Meanings of signal classes in the terminal table shown below are as follows. This function allows the operator to select proper engine torque and pump absorption torque according to the type of work. Four modes are provided: P, E, B and L. Using the work mode switch on the monitor panel, the operator is required to select one of them.
The pump controller detects the speed of the engine governor set with the fuel control dial and the actual engine speed N and controls them so that the pump will absorb all the torque at each output point of the engine, according to the pump absorption torque set in each mode. If the pump load increases and the pressure rises, engine speed N lowers. At this time, the controller lowers the pump discharge so that the engine speed will be near the maximum output point. If the pressure lowers, the controller increases pump discharge Q so that the engine speed will be near the maximum output point.
By repeating these operations, the controller constantly uses the engine near the maximum output point. In B or L mode, the controller controls the pump absorption torque through the pump and engine compound control function to decrease engine speed N while maintaining engine torque T constant along the constant horsepower curve.
This ensures reduced fuel consumption. Function to control pump during travel. Function to control when emergency pump drive switch is turned on. Function The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved. Operating condition for turning on cut-off function. By this operation, the hydraulic force is increased further. Power maximizing function. Each function is set automatically as shown below.
Function Engine and pump control. Machine push-up function. The auto-deceleration function automatically reduces the engine speed to its medium speed range when the all control levers are set in NEUTRAL while waiting for a dump truck or work to reduce the fuel consumption and noise.
If any lever is operated, the engine speed instantly returns to the speed set with the fuel control dial. Operation When control levers are set in neutral.
When any control lever is operated. The engine automatic warm-up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts. The overheat prevention function reduces the pump load when coolant or hydraulic oil temperature is too high during operation to protect the engine from overheating.
After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up the engine. Engine speed: Max. Auto-warm-up operation time: Min. If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to protect the engine from overheating. Automatic reset. Manual reset. Monitor alarm lamp: Lights up.
Lower pump discharge. Function The swing lock and swing holding brake function are provided as a swing control function. The swing holding brake function automatic is used to prevent hydraulic drift after the machine stops swinging. Operation If swing lever is set in neutral, swing brake operates in about 7 sec. If swing lever is operated, brake is released and machine can swing freely. Swing lock operates and machine is locked from swinging.
Even if swing lever is operated, swing lock is not reset and machine does not swing. Swing holding brake release switch 1. Note that if swinging is stopped on a slope, the upper structure may swing by its gravity. Swing lock is canceled. Swing lock is turned on. Quick hydraulic oil warm-up function when swing lock switch is turned on. If the work equipment is relieved under this condition, the hydraulic oil temperature rises quickly and the warm-up time can be shortened.
Function The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during travel or allowing operator to change travel speed automatically or manually. Pump control function during travel.
Travel speed change function. Manual change with travel speed switch. If one of Lo, Mi and Hi is selected with the travel speed switch, the pump controller controls the pump capacity and motor capacity at each gear speed as shown below to change the travel speed. Travel speed switch PCLC Automatic change by engine speed. If the fuel control dial is used to set the engine speed to less than 1, rpm, the travel speed changes to Lo when the machine is traveling in Mi or Hi, and the travel speed will not change to Mi or Hi.
Automatic change by pump discharge pressure. The travel speed switch will stay at Hi or Mi. This function is available only with the attachment specification. The function acts as follows according to the flow command and working mode from the monitor. It throttles the attachment PPC pressure and controls the flow when the pedal is depressed fully. In B mode and the other modes, it switches to attachment single acting B or double acting other modes.
Specifications Type of contacts:. Normally open contacts Operating ON pressure:. The junction block has 6 PPC oil pressure switches.
This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller. The pump pressure sensor is installed to the input circuit of the control valve. It converts the pump discharge pressure into a voltage and transmits it to the pump controller.
The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part, the diaphragm is deformed. The deformation in the diaphragm causes the resistance of the gauge to change. This causes a change in the output voltage, which is transmitted to the amplifier voltage amplifier. The relationship between the pressure applied to sensors P and output voltage E is shown in the figure below.
The amplifier magnifies output voltage E and transmits it to the pump controller. The monitor system notifies the operator of machine status. It monitors the condition of the machine with sensors installed on various parts of the machine, processes and immediately displays the obtained information on the panel. The information that appears on the panel is roughly divided as follows.
Alarms that are issued when the machine has troubles. Machine status, including coolant temperature, hydraulic oil temperature and fuel level The machine monitor also has various mode selector switches and functions to operate the machine control system. The machine monitor has the functions to display various items and the functions to select modes and electric parts. The switches are flat sheet switches. Precautions on the machine monitor display. Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal.
The machine monitor display may temporarily disappear if it happens; it is quite normal. The screen normally displayed on the monitor has a blue or white background.
For this reason, blue spots will not cause any problem since the liquid crystal lights up red, blue, and green spots when displaying white. Preheater operates at low temperature and symbol keeps lighting up for up to about 30 seconds and then goes off after engine starts.
Time after setting. The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot be obtained due to disconnection of CAN. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are displayed. Symbols appear in the order in which they occur from the upper left.
When symbols are displayed, if the hydraulic oil temperature is high or low, only its symbol is displayed. Condition of hydraulic oil. Buzzer cancel switch Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer. If a new abnormality is detected, the alarm buzzer sounds. Depending on the alarm buzzer type, it does not stop even if you press the buzzer cancel switch.
Auto-deceleration switch The auto-deceleration switch toggles the auto-deceleration function on and off. When the working mode is switched, it is automatically set to ON. When it is set to ON, the auto-deceleration monitor appears. Guidance icon and function switch The function switches differ depending on the screen display. Each guidance icon shows the function of the switch below it.
Switches with no guidance icon are disabled. The functions shown by the guidance icons are as shown in the table below. Check the working mode on the working mode monitor. F5: Returns to the working mode selector screen. F6: Specifies the breaker mode. If B mode is specified as a working mode when you start the monitor, the buzzer sounds and the following message appears. F5: Starts up in E mode. F6: Starts up in B mode. Travel speed selector switch Each time you press the travel speed selector switch, the travel speed setting switches as shown below.
The travel speed setting is confirmable on the travel speed monitor. The relationship between the speed setting and the monitor display is shown in the table below. Window washer switch While the switch is being pressed, window washer liquid is sprayed out.
There is a time delay before the wiper starts. The wiper operation setting is confirmable on the wiper monitor. The relationship between the wiper setting and the monitor display is shown in the table below. Air conditioner control switch To operate the air conditioner, use the air conditioner control switches. Another pressing switches among modes. If you do no operation at least 5 sec.
For an optional-camera-equipped machine, pressing the F3 on the normal screen switches to the camera image. For a machine with no camera equipped, the guidance icon for switching to the camera screen does not appear; even if you press the switch, the screen does not switch to the camera image. Up to three cameras are mountable.
F1: Displays the image of No. F2: Displays the image of No. F3: Displays the image of No. F4: Displays the images of No. F5: Returns to the normal screen. Making operation of air conditioner button 1 with the camera screen displayed may switch to the air conditioner operation screen.
F6, or no operation for 5 sec. If it appears, return to the normal screen with F5 to check the alarm display. If it appears, you must move the machine to safe posture immediately and make inspections. Pressing F4 on the normal screen when the service meter is displayed in the top center of the screen switches the display to the time, and doing so when the time is displayed switches the display to the service meter.
F1: Displays the next page. Displays the top page when the last page is displayed. F2: Displays the previous page. Displays the last page when the top page is displayed. F3: Selects highlights an item one down. F4: Selects highlights an item one up. F6: Switches to the maintenance time reset screen. No operation at least 30 sec. If the remaining time on the maintenance table screen is less than 30 hours, the relevant items are highlighted in yellow, and if 0 hours, they are done in red.
On the maintenance time reset screen, reset the remaining time for the selected item to return to the default. F5: Cancels the reset to return to the maintenance table screen.
F6: Resets the remaining time to return to the normal screen. The time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the remaining time. The relationship is as shown in the table below. Display None. Condition Remaining time for maintenance for all items is more than 30 hours. There is one or more items with less than hour remaining time for maintenance. You can lock the maintenance time by a password to prevent it from carelessly being reset.
Pressing F6 on the normal screen enters the user mode, switching to the user menu screen. In user mode, you can specify items relating to the machine monitor and machine shown below. F6: Switches to the setting screen for the selected item. In user mode, no switch operation at least 30 sec. For an attachment-equipped machine, this menu allows you to adjust a flow rate in B mode and ATT mode. For a machine with no attachment, this menu does not appear.
F5: Cancels changes you made before confirming them with F6 to return to the menu screen. F6: Moves to the setup items of the selected highlighted item. Selecting B switches to the breaker setting menu, and selecting ATT switches to the attachment setting menu.
You can lock this menu with a password. Enabling the password lock locks the maintenance reset screen at the same time.
On this screen, select the breaker setting selection screen or breaker flow rate setting screen. F6: Switches to the setting screen for the selected highlighted item. Breaker setting selection screen. F5: Returns to the breaker setting menu screen. F6: Specifies the selected highlighted item as a flow rate in breaker mode. Breaker flow rate setting screen. F6: Switches to the flow rate level setting screen for the selected highlighted item.
F3: Decreases the flow rate. F4: Increases the flow rate. F5: Returns to the flow rate setting screen without changing the flow rate. F6: Returns to the flow rate setting screen after specifying the flow rate. Flow level. On this screen, select the attachment setting screen or breaker flow rate setting screen. Attachment setting selection screen. F5: Returns to the attachment setting menu. F6: Specifies the selected highlighted item as a flow rate in attachment mode.
Attachment flow rate setting screen. When there is a message, the message monitor appears on the upper left of the normal screen.
The lighting green monitor indicates that there are messages to be read. The lighting blue monitor appears when you have not sent replies yet after opening messages which accept replies. F6: Returns to the user mode screen. If it appears, enter the selected item number provided in the message using the switches of the machine monitor, and press F6.
Press F6 and the entered value will be sent. Messages will be deleted when their validity expire or a new message is received. Separately from the message display for users above, the service menu is provided with message display for service.
Selecting the Screen adjustment from the user menu and pressing F6 switches to the screen adjustment screen. From this menu, you can adjust the brightness, contrast, and luminance of the machine monitor screen. When the light switch is in Night mode ON, the night mode screen is adjustable.
F2: Returns all adjusted values to the defaults. F3: Decreases the value indicated by the indicator one graduation left. F4: Increases the value indicated by the indicator one graduation right. F6: Confirms the changes and moves to the next item. For a camera-equipped machine, the brightness, contrast, and illuminance of the camera screen are also adjustable.
For a camera-equipped machine, selecting Screen adjustment from the user menu switches to the screen for selecting a screen you want to adjust. The adjustment methods for the camera screen and normal screen are the same. The background when adjusting the camera screen is the No. Selecting the Clock adjustment from the user menu and pressing F6 switches to the clock adjustment screen. On this screen, you can change the setting of the time displayed on the normal screen. Time setting Set the clock time.
If the time setting item is not highlighted, press F6 to highlight it. The time display part is highlighted. F3: Advances the clock one hour. F4: Sets the clock back one hour.
F5: Cancels changes you made before confirming them with F6 to return to the user menu. F6: Confirms the changes and moves to minute setting. The minute display part is highlighted. F3: Advances the clock one min. F4: Set the clock back one min. F5: Cancels changes you made before confirming them with F6 to return to the use menu. F3: Moves to the item one right.
F4: Moves to the item one left. F5: Cancels the changes to return to the user menu. F6: Confirms the changes and moves to summer time. Summer time. Selecting ON for this sets the time forward one hour. Setting OFF returns to the ordinary time. F5: Cancels changes you made before confirming them with F6 to return to the user menu screen. F6: Confirms the changes and moves to the time setting. Selecting the Language from the user menu screen and pressing F6 switches to the language setting screen.
From this menu, you can change the language to be displayed on the monitor. Available languages are as follows. F6: Cancels the changes to return to the user menu. Selecting the Economy mode adjustment from the user menu and pressing F6 switches to the Economy mode setting screen. From this menu, you can adjust engine output to improve fuel consumption in E mode.
The fuel consumption level is specified to one of four levels from E0 to E3. The larger the value, the better the fuel consumption, but the smaller the work rate. It is displayed only when all the following conditions are met. This screen switches to the normal screen if one of the following conditions occurs. When you switch to the normal screen by pressing F5, this screen does not appear even if the engine continues to run at idle.
If the engine continues to run at least five min. Continuously pressing auto-deceleration switch 1 and buzzer cancel switch 2 at the same time when setting the starting switch to the OFF position, the service meter will appear on the screen in 3 to 5 sec. Continuously pressing the buzzer cancel switch 1 and F2 at the same time on the password input screen or normal screen causes the entire LCD to light in white. Release F2 and buzzer cancel switch in order.
If any part of the display is black, the LCD is broken. Pressing any function switch returns to the previous screen. If there is any problem in machine operation, the user code and failure code are displayed on the monitor to advise the operator of the steps to take.
These codes appear on the normal screen. On the normal screen, user code 1 and failure code 2 are displayed on the portion for the hydraulic oil temperature gauge. The signals from the sensors are input to the monitor panel directly. Either side of a sensor of contact type is always connected to the chassis ground. Type of sensor. Operation map 2. Service meter 3. Position information 4. Communication antenna connection 2.
Connector A 14 poles 3. This terminal sends various machine information based on the network signals and input signals obtained through the machine monitor, as well as GPS position data, via wireless communication. This terminal can send information via communication antenna.
Input and output signals Connector A Pin No. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.
These standard values are not the standards used in dealing with claims. When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts. Between fan pulley and alternator pulley Deflection when pressed with finger force of approx.
Between fan pully and compressor pully Deflection when pressed with finger force of approximately Boom control valve Arm control valve Bucket control valve Swing control valve Travel control valve. Engine stopped At center of control lever grip Max.
Hydraulic oil temperature: Within operation range Engine at high idling At center of control lever grip At tip in case of pedal Max. Hydraulic oil temperature: Within operation range Engine at high idling Working mode: P mode Hydraulic pump output pressure with all measurement circuits relieved Values inside parenthesis: Hydraulic oil pressure with one-touch power max.
Hydraulic oil temperature: Within operation range Engine running at high idling Working mode: P mode Swing circle misalignment amount when stopping after one turn. Hydraulic oil temperature: Within operation range Engine running at high idling Working mode: P mode Time required for passing points 90 and degrees from starting point.
Hydraulic oil temperature: Within operation range Engine running at high idling Working mode: P mode Time required for 5 more turns after making initial one turn. Hydraulic oil temperature: Within operation range Engine stopped Keeping upper structure transverse on slope of 15 degrees Notching a mating mark on inner and outer races of swing circle Mating mark misalignment amount during 5 minutes Hydraulic oil temperature: Within operation range Engine running at high idling Swing lock switch: ON Leakage amount for one minute during swing relief.
Hydraulic oil temperature: Within operation range Engine running at high idling Working mode: P mode Time required for track shoes to make 5 turns after making one initial idle turn. Hydraulic oil temperature: Within operation range Engine running at high idling Working mode: P mode Flat ground Time required for traveling 20 m after 10 m trial run. Hydraulic oil temperature: Within operation range Engine at high idling Working mode: P mode Travel speed: Lo Solid and flat ground Swerving amount while traveling 20 m X after initial 10 m trial run.
Hydraulic oil temperature: Within operation range Engine stopped Parking machine on slope of 12 degrees with sprocket facing up the slope Sliding distance for 5 minutes Hydraulic oil temperature: Within operation range Engine at high idling Traveling with sprocket locked Oil leakage amount for one minute with traveling in relief condition.
Hydraulic oil temperature: Within operation range Flat and level ground Work equipment in measurement posture as illustrated above Bucket load: 3, kg Engine stopped Work equipment control lever in NEUTRAL position Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting. Hydraulic oil temperature: Within operation range Engine running at high idling Working mode: P mode Time required from raise stroke end till bucket touches ground.
Hydraulic oil temperature: Within operation range Engine running at high idling Working mode: P mode Time required from dumping stroke end to digging stroke end. Hydraulic oil temperature: Within operation range Engine running at low idling Working mode: P mode Time required from raise stroke end till bucket touches ground and pushes up machine front.
Hydraulic oil temperature: Within operation range Engine running at low idling Working mode: P mode Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again. Hydraulic oil temperature: Within operation range Engine running at high idling Leakage amount for one minute with cylinder or travel to be measured in relief condition. Hydraulic oil temperature: Within operation range Engine at high idling Working mode: P mode Traveling speed: Lo Flat and level ground Swerving amount X when traveling 20 m after initial trial run of 10 m.
The error is large near the point where the graph curves, so avoid measuring at this point. Oil pressure in work equipment, swing and travel circuits, basic pressure of L control circuit and oil pressure of pump PC control circuit. Sketches of special tools Remark Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. Engine coolant temperature:.
Within operating range Hydraulic oil temperature:. Within operating range 1. Preparation work. Operate the machine monitor so that the engine speed can be monitored. Measuring low idle speed. Start the engine and set the fuel control dial to the low idle MIN position. Set all the control levers and pedals for work equipment, swing and travel to the neutral and measure the engine speed.
Measuring high idle speed. Start the engine and set the fuel control dial to the high idle MAX position. Set the working mode in the power mode P and turn the auto-decelerator OFF.
Measuring the engine speed when 2-pumps are relieved. Start the engine and move the arm cylinder to the IN stroke end. Set the fuel control dial in the high idle MAX position and set the working mode in the power mode P. Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and measure the engine speed.
Measuring the engine speed when 2-pumps relief and power maximizing near rated speed. While operating the left work equipment control lever to relieve the arm at the IN stroke end and depressing the power maximizing switch, measure the engine speed.
Thus measurement of the engine speed must be completed within that period. Measuring the speed when auto-deceleration speed is in operation. Start the engine, set the fuel control dial in the high idle position MAX , and turn the auto-decelerator ON. Set all the control levers and pedals for work equipment, swing and travel to neutral and measure the engine speed when the auto-decelerator is operated.
This level is the engine speed when operation of the auto-deceleration is turned on. Start the engine and keep it running until temperature of the engine coolant and hydraulic oil rise to the operating range. Run the engine at middle or higher speed and drain oil from the hose. Repeat operation until the oil is drained out. Accordingly, be sure to drain the oil. Measure the air boost pressure at high idle under the following conditions.
Remove the measurement tools after the measurement, and make sure that the machine is back to normal condition. Be careful not to touch any hot part when removing or installing the measuring instruments. When recording official data, use smoke meter B2. Measuring with handy smoke checker B1. Fit a sheet of filter paper to smoke checker B1. Insert the exhaust gas intake pipe into the exhaust pipe.
Start the engine and keep it running until the engine coolant temperature rises to the operating range. Start the engine and accelerate it suddenly or run it at high idle and then operate the handle of smoke checker B1 in order to suction exhaust gas to the filter paper. Take out the filtering paper and compare it with the attached scale for judgement.
Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition. Measuring with smoke meter B2. Insert probe [1] of smoke meter B2 to the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip. Connect the probe hose, receptacle of the accelerator switch and air hose to smoke meter B2. Connect the power cable to an AC receptacle. Loosen the cap nut of the suction pump and fit in the filter paper. Turn on the power switch of smoke meter B2.
Accelerate the engine suddenly or run it at high idle and then depress the accelerator pedal of smoke meter B2 to collect the exhaust gas into the filter paper. Put the polluted filtering paper on non-polluted filtering paper more than 10 sheets in the filtering paper holder, and read the indicated value. Remove cap 6 , set gear C1 and rotate the crank shaft forward to set No.
After setting No. Adjust the valve clearance in the following procedure. Insert clearance gauge C2 to the clearance between rocker lever 8 and cross head 9. Loosen locknut 10 and adjust the valve clearance using adjustment screw PCLC 24 Pages.
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