799-601-7370 • Adapter for relay 1
Troubleshooting for chassis/
T 799-601-7500 T-adapter assembly 1
sensors/wiring harnesses
799-601-7520 • Adapter for 070 1
799-601-9000
799-601-9200
799-601-9030 • Adapter for DT 1
799-601-9110 • Adapter for DT (GR) 1
799-601-9350 • Adapter for DRC 1
799-601-9360 • Adapter for DRC 1
Measuring wear on sprocket — 796-627-1120 Wear gauge 1
Measuring coolant tempera-
— 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and depressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Ruler 1
hydraulic drift available
Measuring work equipment Commercially
— Stopwatch 1
speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
a For the model names and part Nos. of the T-adapters and boxed used for troubleshooting for the
machine monitor, controllers, sensors, actuators and wiring harnesses, see “Troubleshooting, List of T-
boxes and T-adapters”.
Measuring engine speed 1 4) Measuring the engine speed when 2

pumps are relieved and power maximizing
1. Turn on the starter switch and then switch the is turned on (near the rated speed):
machine monitor display to “Monitoring”. 1] Start the engine and set the fuel dial
a Fro the operating method of the machine to the high idle (MAX) position.
monitor, see “Special functions of machine 2] Set the working mode switch to P-
monitor”. mode.
a Monitoring code: 01002 Engine speed 3] Put the arm in IN relief position and
01006 Engine speed ke ep t he powe r max. s wi tc h
a Code 01002 represents the engine con- depressed.
troller information and code 01006 repre- a The power maximizing function is
sents the pump controller information. reset automatically in about 8.5 sec-
Either of the codes is usable for the mea- onds even if the switch is b eing
surement. depressed. Thus measurement of the
a Engine speed is indicated in multiple of 1 engine speed must be completed
r/min (1 rpm). within that period.
5) Measuring the speed when the auto-
decelerator is in operation:
1] Start the engine and set the fuel dial
to the high idle (MAX) position.
2] Turn on the auto-deceleration switch.
3] Set the work equipment, swing and
travel levers to the neutral position.
a The engine speed will be slowed
down to a certain level in about 5 sec-
onds from setting all levers in neutral.
This level is the engine speed when
operation of the auto-deceleration is
turned on.
2. Start the engine and keep it running until tem-

perature of the engine coolant and hydraulic oil
rise to the operating range.
3. Measure the engine speed under the respec-

tive conditions listed below.
1) RPM at low idle:
to the low idle (MIN) position.
2) RPM at high idle:
2] Set the working mode switch to P-
mode.
3] Turn off the auto-deceleration switch.
3) Measuring the engine speed when 2-
pumps are relieved:
2] Set the working mode switch to P-
mode.
3] Put the arm in the IN relief position.
Measuring air boost pressure 1 3. Run the engine at middle or higher speed and
drain oil from the hose.
a Air boost pressure measuring tools a When draining the oil, open the self seal of
Symbol Part No. Part name the hose by inserting approximately half of
the gauge and hose connection. Repeat
799-201-2202 Boost gauge kit
A operation until the oil is drained out.
799-401-2220 Hose a If Pm kit (A) is available, the air-bleeding
coupling (790-261-1130) in that kit may be
a Be careful not to touch any hot part of the used.
engine when removing or installing the mea- a If oil is left in the hose, the gauge does not
surement tools. work. Accordingly, be sure to drain the oil.
1. Open the inspection cover of the engine hood 4. Start the engine and keep it running until tem-
and remove intake air measuring plug (1). perature of the engine coolant and hydraulic oil
a The plug removed can be any of the plug rise to the operating range.
provided on the right and left side.
5. Set the working mode switch to P-mode.
6. Measure the intake air pressure (boost pres-

sure) when the engine is set to high idle and
the boom RAISE side is relieved.
2. Install nipple [1] of the boost gauge kit A and

connect gauge [2] to it.
7. Remove the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
Measuring exhaust temperature 1 5. A procedure of measuring periodical exhaust

temperature for preventive maintenance ser-
a Measuring tools for exhaust temperature vices (Pm clinic)
Symbol Part No. Part name 1) Set the working mode switch to P-mode.
2) Measure the exhaust temperature when
B 799-101-1502 Digital thermometer
the engine is set to high idle and the arm
k
IN side is relieved.
Before installing or removing the measur-
ing tools, make sure the manifold tempera- a Measure and record the exhaust tempera-
ture after making sure it is stabilized.
ture is sufficiently low.
1. Open the engine hood and remove the

exhaust temperature measuring plug (1).

2. Install sensor [1] of digital thermometer B and
connect it to meter [2].
a Clamp the digital thermometer harness so
that it may not be accidentally contacted
against a hot part.

4. A procedure of measuring the maximum in

troubleshooting
Measurement of the maximum exhaust tem-
perature must be done under actual working
conditions.
a PEAK mode of the digital thermometer
shall be used.
Measuring exhaust gas color 1

a Exhaust gas color measurement tools
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available
k Be careful not to touch the highly heated

parts, while removing and installing a mea-
surement tool.
a If no compressed air or power is not available
in the field, use Handy Smoke Checker C1. For
recording official data, use Smoke Meter C2. 2) Connect the probe hose, accelerator switch
outlet and air hose to the smoke meter C2.
1. Measurement with Handy Smoke Checker C1 a Keep the pressure of the supplied com-
1) Fit a filtering paper to Handy Smoke pressed air at 1.5 MPa {15 kg/cm 2} or
Checker C1. below.
2) Insert the exhaust gas intake port to 3) Connect the power cable to an AC receptacle.
exhaust pipe (1). a Confirm that the smoke meter power
3) Start the engine and keep it running until switch is in the OFF position, before
the engine coolant temperature rises to connecting the power cable to an outlet.
the operating range. 4) Loosen the cap nut of the suction pump
4) Start the engine and accelerate it sud- and fit in the filter paper.
denly or run it at high idle and then oper- a Fit the filtering paper securely so that
ate the lever of smoke checker C1 in order air may not leak.
to suction exhaust gas to the filter paper. 5) Move the Smoke Meter C2 power switch
to the ON position.
5) Take out the filtering paper and compare it 6) Start the engine and keep it running until
with the attached scale for judgement. the engine coolant temperature rises to
6) Remove the measurement tool after the the operating range.
measurement, and make sure that the 7) Let the exhaust gas stay on the filtering
machine is back to normal condition. paper by depressing the accelerator pedal of
Smoke Meter C2, when the engine speed is
2. Measurement with Smoke Meter C2 suddenly accelerated or kept at high idle.
1) Insert probe [1] of smoke meter C2 to the 8) Put the polluted filtering paper on non-pol-
outlet of exhaust pipe (1) and fix it to the luted filtering paper (more than 10 sheets)
exhaust pipe with a clip. in the filtering paper holder, and read the
indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
Adjusting valve clearance 1

a Valve clearance adjustment tools
Commercially
D Clearance gauge
available
1. Open the inspection cover of the engine hood

and remove the head cover (1) of every cylin-
der.
a As for No.1 and 2 cylinders, remove the
air intake connector on the head cover,
too.
5. When No. 1 cylinder is at the top dead center,
adjust valve clearances indicated with a black
bullet mark in the chart below in the following
manner.
2. Remove the belt protection covers (two cov-

ers) and then loosen the tension of the fan belt
and alternator belt.
a The belts are loosened for confirming the
timing mark. 6. Insert clearance gauge D in the clearance
between rocker arm (5) and crosshead (6) and
3. Remove radiator under cover. adjust the valve clearance with adjustment
screw (3).
4. Rotate the crankshaft forward to bring the a With the clearance gauge being inserted,
stamped “1.6TOP” line (a) of the damper to turn the adjustment screw until it allows
pointer (2) and set the No. 1 cylinder to the the clearance gauge to move slightly.
compression top dead center.
a Crank the crank shaft using the crank pul-
ley mounting bolt (Bolt width: 24 mm). In
this case, turn the bolt in the normal rota-
tion to prevent its loosening.
a When No. 1 cylinder is at the top dead
center, its rocker arm can be manually
moved as much as the valve clearance.If
it cannot be moved, that means that No. 1
cylinder is not yet at the top dead center.
In that case, rotate it by one more turn.
7. While fixing adjustment screw (3), tighten lock-

nut (4).
3 Locknut: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
a It is also allowed to adjust respective cylin-

ders in the firing order by turning the crank
shaft 120° at a time.
q Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Air intake connector clamp:
9.8 ± 0.5 Nm {100 ± 5 kgm}
a Adjust the belt tension referencing “Test-
ing and adjusting fan belt and alternator
belt tension”.
Measuring compression pressure1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Compression pressure measurement tools (Do not pry the injector top up).
1 795-502-1590 Compression gauge
E 795-471-1420 Adapter
2
6217-71-6112 Gasket
k Be careful not to get burnt by touching the

exhaust manifold or muffler, or get caught
with a rotating parts, while taking measure-
ment of compression pressure.
a Before measuring the compression pressure,
make sure the engine is warmed up.
(Engine oil temperature: 40 – 60°C)
1. Run the engine for warm up until the engine oil 5. Install adapter E2 to the injector mounting hole
reaches 40 – 60°C. and connect compression gauge E1 to it.
a Fit the gasket to the adapter end without
2. Open the inspection cover of the engine hood fail.
and remove the head cover (1) of the cylinder a Fix the adapter with the injector holder.
to be tested. 3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
6. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a See “Adjusting valve clearance”.
3. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance”.
4. Disconnect fuel high-pressure tube (3) and injec-

tor wiring harness (4) and remove injector (5).
a Before disconnecting the fuel high-pres-
sure tube, loosen all center clamps.
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
pull them outside the rocker arm housing
(Loosen the 2 terminal nuts alternately).
7. Referencing “Special functions of machine 3 Rocker arm assembly mounting

monitor”, set the no injection cranking and the bolt:
engine speed measurement mode. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will a Adjust the valve clearance. For
be dangerous. Accordingly, be sure to details, see “Adjusting valve clear-
set the engine in this mode. ance”.
8. Rotate the engine with the starting motor and 3 Cylinder head cover mounting bolt:
measure the compression pressure. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
a Read the pressure gauge pointer when it
is stabilized.
9. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector, injector wiring harness,
and fuel high-pressure tube according to
the following procedure.
1) Install the O-ring and gasket to injector
(11).
2) Fit holder (12) to injector (11) to tempo-
rarily assemble them as a unit to the cylin-
der head.
3) Fit mounting bolt (13) to spherical washer
(14) to tighten them to the cylinder head.
3 Spherical part of washer:
Engine oil (SAE30DH)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4) Install wiring harness (15) to the rocker
arm housing and fix it with mounting bolt
(16).
5) Insert wiring harness (15) into holder (17).
6) Alternately tighten 2 nuts at wiring harness
(15) end to injector (11).
3 Nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
7) Tighten tube (18) to injector (11).
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
8) Tighten the clamping bolt of the fuel pip-
ing.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
Measuring blow-by pressure 1

a Blow-by pressure measurement tools
.

F 799-201-1504 Blow-by checker
1. Remove the engine under cover (1).
2. Install nozzle [1] of blow-by checker F to blow-

by hose (1) and connect it to gauge [2] using
the hose.

4. Measure the blow-by pressure under the fol-

lowing conditions while setting the engine to
high idle.
q Working mode: P-mode
q Swing lock switch: ON (high pressure relief)
q Work equipment, swing and travel: Arm IN
relief position
a Read off the blow-by pressure value,
when the needle of the gauge steadies
itself.

Measuring engine oil pressure 1 4. Run the engine until the engine coolant is
heated up to the operating range.
a Engine oil pressure measurement tools
Symbol Part No. Part name 5. Measure the engine oil pressure at low idle
and also at high idle.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge

and remove the bracket (2) for clamping.

2. Remove the oil pressure measurement plug

(1) on the cylinder block.
3. Install nipple [1] of hydraulic tester G1 and con-

nect it to hydraulic tester G2.
Handling fuel system parts 1 Releasing residual pressure from

fuel system 1
a Precautions for checking and maintaining fuel
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for-
eign matter enters this system, it can cause a Low-pressure circuit: Between Feed pump –
trouble. Fuel filter – Fuel supply
When checking and maintaining the fuel sys- pump
tem, take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly High-pressure circuit: Between Fuel supply
with clean fuel. pump – Common rail –
a Precautions for replacing fuel filter cartridge Fuel injector
Be sure to use the Komatsu genuine fuel filter a The pressure in both low-pressure circuit and
cartridge. high-pressure circuit lowers to a safety level
Since the common rail fuel injection system automatically 30 seconds after the engine is
(CRI) consists of more precise parts than the stopped.
conventional fuel injection pump and nozzle, it a Before checking the fuel system and installing
employs a high-efficiency special filter to pre- and removing its parts, the residual pressure in
vent foreign matter from entering it. the fuel system must be released completely.
If a filter other than the genuine one is used, Accordingly, observe the following.
the fuel system may have a trouble. Accord- k Before checking the fuel system, or install-
ingly, never use such a filter. ing or removing its parts, wait at least 30
seconds after stopping the engine until the
residual pressure in the fuel system is
released. (Do not start the work just after
stopping the engine since there is residual
pressure.)
Measuring fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
H
Adapter
795-471-1450
3 (8 × 1.25 mm o R1/8)
07005-00812 Seal washer
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head.
4. After finishing testing, remove the testing tools

and return the removed parts.
2. Install nipple [1] of adapter H3 and hydraulic

tester H1 and connect them to hydraulic tester
H2.
Handling during cylinder cut-out Handling during no injection

operation 1 cranking operation 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The pur- pose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no-injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When a cylinder is selected for the reduced a See the section of “Special functions of
cylinder mode operation, if the engine speed machine monitor” when turning on the no injec-
and output do not change from the normal tion cranking operation.
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q Leakage from the cylinder head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a See the section of “Special functions of
machine monitor” when turning on the cyl-
inder cut-out operation.
Measuring fuel return rate and leakage 1
a Testing tools for leakage from pressure limiter 1. Preparation work

and return rate from injector 1) Remove tube (3) between common rail (1)
and return block (2).
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
2) Insert spacer J1 to return block (2) side
and retighten it with the currently removed
joint bolt.
a Be sure to fit the gaskets to both ends
of the spacer.
3) Insert joint J2 to common rail (1) side and
retighten it with the currently removed joint
bolt.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect inspection hose J3 to the tip of

joint J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injec-
tor.
a Disconnect both ends of the injector.
1) Disconnect fuel return hose (4) of return
2. Testing leakage from pressure limiter block (2).
1) Adjust routing to prevent its slacking of a Place a plug on the fuel hose side
inspection hose J3 and insert the hose and then fix it to the fuel tank.
end to the oil pan (saucer). Plug: 07376-70315
2) Referencing “Measuring engine speed”,
set up the condition necessary for check-
ing the engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
2) Connect inspection hose J4 to return
1,600 Max. 10 block (2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
3) Adjust routing to prevent its slacking of

inspection hose J4 and insert the hose
end to the oil pan (container).
7) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
4) Referencing “Measuring engine speed”, tools and return the removed parts.
set up the condition necessary for check-
ing the engine speed.
5) Run the engine at the rated output.
6) After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
Bleeding air from fuel circuit 1

a If fuel is used up, or if a fuel circuit part is
removed or installed, bleed air from the fuel cir-
cuit according to the following procedure.
1. Loosen plug (2) at the top of fuel main filter (1)

to remove plug (3).
a Don't touch fuel pre-filter (4). It is situated
in the suction side.
2. Loosen lever-fixing butterfly screw (6) of prim-

ing pump (5) to remove it from the tap.
3. Repeat priming by pressing lever (7) of the

priming pump until the fuel from plug (2)
becomes free from bubbles. Then install plug
(2).
4. Continue priming one or two times to make

sure the fuel comes out of plug (1). Then
tighten plug (1).
5. Then conduct approximately 20 times of addi-

tional priming and install butterfly screw (6) of
priming pump.
3 Butterfly screw tightening torque:
11.7 Nm {1.2 kgm}
Checking fuel circuit for leakage 1 8. Run the engine at high idle and load it.
a When testing the engine mounted on the
k Very high pressure is generated in the high- machine, stall the torque converter or
pressure circuit of the fuel system. If fuel relieve the oil pressure from the hydraulic
leaks while the engine is running, it is dan- pump.
gerous since it can catch fire.
After testing the fuel system or removing 9. Inspect the fuel piping and devices for fuel
its parts, test it for fuel leakage according leakage.
to the following procedure. a Inspect mainly around the high-pressure
a Clean and degrease the engine and the parts circuit parts coated with the color checker
around it in advance so that you can test it eas- for fuel leakage.
ily for fuel leakage. a If any fuel leakage is detected, repair it
and inspect again from step 1.
1. Spray color checker (developer) over the fuel a If no fuel leakage is detected, inspection is
supply pump, common rail, fuel injector, and completed.
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and check again from step 1.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
Checking and adjusting fan belt 4. Slide alternator (7) by rotating adjusting nut
and alternator belt 1 (6), adjust V belt (8) tension and tighten lock-
nut (5).
Checking a Nut (6):
1. Open the engine hood and remove the belt q Tightening the locknut clockwise
protection covers (2 covers). moves it to the belt-loosening side.
q Tightening the locknut counterclock-
2. Press the intermediate point of the belt wise moves it to the belt-tightening
between fan pulley and compressor pulley with side.
a finger and measure deflection (a) of the belt. a Check the pulleys for breakage, V-groove
a Deflection (a) when pressing force of for wear, V-belt for wear and contact of the
approx. 58.8 kg {approx. 6 kg} is applied: V-belt and V-groove for any trouble.
Approx. 13 mm a A belt must be replaced with a new one
when it is elongated so as to eliminate the
adjustment allowance, or when cuts or
cracks are visible on it.
5. Tighten mounting bolt (3) and fixing bolt (4).

a When a V-belt is replaced, adjust the ten-
sion again after operating the machine for
an hour.
Adjusting
a If the V belt deflection is abnormal, adjust it
according to the following procedure.

and remove the bracket (1) and cover (2).
2. Loosen mounting bolt (3) and fixing bolt (4).
3. Loosen locknut (5).
Checking and adjusting air 3. Slide compressor (6) by loosening locknut (4)
conditioner compressor belt and rotating adjusting nut, adjust V-belt (7) ten-
sion and tighten locknut (5).
tension 1 a Check the pulleys for breakage, V-groove
Checking for wear, V-belt for wear and contact of the
1. Open the engine hood and remove the belt V-belt and V-groove for any trouble.
protection covers (2 covers). a A belt must be replaced with a new one
when it is elongated so as to eliminate the
2. Press the intermediate point of the belt between adjustment allowance, or when cuts or
air compressor pulley and drive pulley with a fin- cracks are visible on it.
ger and measure deflection (a) of the belt. 4. Tighten mounting bolt (2) and fixing bolt (3).
a Pressing force: Deflection (a) when press- a When a V-belt is replaced, adjust the ten-
ing force of approx. 58.8 N {approx. 6 kg} sion again after operating the machine for
is applied: 14 – 16 mm an hour.
Adjusting
a If the belt deflection is abnormal, adjust it
and remove cover (1).
2. Loosen mounting bolt (2) and fixing bolt (3).
Measuring swing circle bearing 3. Set dial gauge to the zero point.
clearance 1
a Swing circle bearing clearance measurement
tools
Commercially
K Dial gauge
available
a Follow the steps explained below when mea-

suring clearance in the swing circle bearing on
the actual machine.
k Be careful not to put a hand or foot under
the undercarriage, while taking measure- 4. Hold the arm nearly perpendicular to the
ment. ground, and lower the boom until the track
shoes will be lifted at the machine front.
1. Fix dial gauge K to outer lace (1) or inner lace a The upper structure is raised at the front
(2) of the swing circle and contact the probe and lowered at the rear at that time.
against the end face of inner lace (2) or outer
lace (1) on the opposite side. 5. From this state, read the dial gauge K value.
a Set dial gauge K in the front side or rear a The value indicated by dial gauge K is the
side of the machine. clearance of the bearing.
2. Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth 6. Return the machine to the condition of step 2
tip level with the lower height of the revolving and check that dial gauge K indicates zero
frame. point.
a The upper structure is lowered at the front a If zero value is not indicated, repeat the
and raised at the rear at that time. steps in Items 3 through 5.
Checking and adjusting track Adjusting

shoe tension 1 a If the track shoe tension is not proper, adjust it
in the following manner.
Checking
1. Run the engine at low idle and drive the 1. When the tension is too strong
machine forward by the length of track on Loosen valve (3) to discharge the grease.
ground, and then stop slowly. k Do not loosen the valve more than 1
turn. Otherwise, the valve may jump
2. Place steel bar [1] on the track shoe between out be cau se o f t he hig h-p res sur e
the idler (1) and the 1st carrier roller (2). grease inside.
a L beam is recommended for bar [1]
because of its deflection-free nature. 2. When the tension is too weak
Add grease through valve (3).
3. Measure maximum clearance (a) between a If the normal track shoe tension is not
steel bar [1] and track shoe. restored even after greasing, move the
q Standard maximum clearance (a): 10 – 30 mm machine slowly back and forth.
Measuring and adjusting oil 2) Fit nipple L2 and connect it to oil pressure
pressure in work equipment, gauge [1] of hydraulic tester L1.
a The oil pressure gauges used shall
swing, and travel circuits 1 be 58.8 MPa {600 kg/cm2}.
a Measuring and adjusting tools for hydraulic oil
pressure in hydraulic circuit for work equip-
ment, swing and travel
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
a The oil pressure in the work equipment, swing,

and travel circuits can be checked with moni-
toring function of the monitor panel, too (For
details, see “Special functions of monitor
panel”).
3) Start the engine and keep it running until
q Monitoring code: 01100 F pump pressure
the hydraulic oil pressure rises to the
01101 R pump pressure
operating range.
q Pump oil pressure is indicated in multiples of
1 MPa (1 kg/cm2, 1PSI).
Measuring
1. Preparation work
k Lower the work equipment to the
ground and, after stopping the engine,
release residual pressure in the piping
by operating the control lever several
times. Then loosen the oil filler cap
gradually to release pressure inside
the tank.
1) Open the pump room cover and remove
oil measuring plugs (1) and (2).
q (1): Front pump discharge pressure

measuring plug
q (2): Rear pump discharge pressure
measuring plug
2. Combination of pump, actuator, and valve a Turning on the swing lock switch
a When the oil from the pumps is divided, always turns on the 2-stage relief
the front pump and rear pump act inde- solenoid valve, causing the high-pres-
pendently on each actuator.Note that dif- sure relief. Accordingly, keep the
ferent actuators relieve different valves. swing lock switch turned OFF.
a When the work equipment circuit or swing
circuit is relieved singly, the oil of the 5. Measurement of swing relief pressure
pumps is diverted. 1) Start the engine and move the swing lock
a The actuators in the table are arranged in switch to the ON position.
the order when the control valve is seen 2) Measure hydraulic oil pressure when the
from the front of the machine. engine is running at high idle and the
swing circuit is relieved.
Pump Actuator Valve relieved
a Hydraulic oil pressure when the swing
(F unload valve) (F main relief valve) motor safety valve is relieved is dis-
Service Safety valve for service played.
Boom Hi a The relief pressure of the swing motor
F main relief valve is lower than the main relief pressure.
Arm Hi
Front
Bucket F main relief valve
6. Measurement of travel circuit relief pressure
Left travel F main relief valve 1) Start the engine, and lock the travel.
Raise: F main relief valve k Insert pin [2] between the sprocket
Boom
Lower: Safety-suction valve and the track frame to positively
(Pump merge-divider valve) (Travel junction valve) lock the travel circuit.
(Self pressure reducing valve)
Swing Swing motor safety valve
Rear Right travel R main relief valve
Arm Lo R main relief valve
(R unload valve) (R main relief valve)
(Centralized safety valve) (Back pressure valve)
3. Measurement of unload pressure

1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idle and all the
control levers are moved to the NEUTRAL
position. 2) Measure the pressure when the engine is
a Hydraulic oil pressure when the set to high idle and the travel circuit is
unload valve unloads is displayed. relieved.
a Hydraulic oil pressure with the main relief
4. Measurement of work equipment relief valve in relief condition is displayed. In
pressure the travel circuit relief, the pressure is
1) Start the engine and move the cylinder to high pressure relief all the time.
be measured to its stroke end. Adjusting
2) Measure hydraulic oil pressure when the a Adjustment of the unload valve is not available.
cylinder is relieved while the engine is run-
ning at high idle. 1. Adjustment of main relief pressure
a The pressure measured when the a When the relief pressure of the work
main relief valve is relieved is indi- equipment circuit or travel circuit is abnor-
cated. mal, adjust main relief valves (3) and (4)
a If the power maximizing switch is according to the following procedure.
released, the main relief valve is q (3): Front main relief valve
relieved at low pressure. If the former q (4): Rear main relief valve
is pressed, the latter is relieved at a When adjusting the main relief valve on
high pressure. the front pump side, remove the top cover
of the control valve.
a When adjusting the main relief valve on 2. Adjustment of boom LOWER relief pressure
the rear pump side, remove the under (on the side where high pressure is set)
cover of the control valve (when it is a If the high relief pressure for boom
installed). LOWER is not normal, adjust the high
a As for the main relief valve, be sure to pressure set side of safety-suction valve
adjust its low-pressure relief pressure (8) for boom LOWER according to the fol-
alone (adjusting the low-pressure relief lowing procedure.
pressure automatically sets the high-pres- a The the high-pressure relief pressure
sure relief pressure, too.). mode denotes the state in which the
a When the low-pressure relief pressure is machine push-up switch is turned on, dis-
turned on, the 2-stage relief valve is OFF abling to apply the pilot pressure to the
and thus the pilot pressure is not applica- switching port.
ble to the switching port.
1) Disconnect pilot hose (9).

2) While fixing holder (10), loosen locknut
1) Disconnect pilot hose (5).
(11).
2) While fixing holder (6), loosen locknut (7).
3) Turn holder (10) to adjust the pressure.
3) Turn holder (6) to adjust the pressure.
a Turning the holder clockwise increases
a Turning the holder clockwise increases
the pressure. Turning it counterclock-
the pressure. Turning it counterclock-
wise decreases the pressure.
wise decreases the pressure.
a Quantity of adjustment per turn of
a Quantity of adjustment per turn of
holder:
holder:
Approx. 25.3 MPa {Approx. 258 kg/cm2}
Approx. 20.5 MPa {Approx. 209 kg/cm2}
4) While fixing holder (10), tighten locknut
4) While fixing holder (6), tighten locknut (7).
3 Locknut: 49.0 – 58.8 Nm {5 – 6 kgm}
(11).
3 Locknut:
93 – 123 Nm {9.5 – 12.5 kgm}
5) Connect pilot hose (5).

6) Check the pressure again after the adjust-
ment, following the aforementioned steps
for measurement.
5) Connect pilot hose (9). 4. Adjustment of swing relief pressure

6) Check the pressure again after the adjust- a If the swing relief pressure is abnormal,
ment, following the aforementioned steps adjust safety valve (14) of the swing motor
for measurement. according to the following procedure.
a Adjusting the high pressure set side
changes setting of the low pressure
side. Thus, this side requires adjust-
ment, too.
3. Adjustment of boom LOWER relief pressure

(on the side where low pressure is set)
a When the low relief pressure for boom
LOWER is not normal or when the high
pressure set side was adjusted, adjust the
low pressure side of safety-suction valve
(8) for boom LOWER according to the fol-
lowing procedure.
a The low-pressure relief pressure mode
denotes the state in which the machine
push-up switch is turned off, disabling to 1) While fixing adjusting screw (15), loosen
apply the pilot pressure to the switching port. locknut (16).
1) Disconnect pilot hose (9). 2) Turn adjustment screw (15) to adjust the
2) While fixing holder (12), loosen locknut pressure.
(13). a Adjustment screw:
3) Turn holder (10) to adjust the pressure. q Turning it clockwise increases
a Turning the holder clockwise increases the pressure.
the pressure. Turning it counterclock- q Turning it counterclockwise
wise decreases the pressure. decreases the pressure.
a Quantity of adjustment per turn of a Quantity of adjustment per turn of
holder: adjusting screw:
Approx. 25.3 MPa {Approx. 258 kg/cm2} 4.70 MPa {47.9kg/cm2}
4) While fixing holder (12), tighten locknut 3) While fixing adjustment screw (15), tighten
(13). locknut (16).
3 Locknut 78 – 93 Nm {8.0 – 9.5 kgm} 3 Locknut:
147 – 196 Nm {15 – 20 kgm}
5) Connect pilot hose (9).

6) Check the pressure again after the adjust- 4) Check the pressure again after the adjust-
ment, following the aforementioned steps ment, following the aforementioned steps
for measurement. for measurement.
Measuring control circuit basic 3. Start the engine and keep it running until the
pressure 1 hydraulic oil temperature rises to the operating
range.
a Control circuit oil pressure inspection and
adjustment tools 4. Measure hydraulic oil pressure, when the
Symbol Part No. Part name engine is running at high idle and all the control
levers are moved to the NEUTRAL position.
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
k Lower the work equipment to the ground
and, after stopping the engine, release
residual pressure in the piping by operating
the control lever several times. Then loosen
the oil filler cap gradually to release pres-
sure inside the tank.
1. Remove the top cover of the control valve and

remove plug (1) for measuring the control cir-
cuit basic pressure.
a The figure shows the control valve side
viewed from inside the pump room.
a It is not allowed to adjust the relief valve of
the control circuit source pressure.
2. Install nipple M2 and connect it to oil pressure

gauge [1] of hydraulic tester M1.
a Use the oil pressure gauge with capacity
6.0 MPa {60 kg/cm2}.
Checking and adjusting pump PC 2) Install nipple N2 and connect it to oil pres-
control circuit oil pressure 1 sure gauge [1] of hydraulic tester N1.
a Use the oil pressure gauge with
a Pump PC control circuit oil pressure checking capacity 60 MPa {600 kg/cm2}.
and adjusting tools q The figure shows the pump discharge
Symbol Part No. Part name pressure side.
1
N
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
a Measurement of the oil pressure in the pump
PC control circuit shall be conducted after
making sure that oil pressure of the work
equipment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
q The figure shows the PC valve output
side.
1. Measurement of PC valve output pressure

(servo piston inlet pressure)
a PC valve output pressure (servo piston
inlet pressure) is measured along with that
of the pump discharge pressure and the
result of the two is compared to each
other.
oil pressure measuring plugs (1), (2), (3)
and (4).
measuring plug
measuring plug
the hydraulic oil temperature rises to the
q (3): Front PC valve output pressure
operating range.
measuring plug
q (4): Rear PC valve output pressure
measuring plug
4) Measure the pump discharge pressure 2) Install nipple N2 and connect it to oil pres-
and PC valve output pressure (pressure at sure gauge [1] of hydraulic tester N1.
servo piston inlet) at the same time after a The oil pressure gauges used shall
setting following conditions with the be 6.0 MPa {60 kg/cm2}.
engine running at high idle.
q Swing lock switch: ON
(Turning 2-stage relief ON induces
high-pressure relief)
q Work equipment, swing and travel:
Arm IN relief
a Method of judgment:
If the follow ing ra tio is obtained
between the pump discharge pres-
sure and PC valve output pressure
(servo piston output pressure), the
PC valve is normal.
Measured oil
Oil pressure ratio
pressure
Pump discharge the hydraulic oil temperature rises to the
1
pressure
operating range.
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If there is any abnormality with PC

valve or servo piston, the PC valve
output pressure (servo piston output
pressure) becomes identical with the
pump discharge pressure or comes to
neighborhood of 0 pressure.
2. Measurement of PC-EPC valve output pressure

PC-EPC valve output measuring plug (5). 4) Measure the hydraulic oil pressure with all
the control levers kept in the NEUTRAL
position and the engine running at high
idle and at low idle.
a You can assume that the PC-EPC
valve output pressure is normal when
the following changes are observed.
Control
Engine Oil pressure
lever
2.94 MPa
Low idle
{30 kg/cm 2}
Neutral
0 MPa
High idle
{0 kg/cm2}

Adjusting 3. Tighten locknut (8).

a If either of the following phenomena occurs 3 Locknut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
and the PC valve seems to be defective, adjust

PC valves (6) and (7) according to the proce-
dure shown below.
q As the working load increases, the engine
speed decreases remarkably.
q The engine speed is normal but the work
equipment speed is low.
q (6): Front pump PC valve
q (7): Rear pump PC valve
a The width across flats of the PC valve
locknut is 13 mm and that of the adjust-
ment screw (inside width) is 4 mm.Do not
turn any other locknuts or adjustment
screws since they affects the hydraulic
pump performance. 4. After the adjustment, make sure that the PC
valve output pressure (servo piston inlet pres-
sure) is normal using the measurement steps
explained earlier.
1. Loosen locknut (8).

a Before loosening the locknut, make
counter mark 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 posi-
tion after turning it in reverse)
2. Turn adjustment screw (9) clockwise or coun-

terclockwise to adjust.
a Adjustment screw:
q Turn it clockwise when the work
equipment speed is low (to increase
pump absorption torque).
q Turn it counterclockwise when the
engine speed lowers (to decrease
pump absorption torque).
a Following indicates the range of adjust-
ment available from the adjusting screw.
q Counterclockwise: Within 1 turn
q Clockwise: Within 1 turn
Checking and adjusting pump LS 2) Install nipple O2 and connect it to oil pres-
control circuit oil pressure 1 sure gauge [1] of hydraulic tester O2.
a The oil pressure gauges used shall
a Pump LS control circuit oil pressure checking be 60 MPa {600 kg/cm2}.
and adjusting tools q The figure shows the pump discharge
Symbol Part No. Part name pressure side.
1
O 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
Measuring
a Measurement of the oil pressure in the pump
LS control circuit shall be conducted after mak-
ing sure that oil pressure of the work equip-
ment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
and, after stopping the engine, release q The figure shows the LS valve output
residual pressure in the piping by operating side.
1. Measuring LS valve output pressure (servo

piston inlet pressure)
a PC valve output pressure (servo piston
inlet pressure) is measured along with that
of the pump discharge pressure and the
result of the two is compared to each other.
1) Remove oil pressure measuring plugs (1),
(2), (3) and (4).
measuring plug
measuring plug 3) Run the engine until the hydraulic oil tem-
q (3): Front pump LS valve output perature reaches the operating range and
pressure measuring plug then push up the measurement side track
q (4): Rear pump LS valve output pres- shoe with the work equipment.
sure measuring plug q When measuring the front circuit:
Left track shoe
q When measuring the rear circuit:
Right track shoe
k Provide a working area of suffi-
cient space, as the raised track
shoe will be idly rotated.
2. Measurement of LS differential pressure

a LS differential pressure can be obtained
by measuring the pump discharge pres-
sure and LS pressure (actuator load pres-
sure) at the same time and computing the
difference between the two pressures.
oil pressure measuring plugs (1), (2), (5)
and (6).
measuring plug
measuring plug
4) Measure the pump discharge pressure

and LS valve output pressure (pressure at
servo piston inlet) at the same time after
setting follo wing conditions with the
engine running at high idle.
When all levers are at neutral and
when travel lever is at half stroke (one
side of travel is at idle)
a Let the raised track shoe idly rotate,
paying enough attention to the sur-
roundings for safety.
a Judgement method:
q (5): Front pump LS pressure measur-
When the ratio between the pump
ing plug
discharge pressure and LS valve out-
q (6): Rear pump LS pressure measur-
put pressure (servo piston output
ing plug
pressure) reaches the following val-
ues, both pressures are judged nor-
mal.
Oil pressure ratio
Measured oil Travel lever
pressure All levers
moved half-
at neutral
way
Pump discharge
Almost 1
pressure
same
LS valve output pressure Approx. 0.6
pressure (Approx. 3/5)

2) Install nipple O2 and connect it to the oil
pressure gauge of differential pressure
gauge O3 or hydraulic tester O1.
a When using differential pressure
gauge:
Connect the pump discharge pres-
sure to the high pressure side (back
side) and LS pressure to the low
pressure side (bottom side).
The di ffer en tia l pre ss ure g aug e
needs 12 DCV power. Thus connect a
battery to it.
a When using the oil pressure gauge:

The oil pressure gauges used shall
be 60 MPa {600 kg/cm2}.
Differential pressure is approximately
2.9 MPa {30 kg/cm 2 } at maximum.
Thus measure the pressure recon-
necting the same gauge.
q The figure shows the pump discharge
pressure side.
4) Measure the pump discharge pressure and

LS pressure (actuator load pressure) at the
same time after setting the following condi-
tions with the engine running at high idle.
q Travel speed: Hi
When all levers are at neutral and
when travel lever is at half stroke (one
q The figure shows the LS pressure side of travel is at idle)
side. a Let the raised track shoe idly rotate,
paying enough attention to the sur-
roundings for safety.
a Calculating LS differential pressure
(When the o il pressure gauge is
used):
LS differential pressure = Pump dis-
charge pressure – LS pressure
a If LS differential pressure is in the fol-
lowing conditions, it is judged normal.
LS differential
Operation of levers
pressure
Unload pressure
When all levers at neu-
(See “Standard
tral
value table”)
3) Run the engine until the hydraulic oil tem- Maximum LS
perature reaches the operating range and differential pres-
Travel lever moved
sure
then push up the measurement side track halfway (Travel at idle)
(See “Standard
shoe with the work equipment.
value table”)
q When measuring the front circuit:
Left track shoe
q When measuring the rear circuit:
Right track shoe
k Provide a working area of suffi-
cient space, as the raised track
shoe will be idly rotated.
3. Measurement of LS-EPC valve output pressure 4) Measure the oil pressure when the engine
1) Open the pump room cover and remove is running at high idle and the travel speed
LS-EPC valve output measuring plug (7). switch and travel control lever are oper-
ated.
a If LS-EPC valve output pressure
changes to the following values, the
pressure is normal.
Travel
Travel lever Oil pressure
speed
Approx. 2.94 MPa
Lo Neutral
{Approx. 30 kg/cm2}
Fine travel
Hi lever control 0 MPa {0 kg/cm2}
(Note)
Note: Operate the travel control lever

slightly to the extent that the PPC oil
2) Install nipple O2 and connect it to oil pres- pressure switch is turned ON (Stop
sure gauge [1] of hydraulic tester O1. the operation short of starting the
a Use the oil pressure gauge with machine).
capacity 6.0 MPa {60 kg/cm2}. 5) Remove the measurement tool after the

operating range.
Adjusting
a If the LS differential pressure is abnormal,
adjust LS valves (8) and (9) according to the
following procedure.
q (8): Front pump LS valve
q (9): Rear pump LS valve
1. While fixing adjusting screw (10), loosen lock-

nut (11).
2. Turn adjusting screw (10) to adjust the pres-

sure.
a Adjustment screw
q Turned to the right, the differential
pressure is increased.
q Turned to the left, the differential
pressure is decreased.
a Quantity of adjustment per turn of adjust-
ment screw (LS differential pressure):
1.3 MPa {13.3 kg/cm2}
3. After the adjustment, confirm that LS differen-

tial pressure is normal, following the steps for
measurement explained earlier.
Measuring solenoid valve output

pressure 1 2. Install adapter P2 or P3 and connect the cur-
rently disconnected hose again.
a Solenoid valve output pressure measurement
tools 3. Install nipple [1] of hydraulic tester P1 and con-
Symbol Part No. Part name nect it to oil pressure gauge [2].
a Use the oil pressure gauge with capacity
1 5.9 MPa {60 kg/cm2}.
790-261-1204 Digital hydraulic tester a Figure shows the outlet hose of the 2-
799-401-3100 Adapter (Size 02) stage solenoid valve being installed with
P 2 the measuring tool.
02896-11008 O-ring
799-401-3200 Adapter (Size 03)
3
02896-11009 O-ring
a Measure the solenoid valve output pressure

after confirming that the control circuit source
pressure is normal.
1. Remove the control valve top cover and dis- 4. Start the engine and keep it running until the
connect outlet hoses (1) to (7) of the target hydraulic oil temperature rises to the operating
solenoid valve of measurement. range.
a A quick coupler is attached to the solenoid
valve of PPC lock solenoid valve's outlet
hose. Thus, measurement shall be con-
ducted on PPC valve side (back side of
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 shifting solenoid valve
5 Merge-divider solenoid valve
6 Travel junction solenoid valve
7 PPC lock solenoid valve 5. Run the engine at high idle and operate the con-
trol levers and switches to turn the solenoid valve
ON or OFF. Measure the oil pressure when the
valve is turned on and also when turned off.
a For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing
“Table for functioning conditions” for each
solenoid valve.
a The operating condition of the solenoid
valve can be checked with the monitoring
function of the machine monitor (For the
operating procedure, see “Special func-
tions of machine monitor”.
a When each output pressure shows the fol-

lowing values, it is judged normal.
Solenoid valve Output pressure
OFF (De-energized) 0 MPa {0 kg/cm2}
Almost the same pres-
sure as the control cir-
ON (Energized)
cuit basic pressure (See
“Standard values table”)

Table for functioning conditions – 2-stage relief solenoid valve

Opera-
Operating condition
tion
Overheat 1st setting is ON
OFF
All of work equipment, swing, and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
L-mode is selected ON
Boom LOWER signal is ON
Signals other than the swing single are ON
P or E-mode is selected Left knob switch is ON
Swing single is ON
OFF
Other than above conditions
Table for functioning conditions – machine push up solenoid valve

Opera-
Operating condition
tion
OFF ON
Machine push-up switch
ON OFF
Table for functioning conditions – Swing holding brake solenoid valve

Opera-
Operating condition
tion
All are OFF OFF
Work equipment, swing, and travel signals
Any one is ON ON
Table for functioning conditions – Travel speed shifting solenoid valve

Opera-
Operating condition
tion
Overheat 2nd setting is ON
Fuel control dial is at 1,200 rpm or below
Travel speed switch is at Lo
OFF
Travel signal is OFF
F or R pump pressure is at 32.3 MPa {330 kg/cm2} or
Travel speed switch is at Mi or Hi above
Travel signal is ON
F or R pump pressure is at 18.6 MPa {190 kg/cm2} or
below ON
Table for functioning conditions – Merge/divide solenoid valve

Opera-
Operating condition
tion
When B mode is
Service single ON
selected
Travel is operated single ON
2
F or R pump pressure is at 19.6 MPa {200 kg/cm }
When a L-mode is not or above
Work equip- selected F or R pump pressure is at 14.7 MPa {150 kg/cm2}
Travel single signal ment, swing, OFF
or below
is ON and service
singles are F or R pump pressure is at 16.7 MPa {170 kg/cm2}
ON
ON or above
When L mode is selected
F or R pump pressure is at 11.8 MPa {120 kg/cm 2}
OFF
or below
Arm IN and bucket CURL F or R pump pressure is at 24.5 MPa {250 kg/cm }
2
ON
Travel signal is Swing sig- PPC pressure are or above
OFF nal is OFF 1.9 MPa {19.5 kg/cm2} or F or R pump pressure is at 19.6 MPa {200 kg/cm2}
above or below OFF
Table for functioning conditions – Travel junction solenoid valve

Opera-
Operating condition
tion
Travel steering signal is ON
Travel lever is oper- F or R pump pressure is at 34.3 MPa {350 kg/cm2} ON
Travel steering signal is OFF ated singly or above
Other than above conditions OFF
Table for functioning conditions – PPC lock solenoid valve

Opera-
Operating condition
tion
Lock OFF
Work equipment lock lever
Free ON
Measuring PPC valve output

pressure 1
a PPC valve output pressure measurement tools
1
Q 790-261-1204 Digital hydraulic tester
2 799-301-1740 Joint (PF1/4 + PT1/4)

sure inside the tank. 3. Connect nipple [1] of joint Q2 and hydraulic
tester Q1 and connect them to oil pressure
1. Remove the control valve top cover and the gauge [2].
operator cab under cover (front side). a Joint Q2 shall be used only when the mea-
surement is taken at the pressure sensor
2. Remove PPC hydraulic switch or PPC pres- installation position.
sure sensors (1) to (10) of the target circuit of a The oil pressure gauges used shall be 6.0
measurement. MPa {60 kg/cm2}.
a PPC pressure sensor for arm IN and a Figure shows the measuring tools being
bucket CURL detects errors in the electri- installed at the installation position of PPC
cal system as the starter switch is turned pressure sensor for arm IN circuit.
on when the connector is disconnected.
After removing the pressure sensor, con-
nect it to the connector again and then
clamp it to a nearby bracket.
Circuit to be mea- Circuit to be mea-
No. No.
sured sured
1 Boom RAISE (S06) 6 Bucket DUMP (S05)
2 Boom LOWER (S02) 7 Swing LEFT (S07)
3 Arm IN (S04) 8 Swing RIGHT (S03)
4 Arm OUT (S08) 9 Travel (S30)
5 Bucket CURL (S01) 10 Steering (S31)
4. Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.
5. Measure the pressure when the engine is run- Adjusting play of work equipment
ning at high idle and the control lever of the cir- and swing PPC valves 1
cuit to be measured is kept in the NEUTRAL
position and at the full stroke. a If there is excessive play in the work equip-
a If PPC valve output pressure is at the level ment or swing lever, adjust it in the following
shown below, it is judged normal. manner.
1. Remove work the equipment and swing PPC

Operation of levers Oil pressure
valve assembly.
Neutral 0 MPa {0 kg/cm 2}
Almost the same pres- 2. Remove boot (1).
sure as the control cir-
Stroke end
cuit basic pressure (See 3. Loosen locknut (2) and push disc (3) into pis-
“Standard values table”) ton (4) until it touches the heads of 4 pistons
(4).
a Do not move the piston while doing this
6. Remove the measurement tool after the mea- work.
back to normal condition. 4. Keep disc (3) in place and tighten locknut (2) to
the specified tightening torque.
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
5. Install boot (1).
6. Install the work equipment and swing PPC

valve assembly.
Inspecting locations of hydraulic 2. Inspection of arm cylinder

drift of work equipment 1 1) Stop the arm cylinder at a position approx-
imately 100 mm in front of the IN stroke
a If hydraulic drift occurred on the work equip- end and then stop the engine.
ment (cylinder), check to see if the cause is on
the cylinder packing side or control valve side
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same pos-
ture as when measuring hydraulic drift,
and stop the engine.
a Fill the bucket with earth or apply the
rated load to the bucket.
2) Operation the arm control lever in the IN

position
q If the lowering speed is increased at
this time, the cylinder packing is
defective.
q If the lowering speed does not
change at this time, the control valve
is defective.
a Operate the control lever with the engine
starting switch in the ON position.
2) When inspecting the boom cylinder, shift a If pressure in the accumulator has
the boom control lever to RAISE side and dropped, run the engine for approx.
when inspecting the bucket cylinder, shift 10 seconds to charge the accumula-
the bucket control lever to CURL side. tor again.
q If, as the result, drifting speed
increases, failure on the cylinder [Reference] Reasons why the lowering
packing should be suspected. speed is increased by the above operation
q If the speed remains unchanged, fail- when the cylinder packing is the cause of
ure on the control valve should be the hydraulic drift:
suspected. 1) If the work equipment is set to the
a Operate the control lever with the above posture (holding pressure
engine starting switch in the ON posi- applied to the bottom end), the oil at
tion. the bottom end leaks to the head end.
a If pressure in the accumulator has However, the volume at the head end
dropped, run the engine for approx. is small than the volume at the bottom
10 seconds to charge the accumula- end by the volume of the rod end, so
tor again. the internal pressure at the head end
increases because of the oil flowing in
from the bottom end.
2) If the internal pressure of the head
end increases, the pressure at the
bottom end also rises in proportion to
this and balanced at certain level (this
level depends on the volume of leak-
age). As the pressure is balanced, the
drifting speed is decreased.
3) If the lever is then operated according

to the procedure given above, the cir-
cuit at the head end is opened to the
drain circuit (the bottom end is closed
by the check valve), so the oil at the
head end flows to the drain circuit and
the downward movement becomes
faster.
3. Inspection of PPC valve

Measure the amount of hydraulic drift of the
work equipment when the accumulator is
charged with pressure and the lock lever is put
to the LOCK and FREE positions.
a Operate the control lever with the engine
starting switch in the ON position.
a If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again.
a If the lock and free position cause any dif-
ference in the hydraulic drift volume, the
PPC valve is defective (internal failure).
Releasing residual pressure from 3. Releasing residual pressure from swing

hydraulic circuit 1 motor circuit
a The residual pressure in the swing motor
1. Releasing residual pressure from hydrau- circuit can be released by performing the
lic tank same operation for “Releasing residual
k Since the hydraulic tank is enclosed pressure from hydraulic cylinder circuit”
and pressurized, release the residual (Operate the lever in the swing direction
pressure from it when removing a hose only, however).
or a plug connected to it.
1) Lower the work equipment to the ground 4. Releasing residual pressure from travel
in a stable position and stop the engine. motor circuit
2) Loosen oil filler cap (1) of the hydraulic a Since the control valve spool of the travel
tank gradually to release the air in the motor circuit is open, the pressure in this
tank. circuit can be released by performing the
same operation as that for “Releasing
residual pressure from hydraulic tank”.
2. Releasing residual pressure from hydrau-

lic cylinder circuit
k When disconnecting a pipe between a
hydraulic cylinder and the control
valve, release the residual pressure
from the piping according to the follow-
ing procedure.
1) Release residual pressure from the
hydraulic tank. For details, see “Releasing
residual pressure from hydraulic tank”.
a Keep the oil filler cap of the hydraulic
tank being removed.
2) Turn the starting switch ON and set the
lock lever in the FREE position, and then
operate the right and left work equipment
control levers forward, backward, to the
right, and to the left.
a The control valve is operated by the
pressure stored in the accumulator.
This pressure in the accumulator,
however, is used up after the control
valve is operated 2 – 3 times.
3) Run the engine at low idle for 5 seconds to
increase the pressure in the accumulator.
k The engine does not start until the lock
lever is set in the LOCK position once.
4) Repeat steps 2) and 3) above 2 – 3 times,
and the residual pressure in the piping is
released completely.
Measuring oil leakage amount 1 k Release the residual pressure from

the piping on the arm cylinder
a Measuring tools for oil leakage head side. For details, see “Releas-
Symbol Part No. Part name ing residual pressure from hydrau-
lic circuit” (Operate the lever in the
Commercially
R Measuring cylinder arm IN direction only, however).
available
3) Disconnect hose (2) on the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the
1. Measuring oil leakage from boom cylinder
1) Start the engine and keep it running until hose at the cylinder bottom end.
the hydraulic oil temperature rises to the a Use the following parts to block the
operating range. hose side.
2) Move the boom cylinder to the RAISE 07379-01044 (Flange #10)
stroke end and stop the engine.
k Release the residual pressure from
the piping on the boom cylinder head
side. For details, see “Releasing
residual pressure from hydraulic cir-
cuit”. (Operate the lever in the boom
RAISE direction only, however).
3) Disconnect hose (1) on the cylinder head
end and block the hose end with a plate.
hose at the cylinder bottom end.
a Use the following parts to block the
hose side.
07379-01044 (Flange #10)
4) Run the engine at high idle and relieve the
arm circuit by moving the arm IN.
k Take care not to “move the arm OUT”.
5) Continue this condition for 30 seconds,
then measure the oil leakage amount for
one minute.
6) After the measurement, make sure that
the machine is back to normal condition.
3. Measurement of oil leakage amount from

bucket cylinder
operating range.
2) Move the bucket cylinder to the CURL
4) Run the engine at high idle and relieve the stroke end and stop the engine.
k Release the residual pressure from
boom circuit by raising the boom.
k Take care not to “lower the boom”.
the piping on the bucket cylinder head
5) Continue this condition for 30 seconds, side. F or detai ls, se e “Re leasin g
then measure the oil leakage amount for residual pressure from hydraulic cir-
one minute. cuit” (Operate the lever in the bucket
6) After the measurement, make sure that CURL direction only, however).
the machine is back to normal condition. 3) Disconnect hose (3) on the cylinder head
side and block the hose side with a plate.
arm cylinder hose at the cylinder bottom end.
operating range.
2) Move the arm cylinder to the IN stroke end
a Use the following parts to block the a Continue this condition for 30 sec-
hose side. onds, then measure the oil leakage
07379-01044 (Flange #10) amount for one minute.
a After measurement 1 time, swinging
180°, and then measure again.

travel motor
1) Take off the travel motor cover.
2) Run the engine until the hydraulic oil is
heated up to the operating range and then
lock the travel lever to stop the engine.
k Insert pin [1] between the sprocket
and the track frame to positively
lock the travel circuit.
4) Run the engine at high idle and relieve the

bucket circuit by curling the bucket.
k Take care not to “Dump the
bucket”.
5) Continue this condition for 30 seconds,
then measure the oil leakage amount for
one minute.

swing motor
3) Disconnect drain hose (5) of the travel
operating range.
motor and block the hose side with a plug.
2) Disconnect drain hose (4) and block the
hose side with plugs.
hose side.
07376-70522 (Plug #05)
hose side.
07376-70522 (Plug #05)
3) Turn the swing lock switch to the ON posi-

tion.
4) Run the engine at high idle, relieve the
swing circuit, and measure the oil leakage.
4) Run the engine at high idle, relieve the

travel circuit, and measure the oil leakage.
k Wrong operation of the lever can
cause an accident. Accordingly,
make signs and checks securely.
a Continue this condition for 30 sec-
onds, then measure the oil leakage
amount for one minute.
a Measure several times, moving the
motor a little (changing the position of
the valve plate and cylinder and that
of the cylinder and piston) each time.
Bleeding air from various parts 1

Air bleeding items Air bleeding procedure
1 2 3 4 5 6
Bleeding air Checking oil
Bleeding air Bleeding air Bleeding air
from Starting level and
from cylin- from swing from travel
hydraulic engine starting
der motor motor
Contents of work pump work
• Replacing hydraulic oil q q
q q q q
• Cleaning strainer (See note) (See note)
• Replacing return filter element q o o o q
• Replacing and repairing hydraulic
pump q q q o o q
• Removing suction piping
• Replacing and repairing control
valve q q o o q
• Removing control valve piping
• Replacing and repairing cylinder
q q o o q
• Removing cylinder piping
• Replacing and repairing swing
motor q o q o q
• Removing swing motor piping
• Replacing and repairing travel
motor q o o q q
• Removing travel motor piping
• Replacing and repairing swivel joint
q o o o q
• Removing swivel joint piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Bleeding air from hydraulic pump

1) Loosen air bleeder (1) to make sure oil
oozes out through the air bleeder.
2) When oil does not flow out, disconnect
drain hose (2) and then fill up the pump
case with oil fed from the drain port.
a Fix the drain hose mouthpiece in a
position higher than the oil level in the
hydraulic tank.
a Continue supplying oil to the pump
case until air is eliminated from the
flowing out oil.
3) After making sure that the oil from bleeder
(1) is free from mixed air, tighten the
bleeder.
2. Starting engine
3 Air bleeder:
When running the engine after performing step
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
1, keep its speed at low idle for 10 minutes.
a When the drain hose was discon-
a If the engine coolant temperature is low
nected for above operation, connect it
and the automatic warm-up operation is
again after tightening the bleeder.
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 sec-
onds, and the automatic warm-up opera-
tion is reset).
3. Bleeding air from hydraulic cylinder 5. Bleeding air from travel motor
a In case a cylinder is replaced with new 1) Take off the travel motor cover.
one, it is advised to bleed air from the new 2) Start the engine and run it at low idle.
one before mounting the work equip- 3) Loosen bleeder (4) to make sure oil oozes
ment.It is especially so with the boom cyl- out.
inder, because its rod does not extend to 4) After making sure that the oil from bleeder
the stroke end of LOWER side, after the (4) is free from mixed air, tighten the
work equipment is mounted. bleeder.
1) Start the engine and keep running at low 3 Air bleeder:
idle for 5 minutes. 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
2) Raise and lower the boom 4 to 5 times
with the engine running at low idle.
a Stop the piston approximately 100
mm in front of the stroke end so that it
may not be relieved.
3) While running the engine at high idle, per-
form step 2).
4) While running the engine at low idle, move
the piston rod to the stroke end and
relieve the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
4. Bleeding air from swing motor

1) Start the engine and run it at low idle.
5) Using the work equipment, lift the track
2) Loosen S port hose (3) gradually to make
shoe of one side.
sure oil oozes out through the S port hose.
6) Gradually run the lifted track shoe at idle
k In this case, don't try to turn on the
for approximately two minutes.
swing operation.
a Repeat the same for the opposite
3) When oil does not flow out, stop the
side track shoe.
engine once, disconnect S port hose and
then fill up the motor case with oil.
a As the motor case is filled up with oil,
connect S port hose once and then
repeat steps 1) and 2).
4) After making sure that the oil from S port
hose is free from mixed air, tighten the
hose.
5) Perform two times minimum of swing
operation in left and right directions at
slow speeds.
6. Checking oil level and refilling

1) Run the engine, retract the arm cylinder
and bucket cylinder to the stroke ends,
lower the work equipment to the ground,
2) Check the oil level by sight gauge (5) on

the rear side of the hydraulic tank.
a The oil level is acceptable if it is situ-
ated between H and L lines.
a If the oil level is below line L, it is
insufficient. Add oil.
UEN02644-00
PC450/LC/LCD/LCHD-8 Hydraulic excavator

Form No. UEN02644-00
© 2007 KOMATSU
All Rights Reserved
Printed in Belgium 10-07 (01)
56
UEN02645-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Testing and adjusting, Part 2
Special functions of machine monitor ............................................................................................................. 2
Special functions of machine monitor 1

Air conditioner specification
Heater specification Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.
Upper section of machine monitor (Switch sec-

tion)
[F1]: F1 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
Lower section of machine monitor (Switch sec-

tion)
[1]: Numeral 1 input switch/Auto-decelerator
switch
[2]: Numeral 2 input switch/Working mode selector
Heaterless specification switch
[3]: Numeral 3 input switch/Travel speed shifting
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner or
heater switch
heater switch
heater switch
heater switch
Switch having no numerals: Air conditioner or
heater switch
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display.
a The difference between the air conditioner
specification, heater specification, and heater-
less specification is only the functions of the
switches in this section.
Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
t Operator mode (Outline) Service mode
6p 20p
A Display of KOMATSU logo 6p Monitoring 21p
A Display of inputting password 7p Mechanical Systems 26p
Abnormality
A Display of check of breaker mode 7p Electrical Systems 27p
Record
A Display of check before starting 7p Air-conditioning System/Heater System 33p
A Display of warning after check before starting 8p Maintenance Record 34p
A Display of ending of maintenance interval 8p Maintenance Mode Change 35p
A Display of check of working mode and travel speed 8p Phone Number Entry 37p
A Display of ordinary screen 8p Key-on Mode 38p
A Display of end screen 9p Unit 39p
B Selection of auto-deceleration 9p With/Without Attachment 40p
O (Special operation)
B Selection of working mode 9p Default Attachment/Maintenance Password 41p

B Selection of travel speed 10p Camera 42p
B Operation to stop alarm buzzer 10p ECO Display 43p
B Operation of windshield wiper 11p Breaker Detect 44p
B Operation of window washer 11p Pump Absorption Torque (F) 45p
B Operation of air conditioner/heater 11p Pump Absorption Torque (R) 46p
Adjustment
Operation to display camera mode Low Speed 47p
B 12p
(if camera is installed)
Attachment Flow Adjustment 48p
B Operation to display clock and service meter 12p
Cylinder Cut-Out 49p
B Check of maintenance information 13p
No Injection 50p
Setting and display of user mode
B 13p Fuel Consumption 52p
(Including KOMTRAX messages for user)
C Display of energy-saving guidance 14p Terminal Status 53p
C Display of caution monitor 14p KOMTRAX GPS & Communication Status 54p
Settings MODEM S/N (TH300) 55p
C Display of automatic judgment of breaker 15p
C Display of user code and failure code 15p MODEM IP Address (TH200) 56p
O (Special operation) Display of KOMTRAX message 57p
Function of checking display of LCD

D 17p
(Liquid Crystal Display)
D Function of checking service meter 17p
Function of changing attachment/maintenance
D 18p
password
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
Operator mode (Outline) a Display pattern of operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/opera- starting switch is turned ON to time when
tion of each function/display, see the Structure, screen changes to ordinary screen depends on
function and maintenance standard, or Opera- the setting and condition of the machine.
tion and Maintenance Manual. A : When engine start lock is set effective
a The following are the displays or functions of B : When engine start lock is set ineffective
the operator mode explained in this section C : When working mode at start is set to
(including some items which need special breaker mode (B)
operations). D : When there is abnormal item in check-
before-starting items
Display pattern E : When there is maintenance item which is
A B C D E not maintained after specified interval
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 — — — —
Display of check of breaker mode — — 2 — —
Display of KOMATSU logo
Display of check before starting 3 2 3 2 2
Whe n t he sta rti ng sw it ch is tu rn ed ON , t he
Display of warning after check
before starting
— — — 3 — KOMATSU logo is displayed for 2 seconds.
a After the KOMATSU logo is displayed for 2
Display of ending of maintenance
interval
— — — — 3 seconds, the screen changes to “Display of
inputting password”, “Display of check of
Display of check of working mode
and travel speed
4 3 4 4 4 breaker mode (if B mode is set)”, or “Display of
check before starting”.
Display of ordinary screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner/heater
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Check of maintenance information a The following screen may be displayed instead
Setting and display of user mode (including of the above Display of inputting password
KOMTRAX messages for user) screen.
Display of energy-saving guidance a If this screen is displayed, call the person
Display of caution monitor responsible to operation of KOMTRAX in your
Display of automatic judgment of breaker Komatsu distributor and ask for remedy.
Display of user code and failure code
O (Special operation)
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing attachment/maintenance pass-
word
Display of inputting password

After the KOMATSU logo is displayed, the screen
to input the engine start lock password is displayed.
a This screen is displayed only when the engine
start lock function is set effective.
a If the password is input normally, the screen
changes to “Display of check of breaker mode
(if B mode is set)” or “Display of check before
starting”.
a The machine monitor has some password
functions other than the engine start lock.
Those functions are independent from one
another.
Display of check before starting

When the screen changes to the check-before-
starting screen, the check before starting is carried
out for 2 seconds.
a If any abnormality is detected by the check
before starting, the screen changes to “Display
of warning after check before starting” or “Dis-
play of ending of maintenance interval”.
a If no abnormality is detected by the check
before starting, the screen changes to “Display
of check of working mode and travel speed”.
a The monitors (6 pieces) displayed on the screen
are the items under the check before starting.
Display of check of breaker mode
When the starting switch is turned ON, if the work-
ing mode is set to the breaker mode [B], a message
to inform the operator of starting in the breaker
mode is displayed on the screen.
k If an attachment other than the breaker is
used while the working mode is set to the
breaker mode [B], the machine may move
unexpectedly or may not operate normally
or the hydraulic components may be dam-
aged.
a After operation to check of the breaker mode is
finished, the screen changes to “Display of
check before starting”.
If No is selected: Working mode is set to econ-
omy mode [E]
If Yes is selected: Working mode is set to
breaker mode [B]
Display of warning after check before starting Display of check of working mode and travel
If any abnormality is detected by the check before speed
starting, the warning monitor is displayed on the If the check before starting is finished normally, the
screen. screen to check the working mode and travel speed
a The following figure shows that the engine oil is displayed for 2 seconds.
level monitor (a) is warning of low of engine oil a After display of check of the working mode and
level. travel speed is finished, the screen changes to
“Display of ordinary screen”.
Display of ending of maintenance interval

When the check before starting is carried out, if a Display of ordinary screen
maintenance item is near or after the end of the set If the machine monitor starts normally, the ordinary
interval, the maintenance monitor is displayed for screen is displayed.
30 seconds to urge the operator to maintenance. a Service meter (a) or a clock is displayed at the
a This screen is displayed only when the mainte- center upper section of the screen (The ser-
nance function is effective. The color of the vice meter or clock is selected with [F4]).
maintenance monitor (yellow or red) indicates a ECO gauge (b) is displayed at the right end of
the length of the time after the maintenance the screen (It is turned ON and OFF in the ser-
interval. vice mode).
a Set or change the maintenance function in the
service mode.
a After display of this screen is finished, the
screen changes to “Display of check of work-
ing mode and travel speed”.
Display of end screen Selection of working mode

When the starting switch is turned OFF, the end Select a working mode according to the following
screen is displayed for 5 seconds. procedure.
a Another message may be displayed on the 1. While the ordinary screen is displayed, press
end screen, depending on the message dis- the working mode selector switch, and the
play function of KOMTRAX. working mode selection screen is displayed.
a The following figure is the working mode
selection screen displayed when "With
attachment" is set (If "With attachment" is
not set in the service mode, the attach-
ment mode [ATT] is not displayed).
Selection of auto-deceleration
While the ordinary screen is displayed, if the auto-
deceleration switch is pressed, large auto-deceler-
ation monitor (a) is displayed for 2 seconds and the
setting of the auto-deceleration is changed. 2. Operate the function switches or working mode
a Each time the auto-deceleration switch is selector switch to select and confirm the work-
pressed, the auto-deceleration is turned ON ing mode which you will use.
and OFF alternately. Function switches
a If the auto-deceleration is turned ON, large q [F3]: Move to lower working mode
monitor (a) and auto-deceleration monitor (b) q [F4]: Move to upper working mode
are displayed simultaneously. q [F5]: Cancel selection and return to ordi-
a If the auto-deceleration is turned OFF, auto- nary screen
deceleration monitor (b) goes off. q [F6]: Confirm selection and return to ordi-
nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
a If you do not touch any of the function
switches and working mode selector
switch for 5 seconds, the selection is con-
firmed and the screen changes to the ordi-
nary screen.
3. When the ordinary screen is displayed again, Selection of travel speed

large working mode monitor (a) is displayed for While the ordinary screen is displayed, if the travel
2 seconds, and then the setting of the working speed shifting switch is pressed, large travel speed
mode is changed. monitor (a) is displayed for 2 seconds and the set-
a When large monitor (a) is displayed, the ting of the travel speed is changed.
display of working mode monitor (b) is a Each time the travel speed shifting switch is
changed, too. pressed, the travel speed is changed to Lo, Mi,
Hi, and Lo again in order.
a When large monitor (a) is displayed, the dis-
play of travel speed monitor (b) is changed,
too.
<Precautions for selecting breaker mode [B]>

q If breaker mode [B] is selected, both of the
control of the hydraulic pump and the setting of
the hydraulic circuit are changed.
q If an attachment other than the breaker is
used, the machine may move unexpectedly or Operation to stop alarm buzzer
may not operate normally or the hydraulic While the alarm buzzer is sounding, if the alarm
components may be damaged. buzzer cancel switch is pressed, the alarm buzzer
q After the breaker mode is selected, the screen stops.
to confirm the selection of the breaker mode is a Even if the alarm buzzer cancel switch is
displayed (The buzzer sounds intermittently pressed, the screen does not change.
while this screen is displayed).
q If the setting is confirmed on this screen, the
screen changes to the ordinary screen.
If No is selected:
Screen returns to screen to select working
mode.
If Yes is selected:
Working mode is set to breaker mode [B]
Operation of windshield wiper Operation of air conditioner/heater

While the ordinary screen is displayed, if the wiper While the ordinary screen is displayed, press the air
switch is pressed, large wiper monitor (a) is dis- conditioner switch or heater switch, and the air con-
played for 2 seconds and the windshield wiper ditioner adjustment screen or heater adjustment
starts or stops. screen is displayed.
a Each time the wiper switch is pressed, the a While the air conditioner adjustment screen or
windshield wiper setting is changed to INT, heater adjustment screen is displayed, if you
ON, OFF, and INT again in order. do not touch any switch for 5 seconds, the
a When large monitor (a) is displayed, the dis- screen changes to the ordinary screen.
play of wiper monitor (b) is changed or turned a Air conditioner specification
OFF, too.
a If the windshield wiper is turned OFF, large
monitor (a) is not displayed.
a Heater specification
Operation of window washer

While the ordinary screen is displayed, if the win-
dow washer switch is pressed, the washing liquid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen does not change.
Operation to display camera mode (if camera is Operation to display clock and service meter
installed) While the ordinary screen is displayed, press [F4],
When a camera is installed, if [F3] is pressed, the and section (a) changes to the service meter and
multi-display changes to the camera image (Set the clock alternately.
connection of the camera in the service mode). a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the sum-
mer time with the user mode function.
a Up to 3 cameras can be connected. If the cam-

era mode is selected, however, only the image
of camera 1 is always displayed.
a If a caution is generated in the camera mode,

the caution monitor is displayed at the left
upper of the screen (The low hydraulic oil tem-
perature caution is not displayed there, how-
ever).
a When an error that there is a user code occurs
in the camera mode, if you do not touch any
control lever for 10 seconds, the screen
changes to the ordinary screen and displays
the error information.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
Check of maintenance information Setting and display of user mode

While the maintenance monitor or ordinary screen (Including KOMTRAX messages for user)
is displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6],
screen is displayed. and the user menu screen is displayed.
a To reset the time left after finishing mainte- a There are following items in the user menu.
nance, more operations are necessary.
Breaker/Attachment Settings
User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment
a The breaker/attachment setting menu is dis-

played only when "With attachment" is set in
the service mode.
[KOMTRAX message] Display of energy-saving guidance

q There are 2 types of KOMTRAX message; 1 is When the machine is set in a certain operating con-
for the user and the other is for the service. dition, the energy-saving guidance screen is dis-
q For user: played automatically to urge the operator to the
A message transmitted from the KOMTRAX energy-saving operation.
base station for the user. If it is received, the a The energy-saving guidance is displayed when
message monitor is displayed on the ordinary the following condition is satisfied while the
screen. To see the contents of the message, display setting is set effective in the service
operate "User Message" in the above user mode.
menu. a Condition for display:
q For service: Engine is running + All levers have been in
A message transmitted from the KOMTRAX neutral for 5 minutes + Caution (Note) or user
base station for the service. Even if it is code is not generated (Note)
received, nothing is displayed on the ordinary Note: Excluding hydraulic oil low temperature
screen. To see the contents of the message, caution
operate "KOMTRAX message" display in the a If any lever or pedal is operated, or [F5] is
service menu. pressed, the screen returns to the ordinary
screen.
Display of caution monitor

If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution mon-
itor flashes at the left upper of the screen when
the caution is generated.
Display of automatic judgment of breaker Display of user code and failure code
If the op erator per forms brea ker work in an If an abnormality which displays a user code and a
improper working mode, the breaker automatic failure code occurs on the ordinary screen or cam-
judgment screen is displayed to urge the operator era mode screen, all the information of the abnor-
to select a proper working mode. mality is displayed.
a The breaker automatic judgment is displayed (a): User code (3 digits)
when the following condition is satisfied while (b): Failure code (5 or 6 digits)
the display setting is set effective in the service (c): Telephone mark
mode. (d): Telephone No.
a Condition for display: a This screen is displayed only when an abnor-
When the pump controller measures the rear mality (failure code) for which a user code is
pump pressure for a certain time, the obtained set occurs.
value is similar to the pulsation wave form of a The telephone mark and telephone No. are
breaker operation which is held in the control- displayed only when the telephone No. is reg-
ler in advance. istered in the service mode.
a The breaker automatic judgment function is set a If multiple abnormalities occur simultaneously,
to Not used (Not displayed) when delivered. all the codes are displayed repeatedly in order.
a If this screen is displayed, check the setting of a Since the information of the displayed failure
the working mode. If the breaker is being code is recorded in the abnormality record in
used, select the breaker mode [B]. the service mode, check the details in the ser-
a To return to the ordinary screen, press [F5]. vice mode.
a When the caution monitor is also displayed,

the telephone mark is not displayed.
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
Move the swing brake cancel switch up to release the brake.
When applying the swing brake, operate the swing lock switch
E03 Swing brake system error manually. Depending on the cause of the problem, it may not
be possible to release it. In any case, have inspection carried
out immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried
E11
Output reduced to protect engine out immediately.
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error
out immediately.
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the
a When finishing the operation of the switches, LCD, hold down the switches until the LCD dis-
release [F2] first. plays normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continu-
part is indicated in black. ously, blue points (points which do not go off)
a The LCD panel sometimes has black points may be seen on this screen. This phenomenon
(points which are not lighted) and bright points does not indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.
Function of changing attachment/maintenance 3. After the New password input screen is dis-
password played, input a new password with the numeral
When changing the attachment/maintenance pass- input switches and confirm it with the function
word used for the attachment setting function and switch.
maintenance setting function, follow these proce- a Set a new password of 4 – 6 digits (If it
dures. has only 3 or less digits or has 7 or more
1. While the ordinary screen is displayed, perform digits, it is not accepted).
the following operation with the numeral input q [F5]: Reset input numeral/Return to ordi-
switches. nary screen
q Operation of switches (While pressing [4], q [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
4. After the New password input screen is dis-

played again, input a new password again with
the numeral input switches and confirm it with
the function switch.
q [F5]: Reset input numeral/Return to ordi-
2. After the Attachment/Maintenance PASS- nary screen
WORD screen is displayed, input the current q [F6]: Confirm input numeral
password with the numeral input switches and a If a password different from the password
confirm it with the function switch. input before is input, the message to input
q [F5]: Reset input numeral/Return to ordi- again is displayed.
nary screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is dis-
played, the password is changed successfully.
t Service mode a The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows (including
perform the following operation. some items which need special opera-
This operation is always required when you use the tions).
service mode. 01 Monitoring
Mechanical Systems
1. Check of display of screen and operation of
switches 02 Abnormality Electrical Systems
While the ordinary screen is displayed, perform Record
Air-conditioning System/Heater
the following operation with the numeral input System
switches. 03 Maintenance Record
q Operation of switches (While pressing [4],
04 Maintenance Mode Change
perform the operation in order):
[4] + [1] o [2] o [3] 05 Phone Number Entry
a This operation of the switches is accepted Key-on Mode
only while the ordinary screen is displayed. Unit
With/Without Attachment
Attachment/Maintenance
06 Default
Password
Camera
ECO Display
Breaker Detect
Pump Absorption Torque (F)
Pump Absorption Torque (R)
07 Adjustment
Low Speed
Attachment Flow Adjustment
08 Cylinder Cut-Out
09 No Injection
2. Selection of service menu
10 Fuel Consumption
When the Service menu screen is displayed,
the service mode is selected. Select a service Terminal Status
menu you use with the function switches or 11 KOMTRAX GPS & Communication Status
numeral input switches. Settings MODEM S/N (TH300)
q [F3]: Move to lower menu
MODEM IP Address (TH200)
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select “Monitoring” on the service menu
screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Double-
click or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
2. Selecting monitoring items monitoring is executed.
After the “Monitoring selection menu screen” is a If monitoring items are selected up to the
displayed, select items to be monitored with limit number, monitoring is executed auto-
th e f u n ct i o n s w i tc h e s o r n u me r a l i n pu t matically.
switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Reset input numeral/Return to ser-
vice menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
a Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that item
with [F6].
a If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
a Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.
4. Executing monitoring 6. Changing machine setting mode

After the “Executing monitoring screen” is dis- To change the setting of the working mode,
played, perform the necessary operation of the travel speed, or auto-deceleration during moni-
machine and check the monitoring information. toring, operate the corresponding switch under
a Monitoring information is indicated by the current condition, and the mode setting
value, ON/OFF, or special display. screen is displayed.
a The unit of display can be set to SI unit, While this screen is displayed, if the corre-
metric unit, or inch unit with the Initializa- sponding switch is operated further, the corre-
tion function in the service mode. sponding mode is changed.
a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the
screen returns to the ordinary screen after
monitoring is finished.
5. Holding monitoring information

The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold information (displayed data)
q [F5]: Return to monitoring selection menu
screen
a If the working mode is changed to breaker
mode [B], t he s creen t o co nfirm the
change of the setting is displayed as in
changing the working mode on the ordi-
nary screen.
Monitoring items table

Unit (Initial setting: ISO) Com-
Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
00200 Controller Model Select — PUMP
00201 Machine ID — ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm2 psi PUMP
01101 R Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket Dump PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr.(F) mA mA mA PUMP
01302 PC-EPC Sol. Curr.(R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divider Sol. Curr.(Main) mA mA mA PUMP
08001 Merge-divider Sol. Curr.(LS) mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value indication
36500 Boost Pressure kPa kg/cm2 psi ENG (including atmospheric
pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sonser Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode — ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP

Code ponent
charge
Swing ON•OFF PUMP
Travel ON•OFF PUMP
Boom Lower ON•OFF PUMP
01900 Pressure Switch 1
Boom Raise ON•OFF PUMP
Arm Curl ON•OFF PUMP
Arm Dump ON•OFF PUMP
Bucket Curl ON•OFF PUMP
Bucket Dump ON•OFF PUMP
01901 Pressure Switch 2
Service ON•OFF PUMP
Travel Steering ON•OFF PUMP
Travel Junction ON•OFF PUMP
Swing Brake ON•OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON•OFF PUMP
2-Stage Relief ON•OFF PUMP
Travel Speed ON•OFF PUMP
02301 Solenoid Valve 2 Service Return ON•OFF PUMP
Lever Sw. ON•OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON•OFF PUMP
Swing Brake Sw. ON•OFF PUMP
Model Select 1 ON•OFF PUMP
02201 Switch Input 2
Overload Alarm ON•OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON•OFF PUMP
Window Limit SW. ON•OFF PUMP
02204 Switch Input 5 P Limit SW. ON•OFF PUMP
W Limit SW. ON•OFF PUMP
Key Switch ON•OFF MON
Start ON•OFF MON
04500 Monitor input 1 Preheat ON•OFF MON
Light ON•OFF MON
Rad. Level ON•OFF MON
Air cleaner ON•OFF MON
04501 Monitor Input 2 Eng. Oil Level ON•OFF MON
Battery Charge ON•OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON•OFF MON
F1 ON•OFF MON
F2 ON•OFF MON
Monitor Function F3 ON•OFF MON
04503
Switches F4 ON•OFF MON
F5 ON•OFF MON
F6 ON•OFF MON
SW1 ON•OFF MON
SW2 ON•OFF MON
Monitor 1st & 2nd SW3 ON•OFF MON
04504
Row Switches SW4 ON•OFF MON
SW5 ON•OFF MON
SW6 ON•OFF MON

Code ponent
charge
SW7 ON•OFF MON
SW8 ON•OFF MON
Monitor 3rd & 4th SW9 ON•OFF MON
04505
Row Switches SW10 ON•OFF MON
SW11 ON•OFF MON
SW12 ON•OFF MON
SW13 ON•OFF MON
Monitor 5th Row
04506 SW14 ON•OFF MON
Switches
SW15 ON•OFF MON
18800 Water In Fuel ON•OFF ENG WIF: Water In Fuel
20216 ECM Build Version — ENG
20217 ECM CAL Data Ver — ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No — ENG
20227 Monitor Ass'y P/N — MON
20402 Monitor Serial No — MON
20228 Monitor Prog. P/N — MON
20229 Pump Con. Ass'y P/N — PUMP
20403 Pump Con. Serial No — PUMP
20230 Pump Con. Prog. P/N — PUMP
a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit selecting in Initialization of the
service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
Abnormality Record (Mechanical Systems) 3. Information displayed on “abnormality record”

The machine monitor classifies and records the screen
abnormalities which occurred in the past or which On the “Mechanical Systems” screen, the fol-
are occurring at present into the mechanical sys- lowing information is displayed.
tems, electrical systems, and air-conditioning sys- (a) : Occurrence order of abnormalities from
tem or heater system. latest one/Total number of records
To check the mechanical system abnormality (b) : Failure code
record, perform the following procedures. (c) : Contents of trouble
(d) : Number of occurrence time (Displayable
1. Selecting menu range: 0 – 65,535 times)
Select “Abnormality Record” on the “Service (e) : Service meter reading at first occurrence
Menu” screen. (f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if
displayed)
q [F5]: Return to abnormality record screen
a If no abnormality record is recorded, "No
abnormality record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
a For all the failure codes that the machine
2. Selecting sub menu monitor can record, see the failure codes
After the “Abnormality Record” screen is dis- table in “Abnormality Record (Electrical
played, select “Mechanical Systems” with the Systems)”.
function switches or numeral input switches.
q [F5]: Return to service menu screen
numeral input switches to select the record
a The following figure shows the display of
the air conditioner specification. The
heater specification and heaterless speci-
fication are different from each other in the
display of "03 Air-conditioning System",
which may not be displayed in the heater-
less specification.
4. Resetting abnormality record

The con tents of th e me cha nic al s yst em
abnormality record cannot be reset.
Abnormality Record (Electrical Systems)

The machine monitor classifies and records the
abnormalities which occurred in the past or which
are occurring at present into the mechanical sys-
tems, electrical systems, and air-conditioning sys-
tem.
To check the electrical system abnormality record,
perform the following procedures.
3. Information displayed on “abnormality record”
1. Selecting menu screen
Select “Abnormality Record” on the “Service On the “Electrical Systems” screen, the follow-
Menu” Screen. ing information is displayed.
(a) : Occurrence order of abnormalities from
latest one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if
displayed)
2. Selecting sub menu q [F5]: Return to “abnormality record” screen
After the “Abnormality Record” screen is dis- a If no abnormality record is recorded, "No
played, select “Electrical Systems” with the abnormality record" is displayed.
function switches or numeral input switches. a If the number of occurrence time is 1 (first
q [F3]: Move to lower item occurrence), the service meter reading at
q [F4]: Move to upper item the first occurrence and that at the last
q [F5]: Return to service menu screen occurrence are the same.
q [F6]: Confirm selection a If [E] is displayed on the left of a failure
a You may enter a 2-digit code with the code, the abnormality is still occurring or
numeral input switch es to select the resetting of it has not been confirmed.
record of that code and confirm it with a For all the failure codes that the machine
[F6]. monitor can record, see the failure codes
a The following figure shows the display of table.
the air conditioner specification. The
heater specification and heaterless speci-
fication are different from each other in the
display of "03 Air-conditioning System",
which may not be displayed in the heater-
less specification.
4. Resetting abnormality record 3) After the “Electrical Sys. Error Reset”

1) While the “Electrical Systems” screen is screen is displayed, operate the function
displayed, perform the following operation switches.
with the numeral input switches. q [F5]: Return to “Electrical systems”
q Operation of switches (While pressing screen (Reset mode)
[4], perform the operation in order): q [F6]: Execute reset
[4] + [1] o [2] o [3] a The following figure shows the screen
displayed when the items are reset
one by one (which is a little different
from the screen displayed when all
the items are reset together).
2) Check that the screen is set in the reset

mode, and then reset the items one by
one or together with the function switches.
a If the screen is set in the reset mode,
[CLEAR] graphic mark is indicated at 4) If the screen to notify completion of reset
[F2]. is displayed and then the “Electrical Sys-
q [F2]: Reset all items tems” (reset mode) screen is displayed,
q [F3]: Move to lower item the reset of the abnormality record is com-
q [F4]: Move to upper item pleted.
q [F5]: Return to abnormality record a After a while, the screen returns to
screen the “Electrical Systems” screen.
q [F6]: Reset selected item
a To reset items one by one: Select the
item to be reset with [F3] or [F4] and
press [F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless
of selection of the items.
a If [E] is displayed on the left of a fail-
ure code, the resetting operation is
accepted but the information is not
reset.
Failure codes table

User Alarm Component Category of
Failure code Trouble (Displayed on screen)
code buzzer in charge record
Electrical
989L00 Engine Controller Lock Caution 1 MON
system
Electrical
989M00 Engine Controller Lock Caution 2 MON
system
Electrical
989N00 Engine Controller Lock Caution 3 MON
system
Mechanical
AA10NX Air Cleaner Clogging MON
system
Mechanical
AB00KE Charge Voltage Low MON
system
Mechanical
B@BAZG Eng Oil Press. Low e ENG
system
Mechanical
B@BAZK Eng Oil Level Low MON
system
Mechanical
B@BCNS Eng Water Overheat e ENG
system
Mechanical
B@BCZK Eng Water Level Low e MON
system
Mechanical
B@HANS Hydr Oil Overheat e PUMP
system
Electrical
E10 CA111 EMC Critical Internal Failure q ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error q ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
system
Electrical
E14 CA131 Throttle Sensor High Error q ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
system
Electrical
E11 CA155 Chg Air Temp High Speed Derate q ENG
system
Electrical
E15 CA187 Sens Supply 2 Volt Low Error q ENG
system
Electrical
E11 CA221 Ambient Press Sens High Error q ENG
system
Electrical
E11 CA222 Ambient Press Sens Low Error q ENG
system
Electrical
E15 CA227 Sens Supply 2 Volt High Error q ENG
system
Mechanical
CA234 Eng Overspeed ENG
system
Electrical
E15 CA238 Ne Speed Sens Supply Volt Error q ENG
system
Electrical
E10 CA271 IMV/PCV1 Short Error q ENG
system
Electrical
E10 CA272 IMV/PCV1 Open Error q ENG
system
Electrical
E11 CA322 Inj #1 (L#1) Open/Short Error q ENG
system

Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility q ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error q ENG
system
Electrical
E15 CA352 Sens Supply 1 Volt Low Error q ENG
system
Electrical
E15 CA386 Sens Supply 1 Volt High Error q ENG
system
Electrical
E15 CA428 Water in Fuel Sensor High Error q ENG
system
Electrical
E15 CA429 Water in Fuel Sensor Low Error q ENG
system
Electrical
E15 CA435 Eng Oil Press Sw Error q ENG
system
Electrical
E10 CA441 Battery Voltage Low Error q ENG
system
Electrical
E10 CA442 Battery Voltage High Error q ENG
system
Electrical
E11 CA449 Rail Press Very High Error q ENG
system
Electrical
E11 CA451 Rail Press Sensor High Error q ENG
system
Electrical
E11 CA452 Rail Press Sensor Low Error q ENG
system
Electrical
E11 CA488 Chg Air Temp High Torque Derate q ENG
system
Electrical
E15 CA553 Rail Press High Error q ENG
system
Electrical
E15 CA559 Rail Press Low Error q ENG
system
Electrical
E15 CA689 Eng Ne Speed Sensor Error q ENG
system
Electrical
E15 CA731 Eng Bkup Speed Sens Phase Error q ENG
system
Electrical
E10 CA757 All Continuous Data Lost Error q ENG
system
Electrical
E15 CA778 Eng Bkup Speed Sensor Error q ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
system
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
system
Electrical
E11 CA2249 Rail Press Very Low Error q ENG
system
Electrical
E11 CA2311 IMV Solenoid Error q ENG
system
Electrical
E15 CA2555 Grid Htr Relay Volt High Error q ENG
system

Electrical
E15 CA2556 Grid Htr Relay Volt Low Error q ENG
system
Electrical
E01 D19JKZ Personal Code Relay Abnormality q MON2
system
Electrical
D862KA GPS Antenna Discon MON2
system
Electrical
E0E DA22KK Pump Solenoid Power Low Error q PUMP
system
Electrical
DA25KP 5 V Sensor 1 Power Abnormality PUMP
system
Electrical
DA29KQ Model Selection Abnormality PUMP
system
Electrical
E0E DA2RMC CAN Discon (Pump Con Detected) q PUMP
system
Electrical
DAFGMC GPS Module Error MON2
system
Electrical
E0E DAFRMC CAN Discon (Monitor Detected) q MON
system
Electrical
DGH2KB Hydr Oil Sensor Short PUMP
system
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP
system
Electrical
DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP
system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP
system
Electrical
DHX1MA Overload Sensor Abnormality (Analog) PUMP
system
Electrical
DW43KA Travel Speed Sol Discon PUMP
system
Electrical
DW43KB Travel Speed Sol Short PUMP
system
Electrical
E03 DW45KA Swing Brake Sol Discon q PUMP
system
Electrical
E03 DW45KB Swing Brake Sol Short q PUMP
system
Electrical
DW91KA Travel Junction Sol Discon PUMP
system
Electrical
DW91KB Travel Junction Sol Short PUMP
system
Electrical
DWA2KA Service Sol Discon PUMP
system
Electrical
DWA2KB Service Sol Short PUMP
system
Electrical
DWK0KA 2-stage Relief Sol Discon PUMP
system
Electrical
DWK0KB 2-stage Relief Sol Short PUMP
system
Electrical
E02 DXA8KA PC-EPC (F) Sol Discon q PUMP
system

Electrical
E02 DXA8KB PC-EPC (F) Sol Short q PUMP
system
Electrical
E02 DXA9KA PC-EPC (R) Sol Discon q PUMP
system
Electrical
E02 DXA9KB PC-EPC (R) Sol Short q PUMP
system
Electrical
DXE0KA LS-EPC Sol Discon PUMP
system
Electrical
DXE0KB LS-EPC Sol Short PUMP
system
Electrical
DXE4KA Service Current EPC Discon PUMP
system
Electrical
DXE4KB Service Current EPC Short PUMP
system
Electrical
DXE5KA Merge-divider Main Sol Discon PUMP
system
Electrical
DXE5KB Merge-divider Main Sol Short PUMP
system
Electrical
DXE6KA Merge-divider LS Sol Discon PUMP
system
Electrical
DXE6KB Merge-divider LS Sol Short PUMP
system
Electrical
DY20KA Wiper Working Abnormality PUMP
system
Electrical
DY20MA Wiper Parking Abnormality PUMP
system
Electrical
DY2CKA Washer Drive Discon PUMP
system
Electrical
DY2CKB Washer Drive Short PUMP
system
Electrical
DY2DKB Wiper Drive (For) Short PUMP
system
Electrical
DY2EKB Wiper Drive (Rev) Short PUMP
system
a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
a User code
Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
a Alarm buzzer
q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop
the buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
a Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
a Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.
Abnormality Record (Air-conditioning System/ 3. Information displayed on “abnormality record”

Heater System) screen
The machine monitor classifies and records the On the “Air-conditioning System” or “Heater
abnormalities which occurred in the past or which System” screen, the following information is
are occurring at present into the mechanical sys- displayed.
tems, electrical systems, and air-conditioning (a): System/Component name
abnormalities or heater abnormalities. (b): Number of occurrence time
To check the air-conditioning abnormality record or (c): Condition (Normal or abnormal)
heater abnormality record, perform the following q [F2]: Reset abnormality record
procedures. q [F5]: Return to abnormality record screen
a All the following figures show the air condi- a If [E] is displayed on the left of a condition,
tioner specification. the abnormality is still occurring or reset-
ting of it has not been confirmed.
1. Selecting menu a If CAN disconnection is displayed in Com-
Select “Abnormality Record” on the “Service munication condition, communication can-
Menu” screen. not be carried out normally. Accordingly,
the conditions of other items are turned
OFF.
2. Selecting sub menu

After the “Abnormality Record” screen is dis-
played, select “Air-conditioning System” or 4. Resetting abnormality record
“Heater System” with the function switches or While the “abnormality record” screen is dis-
numeral input switches. played, press [F2], and the number of occur-
q [F3]: Move to lower item rence time of abnormality is reset. If it is
q [F4]: Move to upper item confirmed at this time that the abnormality has
q [F5]: Return to service menu screen been reset, the display changes to Normal.
a You may enter a 2-digit code with the a Heater specification
numeral input switch es to select the In the heater specification, the display of “Air-
record of that code and confirm it with conditioning” is replaced with “Heater” and the
[F6]. items which are not related to the heater are
not displayed.
a Heaterless specification
In the heaterless specification, the abnormality
record menu and screen are not displayed.
Maintenance Record a The following items can be selected in the

The machine monitor records the maintenance maintenance record.
information of the filters, oils, etc., which the opera- 01 Engine oil change
tor can display and check by the following opera- 02 Engine oil filter change
tions. When maintenance is carried out, if the data
03 Fuel main filter change
are reset in the operator mode, the number of the
41 Fuel pre-filter change
times of maintenance is recorded in this section.
04 Hydraulic oil filter change
05 Hydraulic tank breather change
1. Selecting menu 06 Corrosion resistor change
Select “Maintenance Record” on the “Service 07 Damper case service
Menu” screen. 08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change
3. Items displayed on maintenance record screen

The following items are displayed.
(a) : Maintenance items
(b) : Number of times of replacement up to now
(c) : Service meter reading (SMR) at previous
replacement
2. Selecting maintenance record item

After the “Maintenance Record” screen is dis-
played, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
numeral input switches to select the item
of that code.
Maintenance Mode Change a The following items can be selected on

The operating condition for maintenance function in the Change of maintenance mode screen.
the operation mode can be set and changed with 00 Maintenance mode on/off
this menu. 01 Engine oil change int.
q Set function effective or ineffective
02 Engine oil filter change int.
q Change set replacement interval (by items)
03 Fuel main filter change int.
q Initialize all set replacement intervals
41 Fuel pre filter change int.
1. Selecting menu 04 Hyd oil filter change int.
Select of “Maintenance Mode Change” on the 05 Hyd tank breather change int.
“Service Menu” screen. 06 Corrosion resistor change int.
07 Damper case service int.
08 Final drive case oil change int.
09 Machinery case change int.
10 Hydraulic oil change int.
99 Initialize all items
3. Contents of setting of Maintenance mode on/

off
After selecting “Maintenance Mode On/Off”, if
the screen is displayed, set ON or OFF with
the function switches.
q ON: Functions of all maintenance items
are set effective in operator mode
2. Selecting sub menu q OFF: Functions of all maintenance items
After the “Maintenance Mode Change” screen are set ineffective in operator mode
is displayed, select an item to change the set- q [F3]: Move to lower item
ting with the function switches or numeral input q [F4]: Move to upper item
switches. q [F5]: Cancel selection and return to Main-
q [F1]: Move to next page (screen) tenance mode change screen
q [F2]: Move to previous page (screen) q [F6]: Confirm selection and return to
q [F3]: Move to lower item Maintenance mode change screen
q [F4]: Move to upper item a Even if ON/OFF of each item has been
q [F5]: Return to service menu screen set, if the above setting is changed, it is
a You may enter a 2-digit code with the applied.
numeral input switches to select the item
4. Contents of setting of each maintenance item 5. Function of initializing all items

After selecting each maintenance item, if the After selecting “All Default Value”, if the screen
screen is displayed, set the item with the func- is displayed, set with the function switches.
tion switches. q If this operation is executed, the set val-
q Initial value: Maintenance interval set in ues of all the maintenance items are ini-
machine monitor (Recommended by man- tialized.
ufacturer and not changeable). q [F5]: Return to Maintenance mode change
q Set value: Maintenance interval which can screen
be set freely. Maintenance functions in q [F6]: Execute initialization
operator mode operate on basis of this set a A while after [F6] is pressed, the initializa-
time (which is increased or decreased by tion completion screen is displayed. Then,
50 hours). if the “Maintenance Mode Change” screen
q ON: Maintenance function of this item is is displayed, initialization is completed.
set effective in operator mode.
q OFF: Maintenance function of this item is
set ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance mode
change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
ch a n g e s t o t h e M a i n t e n a n c e m od e
change screen with [F5], the setting is
effective.
a If the set value of an item set to “ON” is
changed after 1 or more operating hours
since the start of setting, the change is
recognized as a resetting operation.
Phone Number Entry a If [F6] is pressed without inputting a digit,

The telephone No. displayed when the user code/ there is not information of telephone No.
failure code is displayed in the operator mode can Accordingly, no telephone No. is displayed
be input and changed according to the following in the operator mode.
procedure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.
1. Selecting menu
Select “Phone Number Entry” on the “Service
Menu” screen.
2. Registering and changing telephone No.

After the “Phone Number Entry” screen is dis-
played, register or change the telephone No.
q [F2]: Reset all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Reset input digit/Return to service
menu
q [F6]: Confirm input
a Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and over-
write it with the correct digit.
Default (Key-on Mode) q Mode at Previous Key-off: Final mode in

Check or change various settings related to the previous operation is displayed when key
machine monitor and machine by "Default". is ON
The function of working mode with key ON is used q [F3]: Move to lower item
to set the working mode displayed on the machine q [F4]: Move to upper item
monitor when the starting switch is turned ON. q [F5]: Cancel selection and return to
“Default” screen
1. Selecting menu q [F6]: Confirm selection and return to
Select “Default” on the “Service Menu” screen. “Default” screen
a When the machine is delivered, Mode at
previous key-OFF is set.
a If "With attachment" is not set, the attach-
ment mode cannot be selected.
a While Attachment mode [ATT] is selected,
if "Without attachment" is set, Power
mode [P] is displayed when the key is
turned ON.
a If the engine is stopped while breaker
mode [B] is selected in the operator mode,
Breaker mode [B] is always displayed,
regardless of the above setting.

After the “Default” screen is displayed, select
“Key-on Mode” with the function switches or
numeral input switches.
a Select this item similarly to an item on the
“Service Menu” screen.
3. Selecting mode
After the “Key-on Mode” screen is displayed,
select the mode to be set with the function
switches.
q Power Mode: [P] is displayed when key is
ON
q Economy Mode: [E] is displayed when key
is ON
q Lifting Mode: [L] is displayed when key is
ON
q Breaker Mode: [B] is displayed when key
is ON
q Attachment Mode: [ATT] is displayed
when key is ON
Default (Unit) a When the machine is delivered, the SI unit

Check or change various settings related to the system is set.
machine monitor and machine by "Default".
The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting menu
Select “Default” on the “Service Menu” screen.

“Unit” with the function switches or numeral
input switches.
3. Selecting unit
After the “Unit” screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to
q [F6]: Confirm selection and return to
Default (With/Without Attachment) a When an attachment is installed, if this

Check or change various settings related to the setting is not carried out normally, the
machine monitor and machine by "Default". attachment cannot be set in the operator
The "With/Without attachment" function is used to mode. As a result, the attachment may not
set an installed or a remove attachment. work normally or the hydraulic compo-
nents may have trouble.
1. Selecting menu
Select "Default" on the “Service Menu” screen.

After the "Default" screen is displayed, select
“With/Without Attachment” with the function
switches or numeral input switches.
3. Selecting With/Without
After the “With/Without Attachment” screen is
displayed, select the setting with the function
switches.
q Without Attachment:
When attachment is not installed
q With Attachment:
When attachment is installed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
Default screen
q [F6] : Confirm selection and return to
Default screen
Default (Attachment/Maintenance Password) 3. Selecting Disable/Enable

Check or change various settings related to the After the Attachment/Maintenance Password
machine monitor and machine by "Default". screen is displayed, select the setting with the
The function of setting attachment/maintenance function switches.
password is used to set the display of the password q Disable : Password screen is not dis-
screen when the functions related to the attach- played
ment and maintenance are used in the operator q Enable : Password screen is displayed
mode. q [F3] : Move to lower item
q [F4] : Move to upper item
1. Selecting menu q [F5] : Cancel selection and return to
Select “Default” on the “Service Menu” screen. "Default" screen
q [F6] : Confirm selection and return to
"Default" screen

“Attachment/Maintenance Password” with the 4. Displaying attachment/maintenance password
function switches or numeral input switches. screen
a Select this item similarly to an item on the When the following operation is performed, the
“Service Menu” screen. password screen is displayed in the operator
mode.
q Maintenance mode: The Maintenance
table screen is changed to the Mainte-
nance interval reset screen.
q User mode: On the User menu screen, the
Breaker/A ttac hment set ting menu is
selected and the screen is changed to the
Attachment setting menu screen.
5. Changing attachment/maintenance password

The password can be changed by operating
the switches specially in the operator mode.
a See Attachment/Maintenance password
changing function in the operator mode.
a Default password: [000000]
a If the password setting is changed from
Enable to Disable, the password is reset
to the default. When Enable is set again,
be sure to set a new password.
a The attachment/maintenance password is
different from the engine start lock pass-
word.
Default (Camera) 3. Selecting camera setting

Check or change various settings related to the After the “Camera” setting screen is displayed,
machine monitor and machine by "Default". select the setting with the function switches.
The camera setting function is used to set installa- q OFF: Camera is not used
tion and removal of a camera. q Original Image: Image of connected cam-
era is displayed in origi-
1. Selecting menu nal position (as in mirror,
Select “Default” on the “Service Menu” screen. used as back monitor)
q Reverse Image: Image of connected cam-
era is displayed in reverse
position (as seen directly,
used as front or side mon-
itor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation
and return to “Default” screen
q [F6]: Confirm selection in each line
a After “Camera” screen is displayed, cam-
era 1 can be always set. When 2 or more
cameras are connected, if camera 1 is set,
the screen changes to setting of camera 2
automatically.
2. Selecting sub menu a After confirming the setting of each line
After the “Default” screen is displayed, select with [F6], return to the "Default" screen
“C am er a” w it h th e fu nc t io n sw it c he s or with [F5], and the setting is effective.
numeral input switches. a If a camera is connected but not set nor-
a Select this item similarly to an item on the mally with this function, the graphic mark
“Service Menu” Screen. of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of
the camera cannot be used.
a If 2 or more cameras are connected, be
sure to set the use of them from camera 1
in order.
a The function of displaying 2 images simul-
taneously is effective when use of camera
1 and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizon-
tally.
Default (ECO Display) a If ECO display is turned ON, ECO is dis-

Check or change various settings related to the played when the screen changes to the
machine monitor and machine by "Default". ordinary screen. Even if the energy saving
The ECO display setting function is used to set the guidance is turned ON, however, it is not
display of the ECO gauge and energy saving guid- displayed if the condition for display is not
ance. satisfied on the ordinary screen.
1. Selecting menu
Select “Default” on the “Service Menu” screen.
a Display of ECO gauge (a)

“ECO Display” with the function switches or
a Display of energy saving guidance
3. Selecting display setting

After the “ECO Display” screen is displayed,
select the setting with the function switches.
q ON : Display ECO
q OFF: Do not display ECO
q [F3] : Move to left item
q [F4] : Move to right item
q [F5] : Cancel setting before confirmation
and return to "Default" screen
q [F6] : Confirm selection in each line
a After confirming the setting of the upper
and lower lines with [F6], return to the
"Default" screen with [F5], and the setting
is effective.
Default (Breaker Detect) 3. Selecting display setting

Check or change various settings related to the After the "Breaker Detect" screen is displayed,
machine monitor and machine by "Default". select the setting with the function switches.
The function of setting breaker automatic judgment q [F3]: Move to lower item
is used to set the display to give warning when the q [F4]: Move to upper item
breaker is used in an improper working mode. q [F5]: Cancel selection and return to
Default screen
1. Selecting menu q [F6]: Confirm selection and return to
Select “EDefault” on the “Service Menu” screen. Default screen
a When the machine is delivered, Disable is
set.

After the “Default” screen is displayed, select a Display of "Breaker Detect"
"Breaker Detect" with the function switches or
“Service menu” screen.
Adjustment (Pump Absorption Torque (F)) 3. Selecting absorption torque

The operator can adjust various items related to the After the "Pump Absorption Torque (F)" screen
machine with the machine monitor. is displayed, select a set value on the right side
The pump absorption torque (F) function is used to with the function switches.
finely adjust the absorption torque on the front side q Set value: For actual torque adjustment
of the hydraulic pump. value, see table
q [F3]: Increase set value
1. Selecting menu q [F4]: Decrease set value
Select “Adjustment” on the “Service Menu” screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque (F)” with the
function switches or numeral input switches. a Relationship between set value and
a Select this item similarly to an item on the torque adjustment value
“Service Menu” screen. Set
Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}
Adjustment (Pump Absorption Torque (R)) 3. Selecting absorption torque

The operator can adjust various items related to the After the "Pump Absorption Torque (R)" screen
machine with the machine monitor. is displayed, select a set value on the right side
The pump absorption torque (R) function is used to with the function switches.
finely adjust the absorption torque on the rear side q Set value: For actual torque adjustment
of the hydraulic pump. value, see table
q [F3]: Increase set value
1. Selecting menu q [F4]: Decrease set value
Select “Adjustment” on the “Service Menu” screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen

select “Pump Absorption Torque (R)” with the
function switches or numeral input switches. a Relationship between set value and torque
a Select this item similarly to an item on the adjustment value
“Service Menu” screen. Set
Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}
Adjustment (Low speed) 3. Selecting travel Low speed

The operator can adjust various items related to the After the "Low Speed" setting screen is dis-
machine with the machine monitor. played, select a set value on the right side with
The travel Low speed setting function is used to the function switches.
finely adjust the travel Low speed. q Set value: For actual travel Low speed
value, see table
1. Selecting menu q [F3]: Increase set value
Select “Adjustment” on the “Service Menu” screen. q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen

select “Low speed” with the function switches
or numeral input switches.
a Select this item similarly to an item on the a Relationship between set value and travel
“Service Menu” screen. Low speed value
Set
Code Travel Low speed value
value
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
Adjustment (Attachment Flow Adjustment) 3. Selecting distribution of oil flow

The operator can adjust various items related to the After the screen of "Attachment Flow Adjust-
machine with the machine monitor. ment" is displayed, select a set value on the
The function of "Attachment Flow Adjustment" is right side with the function switches.
used to finely adjust the oil flow to the attachment in q Set value: For actual distribution of flow,
compound operation. see table
1. Selecting menu q [F3]: Increase set value
Select “Adjustment” on the “Service Menu” q [F4]: Decrease set value
screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen

select “Attachment Flow Adjustment” with the
function switches or numeral input switches. a Relationship between set value and distri-
a Select this item similarly to an item on the bution of flow to attachment
“Service Menu” screen. Set Distribution of flow to
Code
value attachment
000 50 %
001 70 %
044
002 100 %
003 40 %
Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" oper-
ation with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1. Selecting menu
Select “Cylinder Cut-Out” on the “Service
Menu” screen.
3. Resetting Cut-Out cylinder

When changing a cylinder to be Cut-Out or
when Cylinder Cut-Out operation is finished,
select a Cut-Out cylinder to be reset with the
function switches.
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue,
the cylinder is reset.
a If the machine monitor resets a Cut-Out
cylinder but the engine controller cannot
reset that Cut-Out cylinder, the background
2. Selecting cylinder to be disabled (a) of the cylinder No. becomes red.
After the "Cylinder Cut-Out" screen is dis- a The Cut-Out operation is not automatically
played, select a cylinder to be Cut-Out with the reset after the screen returns to the opera-
function switches. tor mode. Accordingly, be sure to perform
q [F1]: Move selection mark (R) to left the resetting operation after the cylinder
q [F2]: Move selection mark (R) to right cut-out operation is finished.
q [F3]: Reset holding
q [F4]: Hold 4. Function of holding displayed information
q [F5]: Return to service menu screen If [F4] is pressed during the cylinder Cut-Out
q [F6]: Confirm selection operation, the displayed information is newly
a This operation may be performed while held (c) (The real-time information is kept dis-
the engine is running. played on the left side).
a When [F6] is pressed, if background (a) of While the information is held, if [F3] is pressed,
the selected cylinder No. becomes white, the holding function is reset.
the cylinder is Cut-Out. a The holding function is effective, regard-
a If the machine monitor Cut-Out a cylinder less of setting of the reduced cylinder
but the engine controller cannot Cut-Out mode operation.
that cylinder, the background (a) of the
cylinder No. becomes yellow.
a One or more cylinders can be Cut-Out.
a In the cylinder Cut-Out operation, the
auto-d ece le rat ion fu nc tio n c an be
selected. If the auto-deceleration is turned
ON, auto-deceleration monitor (b) is dis-
played.
[Reference] No Injection
q If a normally operating cylinder is Cut-Out, If the engine is operated after long storage of the
the following phenomena occur. machine, it may be worn or damaged because of
1) Lowering of engine speed insufficient lubrication with oil. To prevent this, the
2) Increase of final injection rate com- function to lubricate the engine before starting it by
mand (quantity) cranking it without injecting fuel is installed.
q If the engine is running near the high idle, Set the no-injection cranking while the engine is
however, the engine speed may not lower stopped.
for the reason of engine control.
q In this case, lower the engine speed with 1. Selecting menu
the fuel control dial and judge by increase Select “No Injection” on the “Service Menu”
of the injection rate command. screen.
2. Displaying check screen

If the "No injection" screen is displayed, the
machine monitor asks the operator if no injec-
tion cranking should be performed. Answer
with the function switch.
q [F5]: Do not perform (Return to Service
menu screen)
q [F6]: Perform
a While the screen is changing to the follow-
ing screen, the screen of "Communication
between controllers is being checked" is
displayed.
3. Starting no injection cranking 5. Prohibiting no injection cranking

If no injection cranking (Fuel injection in no cyl- If the operator tries to perform the no injection
inders) becomes effective, that is displayed on cranking while the engine is running, the mes-
the screen. Under this condition, crank the sage that the engine is running is displayed
engine with the starting motor. and the no injection cranking is not set effec-
a While the screen is changing to the follow- tive.
ing screen, the screen of "Setting is being a This function can be selected even while
prepared" is displayed. the engine is running. If the no injection
a Limit the cranking time to 20 seconds to cranking is performed, however, the mes-
protect the starting motor. sage of "Engine is running" is displayed
on the screen.
4. Finishing no injection cranking

After completing the no injection cranking
operation, press [F6], and finish of no injection
cranking is displayed and the screen returns to
the “Service Menu” screen automatically.
Fuel Consumption 3. Display and function during measurement

This function calculates the hourly fuel consump- Clock mark (a) flashes during measurement.
tion from the actual fuel consumption in a measur- a While the fuel consumption is being mea-
ing period and indicates it. sured, the operator can work with the
1. Selecting menu operator mode and other functions. Mea-
Select “Fuel Consumption” on the “Service surement is not finished until this screen is
Menu” screen. displayed again and [F1] is pressed (Even
if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).
2. Starting measurement
After the screen of “Fuel Consumption” is dis-
played, start measurement with the function
switches.
q [F1]: Start 4. Finishing measurement
q [F2]: Clear Press [F1], and measurement is finished and
q [F5]: Return to Service menu screen the data are displayed on the finishing date
a When the screen of Fuel consumption is and time side.
displayed, if a data is indicated, it is the
data of the previous measurement. This 5. Displaying fuel consumption
data is not an obstacle to new measure- If the measurement is finished, the hourly fuel
ment and can be reset by pressing [F2]. consumption calculated from the fuel con-
a If [F1] is pressed, the data is displayed on sumption calculated by the engine controller
the starting date and time side and mea- and the elapsed time are displayed.
surement starts.
a The display unit of the fuel changes

according to the unit set with the default
(unit setting) function.
SI and meter: l/h
inch: gal/h
KOMTRAX Settings (Terminal Status) 3. Contents of display of terminal status

The setting condition and operating condition of On the “Terminal Status” screen, the following
KO MT RA X c an b e ch ec k ed w it h D is pl ay of items are displayed.
KOMTRAX setting. q Terminal type: Model name of KOMTRAX
Setting condition of terminal is used to check the communication MODEM
setting condition of the KOMTRAX terminal. q KOMTRAX communication: Executing con-
dition of station opening inspection
1. Selecting menu q GMT time: Greenwich Meant Time
Select “KOMTRAX Settings” on the “Service q [F5]: Return to KOMTRAX settings screen
Menu” screen.

After the “KOMTRAX Settings” screen is dis-
played, select “Terminal Status” with the func-
tion switches or numeral input switches.
Service menu screen.
a The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200 is installed, “03 IP Adress” is dis-
played.
KOMTRAX Settings (GPS & Communication Status) 3. Contents of display of GPS & communication
The setting condition and operating condition of status
KOMTRAX can be checked with “KOMTRAX Set- On the screen of “GPS & Communication Sta-
tings”. tus”, the following items are displayed.
GPS & communication status is used to check the q Positioning: Positioning condition of GPS
condition of positioning and communication of the q Communication: Communication environ-
KOMTRAX terminal. ment of communication MODEM and con-
nec tin g c on dit ion of co mmu nica tio n
1. Selecting menu MODEM
Select “KOMTRAX Settings” on the “Service q Number of message not yet sent: Number
Menu” screen. of mails which are saved in machine mon-
itor and not transmitted yet
q [F5]: Return to KOMTRAX settings screen

played, select GPS & communication status
with the function switches or numeral input
switches.
a The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200 is installed, “03 IP Adress” is dis-
played.
KOMTRAX Setting (MODEM S/N: TH300) 3. Contents of display of Modem S/N

The setting condition and operating condition of The serial No. of TH300 Modem is displayed.
KO MT RA X c an b e ch ec k ed w it h D is pl ay of q [F5]: Return to KOMTRAX settings screen
KOMTRAX setting.
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.
1. Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” screen.

played, select “Modem S/N” with the function
KOMTRAX Settings (IP Address: TH200) 3. Contents of display of IP address

The setting condition and operating condition of The telephone No. and IP address (2 systems)
KO MT RA X ca n b e ch ec k ed w it h D is pl ay of of TH200 MODEM are displayed.
KOMTRAX settings. q [F5]: Return to KOMTRAX setting screen
IP address is used to check the IP address of the a The IP address is a No. specific to each
KOMTRAX communication MODEM. MODEM which is required when commu-
nication is made between the MODEM
1. Selecting menu and the server.
Select "KOMTRAX Settings" on the service
menu screen.

played, select “IP Address” with the function
Display of KOMTRAX message 3. Display of message (with return mail function)

Special messages for the serviceman sent from the If a box to enter a value with the numeral keys
KOMTRAX base station (a distributor, etc.) can be is displayed under the message, enter a
checked with this function. proper number with the numeral input switches
If there is setting in a message, a return mail can be and function switches and confirm it, and the
sent by using numeral input switches. information is returned to the KOMTRAX base
station.
1. Operation to display menu q [F5]: Return to service menu screen
Select "Service message" on the service menu q [F6]: Confirm and return input value
screen. a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
played when it is rece ived as in th e
operator mode.
2. Display of message (Read-only)

If there is a message, its contents are dis-
played. If there is not a message, "No mes-
sage" is displayed.
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
pl ayed w hen it is rec eived a s in th e
operator mode.
UEN02645-00

© 2007 KOMATSU
All Rights Reserved
58
UEN02662-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Testing and adjusting, Part 3
Handling voltage circuit of engine controller ................................................................................................... 2
Preparation work for troubleshooting of electrical system .............................................................................. 3
Procedure for testing diodes ........................................................................................................................... 8
Pm Clinic service ............................................................................................................................................ 9
Handling voltage circuit of engine

controller 1
1. Before disconnecting or connecting a connec-
tor between the engine controller and engine,
be sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
Preparation work for 4) Insert or connect troubleshooting T-adapt-

troubleshooting of electrical ers in or to connectors CM01, CM02, and
CM03 of machine monitor (4).
system 1 a Connectors CM02 and CM03 are of
a When carrying out troubleshooting of an elec- the same type. When returning them,
tric circuit related to the machine monitor, check the mark plates of the mount-
e n g i n e c o n t r o l l e r, p u m p c o n t r o l l e r, o r ing brackets and take care not to
KOMTRAX communication MODEM, expose make a wrong connection.
the related connectors according to the follow-
ing procedure.
a Disconnect and connect the connectors having
special locking mechanisms according to the
procedure shown below.
1. Machine monitor
1) Remove 2 mounting bolts and cover (1).
a One of the mounting bolts is installed
in the cover on the right of the day-
light sensor.
a While removing the mounting bolts,
disconnect connector P31 of the day-
light sensor.
2) Remove cover (2).
a The cover is fixed with clips. Remove 2. Engine controller
it by pull it up. 1) Open the engine hood cover on the con-
a While removing the cover, discon- trol valve side.
nect connector M04 of the cigarette 2) Remove cover (1).
lighter.
3) Insert or connect troubleshooting T-adapt-

3) Remove 1 mounting bolt and duct (3). ers in or to connectors ENG, CE02, and
CE03 of engine controller (2).
a Connectors are fixed with screw.
Loosen the screws before discon-
necting them.
a When returning the connectors back
to their position, tighten them to the
specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
7) Connect the troubleshooting adapters to

connectors C01 and C02 of pump control-
ler (12).
a Install the adapters to only the wiring
harness side.
3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove the 5 mounting bolts and cool &
hot box (6).
a While removing the cool & hot box, a The connectors of the pump control-
disconnect the drain hose. ler have a special locking mecha-
3) Remove the 2 mounting bolts, 1 fastener, nism. Disconnect them according to
and magazine box (7). steps (a) – (c) and connect them
4) Remove the 3 mounting bolts and cover according to steps (d) – (f) as shown
(8). below.
5) Remove fuse box cover (9) and cover Disconnection: (a) Unlock – (b)
(10). Slide lever – (c) Disconnect connec-
a Since the underside of cover (10) is tor.
clamped, pull it up. Connection: (d) Position connector –
6) Remove the 7 mounting bolts and cover (e) Slide lever – (f) Lock.
(11).
4. KOMTRAX communication module 5. Atmospheric pressure sensor (AMBAIR

1) Slide the operator's seat and seat stand to PRESSURE)
the forward end. Engine Ne speed sensor (CRANK SENSOR)
2) Remove the 5 mounting bolts and cool & Engine Bkup speed sensor (CAM SENSOR)
hot box (6). Engine oil pressure switch (OIL PRESSURE
a While removing the cool & hot box, SWITCH)
disconnect the drain hose. Disconnection and connection of con-
3) Remove the 2 mounting bolts, 1 fastener, nectors
and magazine box (7). The connectors of the atmospheric pres-
4) Remove the 3 mounting bolts and cover sure sensor, engine Ne speed sensor,
(8). engine Bkup speed sensor, engine oil
5) Remove fuse box cover (9) and cover pressure switch have a special locking
(10). mechanism. Disconnect them according
a Since the underside of cover (10) is to st eps (a ) – (c) a nd conn ect them
clamped, pull it up. according to steps (d) – (f) as shown
6) Remove the 7 mounting bolts and cover below.
(11). Disconnection: (a) Slide lever – (b)
Unlock – (c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
7) Connect troubleshooting T-adapters to con-

nectors CK01 and CK02 of KOMTRAX
communication module (13).
Removal and installation of sensor
a Cable (14) is for the communication
A deep socket is necessary for removal
antenna.
and installation of the engine oil pressure
switch. See "Tools for testing, adjusting,
and troubleshooting".
6. Boost pressure and temperature sensor Precautions for disconnecting connector

(BOOST PRESS & IMT) The direction of the lock of the connector
Disconnection and connection of con- varies with the tightened position of the
nector sensor and the lock may be in a direction
The connector of the boost pressure and in which it is difficult to reset (on the under-
temperature sensor has a special locking side or engine side).
mechanism. Disconnect it according to In this case, pinch the lock in direction (a)
steps (a) – (b) and connect it according to with bent-nose nippers [1] (commercially
steps (c) – (d) as shown below. available), and the lock is reset.
Disconnection: (a) Unlock – (b) Discon- Since the lock clicks when it is reset, dis-
nect connector. connect the connector after a click is heard.
Connection: (c) Connect connector – (d)
Lock.
Precautions for connecting connector

Take care not to connect the connector
reversely.
Removal and installation of sensor Engage lock (e) on the wiring harness side
A torque wrench is necessary for removal with triangular notch (f) on the sensor side
and installation of the boost pressure and (Do not engage lock (e) with square guide
temperature sensor. See "Tools for test- (g) on the opposite side of triangular notch
ing, adjusting, and troubleshooting". (f)).
7. Supply pump IMV solenoid (FUEL REGULATOR)

Disconnection and connection of con-
nector
The connector of the supply pump IMV
solenoid has a special locking mecha-
nism. Disconnect it according to steps (a)
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
8. Common rail pressure sensor (FUEL RAIL 9. Engine coolant temperature sensor (COOL-
PRESS) ANT TEMP)
Disconnection and connection of con- Disconnection and connection of con-
nector nector
The connector of the common rail pres- The connector of the engine coolant tem-
sure sensor has a special locking mecha- perature sensor has a special locking
nism. Disconnect it according to steps (a) mechanism. Disconnect it according to
– (b) and connect it according to steps (c) steps (a) – (b) and connect it according to
– (d) as shown below. steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Discon- Disconnection: (a) Unlock – (b) Discon-
nect connector. nect connector.
Connection: (c) Connect connector – (d) Connection: (c) Connect connector – (d)
Lock. Lock.
Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine coolant tem-
perature sensor. See "Tools for testing,
adjusting, and troubleshooting".
Procedure for testing diodes 1

a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductive directions of the assembled-
type diode are as follows.
2. When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to
the anode (P) side of the diode and
a The conductive direction of the single diode is apply the black (–) lead to the cath-
indicated on the surface of the diode. ode (N) side.
ii) Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Judge the condition of the diode by the
movement of the pointer.
q The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends
on the type and selected range of the
tester, however).
q The pointer moves in both i) and ii):
The diode is defective (Internal short
circuit).
1. When using digital circuit tester q The pointer moves in neither of i) and
1) Set the tester in the diode range and ii): The diode is defective (Internal
check the indicated value. disconnection).
a When an ordinary circuit tester is
used, the voltage of the internal bat-
tery is indicated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black (–) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the
indicated value.
q The indicated value does not change:
The diode does not have conductivity
(Defective).
q The indicated value changes:
The diode has conductivity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is indi-
cated.
Pm Clinic service 1
Model name Serial No. Service meter
T PC400-8
h
T PC450-8 T LC
User's name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm T 800 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
°C m
Operator's opinion
Result of visual inspection
Mechanical equipment system fault history Electrical equipment system fault history
AA10NX times/1st time h/last h times/1st time h/last h
AB00KE times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
Items related to engine
Items related to oil pressure
20
(Travel speed : Lo)
2.0
15
12
7
4
Visual check of welded structure

a If a crack is found, illustrate its shape in the drawing.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Arm top bracket 9. Boom bracket
Left Right Left Right Left Right
2. Arm foot 5. Boom cylinder bracket
Left Right Left Right Track frame
Edge plate 6. Arm cylinder bracket 10. Circle bracket
3. Arm top boss Left Right Front Rear
Left Right 7. Boom lower plate Left Right
Left Right
8. Boom foot
Left Right
Undercarriage troubleshooting report 1

(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
Model PC400/450-8 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry DRY
Soil condition Dealer Shoe width (mm)

Working condition nspector Shoe type TRIPLE
Insp.Date(yyyy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 915.6 927.6
R
RH 915.6 927.6
LH 228.90 231.90
M
RH 228.90 231.90
LH 129.0 119.0
RH 129.0 119.0
New Turned
LH 71.5 66.5
New Turned
RH 71.5 66.5
LH 37.0 22.0
RH 37.0 22.0
LH 148.0 134.0
Front
RH 148.0 134.0
LH 148.0 134.0
Rear
RH 148.0 134.0
LH 22.0 28.0
Front
RH 22.0 28.0
LH 22.0 28.0
Rear
RH 22.0 28.0
1 LH 200.0 188.0
2 LH 200.0 188.0
3 LH 200.0 188.0
4 LH 200.0 188.0
5 LH 200.0 188.0
6 LH 200.0 188.0
7 LH 200.0 188.0
8 LH 200.0 188.0
9 LH 200.0 188.0
10 LH 200.0 188.0
1 RH 200.0 188.0
2 RH 200.0 188.0
3 RH 200.0 188.0
4 RH 200.0 188.0
5 RH 200.0 188.0
6 RH 200.0 188.0
7 RH 200.0 188.0
8 RH 200.0 188.0
9 RH 200.0 188.0
1.3 10 RH 200.0 188.0
LH 0.0 6.0
RH 0.0 6.0
Remarks:
UEN02662-00

© 2007 KOMATSU
All Rights Reserved
16

PC450 (LC, HD) - 8 UEN02644-00 Testing & Adjusting

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PC450 (LC, HD) - 8 UEN02644-00 Testing & Adjusting

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UEN02644-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

30 Testing and adjusting 1

Checking fuel circuit for leakage ........................................................................................................ 24

Tools for testing, adjusting and troubleshooting 1

Testing and adjusting Sym-

Testing and adjusting Sym-

Testing and adjusting Sym-

Troubleshooting for chassis/ 799-601-9020 • Adapter for DT 1

Testing and adjusting Sym-

Measuring engine speed 1 4) Measuring the engine speed when 2

2. Start the engine and keep it running until tem-

3. Measure the engine speed under the respec-

6. Measure the intake air pressure (boost pres-

2. Install nipple [1] of the boost gauge kit A and

7. Remove the measurement tool after the mea-

Measuring exhaust temperature 1 5. A procedure of measuring periodical exhaust

1. Open the engine hood and remove the

6. Remove the measurement tool after the mea-

3. Start the engine and keep it running until tem-

4. A procedure of measuring the maximum in

Measuring exhaust gas color 1

k Be careful not to touch the highly heated

Adjusting valve clearance 1

1. Open the inspection cover of the engine hood

2. Remove the belt protection covers (two cov-

7. While fixing adjustment screw (3), tighten lock-

a It is also allowed to adjust respective cylin-

8. After finishing adjustment, return the removed

k Be careful not to get burnt by touching the

(Engine oil temperature: 40 – 60°C)

6. Install rocker arm assembly (2) and adjust the

3. Bring the cylinder to be tested to the compres-

4. Disconnect fuel high-pressure tube (3) and injec-

7. Referencing “Special functions of machine 3 Rocker arm assembly mounting

9. After finishing testing, remove the testing tools

Measuring blow-by pressure 1

Symbol Part No. Part name

1. Remove the engine under cover (1).

2. Install nozzle [1] of blow-by checker F to blow-

3. Start the engine and keep it running until tem-

4. Measure the blow-by pressure under the fol-

5. Remove the measurement tool after the mea-

1. Open the inspection cover of the engine hood

6. Remove the measurement tool after the mea-

2. Remove the oil pressure measurement plug

3. Install nipple [1] of hydraulic tester G1 and con-

Handling fuel system parts 1 Releasing residual pressure from

a Test only the fuel pressure in the low-pressure

1. Remove fuel pressure pickup plug (1) from the

4. After finishing testing, remove the testing tools

2. Install nipple [1] of adapter H3 and hydraulic

Handling during cylinder cut-out Handling during no injection

Measuring fuel return rate and leakage 1

a Testing tools for leakage from pressure limiter 1. Preparation work

a Prepare an oil pan of about 20 l to receive the

4) Connect inspection hose J3 to the tip of

5) After finishing testing, stop the engine.

3. Testing return rate from injector

3) Adjust routing to prevent its slacking of

7) After finishing testing, stop the engine.

4. Work after finishing testing