PC78US-8 Testing and Adjusting
PC78US-8 Testing and Adjusting
PC78US-8 Testing and Adjusting
HYDRAULIC EXCAVATOR
PC78US-8
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PC78US-8
Shop Manual
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30-4 2 PC78US-8
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Sym-
Testing/Adjusting item Part No. Part name Remarks
bol
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm 2}
Testing basic pressure of
L Pressure gauge: 60 MPa
control circuit 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm 2}
Testing and adjusting oil
Pressure gauge: 60 MPa
pressure in pump PC con- M 790-261-1204 Digital hydraulic tester 1
trol circuit {600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-3300 Adapter 1 Size: 03
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm 2}
Pressure gauge: 60 MPa
Testing and adjusting oil 790-261-1204 Digital hydraulic tester 1
pressure in pump LS control N {600 kg/cm2}
circuit Differential pressure
2 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
3
07002-11023 O-ring 2
4 799-401-3300 Adapter 1 Size: 03
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Testing solenoid valve out- 1 {25, 60, 400, 600 kg/cm 2}
P
put pressure Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Testing PPC valve output 1 {25, 60, 400, 600 kg/cm 2}
Q
pressure Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Commercially
Testing oil leakage S Measuring cylinder 1
available
799-601-4101
or T-adapter assembly 1
799-601-4201
For DRC60, Econo (Does not include
799-601-4350 Measurement box 1
799-601-4201)
799-601-4130 T-adapter 1 CAM
Troubleshooting for engine 799-601-4160 T-adapter 1 Ne sensor
T
controller/sensors/actuators 799-601-4220 T-adapter 1 Engine controller
799-601-4240 Socket 1 For ambient pressure sensor
799-601-4190 Socket 1 Common rail pressure sensor
799-601-4340 Socket 1 Injector
795-799-5530 Socket 1 Engine coolant temperature sensor
799-601-4380 Socket 1 Boost pressure sensor
799-601-4260 Socket 1 Engine controller
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Sym-
Testing/Adjusting item Part No. Part name Remarks
bol
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 is not supplied any
799-601-2900 T-adapter assembly 1
more.
or
799-601-7100
or
799-601-7400
or
799-601-8000
For Econo (Does not include
799-601-2600 Measurement box 1
799-601-2700)
799-601-4101
Troubleshooting for chassis or
U
sensors/wiring harnesses 799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
For DT, HD (Does not include
799-601-9320 Measurement box 1
799-601-4100 and 799-601-4201)
799-601-9020 Adapter for DT 1 For DT2P
For DT3P (Does not include
799-601-9030 Adapter for DT 1
799-601-4100 and 799-601-4201)
799-601-9040 Adapter for DT 1
For DT6P (Does not include
799-601-9050 Adapter for DT 1
799-601-4100 and 799-601-4201)
Adapter for DT For DT12P (Does not include
799-601-9110 1
(Gray) 799-601-4100 and 799-601-4201)
For AMP3P (Does not include
799-601-9420 Adapter for AMP 1
799-601-9000 and 799-601-9200)
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Sym-
Testing/Adjusting item Part No. Part name Remarks
bol
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
For X1P (Does not include
799-601-7010 Adapter for X 1
799-601-7000 and 799-601-7100)
799-601-7020 Adapter for X 1 For X2P
For SW6P (Does not include
799-601-7050 Adapter for SWP 1
799-601-8000)
For SW6P (Does not include
799-601-7060 Adapter for SWP 1
799-601-8000)
Troubleshooting for chassis For M1P (Does not include
T 799-601-7080 Adapter for M 1
sensors/wiring harnesses 799-601-7000 and 799-601-7100)
799-601-7090 Adapter for M 1 For M2P
799-601-7110 Adapter for M 1 For M3P
799-601-7130 Adapter for M For M6P
For S16P (Does not include
799-601-7330 Adapter for S 1
799-601-7000 and 799-601-7100)
799-601-7500 T-adapter assembly 1
799-601-7520 Adapter for 070 1 For 070-12P
799-601-7540 Adapter for 070 1 For 070-18P
799-601-9890 Multi-adapter 1 For DT-2, 3, 4/DTM-2P
Box for controller
799-601-4280 1
(PUMP)
799-601-7340 Adapter for M 1 For M8P
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7370 Adapter for relay 1 For REL-6P
Testing coolant tempera-
799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
ture and oil temperature
Testing operating effort and 79A-264-0021 Push-pull scale 1
depressing force 79A-264-0091 Push-pull scale 1
Testing stroke and hydraulic Commercially
Ruler 1
drift available
Testing work equipment Commercially
Stopwatch 1
speed available
Testing voltage and resis- Commercially
Circuit tester 1
tance available
27 mm deep socket (hexagonal),
Removal and installation of Commercially
Deep socket 1 Inside diameter: 24.5 (Equivalent to
engine oil pressure switch available
TONE 4A-27L)
Removel and installation of
coolant temperature sensor
Commercially 21 mm deep socket
(6261-81-6900) Deep socket 1
available (MITOLOY 4ML-21 or equivalent)
Engine serial
No.500001-502653
Removel and installation of
coolant temperature sensor 19 mm deep socket
Deep socket 1
(6261-81-6901) 795T-981-1010 (MITOLOY 4ML-19 or equivalent)
Engine serial No.502654-
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the ma-
chine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Trouble-
shooting (General information on troubleshooting), List of T-boxes and T-adapters".
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-:Socket
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5. Adjust the valve clearances marked with in the 7. After finishing adjustment, remove the adjusting
valve arrangement drawing according to the tools and return the removed parts.
following procedure. Cylinder head cover mounting nut:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
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3. Set the engine in the no-injection cranking mode 3) Connect spill hose connector (6) to injector
with the machine monitor. (1).
Instead of the above work, you may discon- 4) Install high-pressure pipe (5).
nect the wiring harness connectors from all High-pressure pipe flare nut (Both
the injectors so that fuel will not be injected at ends):
all. 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
Since starting of engine is dangerous, be 5) Install fuel scatter prevention cover (3) to the
sure to set the injectors so that they will joint of high-pressure pipe (5).
not inject fuel before starting the check. Install fuel scatter prevention cover (3)
with the slit down (on both injector side
4. Crank the engine with the starting motor and and common rail side).
measure the compression pressure. 6) Install clamp (4) to high-pressure pipe (5).
Read the pressure when the gauge pointer is Install the clamp to the position from
stabilized. which it was removed. (The mounting
bolt goes through the clamp and enters
5. After finishing measurement, remove the the bolt hole of the air intake manifold.
measuring instruments and return the removed Accordingly, if the mounting bolt is in-
parts according to the following procedure. stalled normally, the clamp is installed to
1) Install O-ring (8) and gasket (9) to injector (1). its original position.)
Do not install O-ring (8) to groove "a". 7) Connect wiring harness connector (2) to
injector (1).
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Testing engine oil pressure 2. Remove oil pressure pickup plug (1) from the
engine block.
Testing tools for engine oil pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
E 2 799-401-2320 Gauge
6732-81-3170 Adapter
3
07002-11023 O-ring
Stop the machine on a level ground and low-
er the work equipment to the ground.
Test the engine oil pressure under the following
condition.
Engine coolant temperature: Within operat-
ing range
1. Remove covers (1) and (2).
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Testing fuel return rate and fuel 2) Insert spacer G1 on return block (2) side and
leakage tighten the removed joint bolt again.
Be sure to fit the gaskets to both ends of
Testing tools for fuel return rate and fuel leakage the spacer.
Symbol Part No. Part name 3) Insert joint G2 on common rail (1) side and
1 6151-51-8490 Spacer
tighten the removed joint bolt again.
2 6164-81-5750 Joint
3 07042-20108 Plug Be sure to fit the gaskets to both ends of
Commercially the joint.
4 Hose
available 4) Connect test hose G4 to the end of joint G2.
G Commercially 5) Connect test hose G5 to connector (6) side of
5 Hose
available spill hose (4).
Commercially
6 Measuring cylinder Bind the connecting part of the test hose
available
Commercially with a wire etc. to prevent it from coming
7 Stopwatch off.
available
Lay test hose G4 so that it will not slacken
Prepare an oil pan of about 20 to receive the and put its end in the oil pan.
fuel flowing out during the test.
1. Preparation work
1) Remove tube (3) and spill hose (4) between
common rail (1) and return block (2).
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2. Testing leakage from pressure limiter 3. Testing return rate from injector
1) Lay test hose G4 so that it will not slacken While testing the return rate from the injector,
and put its end in the oil pan. keep the test hose on the pressure limiter
2) Start the engine and keep its speed at 1,600 side connected and keep its end in the oil
rpm with no load. pan.
3) After the engine speed is stabilized, test the 1) Run the engine at the rated output.
leakage in 1 minute with measuring cylinder 2) After the engine speed is stabilized, test the
G6. return rate in 1 minute with measuring
You may test for 20 seconds and judge by cylinder G6.
multiplying the result by 3. You may test for 20 seconds and judge by
If the leakage from the pressure limiter is multiplying the result by 3.
in the following standard range, it is nor- If the supply pump pressure is low, the
mal. engine speed may not rise.
Engine speed Leakage In this case, record the engine speed, too,
(rpm) (cc/min) during the test.
At rated output Max. 20 If the return rate (spill) from the injector is
in the following standard range, it is nor-
mal.
Rated output Limit of return rate
speed (rpm) (spill) (cc/min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230
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1. Fuel tank
2. Priming pump
3. Pre-filter with water separator
4. Main filter
5. Feed pump
6. IMV (Inlet Metering Valve)
7. Overflow valve
8. Rail
9. Injector
10. Safety valve
11. High pressure pump
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Testing swing circle bearing clear- 4. Set the arm almost perpendicular to the ground
ance and lower the boom until the front track shoe
floats.
Testing tools for swing circle bearing clearance At this time the front of the upper structureris-
Symbol Part No. Part name es and the rear lowers.
Commercially
H Dial gauge
available
5. Under this condition, read dial gauge H.
When testing the swing circle bearing clearance The value indicated by dial gauge H is the
installed to the machine, perform the following clearance of the bearing.
procedure. For the standard value, see Structure, func-
Stop the machine on a level ground and low- tion and maintenance standard, "Swing cir-
er the work equipment to the ground. cle".
Do not put your hands or feet under the un-
dercarriage during test.
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2. Decreasing tension
1) Loosen valve (1) to discharge grease, and
then tighten it.
Do not loosen the valve more than 1
turn. If it is loosened more, it may
jump out because of the high-pressure
grease in it.
2) To check that the tension is normal, run the
engine at low idle and move the machine
forward by the length of track on ground, then
stop slowly.
3) After adjusting, check the track shoe tension
again according to the above procedure.
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Testing and adjusting oil pressure 2) Install nipples J2 and connect oil pressure
in work equipment and travel gauges [1] of hydraulic tester J1.
circuits Use the oil pressure gauges of 60 MPa
{600 kg/cm 2}.
Testing
The oil pressure in the work equipment and trav-
el circuits (pump discharge pressure) can be
checked with monitoring function of the machine
monitor, too (For details, see "Special functions
of machine monitor").
Monitoring code: 01100 pump pressure
Test the oil pressure in the work equipment and
travel circuits under the following condition.
Hydraulic oil temperature: Within operating
range
1. Preparation work
1) Open the sand cover and remove oil pres-
sure pickup plugs (1) and (2). 2. Testing unload pressure
(1): Pump discharge pressure port (1) 1) Start the engine, set the working mode in the
check plug power mode (P), and turn the auto-deceler-
(2): Pump discharge pressure port (2) ator OFF.
check plug 2) Run the engine at high idle, set all the levers
and pedals for work equipment control and
travel in neutral, and test the oil pressure.
The pressure tested when the unload
valve is unloaded is indicated.
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Testing and adjusting swing and 2) Install nipple K2 and connect oil pressure
blade circuit oil pressure (Blade gauge [1] of hydraulic tester K1
specification) Use the oil pressure gauge of 60 MPa
{600 kg/cm 2}.
Testing
The oil pressure in the work equipment, swing,
and travel circuits (pump discharge pressure) 2. Testing swing relief pressure
can be checked with monitoring function of the 1) Start the engine, set the working mode to
machine monitor, too (For details, see “Special power mode (P), and turn the swing lock
functions of machine monitor”). switch ON.
Monitoring code: 01100 pump pressure 2) While running the engine at high idle, operate
Test the swing and blade circuit oil pressure un- the left work equipment control lever to
der the following condition. (Blade specification) relieve the swing motor, and measure the oil
Hydraulic oil temperature: Within operating pressure.
range The swing motor safety valve relief pres-
sure is indicated.
1. Preparation work The swing relief pressure is lower than
1) Open the right exterior inspection window the main relief pressure.
and remove oil pressure pickup plug (1).
3. Testing blade (lower) relief pressure
1) Start the engine and set the working mode to
power mode (P).
2) While running the engine at high idle, operate
the blade control lever in the lowering direc-
tion to relieve, and measure the oil pressure.
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1) Loosen locknut (5) of safety valve (2) and 1) Loosen locknut (9) of main relief valve (6)
turn adjustment screw (3). and turn adjustment screw (7).
Do not remove the adjustment nut or Do not remove the adjustment nut or
inside parts will come out. inside parts will come out.
If the adjustment screw is If the adjustment screw is
turned to the right, the set pressure is turned to the right, the pressure is in-
decreased. creased.
turned to the left, the set pressure is turned to the left, the pressure is de-
decreased. creased.
Amount of adjustment per turn of adjust- Amount of adjustment per turn of adjust-
ment screw: ment screw:
4.8 MPa {49.3 kg/cm2} 19.6 MPa {200 kg/cm2}
2) After adjusting, tighten locknut (5). 2) After adjusting, tighten locknut (9).
Locknut: Locknut: 39 – 49 Nm {4 – 5 kgm}
93.2 – 117.7 Nm {9.5 – 12 kgm} 3) Referring to the section of measuring, check
3) Referring to the section of measuring, check the relief pressure again.
the relief pressure again.
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Testing control circuit basic pres- 3. Start the engine, set the working mode in the
sure power mode (P), and turn the auto-decelerator
OFF.
Testing tools for control circuit basic pressure
Symbol Part No. Part name 4. Run the engine at high idle, set all the levers and
799-101-5002 Hydraulic tester
1 pedals for work equipment control, swing
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 × 1.25 mm) control, and travel in neutral, and test the oil
2 pressure.
07002-11023 O-ring
Stop the machine on a level ground and low-
er the work equipment to the ground. Then,
release the residual pressure from the hy-
draulic circuit. For details, see "Releasing re-
sidual pressure from hydraulic circuit".
Test the control circuit basic pressure under the
following condition.
Hydraulic oil temperature: Within operating
range
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Testing and adjusting oil pressure 2) Install nipple M2 and connect it to oil pres-
in pump PC control circuit sure gauge [1] of hydraulic tester M1.
Use the oil pressure gauges of 60 MPa
Testing and adjusting tools for oil pressure in
{600 kg/cm 2}.
pump PC control circuit
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
M 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-3300 Adapter (Size: 03)
Stop the machine on a level ground and low-
er the work equipment to the ground. Then,
release the residual pressure from the hy-
draulic circuit. For details, see "Releasing re-
sidual pressure from hydraulic circuit".
Testing
Before testing the oil pressure in the PC control
circuit, check that the oil pressure in the work 3) Start the engine and operate the arm cylinder
equipment, swing, and travel circuits and the ba- to the arm IN stroke end.
sic pressure of the control circuit are normal. 4) Set the working mode in the power mode (P).
Test the oil pressure in the pump PC control cir- 5) While running the engine at high idle, operate
cuit under the following condition. the right work equipment control lever to
Hydraulic oil temperature: Within operating relieve the arm circuit in the arm IN direction
range and measure the oil pressure.
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6) After finishing test, remove the testing tools 4) Start the engine and set the working mode in
and return the removed parts. the power mode (P).
5) Run the engine at high idle and low idle, set
2. Testing PC-EPC valve basic pressure all the levers and pedals for work equipment
1) Open the engine hood and disconnect pilot control, swing control, and travel in neutral,
pump discharge hose (2). and test the oil pressure at each speed.
2) Install adapter M3 and connect the discon-
nected hose again.
3) Install nipple [1] of hydraulic tester M1 and
connect it to oil pressure gauge [2] of
hydraulic tester M1.
Use the oil pressure gauges of 6 MPa
{60 kg/cm2}.
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3. Adjusting PC valve
When "the engine speed decreases" or "the
engine speed is normal but the work equip-
ment speed decreases" as the load increas-
es, if the pump discharge pressure and LS
differential pressure are normal, adjust the
pump PC valve according to the following
procedure.
Before loosening the locknut, be sure to
make match mark "a".
1) Loosen locknut (3) and rotate adjustment
screw (4) to adjust.
Since the PC valve is eccentric type, in
which direction to rotate it to increase the
torque is unknown. Accordingly, adjust
while monitoring the engine speed.
2) After finishing measurement, tighten locknut
(1).
Locknut: 29.4 – 39.2 {3 – 4 kgm}
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Adjusting LS valve
If the LS differential pressure is abnormal, adjust
the LS valve according to the following proce-
dure.
Before loosening the locknut, be sure to make a
match mark.
1) Loosen locknut (2) and rotate adjustment
screw (3) to adjust.
If the adjustment screw is
Turned to the right, the pressure is in-
creased.
Turned to the left, the pressure is de-
creased.
Amount of adjustment per turn of adjust-
ment screw: 1.27 MPa {13 kg/cm2}
2) After adjusting, tighten locknut (2).
Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}
After adjusting, measure the LS differen-
tial pressure according to the measure-
ment procedure shown above.
When loosening or tightening the locknut,
hold adjustment screw (3) with a spanner
to prevent it from being dragged.
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Testing solenoid valve output 2. Install adapter P2 and connect the disconnected
pressure hose again.
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Testing tools for PPC valve output pressure 4. Start the engine and set the working mode to the
Symbol Part No. Part name power mode (P).
799-101-5002 Hydraulic tester
1
Q 790-261-1204 Digital hydraulic tester
5. While running the engine at high idle, measure
2 799-401-3100 Adapter (Size: 02)
the oil pressure with the control lever in neutral
Stop the machine on a flat ground, lower the and at the stroke end.
work equipment to the ground, and release
the residual pressure, referring to "Releasing
residual pressure in hydraulic circuit".
Before testing the PPC valve output pressure,
ensure that the control circuit basic pressure is
normal.
Test the solenoid valve output pressure under
the following condition.
Hydraulic oil temperature: Within operating
range
1. Disconnect the PPC circuit hose to be tested.
For the host to be disconnected, see "PPC
piping connecting positions".
2. Install adapter Q2 and connect the disconnected If the output pressure is as follows, the PPC
hose again. valve is normal.
Lever operation Output pressure
3. Install nipple [1] of hydraulic tester Q1 and Neutral 0 MPa {0 kg/cm2}
connect it to oil pressure gauge [2]. Almost same as control circuit
Use the oil pressure gauge of 6 MPa Stroke end basic pressure (See “Standard
{60 kg/cm2}. value table”)
The figure shows the testing tools installed to
the bucket dump PPC circuit.
6. After finishing testing, remove the testing instru-
ments and return the removed parts.
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5. Testing oil leakage from travel motor 5) After finishing test, return the removed parts.
1) Remove the travel motor cover.
2) Run the engine, lock the travel mechanism,
and stop the engine.
Put pin [1] between the sprocket and
track frame to lock the travel mecha-
nism securely.
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4. Bleeding air from swing motor 6. Checking oil level and starting work
Carry out this step only when the oil in the 1) Run the engine, retract the arm cylinder and
swing motor case was drained. bucket cylinder to the stroke ends, lower the
If the engine is operated without bleeding air work equipment to the ground, and stop the
from the swing motor, the motor bearing may engine.
be broken.
1) While running the engine at low idle, loosen
the drain hose (2) and tighten it when the oil
flows out.
Do not swing while working.
2) While running the engine at low idle, swing
evenly to the right and left at least 2 turns
each.
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©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
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Operator mode (Outline) Service mode
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A Display of inputting password 7p Mechanical Systems 25p
Abnormality
A Display of check of breaker mode 7p Electrical Systems 26p
Record
A Display of check before starting 7p Air-conditioning System 31p
A Display of warning after check before starting 7p Maintenance Record 32p
A Display of ending of maintenance interval 8p Maintenance Mode Change 33p
A Display of check of working mode and travel speed 8p Phone Number Entry 35p
A Display of ordinary screen 8p Key-on Mode 36p
A Display of end screen 8p Unit 37p
B Selection of auto-deceleration 9p Default With/Without Attachment 38p
B Selection of working mode 9p Attachment/Maintenance Password 39p
B Selection of travel speed 10p ECO Display 40p
B Operation to stop alarm buzzer 10p Pump Absorption Torque 41p
B Operation of windshield wiper 10p Attachment Flow Adjustment 42p
B Operation of window washer 10p ATT EPC1 current adjustment 42p
Adjustment
B Operation of air conditioner/heater 11p ATT EPC2 current adjustment 42p
B Operation to display clock and service meter 11p ATT EPC3 current adjustment 42p
B Check of maintenance information 12p ATT EPC4 current adjustment 42p
Setting and display of user mode Cylinder Cut-Out 43p
B 12p
(Including KOMTRAX messages for user)
No Injection 44p
C Display of energy-saving guidance 13p
Fuel Consumption 46p
C Display of caution monitor 14p
Terminal Status 47p
C Display of user code and failure code 14p KOMTRAX
GPS & Communication Status 48p
Settings
(Special operation)
MODEM S/N (TH300) 49p
Function of checking display of LCD
D 16p Service Message 50p
(Liquid Crystal Display)
D Function of checking service meter 16p
Function of changing attachment/maintenance
D 17p
password
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To reset the time left after finishing mainte- 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
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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.
E03 Swing brake system error 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.
Operations are possible, but have inspection carried out
E20 Abnormality in travel system
immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error
out immediately.
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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- 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 [F5]: Reset input numeral/Return to ordi-
switches. nary screen
Operation of switches (While pressing [4], [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] [5] [5]
This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
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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 "Monitorin g" on the service menu
screen.
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1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" Screen.
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User
Failure code Trouble (Display on screen) Component in charge Category in charge
code
989L00 Engine controller lock caution 1 MON Electrical system
989M00 Engine controller lock caution 2 MON Electrical system
989N00 Engine controller lock caution 3 MON Electrical system
AB00KE Charge voltage low MON Mechanical system
B@BAZG Eng oil press. low ENG Mechanical system
B@BCNS Eng coolant overheat ENG Mechanical system
B@HANS Hydr oil overheat PUMP Mechanical system
E10 CA111 ECM critical internal failure ENG Electrical system
E10 CA115 Eng. Ne and Bkup speed sensor error ENG Electrical system
E11 CA122 Charge air press sensor high error ENG Electrical system
E11 CA123 Charge air press sensor low error ENG Electrical system
E14 CA131 Throttle sensor high error ENG Electrical system
E14 CA132 Throttle sensor low error ENG Electrical system
E15 CA144 Coolant temp. sensor high error ENG Electrical system
E15 CA145 Coolant temp. sensor low error ENG Electrical system
E15 CA153 Charge air temp. sensor high error ENG Electrical system
E15 CA154 Charge air temp. sensor low error ENG Electrical system
E15 CA187 Sensor sup. 2 volt. low error ENG Electrical system
E11 CA221 Ambient air press. sensor high error ENG Electrical system
E11 CA222 Ambient air press. sensor low error ENG Electrical system
E15 CA227 Sensor sup. 2 volt. high error ENG Electrical system
CA234 Eng. overspeed ENG Mechanical system
E15 CA238 Ne speed sensor sup. volt. error ENG Electrical system
E10 CA271 IMV/PCV 1 short error ENG Electrical system
E10 CA272 IMV/PCV 1 open error ENG Electrical system
E11 CA322 Injector #1 (L #1) system open/short error ENG Electrical system
E11 CA324 Injector #3 (L #3) system open/short error ENG Electrical system
E11 CA331 Injector #2 (L #2) system open/short error ENG Electrical system
E11 CA332 Injector #4 (L #4) system open/short error ENG Electrical system
E10 CA351 Inj. drive circuit error ENG Electrical system
E15 CA352 Sensor sup. 1 volt. low error ENG Electrical system
E15 CA386 Sensor sup. 1 volt. high error ENG Electrical system
E15 CA435 Abnormality in engine oil pressure switch ENG Electrical system
E10 CA441 Battery voltage low error ENG Electrical system
E10 CA442 Battery voltage high error ENG Electrical system
E11 CA449 Rail press. very high error ENG Electrical system
E11 CA451 Rail press. sensor high error ENG Electrical system
E11 CA452 Rail press. sensor low error ENG Electrical system
E15 CA553 Rail press. high error ENG Electrical system
E15 CA559 Rail press. low error ENG Electrical system
E15 CA689 Eng. Ne speed sensor error ENG Electrical system
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User
Failure code Trouble (Display on screen) Component in charge Category in charge
code
E15 CA731 Eng. Bkup speed sensor phase error ENG Electrical system
E10 CA757 All persistent data lost error ENG Electrical system
E15 CA778 Eng. Bkup speed sensor error ENG Electrical system
E0E CA1633 KOMNET datalink timeout error ENG Electrical system
E14 CA2185 Throttle sens. sup. volt. high error ENG Electrical system
E14 CA2186 Throttle sens. sup. volt. low error ENG Electrical system
E11 CA2249 Rail press. very low error ENG Electrical system
E11 CA2311 IMV solenoid error ENG Electrical system
D110KB Battery relay drive short PUMP Electrical system
D19JKZ Personal code relay abnormality MON2 Electrical system
D862KA GPS antenna discon MON2 Electrical system
E0E DA22KK Pump solenoid power low error PUMP Electrical system
DA25KP 5 V sensor 1 power abnormality PUMP Electrical system
DA26KP 5 V sensor 2 power abnormality PUMP Electrical system
DA29KQ Model selection abnormality PUMP Electrical system
E0E DA2RMC CAN discon (Pump controller detected) PUMP Electrical system
DAFGMC GPS module error MON2 Electrical system
E0E DAFRMC CAN discon (Monitor detected) MON Electrical system
DGH2KB Hydr oil sensor short PUMP Electrical system
DHPAMA Pump press sensor abnormality PUMP Electrical system
E20 DHS5KX Travel PPC Sensor Abnormality PUMP Electrical system
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP Electrical system
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP Electrical system
DHX1MA Overload sensor abnormality (Analog) PUMP Electrical system
DV20KB Travel alarm S/C PUMP Electrical system
DW43KA Travel speed sol discon PUMP Electrical system
DW43KB Travel speed sol short PUMP Electrical system
E03 DW45KA Swing brake sol discon PUMP Electrical system
E03 DW45KB Swing brake sol short PUMP Electrical system
DWJ0KA Merge-divider sol discon PUMP Electrical system
DWJ0KB Merge-divider sol short PUMP Electrical system
E02 DXA8KA PC-EPC sol discon PUMP Electrical system
E02 DXA8KB PC-EPC sol short PUMP Electrical system
DY20KA Wiper working abnormality PUMP Electrical system
DY20MA Wiper parking abnormality PUMP Electrical system
DY2CKA Washer drive open circuit PUMP Electrical system
DY2CKB Washer drive short circuit PUMP Electrical system
DY2DKB Wiper drive (fwd) short circuit PUMP Electrical system
DY2EKB Wiper drive (rev) short circuit PUMP Electrical system
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4. Contents of setting of each maintenance item If the set value of an item set to "ON" is
After selecting each maintenance item, if the changed after 1 or more operating hours
screen is displayed, set the item with the func- since the start of setting, the change is
tion switches. recognized as a resetting operation.
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1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
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1. Selecting menu
Select "Default" on the "Service Menu" screen.
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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.
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[Reference] No Injection
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.
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.
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.
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2. Starting test
After the screen of "Fuel Consumption" is dis-
played, start test with the function switches.
[F1]: Start
[F2]: Clear 4. Finishing test
[F5]: Return to Service menu screen Press [F1], and test is finished and the data
When the screen of “Fuel consumption” is are displayed on the finishing date and time
displayed, if a data is indicated, it is the side.
data of the previous test. This data is not
an obstacle to new test and can be reset 5. Displaying fuel consumption
by pressing [F2]. If the test is finished, the hourly fuel consump-
If [F1] is pressed, the data is displayed on tion calculated from the fuel consumption cal-
the starting date and time side and test culated by the engine contro ller and the
starts. elapsed time are displayed.
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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 Positioning: Positioning condition of GPS
condition of positioning and communication of the Communication: Communication environ-
KOMTRAX terminal. ment of communication MODEM and con-
ne c t i n g co n d itio n o f c o mmu n i c a t io n
1. Selecting menu MODEM
Select "KOMTRAX Settings" on the "Service Number of message not yet sent: Number
Menu" screen. of mails which are saved in machine mon-
itor and not transmitted yet
[F5]: Return to KOMTRAX settings screen
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1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
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©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
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1. Machine monitor
1) Remove 3 mounting bolts and cover (1).
One of the mounting bolts is installed
in the cover on the right of the sun-
light sensor.
While removing the mounting bolts,
disconnect connector P31 of the sun-
light sensor.
2. Engine controller
1) Open the engine hood.
The engine controller is installed to
the counterweight.
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors CE01, CE02, and
CE03 of engine controller (4).
Connectors CE01 and CE02 are fixed
with screws. When disconnecting
them, loosen the screws.
When returning connectors CE01 and
CE02, tighten the screws to the spec-
ified torque.
Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
2) Remove 1 mounting bolt and duct (2).
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3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove cover (1).
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5. Engine Ne speed sensor (Crank sensor) 6. Boost pressure and temperature sensor
Engine Bkup speed sensor (Cam sensor) (Boost press & IMT)
Engine oil pressure switch (Oil pressure Disconnection and connection of con-
switch) nector
Disconnection and connection of con- The connector of the boost pressure and
nectors temperature sensor has a special locking
The connectors of the engine Ne speed mechanism. Disconnect it according to
se n s o r, e n g i n e B k u p s p e e d s e n s o r, steps (a) – (b) and connect it according to
engine oil pressure switch have a special steps (c) – (d) as shown below.
locking mechanism. Disconnect them Disconnection: (a) Unlock – (b) Discon-
according to steps (a) – (c) and connect nect connector.
them according to steps (d) – (f) as shown Connection: (c) Connect connector – (d)
below. Lock.
Disconnection: (a) Slide lever – (b)
Unlock – (c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
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7. Supply pump IMV solenoid (Fuel regulator) Precautions for connecting connector
Disconnection and connection of con- Take care not to connect the connector
nector reversely.
The connector of the supply pump IMV Engage lock (e) on the wiring harness side
solenoid has a special locking mecha- with triangular notch (f) on the sensor side
nism. Disconnect it according to steps (a) (Do not engage lock (e) with square guide
– (b) and connect it according to steps (c) (g) on the opposite side of triangular notch
– (d) as shown below. (f)).
Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
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Pm Clinic service 1
/ /
Specifications
Main components Attachments Shoe width
Boom Standard ( ) Breaker 450 mm ( )
Arm Standard ( ) ( ) 600 mm
Bucket Standard ( ) ( )
Check of oil/coolant level
Radiator coolant When necessary
Machinery case oil
Engine oil Damper case oil
( )
Hydraulic oil Final drive case oil
Ambient temperature Altitude
°C m
Operator's opinion
Mechanical equipment system fault history Electrical equipment system fault history
989EKX 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@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
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1. Engine
Checking condition
Standard Mea-
Fuel Work- Auto- Service limit
No. Check item Operation of work Unit value for new sured
control ing decel- value
equipment machine value
dial mode eration
1 Engine speed rpm 1,900 – 2,000 1,900 – 2,000
Engine oil MAX All levers in neutral MPa 0.34 – 0.59 0.25
2
pressure {kg/cm2} {3.5 – 6.0} {2.5}
P OFF
3 Engine speed rpm 1,150 – 1,200 1,150 – 1,200
Engine oil MIN All levers in neutral MPa Min. 0.18 0.15
4
pressure {kg/cm2} {Min. 1.8} {1.5}
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4. Hydraulic circuit
[1] [2] [3] [4] [5] [6]
Checking condition
600K 600K 600K 600K 60K 60K
No. Checked part
Fuel Work- Pump for
Operation of work Pump Pump main Pump Pump
control ing Control swing and
equipment main 1 2 LS 1 LS 2
dial mode blade
A
1 Pilot relief valve All lever in neutral — — — — —
B
2 Main relief valve Arm OUT relief — — — — —
C
3 Unload valve All levers in neutral — — — — —
D1 D2
4 LS valve Bucket CURL full — — — —
MAX P
E E
(Bladeless (Blade
Right swing relief — — — —
specifica- specifica-
Swing motor tion) tion)
5
safety valve E E
(Bladeless (Blade
Left swing relief — — — —
specifica- specifica-
tion) tion)
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 3.14 ± 0.3 {32 ± 3} 3.14 ± 0.5 {32 ± 3}
B (Work equipment relief pressure) 26.5 ± 1 {270 ± 10} 26.5 ± 1.5 {270 ± 15}
C (Unload pressure) 2.45 – 4.41 {25 – 45} 2.45 – 4.41 {25 – 45}
D (LS differential pressure when
Approx. 2.11 {Approx. 21.5} Approx. 2.11 {Approx. 21.5}
bucket control lever operated) MPa
{kg/cm2}
Blade
20.6 ± 1 {210 ± 10} 20.6 ± 1.5 {210 ± 15}
specification
E (Swing relief pressure)
Bladeless
22.6 ± 1 {230 ± 10} 22.6 ± 1.5 {230 ± 15}
specification
F (Travel relief pressure) 26.5 ± 1 {270 ± 10} 26.5 ± 1.5 {270 ± 15}
Checked oil pressure Unit Standard value for new machine Service limit value
H1 : H2 = 1 : 0.25
H (Servo control pressure) —
(Oil pressure ratio)
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* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Checking condition
600K 600K 60K 60K 60K
No. Check item
Fuel Work-
Pump Pump Pump Pump
control ing Operation of work equipment Control
main 1 main 2 LS 1 LS 2
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
7 PC-EPC valve All levers in neutral
J3 J3
MAX E — — —
J4 J4
L — — —
Checked oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output pressure 1) Approx. 2.8 {Approx. 29}
J2 (PC-EPC valve output pressure 2) MPa Approx. 1.1 {Approx. 12}
J3 (PC-EPC valve output pressure 3) {kg/cm2} Approx. 2.3 {Approx. 24}
J4 (PC-EPC valve output pressure 4) Approx. 1.4 {Approx. 14}
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©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
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