Pc78us 8
Pc78us 8
HYDRAULIC PC78US -8
EXCAVATOR
SERIAL NUMBERS 15001 and up
SEN04552-03
HYDRAULIC EXCAVATOR
PC78US-8
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC78US-8 00-100 1
100 Index
SEN04552-03 Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04543-03
40 Troubleshooting.......................................................................................................................... SEN04549-01
100 Failure code table and fuse locations ................................................................................ SEN04807-00
200 General information on troubleshooting............................................................................. SEN04808-01 q
301 Troubleshooting by failure code, Part 1 ............................................................................. SEN04809-00
302 Troubleshooting by failure code, Part 2 ............................................................................. SEN04810-00
303 Troubleshooting by failure code, Part 3 ............................................................................. SEN04811-00
304 Troubleshooting by failure code, Part 4 ............................................................................. SEN04812-00
400 Troubleshooting of electrical system (E-mode).................................................................. SEN04813-00
00-100 2 PC78US-8
100 Index
Composition of shop manual SEN04552-03
PC78US-8 00-100 3
100 Index
SEN04552-03 Table of contents
Table of contents 1
01 Specification
100 Specification and technical data SEN04554-01
Specification dimension drawing ................................................................................................................... 2
Working range diagram................................................................................................................................. 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
00-100 4 PC78US-8
100 Index
Table of contents SEN04552-03
PC78US-8 00-100 5
100 Index
SEN04552-03 Table of contents
40 Troubleshooting
100 Failure code table and fuse locations SEN04807-00
Failure code table.......................................................................................................................................... 2
Fuse locations ............................................................................................................................................... 4
200 General information on troubleshooting SEN04808-01
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Checks before troubleshooting ..................................................................................................................... 4
Classification and troubleshooting steps...................................................................................................... 5
Information in troubleshooting table .............................................................................................................. 6
Phenomena looking like troubles and troubleshooting Nos. ......................................................................... 8
Connection table for connector pin numbers ................................................................................................ 11
T- branch box and T- branch adapter table ................................................................................................... 47
301 Troubleshooting by failure code, Part 1 SEN04809-00
Failure code [989L00] Engine controller lock caution 1 ................................................................................ 3
Failure code [989M00] Engine controller lock caution 2 ............................................................................... 4
Failure code [989N00] Engine controller lock caution 3................................................................................ 5
Failure code [AB00KE] Charge voltage low .................................................................................................. 6
Failure code [B@BAZG] Eng oil press. low .................................................................................................. 8
Failure code [B@BCNS] Eng coolant overheat ............................................................................................ 9
Failure code [B@HANS] Hydr oil overheat ................................................................................................... 9
Failure code [CA111] ECM critical internal failure ......................................................................................... 10
Failure code [CA115] Eng. Ne and Bkup speed sensor error ....................................................................... 13
Failure code [CA122] Charge air press sensor high error............................................................................. 14
Failure code [CA123] Charge air press sensor low error .............................................................................. 16
Failure code [CA131] Throttle sensor high error ........................................................................................... 18
Failure code [CA132] Throttle sensor low error ............................................................................................ 20
Failure code [CA144] Coolant temp. sensor high error................................................................................. 22
Failure code [CA145] Coolant temp. sensor low error .................................................................................. 24
Failure code [CA153] Charge air temp. sensor high error ............................................................................ 26
Failure code [CA154] Charge air temp. sensor low error.............................................................................. 28
Failure code [CA187] Sensor sup. 2 volt. low error....................................................................................... 29
Failure code [CA221] Ambient air press. sensor high error .......................................................................... 30
Failure code [CA222] Ambient air press. sensor low error............................................................................ 32
Failure code [CA227] Sensor sup. 2 volt. high error ..................................................................................... 33
Failure code [CA234] Eng. overspeed .......................................................................................................... 34
Failure code [CA238] Ne speed sensor sup. volt. error ................................................................................ 36
Failure code [CA271] IMV/PCV1 short error ................................................................................................. 38
Failure code [CA272] IMV/PCV1 open error ................................................................................................. 39
Failure code [CA322] Injector #1 (L #1) system open/short error ................................................................. 40
Failure code [CA324] Injector #3 (L #3) system open/short error ................................................................. 42
Failure code [CA331] Injector #2 (L #2) system open/short error ................................................................. 44
Failure code [CA332] Injector #4 (L #4) system open/short error ................................................................. 46
302 Troubleshooting by failure code, Part 2 SEN04810-00
Failure code [CA351] Inj. drive circuit error................................................................................................... 3
Failure code [CA352] Sensor sup. 1 volt. low error....................................................................................... 6
Failure code [CA386] Sensor sup. 1 volt. high error ..................................................................................... 8
Failure code [CA435] Abnormality in engine oil pressure switch .................................................................. 10
Failure code [CA441] Battery voltage low error ............................................................................................ 11
00-100 6 PC78US-8
100 Index
Table of contents SEN04552-03
PC78US-8 00-100 7
100 Index
SEN04552-03 Table of contents
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked............................ 18
E-6 Precaution lights up while engine is running .......................................................................................... 20
E-7 Emergency stop item lights up while engine is running.......................................................................... 23
E-8 Engine coolant temperature gauge does not indicate normally.............................................................. 24
E-9 Hydraulic oil temperature gauge does not indicate normally.................................................................. 26
E-10 Fuel level gauge does not indicate normally ........................................................................................ 29
E-11 Contents of display by machine monitor are different from applicable machine................................... 31
E-12 Machine monitor does not display some items..................................................................................... 31
E-13 Function switch does not work ............................................................................................................. 31
E-14 Auto-decelerator does not operate normally ........................................................................................ 32
E-15 Working mode does not change........................................................................................................... 33
E-16 Travel speed does not change ............................................................................................................. 34
E-17 Alarm buzzer cannot be stopped.......................................................................................................... 35
E-18 Windshield wiper and window washer do not operate.......................................................................... 36
E-19 Swing holding brake does not operate normally................................................................................... 40
E-20 Travel alarm does not sound or does not stop sounding...................................................................... 42
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) .................... 43
E-22 While starting switch is in OFF position, service meter is not displayed .............................................. 56
E-23 Machine monitor cannot be set in service mode .................................................................................. 57
E-24 Monitoring function does not display lever control signal normally....................................................... 58
E-25 KOMTRAX system does not operate normally..................................................................................... 74
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04814-00
Information contained in troubleshooting table ............................................................................................. 3
System chart for hydraulic and mechanical systems .................................................................................... 4
H-1 Speed or power of all work equipment, swing, and travel are low.......................................................... 6
H-2 Engine speed sharply drops or engine stalls.......................................................................................... 7
H-3 No work equipment, travel and swing move........................................................................................... 8
H-4 Abnormal noise is heard from around hydraulic pump........................................................................... 8
H-5 Fine control performance or response of work equipment and travel is low .......................................... 9
H-6 Speed or power of boom is low .............................................................................................................. 10
H-7 Speed or power of arm is low ................................................................................................................. 11
H-8 Speed or power of bucket is low............................................................................................................. 12
H-9 Speed or power of blade is low .............................................................................................................. 13
H-10 Work equipment does not move in its single operation ........................................................................ 14
H-11 Hydraulic drift of work equipment is large............................................................................................. 15
H-12 Time lag of work equipment is large..................................................................................................... 17
H-13 Work equipment loaded more is slower during compound operation .................................................. 17
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE....................................... 17
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel ............... 18
H-16 Machine deviates during travel............................................................................................................. 19
H-17 Travel speed is low............................................................................................................................... 20
H-18 Machine cannot be steered easily or steering power is low ................................................................. 21
H-19 Travel speed does not change or it is kept low or high ........................................................................ 22
H-20 Track does not move (only either side) ................................................................................................ 22
H-21 Machine does not swing....................................................................................................................... 23
H-22 Swing acceleration, swing speed and swing power are low................................................................. 24
H-23 Excessive overrun when stopping swing.............................................................................................. 26
H-24 When upper structure stops swinging, it makes large shock ............................................................... 27
H-25 When upper structure stops swinging, it makes large sound ............................................................... 27
H-26 Hydraulic drift of swing is large............................................................................................................. 28
H-27 Flow rate in attachment circuit cannot be adjusted .............................................................................. 29
600 Troubleshooting of engine (S-mode) SEN04815-00
Method of using troubleshooting chart .......................................................................................................... 2
S-1 Starting performance is poor .................................................................................................................. 6
S-2 Engine does not start.............................................................................................................................. 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations .............................................................................................................. 11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
00-100 8 PC78US-8
100 Index
Table of contents SEN04552-03
PC78US-8 00-100 9
100 Index
SEN04552-03 Table of contents
00-100 10 PC78US-8
100 Index
Table of contents SEN04552-03
PC78US-8 00-100 11
SEN04552-03
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
00-100 12
SEN04553-01
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 00-200 1
200 Foreword and general information
SEN04553-01 Safety notice
00-200 2 PC78US-8
200 Foreword and general information
Safety notice SEN04553-01
PC78US-8 00-200 3
200 Foreword and general information
SEN04553-01 Safety notice
00-200 4 PC78US-8
200 Foreword and general information
Safety notice SEN04553-01
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC78US-8 00-200 5
200 Foreword and general information
SEN04553-01 Safety notice
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00-200 6 PC78US-8
200 Foreword and general information
How to read the shop manual SEN04553-01
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
PC78US-8 00-200 7
200 Foreword and general information
SEN04553-01 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 PC78US-8
200 Foreword and general information
Explanation of terms for maintenance standard SEN04553-01
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC78US-8 00-200 9
200 Foreword and general information
SEN04553-01 Explanation of terms for maintenance standard
00-200 10 PC78US-8
200 Foreword and general information
Handling of electric equipment and hydraulic component SEN04553-01
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
PC78US-8 00-200 11
200 Foreword and general information
SEN04553-01 Handling of electric equipment and hydraulic component
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
00-200 12 PC78US-8
200 Foreword and general information
Handling of electric equipment and hydraulic component SEN04553-01
PC78US-8 00-200 13
200 Foreword and general information
SEN04553-01 Handling of electric equipment and hydraulic component
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-200 14 PC78US-8
200 Foreword and general information
Handling of electric equipment and hydraulic component SEN04553-01
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC78US-8 00-200 15
200 Foreword and general information
SEN04553-01 Handling of electric equipment and hydraulic component
00-200 16 PC78US-8
200 Foreword and general information
Handling of electric equipment and hydraulic component SEN04553-01
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
PC78US-8 00-200 17
200 Foreword and general information
SEN04553-01 Handling of electric equipment and hydraulic component
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
00-200 18 PC78US-8
200 Foreword and general information
Handling of electric equipment and hydraulic component SEN04553-01
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC78US-8 00-200 19
200 Foreword and general information
SEN04553-01 Handling of connectors newly used for engines
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
00-200 20 PC78US-8
200 Foreword and general information
Handling of connectors newly used for engines SEN04553-01
q 114 engine
q 107 engine
PC78US-8 00-200 21
200 Foreword and general information
SEN04553-01 Handling of connectors newly used for engines
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 PC78US-8
200 Foreword and general information
How to read electric wire code SEN04553-01
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
tor tric appliance General wiring in extremely
tant low-volt-
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC78US-8 00-200 23
200 Foreword and general information
SEN04553-01 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
00-200 24 PC78US-8
200 Foreword and general information
How to read electric wire code SEN04553-01
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC78US-8 00-200 25
200 Foreword and general information
SEN04553-01 Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
00-200 26 PC78US-8
200 Foreword and general information
Precautions when carrying out operation SEN04553-01
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
PC78US-8 00-200 27
200 Foreword and general information
SEN04553-01 Precautions when carrying out operation
00-200 28 PC78US-8
200 Foreword and general information
Method of disassembling and connecting push-pull type coupler SEN04553-01
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC78US-8 00-200 29
200 Foreword and general information
SEN04553-01 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
00-200 30 PC78US-8
200 Foreword and general information
Method of disassembling and connecting push-pull type coupler SEN04553-01
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
PC78US-8 00-200 31
200 Foreword and general information
SEN04553-01 Standard tightening torque table
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00-200 32 PC78US-8
200 Foreword and general information
Standard tightening torque table SEN04553-01
PC78US-8 00-200 33
200 Foreword and general information
SEN04553-01 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
00-200 34 PC78US-8
200 Foreword and general information
Standard tightening torque table SEN04553-01
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC78US-8 00-200 35
200 Foreword and general information
SEN04553-01 Conversion table
Conversion table 1
Example: Method of using the conversion table to convert from millimeters to inches
00-200 36 PC78US-8
200 Foreword and general information
Conversion table SEN04553-01
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC78US-8 00-200 37
200 Foreword and general information
SEN04553-01 Conversion table
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-200 38 PC78US-8
200 Foreword and general information
Conversion table SEN04553-01
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC78US-8 00-200 39
200 Foreword and general information
SEN04553-01 Conversion table
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
00-200 40 PC78US-8
200 Foreword and general information
Conversion table SEN04553-01
PC78US-8 00-200 41
SEN04553-01
©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)
00-200 42
SEN04554-01
HYDRAULIC EXCAVATOR
PC78US-8
01 Specification 1
PC78US-8 01-100 1
100 Specification and technical data
SEN04554-01 Specification dimension drawing
PC78US-8
Item Unit
1,650 mm arm 2,250 mm arm
Machine weight (with reinforced blade) kg 7,290 7,340
Bucket capacity m3 0.28 0.20
Engine type — Komatsu SAA4D95LE-5 Diesel engine
Engine rated output
• Net [ISO 9249/SAE J1349] kW{HP}/rpm 41 {55}/1,950
• Gross [SAE J1995] 42.8 {57}/1,950
A Overall length mm 5,770 5,785
B Overall height mm 2,730
C Overall width mm 2,330
D Shoe width mm 450
E Tail swing radius mm 1,240
F Crawler overall length mm 2,840
G Distance between tumbler center mm 2,235
Min. ground clearance mm 360
Travel speed (Low/High) km/h 2.9/5.0
Continuous swing speed rpm 10.0
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an
independent engine. While, net denotes the value measured of an engine under the condition essentially the same as
that when it is installed on machine.
01-100 2 PC78US-8
100 Specification and technical data
Working range diagram SEN04554-01
PC78US-8
Working range (mm)
1,650 mm arm 2,250 mm arm
A Maximum digging reach 6,380 6,920
B Maximum digging depth 4,100 4,710
C Maximum digging height 7,300 7,600
D Maximum vertical wall digging depth 3,610 4,030
E Maximum dumping height 5,180 5,500
F Minimum swing radius of work equipment 1,750 2,050
G Maximum reach at ground level 6,240 6,790
H Maximum lift above ground of blade 380 380
I Maximum drop below ground of blade 245 245
PC78US-8 01-100 3
100 Specification and technical data
SEN04554-01 Specifications
Specifications 1
PC78US-8
Machine model
1,650 mm arm 2,250 mm arm
Serial No. 15001 and up
Bucket capacity m3 0.28 0.20
Operating weight kg 7,290 (7,370) 7,340 (7,420)
Max. digging depth mm 4,100 4,710
Max. vertical wall digging depth mm 3,610 4,030
Working ranges
01-100 4 PC78US-8
100 Specification and technical data
Specifications SEN04554-01
PC78US-8
Machine model
1,650 mm arm 2,250 mm arm
Serial No. 15001 and up
Model SAA4D95LE-5
4-cycle, water-cooled, in-line vertical, direct injection type,
Type
with turbocharger and air-cooled aftercooler
No. of cylinders – bore x stroke mm 4 – 95 x 115
Total piston displacement l {cc} 3.260 {3,260}
Rated output
• Net [ISO 9249/SAE J1349] kW{HP}/rpm 41 {55}/1,950
• Gross [SAE J1995] 42.8 {57}/1,950
Performance
Type x No.
Gear type x 2
Capacity cm3/rev 44 x 2 + 33.2 + 7.0
Set pressure
Hydraulic pump
specification
Bladeless
Travel motor
motor
PC78US-8 01-100 5
100 Specification and technical data
SEN04554-01 Specifications
PC78US-8
Machine model
1,650 mm arm 2,250 mm arm
Serial No. 15001 and up
Hydraulic tank Box-shaped, open
Hydraulic oil filter Tank return side
Oil cooler Air-cooled (CF40)
Type Reciprocating piston type
Boom cylinder
Stroke mm 861
Max. length between pins mm 2,123
Min. length between pins mm 1,262
Type Reciprocating piston type
Bucket cylinder
01-100 6 PC78US-8
100 Specification and technical data
Specifications SEN04554-01
PC78US-8 01-100 7
100 Specification and technical data
SEN04554-01 Weight table
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model PC78US-8
Serial No. 15001 and up
Engine assembly (excluding coolant and oil) 419
• Engine (excluding coolant and oil) 315
• Engine mount 30
• PTO 7
• Hydraulic pump 67
Cooling assembly (excluding coolant, oil and fuel) 55
• Radiator (excluding coolant) 7
• Oil cooler (excluding oil) 8
• Aftercooler 6
• Fuel cooler (excluding fuel) 1
Revolving frame 893
Operator cab 330
Operator seat 18
Fuel tank (excluding fuel) 47
Hydraulic tank (excluding hydraulic oil) 70
Control valve 57
Counterweight 732
Additional counterweight 220
Swing motor (including brake valve) 22
Swing circle 104
Swing machinery 47
Center swivel joint 17
Track frame assembly (excluding track shoe)
<Steel shoe spec. and road liner spec.> 1,350
<Rubber crawler spec.> 1,331
• Track frame 777
• Idler assembly 54 x 2
• Recoil spring assembly 40 x 2
• Carrier roller 3.4 x 2
• Track roller 12.4 x 10
• Travel motor (including final drive) 83 x 2
• Sprocket 19 x 2
Track shoe assembly
<City pad shoe (450 mm)> 410 x 2
<Road liner (450 mm)> 450 x 2
<Rubber crawler (450 mm)> 385 x 2
<Triple grouser shoe (600 mm)> 495 x 2
01-100 8 PC78US-8
100 Specification and technical data
Weight table SEN04554-01
Unit: kg
Machine model PC78US-8
Serial No. 15001 and up
Boom assembly 418
Arm assembly
<1,650 mm> 193
<2,250 mm> 212
Bucket link assembly 42
Bucket assembly
<750 mm width (including side cutter)> 204
<650 mm width (including side cutter)> 185
Blade assembly
<Blade (edge-welding type)> 360
<Wide blade (edge-welding type)> 370
<Reinforced blade (BOC type, including BOC)> 392
Boom cylinder assembly 85
Arm cylinder assembly 70
Bucket cylinder assembly 51
Blade cylinder assembly 46
a BOC: Bolt-On Cutting edge
PC78US-8 01-100 9
100 Specification and technical data
SEN04554-01 Table of fuel, coolant and lubricants
a For details of the notes (Note. 1, Note. 2…) in the table, see the Operation and Maintenance Manual.
Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 11.5 11.0
Swing machinery case 2.0 2.0
Final drive case (each side) 1.1 1.1
PTO case 0.4 0.4
Hydraulic system 102 56
Cooling system 10 —
Fuel tank 125 —
01-100 10 PC78US-8
100 Specification and technical data
Table of fuel, coolant and lubricants SEN04554-01
PC78US-8 01-100 11
SEN04554-01
©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)
01-100 12
SEN04555-01
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-100 1
100 Engine and cooling system
SEN04555-01 Engine mount
Engine mount 1
10-100 2 PC78US-8
100 Engine and cooling system
PTO SEN04555-01
PTO 1
PC78US-8 10-100 3
100 Engine and cooling system
SEN04555-01 Cooling system
Cooling system 1
10-100 4 PC78US-8
100 Engine and cooling system
Cooling system SEN04555-01
Specifications
PC78US-8 10-100 5
SEN04555-01
©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)
10-100 6
SEN04556-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-200 1
200 Power train
SEN04556-00
10-200 2 PC78US-8
200 Power train
Power train SEN04556-00
Power train 1
PC78US-8 10-200 3
200 Power train
SEN04556-00 Swing circle
Swing circle 1
10-200 4 PC78US-8
200 Power train
Swing circle SEN04556-00
Unit: mm
No. Item Criteria Remedy
Standard clearance Clearance limit
1 Bearing clearance Replace
0.3 – 1.2 2.0
Specifications
Reduction ratio 80/10 = 8.0
Grease G2-LI
Grease quantity (l) 5.5
PC78US-8 10-200 5
200 Power train
SEN04556-00 Swing machinery
Swing machinery 1
10-200 6 PC78US-8
200 Power train
Swing machinery SEN04556-00
Unit: mm
No. Item Criteria Remedy
Standard clearance Clearance limit
Backlash between swing motor
1 shaft and No. 1 sun gear 0.03 – 0.11 —
Backlash between No. 1 sun gear
2 and No. 1 planetary gear 0.10 – 0.27 0.6
Backlash between No. 1 planetary
3 gear and ring gear 0.12 – 0.38 0.6
Outside diameter of oil seal Standard size Tolerance Repair limit Repair by hard
9 contacting surface on swing 0 chrome-plating or
pinion collar 75 74.8 replace
–0.074
PC78US-8 10-200 7
SEN04556-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
10-200 8
SEN04557-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-300 1
300 Undercarriage and frame
SEN04557-00 Track frame
Track frame 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Track Rebuild
74 78
1 Length at idler guide frame
Idler
73 69 Rebuild or replace
support
Track
158 162 Rebuild
frame
2 Width at idler guide
Idler
156 152 Rebuild or replace
support
10-300 2 PC78US-8
300 Undercarriage and frame
Idler cushion SEN04557-00
Idler cushion 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length length load Free length load
1 Recoil spring Steel shoe, 47.3 kN 42.1 kN Replace
Road liner 412.3 323 {4,826 kg} 402 {4,295 kg}
Rubber 68.5 kN 61.0 kN
crawler 412.3 283 402
{6,985 kg} {6,217 kg}
2. Idler Specifications
3. Support Grease G2-LI
4. Rod
5. Cylinder Grease quantity (cc)
• Steel shoe, Road liner 84
6. Recoil spring • Rubber crawler 208
7. U-packing
8. Collar
9. Nut
10. Valve
11. Grease fitting
PC78US-8 10-300 3
300 Undercarriage and frame
SEN04557-00 Idler
Idler 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
460 —
10-300 4 PC78US-8
300 Undercarriage and frame
Track roller SEN04557-00
Track roller 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
139 —
Rebuild or replace
2 Outside diameter of tread 110 103
3 Flange width 43 —
PC78US-8 10-300 5
300 Undercarriage and frame
SEN04557-00 Carrier roller
Carrier roller 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of tread Rebuild or replace
82 72
10-300 6 PC78US-8
300 Undercarriage and frame
Sprocket SEN04557-00
Sprocket 1
Unit: mm
No. Item Criteria Remedy
Standard size Tolerance Repair limit
1 Wear on tooth bottom diameter +1.0
433.004 –2.0 421
+0.475
5 Thickness at tooth bottom 84.002
–1.150
78
PC78US-8 10-300 7
300 Undercarriage and frame
SEN04557-00 Track shoe
Track shoe 1
10-300 8 PC78US-8
300 Undercarriage and frame
Track shoe SEN04557-00
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Link pitch
154.3 157.3 Reverse or
replace
2 Bushing external diameter 41.3 37.3
3 Link height 74 70
Repair or replace
Link thickness
4 (bushing press fitting part)
20 16
5 89
7 57
8 Internal width 45
11 Pin projection 3
16 Spacer thickness —
PC78US-8 10-300 9
300 Undercarriage and frame
SEN04557-00 Track shoe
Unit: mm
No. Item Criteria Remedy
Tolerance Standard
Standard size
interference
21 Interference
and link
between bushing Shaft Hole
+0.314 +0.042
41 0.232 – 0.334
+0.274 –0.020
22 Interference
and link
between regular pin
24
+0.150
0
–0.198
–0.250
0.198 – 0.400
Tolerance Standard
Standard size
clearance
23 Clearance between regular pin
and bushing
Shaft Hole
+0.150 +0.830
24 0.180 – 0.830 Adjust or replace
0 +0.330
Tolerance Standard
Standard size
(*) Interference between master pin Shaft Hole interference
24 and link +0.020 –0.198
24 0.178 – 0.270
–0.020 –0.250
Tolerance Standard
Standard size
(*) Clearance between master pin Shaft Hole clearance
25 and bushing –0.150 +0.630
24 0.380 – 0.880
–0.250 +0.230
Standard size Repair limit
26 Grouser height a. Replace
42 19
Road liner
Items marked with * are for the dry track.
10-300 10 PC78US-8
300 Undercarriage and frame
Track shoe SEN04557-00
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Grouser height
20 12
6 12
PC78US-8 10-300 11
300 Undercarriage and frame
SEN04557-00 Track shoe
Rubber crawler
(If equipped)
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Wear of lug height
30 5
10-300 12 PC78US-8
300 Undercarriage and frame
Track shoe SEN04557-00
PC78US-8 10-300 13
SEN04557-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
10-300 14
SEN04558-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-401 1
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic component layout drawing
10-401 2 PC78US-8
401 Hydraulic system, Part 1
Hydraulic component layout drawing SEN04558-00
1. Bucket cylinder
2. Arm cylinder
3. Arm anti-drop valve (*3, *4)
4. Boom cylinder
5. Boom anti-drop valve (*2, *4)
6. Attachment selector valve
(machine ready for attachment)
7. Control valve
8. Swing motor
9. Accumulator (for breaker)
(machine ready for attachment)
10. Hydraulic pump
11. Oil filter
(machine ready for attachment)
12. R.H. work equipment PPC valve
13. L.H. work equipment PPC valve
14. Oil cooler
15. Travel motor
16. Blade PPC valve
17. Accumulator (for PPC circuit)
18. 4-spool solenoid valve
19. Multi-control valve (*1, *4)
20. Travel PPC valve
21. Attachment PPC valve
(machine ready for attachment)
22. Center swivel joint
23. Blade cylinder
24. Hydraulic tank
PC78US-8 10-401 3
401 Hydraulic system, Part 1
SEN04558-00 Valve control
Valve control 1
10-401 4 PC78US-8
401 Hydraulic system, Part 1
Valve control SEN04558-00
PC78US-8 10-401 5
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic tank and filter
10-401 6 PC78US-8
401 Hydraulic system, Part 1
Hydraulic tank and filter SEN04558-00
Breather
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
PC78US-8 10-401 7
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
Hydraulic pump 1
Blade specification
Model: LPD45+45
10-401 8 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
Outline
q This pump consists of a variable displacement
swash plate type piston pump, a double gear
pump (1 unit for blade and swinging and the
other for pilot pump) and a servo valve.
1. Main pump
2. Servo valve
3. Double gear pump
4. EPC valve
5. Bleeder
PC78US-8 10-401 9
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
10-401 10 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
PC78US-8 10-401 11
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
Bladeless specification
Model: LPD45+45
10-401 12 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
Outline
q This pump consists of a variable displacement
swash plate type piston pump, a double gear
pump (1 unit for blade and swinging and the
other for pilot pump) and a servo valve.
1. Main pump
2. Servo valve
3. Gear pump
4. EPC valve
5. Bleeder
PC78US-8 10-401 13
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
10-401 14 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
PC78US-8 10-401 15
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
Function Structure
q The pump converts the engine rotation and q Cylinder block (7) is supported on shaft (1)
torque transmitted to its shaft to oil pressure through spline (a). Shaft (1) is supported on
and delivers pressurized oil corresponding to the front and rear bearings.
the load. q The tip of piston (6) is shaped to a concave ball
q It is possible to change the delivery by chang- and integrated with caulked shoe (5). Piston
ing the swash plate angle. (6) and shoe (5) form a spherical bearing.
q There are 2 discharge ports, which can supply q Rocker cam (4) has flat surface (A), and shoe
pressurized oil independently. (5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) is supported on flange (2) and
ball (12) which are fixed to case (3).
q Shoe (5) leads high-pressure oil to flat surface
(A) of rocker cam (4) to form a static pressure
bearing for its sliding.
q Piston (6) in each cylinder chamber of cylinder
block (7) moves relatively in the axial direction.
q Cylinder block (7) rotates relatively to valve
plate (8) while sealing the pressurized oil so
that an appropriate oil pressure balance is
maintained on this surface.
q The oil in the respective cylinder chambers of
cylinder block (7) is sucked and discharged
through valve plate (8).
10-401 16 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q Rocker cam (4) leans around ball (12), and plate angle (a) = 0), the difference between
accordingly angle (a) between center line (X) volumes (E) and (F) inside cylinder block (7)
of rocker cam (4) and the axial direction of cyl- becomes 0.
inder block (7) changes. q Suction and discharge of pressurized oil is not
q (a) is named the swash plate angle. carried out in this state. Namely pumping
action is not performed. (actually, however, the
swash plate angle is not set to 0)
q Swash plate angle (a) is in proportion to the
pump delivery.
q There are an even number (10) of holes on cyl-
inder block and they match the 2 grooves of
valve plate (8) alternately. Oil of quantity for 5
pistons is discharged respectively through
pump discharge ports (P1) and (P2).
PC78US-8 10-401 17
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
Servo valve
10-401 18 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
1. Lever
2. Spool
3. Plug
4. Seat
5. Piston
6. Sleeve
7. Plug
8. Locknut
9. Spring
10. PC-EPC valve
11. Spool
12. Ball
13. Plug
14. LS valve
15. PC valve
PC78US-8 10-401 19
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a n d pu m p d el i v e r y ( Q )
increases.
q Servo piston (11) is used for changing swash
plate angle (a).
q Servo piston (11) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This straight motion is transmitted to rocker
cam (4).
q Rocker cam (4) supported on flange (2) by ball
(12) carries out rotary motion.
10-401 20 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
Function
LS valve PC valve
q The LS valve controls the pump delivery q The PC valve is an equal horsepower control
according to the stroke of the control lever, or valve, which limits the oil flow rate to a certain
the demand flow for the actuator. level (according to the discharge pressure)
q The LS valve senses the flow rate demanded regardless of the control valve stroke so that
by the actuator from differential pressure the pump absorption horsepower will not
(dPLS) between inlet pressure (PPLS) and exceed the engine horsepower when pump
output pressure (PLS) of the control valve and discharge pressure (PP) is high.
controls pump delivery (Q). [(PPLS) is called q If the load during the operation becomes larger
the LS pump pressure, (PLS) the LS pressure, and the pump discharge pressure rises, it
and (dPLS) the LS differential pressure] reduces the pump delivery; and if the pump
q In other words, the pressure loss caused by discharge pressure drops, it increases the
flow of oil through the open area of the control pump delivery.
valve spool (= LS differential pressure (dPLS)) q This pump has 2 discharge ports and the aver-
is detected, and then pump delivery (Q) is con- age of their respective discharge pressures
trolled to keep that pressure loss constant and (P1) and (P2) is sensed.
supply the pump delivery according to the q The average pressure of (P1) and (P2) is
demand flow for the actuator. called (PAVE) and the relationship between it
q Pump discharge pressure (PP), LS pump pres- and the pump delivery [the total deliveries of
sure (PPLS) and LS pressure (PLS) are lead to (P1) and (P2)] is as follows.
the LS valve. The relationship between LS dif-
ferential pressure (dPLS) and pump delivery
(Q) changes as shown in the figure below.
PC78US-8 10-401 21
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
Operation
10-401 22 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
PC78US-8 10-401 23
401 Hydraulic system, Part 1
SEN04558-00 Hydraulic pump
When balanced
10-401 24 PC78US-8
401 Hydraulic system, Part 1
Hydraulic pump SEN04558-00
PC78US-8 10-401 25
SEN04558-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
10-401 26
SEN04559-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-402 1
402 Hydraulic system, Part 2
SEN04559-00 Control valve
Control valve 1
Outline
The control valves of the following types are set.
q 7-spool valve (with blade, without service valve)
q 7-spool valve (without blade, with 1 service valve)
Since each service valve is add-on type, its later addition or removal is available.
A1: To blade cylinder P3: From pump discharge port
A2: To swing motor PA1: From blade RAISE PPC valve
A3: To left travel motor PA2: From swing RIGHT PPC valve
A4: To right travel motor PA3: From left travel REVERSE PPC valve
A5: To boom cylinder PA4: From right travel REVERSE PPC valve
A6: To arm cylinder PA5: From boom RAISE PPC valve
A7: To bucket cylinder PA6: From arm OUT PPC valve
B1: To blade cylinder PA7: From bucket DUMP PPC valve
B2: To swing motor PB1: From blade LOWER PPC valve
B3: To left travel motor PB2: From swing LEFT PPC valve
B4: To right travel motor PB3: From left travel FORWARD PPC valve
B5: To boom cylinder PB4: From right travel FORWARD PPC valve
B6: To arm cylinder PB5: From boom LOWER PPC valve
B7: To bucket cylinder PB6: From arm IN PPC valve
BP: From boom RAISE PPC valve PB7: From bucket CURL PPC valve
LS: To pump LS valve (LS pressure input) PP: To pump LS valve (LS pressure input)
LS1I: LS1 pressure pickup port PT: From pump merge-divider selector solenoid
LS2I: LS2 pressure pickup port PTSW: Pump pressure sensor mounting port
P1: From pump discharge port TB: To tank through bypass check valve
P1I: P1 pressure pickup port TC: To tank through bypass check valve
P2: From pump discharge port TS: To tank
P2I: P2 pressure pickup port TSW: To swing motor
1. Block
2. Blade valve
3. Swing valve
4. Left travel valve
5. Right travel valve
3. Pump merge-divider valve block
7. Boom valve
8. Arm valve
9. Bucket valve
10. Cover
11. LS bypass valve
12. Travel junction valve + LS bypass valve
13. Boom hydraulic drift prevention valve
14. Cooler bypass valve
10-402 2 PC78US-8
402 Hydraulic system, Part 2
Control valve SEN04559-00
7-spool valve 1
PC78US-8 10-402 3
402 Hydraulic system, Part 2
SEN04559-00 Control valve
Sectional view
(1/5)
10-402 4 PC78US-8
402 Hydraulic system, Part 2
Control valve SEN04559-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
25 Suction valve spring diameter
length
5.1 N 4.12 N
39.2 x 4.45 33.5 {0.52 kg} — {0.42 kg}
2.65 N 2.06 N
26 Suction valve spring 36.3 x 4.45 33.3 {0.27 kg} — {0.21 kg}
89.2 N 71.4 N
27 Spool return spring 29.01 x 18.3 27.5 {9.1 kg} — {7.28 kg}
173 N 138 N
28 Spool return spring 29.03 x 18.4 26 {17.66 kg} — {14.1 kg}
181 N 144 N If damaged or
29 Spool return spring 29 x 17.5 25 {18.42 kg} — {14.7 kg} deformed, replace
spring.
136 N 109 N
30 Spool return spring 41.47 x 19.3 38.5 {13.82 kg} — {11.1 kg}
34.3 N 27.5 N
31 Spool return spring 41.1 x 19.3 40.5 {3.5 kg} — {2.8 kg}
104 N 83.2 N
32 Spool return spring 42.3 x 19.2 38.9 {10.6 kg} — {8.48 kg}
136 N 109 N
33 Spool return spring 41.13 x 19.3 38.5 {13.91 kg} — {11.1 kg}
184 N 147 N
34 Spool return spring 41.28 x 15 33.5
{18.74 kg}
—
{15.0 kg}
317 N 253 N
35 Spool return spring 42.4 x 19 34.5
{32.3 kg}
—
{25.8 kg}
PC78US-8 10-402 5
402 Hydraulic system, Part 2
SEN04559-00 Control valve
(2/5)
10-402 6 PC78US-8
402 Hydraulic system, Part 2
Control valve SEN04559-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
12 Spool return spring diameter length
164 N 131 N
45.38 x 14 37.5 {16.74 kg} — {13.4 kg}
13 Pressure
spring
compensation valve
30.85 x 5.2 27
9.81 N
{1.0 kg} —
7.85 N
{0.8 kg}
14 Pressure
spring
compensation valve
33.4 x 14.4 21.5
55.9 N
{5.7 kg} —
44.7 N
{4.56 kg}
If damaged or
15 Pressure
spring
compensation valve
28.0 x 14.4 14.5
13.7 N
{1.4 kg} —
11.0 N
{1.12 kg} deformed, replace
spring.
16 Pressure
spring
compensation valve
20 x 8.4 12
6.86 N
{0.7 kg} —
5.49 N
{0.56 kg}
1.96 N 1.57 N
17 Check valve spring 13.0 x 6.5 9.5 {0.2 kg} — {0.16 kg}
3.92 N 3.14 N
18 Check valve spring 27.2 x 6.9 22 {0.4 kg} — {0.32 kg}
3.92 N 3.14 N
19 Check valve spring 12.3 x 11.4 10.5 {0.4 kg} — {0.32 kg}
1.96 N 1.57 N
20 Check valve spring 21.9 x 5 15.8
{0.2 kg}
—
{0.16 kg}
PC78US-8 10-402 7
402 Hydraulic system, Part 2
SEN04559-00 Control valve
(3/5)
10-402 8 PC78US-8
402 Hydraulic system, Part 2
Control valve SEN04559-00
Block
1. Spool (assistant valve)
2. Main relief valve
Blade valve
3. Suction safety valve
4. Suction valve
5. Spool
6. Check valve
Swing valve
7. Spool
8. Check valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed If damaged or
Outside Installed load Free length Installed load
15 Check valve spring diameter length deformed, replace
spring.
21.9 x 5 15.8 1.96 N — 1.57 N
{0.2 kg} {0.16 kg}
PC78US-8 10-402 9
402 Hydraulic system, Part 2
SEN04559-00 Control valve
(4/5)
10-402 10 PC78US-8
402 Hydraulic system, Part 2
Control valve SEN04559-00
Boom valve
14. Pressure compensation valve F
15. Suction valve
16. Hydraulic drift prevention valve
17. Suction valve
18. Spool
19. Pressure compensation valve R
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed
Outside Installed load Free length Installed load
20 Spool return spring diameter length
15.7 N 12.6 N
19.26 x 7.5 14 —
{1.6 kg} {1.28 kg}
1.96 N 1.57 N If damaged or
21 Check valve spring 21.9 x 5 15.8
{0.2 kg}
—
{0.16 kg} deformed, replace
spring.
73.5 N 58.8 N
22 Valve return spring 34.5 x 17.7 25
{7.5 kg}
—
{6.0 kg}
11.2 N 9.02 N
23 Valve return spring 16.6 x 13 13
{1.14 kg}
—
{0.92 kg}
10.8 N 8.63 N
24 Piston return spring 13 x 8.8 7.5 {1.1 kg} — {0.88 kg}
PC78US-8 10-402 11
402 Hydraulic system, Part 2
SEN04559-00 Control valve
(5/5)
10-402 12 PC78US-8
402 Hydraulic system, Part 2
Control valve SEN04559-00
Arm valve
1. Pressure compensation valve F
2. Suction valve
3. Suction valve
4. Spool
5. Pressure compensation valve R
Bucket valve
6. Pressure compensation valve F
7. Suction valve
8. Suction valve
9. Spool
10. Pressure compensation valve R
Cover
11. Suction safety valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed If damaged or
Outside Installed load Free length Installed load
13 Check valve spring diameter length deformed, replace
spring.
3.92 N 3.14 N
27.2 x 6.9 22 {0.4 kg} — {0.32 kg}
PC78US-8 10-402 13
402 Hydraulic system, Part 2
SEN04559-00 CLSS
CLSS 1
Outline of CLSS 1
Features Composition
q Fine control not influenced by load q CLSS consists of a variable capacity piston
q Controllability enabling digging even under the pump, control valves, and respective actua-
fine control tors.
q Ease of compound operation ensured by flow q The hydraulic pump is configured with pump
divider function using the open area of spool body, PC valve and LS valve.
during compound operations
q Energy saving using variable pump control
10-402 14 PC78US-8
402 Hydraulic system, Part 2
CLSS SEN04559-00
Basic principle 1
PC78US-8 10-402 15
402 Hydraulic system, Part 2
SEN04559-00 CLSS
10-402 16 PC78US-8
402 Hydraulic system, Part 2
CLSS SEN04559-00
PC78US-8 10-402 17
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
a The hydraulic circuit diagram shows the 7-spool valve (with blade, without service valve).
10-402 18 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
PC78US-8 10-402 19
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Unload valve 1
Function Operation
q When the control valve is at HOLD, pump q Pump discharge pressures (PP1) and (PP2)
delivery (Q) discharged by the minimum swash are applied to the right side of unload spool (1),
plate angle is drained to the tank circuit. and LS pressures (PLS1) and (PLS2) are
q Pump discharge pressures (PP1) and (PP2) applied to the left side. (PP1 = PP2, PLS1 =
are set to 2.45 MPa {25.0 kg/cm2} by spring (2) PLS2)
in the valve. [LS pressures (PLS1) and (PLS2) q When the control valve is at HOLD, LS pres-
are 0 MPa {0 kg/cm2}] sures (PLS1) and (PLS2) are 0 MPa {0 kg/cm2}
q Since the pump merge-divider spool is at the and only pump discharge pressures (PP1) and
merge position, pump discharge pressures (PP2) are applied.
(PP1) and (PP2) are merged. q (PP1) and (PP2) are set with only the installa-
q LS pressures (PLS1), (PLS2), and (PLS3) are tion load of spring (2).
merged. q Pump discharge pressures (PP1) and (PP2)
increase to 2.45 MPa {25.0 kg/cm2} which is
the installation load of spring (2).
q Spool (1) moves to the left.
q Pump circuits (PP1) and (PP2) are connected
to tank circuit (T) through the notch of spool
(1).
q Pump discharge pressures (PP1) and (PP2)
are set to 2.45 MPa {25.0 kg/cm2}.
10-402 20 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Function Operation
q When the actuator demand flow is less than q If the work equipment is controlled finely, LS
the pump discharge at the minimum swash pressures (PLS1) and (PLS2) are generated
plate angle during work equipment fine control. and applied to the left side of spool (1). (PP1 =
q Pump discharge pressure (PP1) [(PP2)] is set PP2, PLS1 = PLS2)
to LS pressure (PLS1) [(PLS2)] + 2.45 MPa q Since the open area of the work equipment
{25.0 kg/cm2}. valve spool is narrow, LS pressures (PLS1)
q The differential pressure between pump dis- and (PLS2) are very different from pump dis-
charge pressure (PP1) or (PP2) and LS pres- charge pressures (PP1) and (PP2).
sure (PLS1) or (PLS2) becomes 2.45 MPa q The differential pressure between pump dis-
{25.0 kg/cm2} which is the installation load of charge pressure (PP1) or (PP2) and LS pres-
spring (2). sure (PLS1) or (PLS2) reaches 2.45 MPa {25.0
q Unload spool (1) opens. kg/cm2} by the installation load of spring (2).
q LS differential pressure (dPLS) becomes 2.45 q Spool (1) moves to the left.
MPa {25.0 kg/cm2}. q Pump circuits (PP1) and (PP2) are connected
q Since the pump merge-divider spool is at the to tank circuit (T).
merge position, pump discharge pressures q Pump discharge pressure (PP1) [(PP2)] is set
(PP1) and (PP2) are merged. to the force of spring (2) (2.45 MPa {25.0 kg/
q LS pressures (PLS1), (PLS2), and (PLS3) are cm2}) + LS pressure (PLS1) [(PLS2)].
merged. q LS differential pressure (dPLS) becomes 2.45
MPa {25.0 kg/cm2}.
PC78US-8 10-402 21
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Function Operation
q When the demand flow is less than the maxi- q If the both travel valves are controlled finely,
mum pump delivery during fine control of both LS pressures (PLS1) and (PLS2) are gener-
travel valves. ated and applied to the left side of spool (1)
q Pump discharge pressure (PP1) [(PP2)] is set [(PP1), (PP2), (PLS1) and (PLS2) are divided].
to LS pressure (PLS1) [(PLS2)] + 2.45 MPa q Since the open areas of the both travel valve
{25.0 kg/cm2}. spools are narrow, LS pressures (PLS1) and
q The differential pressure between pump dis- (PLS2) are very different from pump discharge
charge pressure (PP1) or (PP2) and LS pres- pressures (PP1) and (PP2).
sure (PLS1) or (PLS2) becomes 2.45 MPa q The differential pressure between pump dis-
{25.0 kg/cm2} by the installation load of spring charge pressure (PP1) or (PP2) and LS pres-
(2). sure (PLS1) or (PLS2) reaches 2.45 MPa {25.0
q Unload spool (1) opens. kg/cm2} by the installation load of spring (2).
q The excessive oil (maximum pump delivery – q Spool (1) moves to the left.
demand flow) flows to the tank circuit. q Pump circuits (PP1) and (PP2) are connected
q Since the pump merge-divider spool is at the to tank circuit (T).
divider position, pump discharge pressures q The excessive oil (maximum pump delivery –
(PP1) and (PP2) are divided. demand flow) above the strokes of both travel
q LS pressures (PLS1) and (PLS2) are divided. valve spools is drained to tank circuit (T).
q The pump swash plate angle becomes maxi-
mum and the pump delivery becomes maxi-
mum. (for details, see "Pump merge-divider
valve")
10-402 22 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Function Operation
q During operation of both travel valves, when q If the both travel valves are operated to the
the demand flow becomes maximum, draining maximum, LS pressures (PLS1) and (PLS2)
to tank circuit (T) is cut off, and all of pump are generated and applied to the left side of
delivery (Q) flows to both travel circuits. spool (1). [(PP1) and (PP2), and (PLS1) and
q Since the pump merge-divider spool is at the (PLS2) are divided respectively]
divider position, pump discharge pressures q Since the open areas of the both travel valve
(PP1) and (PP2) are divided. spools are wide, LS pressures (PLS1) and
q LS pressures (PLS1) and (PLS2) are divided. (PLS2) are not much different from pump dis-
q The pump swash plate angle becomes maxi- charge pressures (PP1) and (PP2).
mum and the pump delivery becomes maxi- q The differential pressure between pump dis-
mum. (For details, see "Pump merge-divider charge pressure (PP1) or (PP2) and LS pres-
valve".) sure (PLS1) or (PLS2) will not reach 2.45 MPa
{25.0 kg/cm2} which is the installation load of
spring (2).
q Spring (2) pushes spool (1) to the right.
q Pump circuits (PP1) and (PP2) are discon-
nected from tank circuit (T), and all pump deliv-
ery (Q) flows to the actuator circuit.
PC78US-8 10-402 23
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
10-402 24 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
PC78US-8 10-402 25
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Merge-divider valve 1
When control valve is at HOLD and work equipment is operated (including compound operation of
work equipment + travel)
Function Operation
q Pump discharge pressures (PP1) and (PP2) q When the control valve is at HOLD, the right
are merged in pump merge-divider spool (3). and left travel PPC pressure switches and the
LS pressures (PLS1), (PLS2), and (PLS3) are work equipment PPC pressure switch output
also merged. no signals.
q The controller generates no output signals and
the pump merge-divider solenoid valve gener-
ates no output pressure.
q When the work equipment is operated, the
right and left PPC pressure switches do not
output signals and only the work equipment
PPC pressure switch outputs signals.
q The controller generates no output signals and
the pump merge-divider solenoid valve gener-
ates no output pressure.
q Pump discharge pressures (PP1) and (PP2)
are merged and LS pressures (PLS1), (PLS2)
and (PLS3) are also merged (PP1 = PP2,
PLS1 = PLS2 = PLS3).
10-402 26 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
When both travel valves are operated (including operation of either travel valve)
Function Operation
q Pump discharge pressures (PP1) and (PP2) q If only right and left travel valves are operated,
are divided in pump merge-divider spool (3). the right and left travel PPC pressure switches
LS pressures (PLS1), (PLS2), and (PLS3) are output signals but the work equipment PPC
also divided. pressure switch does not output signals.
q The higher one of pump discharge pressures q The controller generates output signals and
(PP1) and (PP2) is output as the LS pressure. the pump merge-divider solenoid valve gener-
ates output pressure.
q If the output pressure reaches 1.47 MPa {15
kg/cm2} which is the installation load of spring
(4), spool (3) is pushed to the left.
q Pump discharge pressures (PP1) and (PP2)
are divided and LS pressures (PLS1), (PLS2),
and (PLS3) are also divided.
q (PP1) and (PLS1) are supplied to the left travel
circuit and (PP2) and (PLS2) are supplied to
the right travel circuit.
q The higher one of pump discharge pressures
(PP1) and (PP2) is output as the LS pressure.
q The pump swash plate angle becomes maxi-
mum and the pump delivery becomes maxi-
mum.
PC78US-8 10-402 27
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Introduction of LS pressure 1
10-402 28 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Travel valve
Operation
q When spool (1) is operated, pump discharge
pressure (PP) flows from flow control valve (2)
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit (A).
q Pressure reducing valve (3) is moved to the
right by actuator circuit pressure (PA) and
notches (c) and (d) are connected to travel
junction circuit (e) and LS circuit (PLS) respec-
tively.
q Actuator circuit pressure (PA) [(A)] is intro-
duced to LS circuit (PLS) through notch (c),
internal check valve and notch (d).
PC78US-8 10-402 29
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
LS bypass valve 1
Function
q The LS bypass valve releases the remaining
pressure of LS pressure (PLS).
q While moderating increasing rate of LS pres-
sure (PLS), this valve generates pressure loss
in the throttle function with this discarded throt-
tle flow, decreasing the effective LS differential
pressure and enhancing stability.
When work equipment valve is operated (including compound operation of work equipment + travel)
Operation
q Since pump merge-divider spool (1) is at the
merge position, the hydraulic oil in LS circuits
(PLS1), (PLS2), and (PLS3) is drained from tip
filter (a) of LS bypass valve (2) on the (P2) side
through orifice (b) to tank circuit (T).
10-402 30 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
When both travel valves are operated (including operation of either travel valve)
Operation
q Since spool (1) is at the divider position, LS cir-
cuits (PLS1) and (PLS2) are divided.
q Hydraulic oil (PLS1) is drained from tip filter (a)
of LS bypass valve (3) on the (P1) side through
orifice (b) to tank circuit (T).
q Hydraulic oil (PLS2) is drained from tip filter (a)
of LS bypass valve (2) on the (P2) side through
orifice (b) to tank circuit (T).
PC78US-8 10-402 31
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
LS select valve 1
Function
q At the time of simultaneous operation of swing
+ boom RAISE, this valve prevents high swing
LS pressure from entering the LS circuit (PLS)
so that the pump flow to the boom cylinder is
secured when the machine starts swinging,
and also prevents the boom RAISE speed
from reducing.
Operation
q The pilot pressure is not generally applied to
the pilot port (BP) except for boom RAISE
operation.
q In this state, pump pressure (PP) is led through
the internal passage of spool (1) to pressure
reducing valve (3) of the swing valve. At the
time of swing operation, there occurs LS pres-
sure (PLS) suitable for the load pressure, and
the pressure is led to the pump LS valve.
10-402 32 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Operation
q At the simultaneous operation of swing + boom
RAISE, the signal pressure of the PPC circuit
is led to the pilot port (BP).
q This pilot pressure (BP) is applied to spool (1).
If it increases and overcomes spring (2), spool
(1) is pushed to the right and the internal pas-
sage is closed. As a result, pump pressure
(PP) is not supplied to pressure reducing valve
(3) of the swing valve any more.
q Swing LS pressure (PLS) is not generated and
only boom RAISE is led to the pump LS valve,
and the pump delivery is controlled with the
boom RAISE LS pressure.
q Pilot pressure (BP) depends on the control
lever (boom RAISE) stroke.
PC78US-8 10-402 33
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Function
q When the machine starts swinging while the
boom is being raised, the boom RAISE merge
valve merges the gear pump flow into the main
pump circuit to increase the boom RAISE
speed.
Operation
q The pilot pressure is not generally applied to
the pilot port (BP) except for boom RAISE
operation.
q In this state, since spool (1) disconnects gear
pump circuit (P3) from main pump circuit (PP),
the pressurized oil from gear pump circuit (P3)
does not connect into main pump circuit (PP).
10-402 34 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Operation
q At the simultaneous operation of swing + boom
RAISE, the signal pressure of the boom RAISE
PPC circuit is led to pilot port (BP).
q This pilot pressure (BP) is applied to spool (1).
If it increases and overcomes spring (2), spool
(1) is pushed to the right and check valve (3) in
it is pushed open. As a result, the pressurized
oil from gear pump circuit (P3) merges into
main pump circuit (PP) to increase the boom
RAISE speed.
PC78US-8 10-402 35
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
10-402 36 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
PC78US-8 10-402 37
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Function
q While the boom lever is not operated, the
hydraulic drift prevention valve prevents pres-
surized oil from leaking from the boom bottom
through spool (1) to prevent the boom from
drifting hydraulically.
Operation
q If the boom is raised, the pressurized oil from
the control valve pushes up poppet (2).
q Pressurized oil from the control valve flows
through the valve into the boom cylinder bot-
tom.
10-402 38 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Operation
q If the control lever is returned to neutral with
the boom raised, the holding pressure on the
boom cylinder bottom side is closed by poppet
(2).
q The pressurized oil flowing in through orifices
(a1) and (a2) is closed by pilot spool (3).
q The boom is held.
PC78US-8 10-402 39
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Operation
q If the boom is lowered, pilot pressure (P1) from
the PPC valve pushes pilot spool (3) and the
pressurized oil in chamber (b) in the poppet is
drained.
q The oil pressure in port (Ab) is raised by the
pressurized oil from the boom cylinder bottom,
but the oil pressure in chamber (b) is lowered
by orifices (a1) and (a2).
q If the pressure in chamber (b) is lowered below
the pressure in port (Ab), poppet (2) opens and
the pressurized oil from port (Ab) flows through
port (Aa) into the control valve.
10-402 40 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Function Operation
q When the boom is lowered and falls due to its q When the boom is lowered and falls due to its
own weight because the bottom pressure (A) own weight, the bottom side pressure (A) in the
in the cylinder (1) is higher than the head pres- boom cylinder (1) will rise above the head side
sure (B), this circuit brings the return flow on pressure (B).
the bottom side to the head side to increase q A part of the return flow on the bottom side
the cylinder speed. passes through the regeneration passage (a)
of the boom spool (2), pushes the check valve
(3) to open it and flows to the head side.
q The boom LOWER speed is increased.
PC78US-8 10-402 41
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Function Operation
q When the head pressure (B) of the cylinder (1) q When the boom is lowered and is in the load
is higher than the bottom pressure (A) while process, the head side pressure (B) of the
the boom is lowered and the boom is in the boom cylinder (1) rises above the bottom side
load process, the check valve (3) will be pressure (A).
closed, and the circuits on the head side and q Check valve (3) is closed by pressure (B) on
the bottom side will be interrupted. the head side and spring (4).
q The circuits on the head side and bottom side
are disconnected.
10-402 42 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
PC78US-8 10-402 43
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
10-402 44 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
Function
q While the machine is traveling straight, if the
right and left travel spools are operated, the
junction circuit is opened to correct the flow dif-
ference between the right and left travel cir-
cuits.
q While the machine is traveling straight, the flow
rates to the right and left travel motors become
almost the same to decrease travel deviation.
q The junction circuit is kept open while the
machine is steered, too, but it does not affect
the steering performance since opening (b) of
travel junction valve spool (3) is narrow.
Operation
PC78US-8 10-402 45
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
10-402 46 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
PC78US-8 10-402 47
402 Hydraulic system, Part 2
SEN04559-00 Functions and operation by valve
Function Operation
q If the travel actuator and another actuator are
During normal operation
operated simultaneously, discarded throttled
flow of LS pressure (PLS) is increased to lower q If boom spool (1) is operated, LS pressure
the pressure compensation accuracy of the (PLS) becomes the same as boom circuit pres-
travel circuit and to decrease lowering of the sure (A).
travel speed. q Since the work equipment valve is operated,
q While only the travel actuator or another actua- pump discharge circuits (PP1) and (PP2), and
tor is operated singly, the LS bleed circuit is LS circuits (PLS1), (PLS2) and (PLS3) are
kept closed. merged respectively by the merge-divider
q In addition, travel junction valve spool (5) valve spool (see "Pump merge-divider valve").
changes from opening (c) (wide) to opening (b) q LS pressure (PLS) is also led to spring cham-
(narrow) by the pressure from the merge- ber (PLSS) of pressure reducing valve (2) of
divider selector solenoid valve for the ease of the travel valve.
correction of the flow difference between the q Since the travel spool is not operated, notch
right and left travel circuits. (a) of pressure reducing valve (2) is closed and
check valves (3) and (4) of the bleed circuit are
also closed.
q While the boom is operated singly, the travel
LS bleed circuit is kept closed.
10-402 48 PC78US-8
402 Hydraulic system, Part 2
Functions and operation by valve SEN04559-00
PC78US-8 10-402 49
SEN04559-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
10-402 50
SEN04560-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-403 1
403 Hydraulic system, Part 3
SEN04560-00
10-403 2 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
PPC valve 1
P: From charge pump P3: L.H. PPC valve: Swing RIGHT port
P1: L.H. PPC valve: Arm IN port R.H. PPC valve: Bucket DUMP port
R.H. PPC valve: Boom RAISE port P4: L.H. PPC valve: Swing LEFT port
P2: L.H. PPC valve: Arm OUT port R.H PPC valve: Bucket CURL port
R.H. PPC valve: Boom LOWER port T: To tank
PC78US-8 10-403 3
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
10-403 4 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x
Installed
10 Centering spring
[For ports (P3) and (P4)]
Outside
diameter
length Installed load Free length Installed load
PC78US-8 10-403 5
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
10-403 6 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
PC78US-8 10-403 7
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
10-403 8 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
a For the operation, see "Work equipment and swing PPC valve".
PC78US-8 10-403 9
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
10-403 10 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
1. Plate
2. Body
3. Piston
4. Seal
5. Valve
6. Damper
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
7 Centering spring diameter
length If damaged or
deformed, replace
108 N 86.3 N spring.
48.57 x 15.5 32.5 —
{11 kg} {8.8 kg}
16.7 N 13.3 N
8 Metering spring 26.53 x 8.15 24.9
{1.7 kg}
—
{1.36 kg}
PC78US-8 10-403 11
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
a For the operation, see "Work equipment and swing PPC valve".
10-403 12 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
8 Centering spring diameter length If damaged or
deformed, replace
147 N 118 N spring.
42.36 x 15.5 32.5 {15 kg} — {12.0 kg}
16.7 N 13.3 N
9 Metering spring 22.73 x 8.1 22 {1.7 kg} — {1.36 kg}
PC78US-8 10-403 13
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
a For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
10-403 14 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
9 Centering spring diameter
length If damaged or
deformed, replace
125 N 100 N spring.
33.9 X 15.3 28.4 {12.7 kg} — {10.2 kg}
16.7 N 13.3 N
10 Metering spring 22.7 X 8.10 22.0 {1.70 kg} — {1.36 kg}
PC78US-8 10-403 15
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
EPC valve
a EPC: Abbreviation for Electromagnetic Proportional Control
10-403 16 PC78US-8
403 Hydraulic system, Part 3
PPC valve SEN04560-00
Function Operation
q EPC valve consists of the proportional sole-
noid and hydraulic valve. When signal current is 0 (coil de-energized)
q Upon receiving signal current (i) from the pump q While the signal current from the controller is
controller, EPC valve generates EPC output not flowing to coil (14), coil (14) is de-ener-
pressure proportional to the intensity of the gized.
current, and outputs it to the control valve. q Spool (11) is pressed to the right by spring
(12).
q Port (P) is closed, and the pressurized oil from
the front pump does not flow to the control
valve.
q The pressurized oil from the control valve is
drained to the tank through ports (C) and (T).
PC78US-8 10-403 17
403 Hydraulic system, Part 3
SEN04560-00 PPC valve
When signal current is very small (coil ener- When signal current is maximum (coil ener-
gized) gized)
q If small signal current flows to coil (5), coil (5) is q If the signal current flows to coil (5), coil (5) is
energized and a leftward thrust is generated in energized.
plunger (6). q Since the signal current is the maximum at this
q Push pin (4) pushes spool to the left and the time, thrust force of plunger (6) becomes the
pressurized oil from port (P) flows to port (C). maximum.
q Pressure in port (C) increases and the total of q Spool (2) is pushed to the left by push pin (4).
the force applied to surface (a) of spool (2) and q The pressurized oil from port (P) flows to port
spring load of spring (3) becomes greater than (C) at the maximum flow rate and the pressure
the thrust force of plunger (6). in the circuit between the EPC valve and con-
q Spool (2) is pushed to the right, port (P) is dis- trol valve becomes maximum.
connected from port (C), and port (C) is con- q Port (T) is closed and the pressurized oil does
nected to port (T). not flow to the hydraulic tank.
q Spool (2) moves up and down so that the pro-
pulsion force of plunger (6) may be balanced
with pressure of port (C) + spring load of spring
(3).
q The pressure in the circuit between the EPC
valve and control valve is controlled in propor-
tion to the signal current.
10-403 18 PC78US-8
403 Hydraulic system, Part 3
Swing motor SEN04560-00
Swing motor 1
Model: LMF30AEL
PC78US-8 10-403 19
403 Hydraulic system, Part 3
SEN04560-00 Swing motor
10-403 20 PC78US-8
403 Hydraulic system, Part 3
Swing motor SEN04560-00
1. Output shaft
2. Shoe
3. Piston
4. Cylinder block
5. Housing
6. Valve plate
7. Center spring
8. Swash plate
9. Brake spring
10. Brake piston
11. Disc
12. Plate
13. Relief valve
14. Check valve
15. Shuttle valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed
Outside Installed load Free length Installed load
16 Check valve spring diameter length If damaged or
deformed, replace
1.57 N 1.27 N spring.
15.5 x 9.0 8.0 {0.16 kg} — {0.13 kg}
1.27 N 0.98 N
17 Shuttle valve spring 33 x 13.8 23 {0.13 kg} — {0.10 kg}
PC78US-8 10-403 21
403 Hydraulic system, Part 3
SEN04560-00 Swing motor
Brake valve
Outline
q The brake valve consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
Function
q When the machine is in the swing holding
mode, control valve (6) closes the motor outlet
circuit, but the motor rotation is continued by
inertial force.
q The motor output, therefore, is abnormally
increased, resulting in damaging the motor.
q In order to prevent the motor damages, the
relief valve relieves the abnormally high pres-
sure to port (S) from the motor outlet side
(high-pressure side) of the motor.
Operation
10-403 22 PC78US-8
403 Hydraulic system, Part 3
Swing motor SEN04560-00
PC78US-8 10-403 23
403 Hydraulic system, Part 3
SEN04560-00 Swing motor
Function
q The swing motor relief valve restricts sudden
rise of the relief pressure to reduce the shocks
generated when the machine starts and stops
swinging.
Operation
10-403 24 PC78US-8
403 Hydraulic system, Part 3
Swing motor SEN04560-00
Operation
PC78US-8 10-403 25
403 Hydraulic system, Part 3
SEN04560-00 Swing motor
10-403 26 PC78US-8
403 Hydraulic system, Part 3
Swing motor SEN04560-00
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
PC78US-8 10-403 27
403 Hydraulic system, Part 3
SEN04560-00 Swing motor
10-403 28 PC78US-8
403 Hydraulic system, Part 3
Swing motor SEN04560-00
PC78US-8 10-403 29
403 Hydraulic system, Part 3
SEN04560-00 Travel motor
Travel motor 1
10-403 30 PC78US-8
403 Hydraulic system, Part 3
Travel motor SEN04560-00
PC78US-8 10-403 31
403 Hydraulic system, Part 3
SEN04560-00 Travel motor
Specifications
Model GM10VA-B
Displacement Hi 30.5
(cm3/rev) Lo 54.3
Rated speed Hi 2,628
(rpm) Lo 1,507
Brake releasing pressure 0.63
(MPa {kg/cm2}) {6.42}
Hi-Lo switching pressure 2.94
(MPa {kg/cm2}) {30}
Reduction ratio 45.97
Outline
3. Brake valve
Consists of various valves. Provides the follow-
ing functions: stops the hydraulic motor
smoothly, prevents running away of hydraulic
motor, prevents generation of abnormally high
pressure when the hydraulic motor is stopped
suddenly.
10-403 32 PC78US-8
403 Hydraulic system, Part 3
Travel motor SEN04560-00
Operation
Operation of motor
At low speed (the motor swash plate angle is maximized.)
1. 2nd travel speed selector solenoid valve q Since 2nd travel speed selector solenoid valve
2. Regulator valve (1) is de-energized, the pressurized oil from
3. Spring hydraulic pump (8) is not fed to port (P).
4. Check valve q Regulator valve (2) is pushed to the left with
5. Regulator piston spring (3) reaction force.
6. Swash plate q The main pressurized oil, sent from the control
7. Parking brake piston valve through check valve (4), is controlled by
8. Hydraulic pump regulator valve (2) and used to shut off the cir-
9. Travel control valve cuit to regulator piston (5).
10. Pump merge-divider valve q The pressurized oil in control chamber (C) is
11. Brake valve drained from port (D) through oil passage (e) of
regulator valve (2).
q Swash plate (6) reaches its maximum tilt
angle, and the machine travels at low speed
with the maximum motor capacity.
PC78US-8 10-403 33
403 Hydraulic system, Part 3
SEN04560-00 Travel motor
1. 2nd travel speed selector solenoid valve q When 2nd travel speed selector solenoid valve
2. Regulator valve (1) is energized, the pressurized oil from
3. Spring hydraulic pump (8) is fed to port (P).
4. Check valve q Regulator valve (2) is pushed to the right with
5. Regulator piston the pressurized oil that is sent to port (P).
6. Swash plate q The main pressurized oil from the control valve
7. Parking brake piston passes through check valve (4), and passes
8. Hydraulic pump through oil passage (F) in regulator valve (2) to
9. Travel control valve control chamber (C), and is used to push regu-
10. Pump merge-divider valve lator piston (5) to the left.
11. Brake valve q Swash plate (6) reaches its minimum tilt angle,
and the machine travels at high speed with the
minimum motor capacity.
10-403 34 PC78US-8
403 Hydraulic system, Part 3
Travel motor SEN04560-00
PC78US-8 10-403 35
403 Hydraulic system, Part 3
SEN04560-00 Travel motor
q If the travel lever is returned to neutral, the q If the machine starts to run away on a slope,
pressurized oil from the control valve is the motor runs idle and the motor inlet port
stopped. (MA) pressure decreases and the pressure in
q Counterbalance valve (2) is pushed back to chamber (D) also decreases through orifice
the right with spring (3) reaction force. (c).
q The oil in chamber (D) flows to port (PA) q When the hydraulic oil pressure in chamber
through orifice (c). However, the back pressure (D) goes below spring (3) reaction force, coun-
is generated by closing of orifice (c), controlling terbalance valve (2) starts to return to the right.
the return speed of counterbalance valve (2) to q The oil in chamber (G) flows to port (PB)
the right. through orifice (f). However, the back pressure
q The oil returning from port (MB) is controlled is generated by closing of orifice (f), controlling
gradually with the moving speed of counterbal- the return speed of counterbalance valve (2) to
ance valve (2) and the shape of the cut part to the right.
stop the motor smoothly. q Counterbalance valve (2) moves to a position
q Even after the pressurized oil flowing to port where the force caused by the machine weight
(PA) is stopped, the motor continues rotation and the hydraulic force at motor inlet port (MA)
because of inertia and can cause cavitation. is balanced with the hydraulic force at motor
q Since check valve (1a) operates at very slight outlet port (MB).
negative pressure, ports (PA) and (MA) open q If motor outlet port (MB) is closed, the hydrau-
to prevent cavitation. lic pressure on the outlet side increases and
rotation resistance is generated.
q The travel speed is controlled according to the
pump delivery to prevent the machine from
running away.
10-403 36 PC78US-8
403 Hydraulic system, Part 3
Travel motor SEN04560-00
Parking brake
When travel lever is operated When travel lever is set to neutral position
q If the travel lever is operated, the pressurized q If the travel lever is returned to neutral, the
oil from the pump moves spool (1) to the left. pressurized oil from the control valve is
q The pressurized oil flows through port (E) to stopped.
chamber (A) of brake piston (2). q The pressurized oil in chamber (A) of brake
q When the hydraulic pressure in chamber (A) piston (2) is drained into the case.
goes above spring (3) reaction force, it pushes q When the hydraulic pressure in chamber (A)
brake piston (2) to the left. goes below spring (3) reaction force, brake pis-
q Plate (4) and disc (5) are relieved of friction ton (2) is pushed back to the right.
force and the parking brake is released. q Brake piston (2) presses plate (4) and disc (5)
together and the parking brake operates.
PC78US-8 10-403 37
403 Hydraulic system, Part 3
SEN04560-00 Center swivel joint
Blade specification
A1: From control valve (R.H. travel REVERSE) A2: To R.H. travel motor port B
B1: From control valve (R.H. travel FORWARD) B2: To R.H. travel motor port A
C1: From control valve (L.H. travel REVERSE) C2: To L.H. travel motor port A
D1: From control valve (L.H. travel FORWARD) D2: To L.H. travel motor port B
E1: From control valve (blade RAISE) E2: To L.H. and R.H. blade cylinder head
F1: From control valve (blade LOWER) F2: To L.H. and R.H. blade cylinder bottom
G1: From 2nd travel speed selector solenoid valve G2: To L.H. and R.H. travel motor port P
DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D1 or
D2
Unit: mm
No. Item Criteria Remedy
Standard size Standard clearance Clearance limit
Clearance between rotor and
5 shaft
Replace
70 0.056 – 0.105 0.111
10-403 38 PC78US-8
403 Hydraulic system, Part 3
Center swivel joint SEN04560-00
Bladeless specification
A1: From control valve (R.H. travel REVERSE) A2: To R.H. travel motor port B
B1: From control valve (R.H. travel FORWARD) B2: To R.H. travel motor port A
C1: From control valve (L.H. travel REVERSE) C2: To L.H. travel motor port A
D1: From control valve (L.H. travel FORWARD) D2: To L.H. travel motor port B
E1: From 2nd travel speed selector solenoid valve E2: To L.H. and R.H. travel motor port P
DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D1 or
D2
Unit: mm
No. Item Criteria Remedy
Standard size Standard clearance Clearance limit
Clearance between rotor and
5 shaft
Replace
60 0.056 – 0.105 0.111
PC78US-8 10-403 39
403 Hydraulic system, Part 3
SEN04560-00 Solenoid valve
Solenoid valve 1
10-403 40 PC78US-8
403 Hydraulic system, Part 3
Solenoid valve SEN04560-00
Check valve
6. Plug
7. Plunger q This valve is installed between port (P) and
PPC solenoid valve. When the engine is
Solenoid valve stopped, plunger (1) is pushed back to the left
with spring (2) reaction force, and the path
8. Coil (ON/OFF type)
between ports (ACC) and (P) is closed to
9. Push pin
maintain the pressure in the accumulator.
10. Valve spool
q When the engine is running, plunger (1) is
11. Sleeve
pushed to the right with the pilot pressure that
12. Stopper
is sent to port (P), and ports (P) and (ACC) are
13. Body
interconnected.
Control relief valve
14. Adjustment screw
15. Locknut
16. Cover
17. Return spring
18. Plunger
PC78US-8 10-403 41
403 Hydraulic system, Part 3
SEN04560-00 Solenoid valve
Solenoid valve
10-403 42 PC78US-8
403 Hydraulic system, Part 3
PPC accumulator SEN04560-00
PPC accumulator 1
Outline
q This accumulator is mounted on the solenoid
valve. If the engine is stopped with the work
equipment is kept at a raised position, the pilot
pressure is supplied to the control valve by the
pressure of the compressed nitrogen gas in
the accumulator. Therefore, the spool can be
operated to lower the work equipment by its
own weight.
Specifications
Gas to be used: Nitrogen gas
Gas capacity: 300 cc
Sealed gas pressure: 1.18 MPa
{12 kg/cm2} (at 80°C)
Maximum operating pressure: 6.86 MPa
{70 kg/cm2}
PC78US-8 10-403 43
403 Hydraulic system, Part 3
SEN04560-00 PPC accumulator
For breaker
(Machine ready for attachment)
1. Cap
2. Core
3. Ring
4. Lid
5. Bladder
6. Shell
Outline
q This accumulator is connected to the attach-
ment piping. When the breaker operates, the
oil pulsation is absorbed by the pressure of
compressed nitrogen gas of the accumulator,
to protect the hydraulic system devices and
piping.
Specifications
Gas to be used: Nitrogen gas
Gas capacity: 480 cc
Sealed gas pressure: 0.1 MPa {1 kg/cm2} (at 80°C)
Maximum operating pressure: 6.86 MPa
{70 kg/cm2}
10-403 44 PC78US-8
403 Hydraulic system, Part 3
Anti-drop valve SEN04560-00
Anti-drop valve 1
(If equipped)
a This valve can be mounted on the boom cylinder and arm cylinder.
a The valve is the standard equipment for the boom cylinder for EU specification.
PC78US-8 10-403 45
403 Hydraulic system, Part 3
SEN04560-00 Anti-drop valve
1. Pilot spool
2. Safety valve
3. Check valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x
Outside Installed Installed load Free length Installed load
4 Spool return spring diameter
length
10-403 46 PC78US-8
403 Hydraulic system, Part 3
Anti-drop valve SEN04560-00
Function
q The anti-drop valve prevents the pressurized
oil from flowing back from the work equipment
cylinder and prevents the work equipment from
falling suddenly when the piping from the con-
trol valve to the work equipment bursts.
Operation
PC78US-8 10-403 47
403 Hydraulic system, Part 3
SEN04560-00 Anti-drop valve
10-403 48 PC78US-8
403 Hydraulic system, Part 3
Anti-drop valve SEN04560-00
PC78US-8 10-403 49
403 Hydraulic system, Part 3
SEN04560-00 Multi-control valve
Multi-control valve 1
(If equipped)
a This valve is the standard equipment for North America specification.
Control pattern switching diagram (Port names correspond to the marks on the above figures.)
10-403 50 PC78US-8
403 Hydraulic system, Part 3
Multi-control valve SEN04560-00
PC78US-8 10-403 51
SEN04560-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
10-403 52
SEN04561-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-500 1
500 Work equipment
SEN04561-00 Work equipment
Work equipment 1
Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between mounting pin size Shaft Hole clearance limit
1 and bushing of revolving frame
and boom –0.030 +0.174 0.130 –
65 –0.100 +0.100 0.274 1.0
Clearance between mounting pin –0.225 –0.062 0.105 – Replace pin and
4 and bushing of arm and link 50 –0.285 –0.120 0.223 1.0 bushing
Clearance between mounting pin –0.225 –0.040 0.131 –
5 and bushing of bucket and link
50
–0.285 –0.094 0.245
1.0
10-500 2 PC78US-8
500 Work equipment
Work equipment SEN04561-00
PC78US-8 10-500 3
500 Work equipment
SEN04561-00 Dimensions of components
Dimensions of components 1
Arm
1,650 mm arm
10-500 4 PC78US-8
500 Work equipment
Dimensions of components SEN04561-00
Unit: mm
PC78US-8
No. Tolerance
Measurement point Standard size
Shaft Hole
–0.030 +0.100
1 — 60
–0.100 0
+1.0
Arm side 71.5
0
2
Cylinder head side 70 ±1.2
–0.030 +0.100
3 — 60
–0.100 0
+0.5
Boom side 220
0
4
–0.5
Arm side 220
–1.0
5 — 142.4 ±2.0
6 — 218.8 ±1.0
7 — 458.6 ±1.0
8 — 1,650 —
9 — 2,093.9 ±3.0
10 — 1,661.2 ±1.3
11 — 258.7 ±0.3
12 — 15.1 ±1.0
13 — 395.1 ±0.1
14 — 342 ±0.1
15 — 312.2 —
16 — 1,066.9 —
–0.225 0
17 — 50
–0.285 –0.150
Link side 200 –1.0
–2.0
18
Bucket side 200 +2.0
0
–0.225 0
19 — 50
–0.285 –0.150
Arm side 188 –0.5
–1.0
20
Bucket side 211 +3.0
0
Min. 1,055 ±1.5
21
Max. 1,765 —
PC78US-8 10-500 5
500 Work equipment
SEN04561-00 Dimensions of components
2,250 mm arm
10-500 6 PC78US-8
500 Work equipment
Dimensions of components SEN04561-00
Unit: mm
PC78US-8
No. Tolerance
Measurement point Standard size
Shaft Hole
–0.030 +0.100
1 — 60
–0.100 0
+1.0
Arm side 71.5
0
2
Cylinder head side 70 ±1.2
–0.030 +0.100
3 — 60
–0.100 0
+0.5
Boom side 220
0
4
–0.5
Arm side 220
–1.0
5 — 228.2 ±2.0
6 — 239.5 ±1.0
7 — 465.5 ±1.0
8 — 2,250 —
9 — 2,702.7 ±3.0
10 — 1,652.1 ±1.3
11 — 259 ±0.3
12 — 7.6 ±0.5
13 — 395.1 ±0.1
14 — 342 ±0.1
15 — 312.2 —
16 — 1,066.9 —
–0.225 0
17 — 50
–0.285 –0.150
Link side 200 –1.0
–2.0
18
Bucket side 200 +2.0
0
–0.225 0
19 — 50
–0.285 –0.150
Arm side 188 –0.5
–1.0
20
Bucket side 211 +3.0
0
Min. 1,055 ±1.5
21
Max. 1,765 —
PC78US-8 10-500 7
500 Work equipment
SEN04561-00 Dimensions of components
Bucket
10-500 8 PC78US-8
500 Work equipment
Dimensions of components SEN04561-00
Unit: mm
PC78US-8
No.
Measurement point Standard size Tolerance
1 — 309.8 ±0.5
2 — 38.6 ±0.5
3 — 97.1° —
4 — 312.2 —
5 — 1,057.2 —
6 — 143.7 —
7 — 8° —
8 — 5.2° —
0
9 — 50
–0.15
10 — 60 —
+0.2
11 — 70 0
+2.0
12 — 200 0
13 — 40 —
14 — 71 —
+1.0
15 — 296
0
16 — 18 —
17 — 100 —
18 — 115 —
19 — 95 —
+3.0
20 — 211
0
21 — 40 —
22 — 24 —
23 — 89.3 —
24 — 87.9 —
25 — 60 —
26 — 66 —
PC78US-8 10-500 9
500 Work equipment
SEN04561-00 Work equipment cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
Blade cylinder
10-500 10 PC78US-8
500 Work equipment
Work equipment cylinder SEN04561-00
Unit: mm
No. Item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
–0.030 +0.262 0.097 –
Boom 65 0.638
–0.076 +0.067 0.338
Clearance between –0.030 +0.151 0.024 –
1 piston rod and bushing Arm 60 0.527 Replace bushing
–0.076 –0.006 0.227
–0.030 +0.151 0.024 –
Bucket 55 0.527
–0.076 –0.006 0.227
–0.030 +0.262 0.097 –
Blade 65 0.638
–0.076 +0.067 0.338
–0.030 +0.174 0.130 –
Boom 60 1.0
–0.100 +0.100 0.274
–0.030 +0.174 0.130 –
Clearance between Arm 60 1.0
–0.100 +0.100 0.274
2 piston rod support
shaft and bushing –0.030 +0.174 0.130 –
Bucket 60 1.0
–0.100 +0.100 0.274
–0.030 +0.174 0.130 –
Blade 70 1.0
–0.104 +0.100 0.278 Replace pin and
–0.030 +0.174 0.130 – bushing
Boom 65 1.0
–0.100 +0.100 0.274
Clearance between Arm 55 –0.030 +0.174 0.130 – 1.0
cylinder bottom –0.100 +0.100 0.274
3 support shaft and
Bucket 50 –0.030 +0.142 0.110 – 1.0
bushing –0.100 +0.080 0.242
Blade 70 –0.030 +0.174 0.130 – 1.0
–0.104 +0.100 0.278
Boom 961 ± 96.1 Nm {98 ± 9.8 kgm}
Boom 2.60 ± 0.26 kNm {265 ± 26.5 kgm} (width across flats: 70 mm)
Arm 2.65 ± 0.26 kNm {270 ± 27.0 kgm} (width across flats: 65 mm)
Tightening torque of
5 cylinder piston locknut
Bucket 2.16 ± 0.22 kNm {220 ± 22.0 kgm} (width across flats: 60 mm)
Blade 3.14 ± 0.31 kNm {320 ± 32.0 kgm} (width across flats: 75 mm)
PC78US-8 10-500 11
SEN04561-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
10-500 12
SEN04562-01
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-600 1
600 Cab and its attachments
SEN04562-01 Air conditioner
Air conditioner 1
10-600 2 PC78US-8
600 Cab and its attachments
Air conditioner SEN04562-01
Specifications
Refrigerant to be used R134a
Refrigerant capacity (g) 780
PC78US-8 10-600 3
600 Cab and its attachments
SEN04562-01 Air conditioner
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Sight glass
6. Dual pressure switch
7. Air conditioner unit
9 Lock
piping
bolt of condenser refrigerant 3.92 – 6.86 {0.4 – 0.7}
(Screw size: M6 x 1.0)
10-600 4 PC78US-8
600 Cab and its attachments
Air conditioner SEN04562-01
PC78US-8 10-600 5
600 Cab and its attachments
SEN04562-01 Air conditioner
10-600 6 PC78US-8
600 Cab and its attachments
Air conditioner SEN04562-01
PC78US-8 10-600 7
600 Cab and its attachments
SEN04562-01 Air conditioner
10-600 8 PC78US-8
600 Cab and its attachments
Air conditioner SEN04562-01
PC78US-8 10-600 9
600 Cab and its attachments
SEN04562-01 Air conditioner
Compressor 1
Specifications
Number of cylinders – bore x
10 – 32 x 20.8
stroke (mm)
Piston capacity
129.2
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Refrigerant oil to be used Denso: ND-OIL 8
Refrigerant oil capacity
180
(cc)
10-600 10 PC78US-8
600 Cab and its attachments
Air conditioner SEN04562-01
Condenser 1
Specifications
Fin pitch (mm) 3.95
Total heat dissipation area (m )
2
3.63
Max. operating pressure (MPa {kg/cm }) 2
3.53 {36}
PC78US-8 10-600 11
600 Cab and its attachments
SEN04562-01 Air conditioner
Receiver 1
Specifications
Effective cubic capacity (cm3) 550
Weight of desiccating agent (g) 290
10-600 12 PC78US-8
600 Cab and its attachments
Air conditioner SEN04562-01
Sensor 1
1. Connector 1. Connector
2. Sensor 2. Sensor
Outline Outline
q The sunlight sensor is installed on top of the q The ambient air temperature sensor is installed
machine monitor of the air duct. in the battery room at the rear left of the
q It senses intensity of the sun light and sends machine.
signals to the air conditioner controller. The q It senses the ambient air temperature and
signal sent to the air conditioner controller is sends signals to the air conditioner controller.
used to control the blower motor and compres- The signal sent to the air conditioner controller
sor. is used to control the compressor. As a result,
temperature of the air blown out of the grille is
Output characteristics adjusted depending on the volume of refriger-
ant circulated in the evaporator.
PC78US-8 10-600 13
SEN04562-01
©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)
10-600 14
SEN04563-01
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 10-700 1
700 Electrical system
SEN04563-01 Electronic control system
*1: If equipped
10-700 2 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
PC78US-8 10-700 3
700 Electrical system
SEN04563-01 Electronic control system
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Fusible link secure safety when the engine is started.
4. Fuse box q The engine does not start until the lock
5. Starting switch lever is set in the "LOCK" position.
6. Engine controller
7. Lock lever 2. The KOMTRAX engine cut circuit is employed
8. PPC lock switch to disable the engine from starting when the
9. Starting motor cut-out relay (for PPC lock) KOMTRAX terminal receives an engine cut
10. Starting motor cut-out relay (for personal code) command issued through external operation.
11. Fuel control dial
12. Safety relay
13. Starting motor
14. Fuel supply pump
15. Sensors
16. Engine controller power cut-off relay A
17. Engine controller power cut-off relay B
18. Machine monitor
19. KOMTRAX terminal
10-700 4 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Starting engine
q When starting switch (5) is turned to "ON"
position, engine controller (6) sends com-
mand current to fuel supply pump (14).
For this reason, a fail-safe mechanism is
provided with the electrical system to stop
the engine when an electrical failure
occurs.
q When starting switch (5) is turned to
"START" with lock lever (7) set in the
"LOCK" position, a starting current is sup-
plied to starting motor (13) causing the
engine to start.
However, as the neutral safety mecha-
nism is provided, the engine will not start if
lock lever (7) is set in the "FREE" position
at this time; starting motor cut-out relay (9)
cuts off the starting current to starting
motor (13).
q Upon receipt of the engine cut-off com-
mand from the external source,
KOMTRAX terminal (19) sends the signal
to machine monitor (18).
Machine monitor (18) causes starting
motor cut-out relay (10) to cut off the start-
ing current to starting motor (13), therefore
the engine does not start.
Stopping engine
q When starting switch (5) is turned to
"OFF" position, the current from the ACC
terminal of starting switch (5) to engine
controller (6) is cut off, and consequently
the command current to fuel supply pump
(14) is cut off.
Fuel supply pump (14) stops fuel feed,
causing the engine speed to go down and
the engine stops.
PC78US-8 10-700 5
700 Electrical system
SEN04563-01 Electronic control system
10-700 6 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Function
q This function is turned ON when 1 of the 5
work modes of P, E, L, ATT and B is selected
with the work mode selector switch of the
machine monitor. The most suitable combina-
tion of engine torque (T) and pump absorption
torque can be selected for the contents of
work. If "Without" is selected for the attach-
ment on the initialization menu of the service
mode, 1 of the 3 modes of P, E and L is select-
able.
q According to the pump absorption torque set at
each mode, based on the engine governor set
speed with the fuel control dial and the actual
engine speed, the controller controls pump
delivery (Q) so that the pump will absorb all
torque at each engine output point.
q When the engine speed (N) is lowered, the
controller prevents the engine from stopping by
throttling the pump absorption torque.
PC78US-8 10-700 7
700 Electrical system
SEN04563-01 Electronic control system
10-700 8 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Control function during travel Control function with emergency pump drive
q In P, ATT or B mode, engine speed (N) at the switch "ON"
matching point is set higher during travel than q If the controller gets out of order and no work is
during working. possible because the hydraulic pump does not
q In E or L mode, engine speed (N) and pump work properly, operating emergency pump
absorption torque are kept constant during drive switch (1) temporarily enables to main-
travel and working. tain functions of the machine with absorption
torques quite similar to those in the E mode.
In this case, a constant current flows from the
battery to the PC-EPC valve, thus the hydrau-
lic pump is not controlled by the controller.
a: Emergency
b: Normal
a Emergency pump drive switch (1) is of the
alternative type. If the machine is operated
after the switch is set to "Emergency (a)" even
though the machine is normal, the user code
"E02" will be shown on the display.
PC78US-8 10-700 9
700 Electrical system
SEN04563-01 Electronic control system
Auto-deceleration function 1
10-700 10 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Function
q When all the control levers are set to NEU-
TRAL for waiting for a dump truck or work, the
engine speed is automatically reduced to a
controlled speed, and fuel consumption and
noise are lowered.
q When any control lever is operated, the engine
speed returns immediately to the speed that is
set with the fuel control dial.
Operation
When control levers are set in neutral
q If all the control levers are kept in neutral for 4
seconds with the engine speed higher than
approx. 1,175 rpm, the engine speed is
decreased to the controlled speed (approx.
1,175 rpm) and held until any control lever is
operated.
PC78US-8 10-700 11
700 Electrical system
SEN04563-01 Electronic control system
10-700 12 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Function
q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after
start-up of the engine.
Operational conditions (all required) Operation
Coolant temperature: Max. 55°C o
Fuel control dial: Max. 1,300 rpm Engine speed: 1,300 rpm
Control levers: NEUTRAL
O
Release conditions (either one required) Release
Coolant temperature: Min. 55°C, and control levers are set to NEUTRAL. o
Engine speed: Any
Fuel control dial: Min. 1,300 rpm, and control levers are set to NEUTRAL.
q Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil tem-
perature becomes too high.
Operational conditions Operation and actions taken Release conditions
Engine speed: Remains same Coolant temperature: Max. 95°C
Coolant temperature: Min. 95°C o • Sends torque control signal to o Hydraulic oil temperature: Max. 95°C
lower the pump absorption • The original conditions are restored if
Hydraulic oil temperature: Min. 95°C
torque and reduce the engine above requirements are met (automatic
load. restoration).
PC78US-8 10-700 13
700 Electrical system
SEN04563-01 Electronic control system
q When the engine is started at low temperatures and the engine speed is increased sharply, the turbo-
charger may be seized. Controlling the engine speed prevents this problem.
q The turbocharger protection time is controlled according to the coolant temperature.
Operational conditions Operating
o Turbocharger protection
Engine oil pressure: Max. 50 kPa {0.51 kg/cm2} (See the following figure)
A: Start engine
B: Duration of turbocharger protection
(approx. 0 – 20 sec)
C: Modulating time (approx. 1.5 sec)
D: 500 rpm
E: 1,175 rpm
F: 2,050 rpm (*1)
10-700 14 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
PC78US-8 10-700 15
700 Electrical system
SEN04563-01 Electronic control system
10-700 16 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Function
PC78US-8 10-700 17
700 Electrical system
SEN04563-01 Electronic control system
10-700 18 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Function
PC78US-8 10-700 19
700 Electrical system
SEN04563-01 Electronic control system
10-700 20 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
1. Battery Function
2. Battery relay q Interlocked with the lock lever, the PPC lock
3. Fusible link switch is turned "OFF" when operating the lock
4. Fuse box lever to "LOCK" position.
5. Starting switch q When the PPC lock switch is turned "OFF", the
6. Lock lever current to the PPC lock solenoid valve is cut-
7. PPC lock switch off, causing neither the work equipment nor
8. Hydraulic pump machine moves even if levers or pedal are
9. Control valve operated.
9a. Pump merge-divider valve
10. PPC lock solenoid valve
PC78US-8 10-700 21
700 Electrical system
SEN04563-01 Electronic control system
10-700 22 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
PC78US-8 10-700 23
700 Electrical system
SEN04563-01 Electronic control system
System components 1
Engine controller
DTP-4P [CN-CE03]
Pin No. Signal name Signal
classification
1 GND C
2 NC —
3 Constant power supply (24 V) A
4 NC —
10-700 24 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
DRC-60P(1) [CN-CE01]
Pin Signal Pin Signal
Signal name Signal name
No. classification No. classification
1 NC — 31 NC —
2 NC — 32 Engine oil pressure switch B
3 NC — 33 NC —
4 NC — 34 NC —
5 NC — 35 NC —
6 NC — 36 Sensor power supply (5 V) A
7 NC — 37 Camshaft speed sensor B
8 NC — 38 NC —
9 NC — 39 NC —
10 Fuel supply pump regulator (+) B 40 NC —
11 Boost temperature sensor B 41 NC —
12 NC — 42 Crankshaft speed sensor B
13 NC — 43 NC —
14 Fuel supply pump regulator (–) C 44 Crankshaft speed sensor GND C
15 NC — 45 Injector #2 (+) D
16 NC — 46 NC —
17 NC — 47 Coolant temperature sensor GND C
18 NC — 48 Sensor GND C
19 Boost pressure sensor B 49 Coolant temperature sensor D
20 Ambient pressure sensor B 50 NC —
21 NC — 51 Injector #4 (–) C
22 NC — 52 NC —
23 NC — 53 Injector #1 (–) C
24 NC — 54 NC —
25 NC — 55 Injector #3 (+) D
26 Crankshaft speed sensor (5 V) A 56 Injector #4 (+) D
27 NC — 57 Injector #1 (+) D
28 NC — 58 Injector #2 (–) C
29 Common rail pressure sensor B 59 Injector #3 (–) C
30 NC — 60 NC —
DRC-60P(2) [CN-CE02]
Pin Signal name Signal Pin Signal name Signal
No. classification No. classification
1 CAN(+) E 31 NC —
2 NC — 32 Engine controller power cut-off relay GND C
3 NC — 33 NC —
4 NC — 34 NC —
5 NC — 35 Fuel control dial (+) B
6 NC — 36 NC —
7 NC — 37 NC —
8 NC — 38 NC —
9 NC — 39 NC —
10 NC — 40 NC —
11 NC — 41 NC —
12 NC — 42 NC —
13 NC — 43 NC —
14 NC — 44 NC —
15 NC — 45 Starting switch ACC signal B
16 NC — 46 NC —
17 NC — 47 NC —
18 NC — 48 NC —
19 NC — 49 NC —
20 NC — 50 NC —
21 CAN (–) E 51 NC —
22 NC — 52 NC —
23 NC — 53 NC —
24 NC — 54 NC —
25 NC — 55 Engine controller power cut-off relay D
26 NC — 56 NC —
27 Fuel control dial (5 V) A 57 NC —
28 Fuel control dial (–) C 58 NC —
29 NC — 59 NC —
30 NC — 60 NC —
PC78US-8 10-700 25
700 Electrical system
SEN04563-01 Electronic control system
Pump controller
10-700 26 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
PC78US-8 10-700 27
700 Electrical system
SEN04563-01 Electronic control system
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
q This dial is installed in the right console box.
Potentiometer (5) is installed inside knob (1).
Turning knob (1) causes potentiometer (5)
shaft to rotate.
q This rotation changes the resistance of the
variable resistor within potentiometer (5), and a
throttle signal is sent to the controller.
q The hatched areas in the graph are error
detection areas. If the throttle voltage is within
the area, the engine speed drops down to low
idle.
10-700 28 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
Resistor
1. Resistor
2. Connector
Specifications
For PC-EPC valve: 30 z
Function
q This resistor sends an appropriate electric cur-
rent to each EPC valve, when the emergency
pump drive switch is turned to "ON".
a No electric current flows in the normal condi-
tion.
PC78US-8 10-700 29
700 Electrical system
SEN04563-01 Electronic control system
1. Connector
2. Sensor
3. O-ring
Specifications
Contact type: Normal close
Function
q This oil pressure switch is installed in the cylin-
der block. It detects engine oil pressure, and
turns the switch "ON" when the pressure goes
below the specified value.
10-700 30 PC78US-8
700 Electrical system
Electronic control system SEN04563-01
1. Plug
2. Switch
3. Connector
Specifications
Contact type: Normal open
Operating pressure to make contact point ON:
490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Operating pressure to break contact point OFF:
294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function
q This oil pressure switch is installed (8 places)
in the control valve. It detects the PPC oil pres-
sure when each actuator is operated, and
turns the switch "ON" when the pressure
exceeds the specified value.
PC78US-8 10-700 31
700 Electrical system
SEN04563-01 Electronic control system
10-700 32 PC78US-8
700 Electrical system
Monitor system SEN04563-01
Monitor system 1
PC78US-8 10-700 33
700 Electrical system
SEN04563-01 Monitor system
Machine monitor 1
10-700 34 PC78US-8
700 Electrical system
Monitor system SEN04563-01
070-12P(1) [CN-CM02]
Pin Input/output Pin Input/output
No. Signal name signal No. Signal name signal
1 Engine oil pressure sensor Input 7 GND (machine signal) —
2 Engine oil level sensor Input 8 CAN terminal signal —
3 Radiator coolant level sensor Input 9 CAN_H Input/output
4 Air cleaner clogging sensor Input 10 CAN_L Input/output
5 Swing lock switch Input 11 USB data (–) Input/output
6 Spare Input 12 USB data (+) Input/output
070-18P(2) [CN-CM03]
Pin Signal name Input/output Pin Signal name Input/output
No. signal No. signal
1 For communication terminal, RS232C CD Input 10 For communication terminal, RS232C CTS Input
2 For communication terminal, RS232C RXD Input 11 For communication terminal, RS232C RI Input
3 For communication terminal, RS232C SG — 12 GND (communication terminal power supply) —
4 GND (communication terminal control signal) — 13 Communication terminal status signal CH1 Input
5 Communication terminal selection signal Input 14 Communication terminal power supply control signal Output
6 For communication terminal, RS232C RTS Output 15 Communication terminal control signal CH1 Output
7 For communication terminal, RS232C TXD Output 16 Communication terminal control signal CH2 Output
8 For communication terminal, RS232C DTR Output 17 Communication terminal status signal CH2 Input
9 For communication terminal, RS232C DSR Input 18 Communication terminal power supply (12 V) Output
070-12P(2) [CN-CM04]
Pin Input/output Pin Input/output
Signal name signal Signal name signal
No. No.
1 GND (peripheral equipment power supply) — 7 Reserved —
2 Peripheral equipment control signal Output 8 Reserved —
3 GND (for peripheral equipment, RS232C) — 9 Reserved —
4 For peripheral equipment, RS232C TXD Output 10 Reserved —
5 For peripheral equipment, RS232C RXD Input 11 Reserved —
6 Reserved — 12 Peripheral equipment power supply (12 V) Output
B60-8P [CN-CM05]
Pin Input/output Pin Input/output
No. Signal name signal No. Signal name signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply) —
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1) —
3 Camera NTSC signal 2 Input 7 GND (Camera signal 2) —
4 Camera NTSC signal 3 Input 8 GND (Camera signal 3) —
PC78US-8 10-700 35
700 Electrical system
SEN04563-01 Monitor system
Display 1
10-700 36 PC78US-8
700 Electrical system
Monitor system SEN04563-01
PC78US-8 10-700 37
700 Electrical system
SEN04563-01 Monitor system
10-700 38 PC78US-8
700 Electrical system
Monitor system SEN04563-01
PC78US-8 10-700 39
700 Electrical system
SEN04563-01 Monitor system
Switches 1
10-700 40 PC78US-8
700 Electrical system
Monitor system SEN04563-01
*3: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at "High". Even if the set temperature is
reached, the fan speed remains the same.
*4: When the fan is set at stop, the air conditioner does not start even if the switch is pressed.
PC78US-8 10-700 41
700 Electrical system
SEN04563-01 Monitor system
Guidance
Function switch Item Function
icon
Starts function.
4 Start
(Used for starting measurement of split fuel consumption.)
Stops function.
5 Stop
(Used for stopping measurement of split fuel consumption.)
Sets selected item back to default.
1 Default
(Used for screen adjustment.)
Moves selection up one page.
F2 2 Move selection
(To the bottom page from the top page.)
10-700 42 PC78US-8
700 Electrical system
Monitor system SEN04563-01
Guidance
Function switch Item Function
icon
Selecting maintenance
1 Selects maintenance screen.
screen
F5
2 Return Returns to the previous screen or condition.
PC78US-8 10-700 43
700 Electrical system
SEN04563-01 Monitor system
q The functions in this mode are displayed in normal operation. Display and setting of these functions are
available from the operator's switch operations.
Display and setting of some functions require special operation of the switch.
q Items available in the operator mode are as follows:
10-700 44 PC78US-8
700 Electrical system
Monitor system SEN04563-01
Oil flow setting for breaker Oil flow setting for attachment
q Oil flow for the breaker can be changed in the q Oil flow for the double-acting attachment can
"Breaker/attachment setting" of the user mode. be changed in the "Breaker/attachment set-
q Oil flow level can be set as follows: ting" of the user mode.
q Oil flow level can be set as follows:
Oil flow level Quantity (l/min) Remarks
1 45 Oil flow level Quantity (l/min) Remarks
2 50 1 20
3 55 2 35
4 60 3 50
5 65 4 65
6 70 5 80
7 75 6 95
8 80 Default 7 110
9 85 8 125 Default
10 90
11 95
Language setting
12 100
13 105
14 110
15 115
PC78US-8 10-700 45
700 Electrical system
SEN04563-01 Monitor system
q The functions in this mode are not accessible from the normal operation screen. Display and setting of
these functions are available by the serviceman's special operations of the switch.
This mode is used for special setting, testing, adjusting or troubleshooting.
q Items available in the service mode are as follows:
Monitoring
Mechanical Systems
Abnormality Record Electrical Systems
Air-conditioning System
Maintenance Record
Maintenance Mode Change
Phone Number Entry
Key-on Mode
Unit
Default With/Without attachment
Attachment/Maintenance Password
ECO Display
Pump Absorption Torque
Adjustment
Attachment Flow Adjustment
Cylinder Cut-Out
No Injection
Fuel Consumption
Terminal Status
GPS & Communication Status
KOMTRAX Settings
Modem IP Address (Model TH201)
Modem S/N (Model TH300)
Display of KOMTRAX message
a For how to operate the service mode functions, see "Special functions of machine monitor" in "Testing
and adjusting".
10-700 46 PC78US-8
700 Electrical system
KOMTRAX system SEN04563-01
KOMTRAX system 1
PC78US-8 10-700 47
700 Electrical system
SEN04563-01 KOMTRAX system
KOMTRAX terminal 1
Model: TH300
q Satellite wave is used.
AMP-10P [CN-CK02]
Pin Input/output
Signal name
No. signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 NC —
B8 NC —
B9 NC —
B10 NC —
10-700 48 PC78US-8
700 Electrical system
Sensor SEN04563-01
Sensor 1
1. Connector
2. Pressure inlet port
Function
q This sensor is installed in the bracket on the side face of the cylinder block.
q This sensor senses the atmospheric pressure and converts it into an electric signal and then outputs
that signal.
1. Connector
2. Sensor
3. O-ring
Function
q This sensor is installed in the intake manifold.
q This sensor senses the boost pressure and boost temperature and converts them into electric signals
and then outputs those signals.
PC78US-8 10-700 49
700 Electrical system
SEN04563-01 Sensor
1. Connector
2. Sensor
3. O-ring
Function
q This sensor is installed in the water pump.
q This sensor senses the coolant temperature and converts it into an electric signal and then outputs that
signal.
1. Connector
2. Sensor
3. O-ring
Function
q The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is
installed in the gear of the camshaft.
q These sensors sense the gear rotations and convert them into pulse signals and then output those sig-
nals.
10-700 50 PC78US-8
700 Electrical system
Sensor SEN04563-01
1. Common rail
2. Sensor
3. Connector
Function
q This sensor is installed in the common rail.
q This sensor senses the fuel pressure and converts it into an electric signal and then outputs that signal.
1. Connector
2. Plug
3. Thermistor
Function
q This sensor is installed in the suction pipe of the hydraulic pump.
q This sensor senses the hydraulic temperature and converts it into an electric signal and then outputs
that signal.
PC78US-8 10-700 51
700 Electrical system
SEN04563-01 Sensor
Function
q This sensor is installed on the side face of the fuel tank.
q This sensor senses the fuel level and converts it into an electric signal and then outputs that signal.
q The float moves up and down according to the fuel level.
q The movement of the float operates the variable resistor through the arm.
10-700 52 PC78US-8
700 Electrical system
Sensor SEN04563-01
Function
q The pump oil pressure sensor is installed in the
control valve, and the boom cylinder bottom oil
pressure sensor is installed in the boom cylin-
der bottom piping.
q The pump pressure sensor senses the pump
discharge pressure and converts it into an
electric signal and then outputs that signal.
q The boom cylinder bottom pressure sensor
senses the cylinder circuit pressure and con-
verts it into an electric signal and then outputs
that signal.
PC78US-8 10-700 53
700 Electrical system
SEN04563-01 Sensor
Function
q This sensor is installed in the control valve
connecting part of the pilot circuit for travel and
swing operation.
q This sensor senses the pilot pressure and con-
verts it into an electric signal and then outputs
that signal.
10-700 54 PC78US-8
700 Electrical system
Sensor SEN04563-01
PC78US-8 10-700 55
SEN04563-01
©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)
10-700 56
SEN04803-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 20-100 1
100 Standard service value table
SEN04803-00 Standard value table for engine related parts
Engine SAA4D95LE-5
• Arm IN relief
0.34 – 0.59 0.25
SAE30 Oil
• At sudden {3.5 – 6.0} {2.5}
Oil pressure acceleration 0.29 – 0.49 0.2
SAE10W Oil
(Hydraulic oil MPa {3.0 – 5.0} {2.1}
temperature: {kg/cm2} Min. 0.18 0.15
Min. 80°C) SAE30 Oil
{Min. 1.8} {1.5}
• Low idle
Min. 0.15 0.13
SAE10W Oil
{Min. 1.5} {1.3}
• Whole speed range
Oil temperature °C 80 – 115 120
(inside oil pan)
• Between crankshaft pulley and
alternator pulley
Fan belt tension • Deflection when pressed with mm 6 – 10 —
finger force of approx.
58.8 N {6 kg}
• Between crankshaft pulley and
Air conditioner compressor pulley
compressor belt • Deflection when pressed with mm 12 – 15 12 – 15
tension finger force of approx.
58.8 N {6 kg}
20-100 2 PC78US-8
100 Standard service value table
Standard value table for chassis SEN04803-00
PC78US-8 20-100 3
100 Standard service value table
SEN04803-00 Standard value table for chassis
Time required
to start swing- sec.
ing
• Run engine at full throttle.
• Hydraulic oil temperature: 45 – 55°C
• Time required to swing 90° and 180° 180° 3.7 ± 0.3 Max. 4.3
from starting point
• Value in { } is measured under rated
bucket load.
20-100 4 PC78US-8
100 Standard service value table
Standard value table for chassis SEN04803-00
Time required to
finish swinging sec. 30 ± 3 Max. 35
Hydraulic drift of mm 0 0
swing (deg) (0) (0)
• Run engine at full throttle.
• Hydraulic oil temperature: 45 – 55°C
• Swing upper structure to 45° on slope of 15°
• Make match marks on swing circle outer race and
track frame.
• Measure deviation of marks made in 15 minutes.
• Run engine at full throttle.
Leakage from
swing motor • Hydraulic oil temperature: 45 – 55°C l/min. Max. 3.5 Max. 7.0
• Relieve swing circle.
Low
speed 36 ± 4 Max. 43
sec
Low 25 ± 2 Max. 29
speed
PC78US-8 20-100 5
100 Standard service value table
SEN04803-00 Standard value table for chassis
Hydraulic drift of mm 0 0
travel
• Stop engine.
• Hydraulic oil temperature: 45 – 55°C
• Stop machine on slope of 30° with sprocket up.
• Measure hydraulic drift of travel made in 5 minutes.
• Run engine at full throttle.
Leakage from
travel motor • Hydraulic oil temperature: 45 – 55°C l/min. Max. 1.1 Max. 1.65
• Lock shoes and relieve travel circuit.
20-100 6 PC78US-8
100 Standard service value table
Standard value table for chassis SEN04803-00
Boom cylinder
(Retraction of Max. 8 Max. 12
cylinder)
Hydraulic drift
• Stop engine.
Blade • Hydraulic oil temperature: 45 – 55°C
(Hydraulic drift Max. 20 Max. 30
of blade tip) • Measure hydraulic drift of blade tip from max. height in
Work equipment
15 minutes.
Leakage from cylin- • Hydraulic oil temperature: 45 – 55°C cc/min. Max. 1.5 Max. 7.5
der (Each cylinder) • Apply relief pressure to cylinder to be measured.
Boom
3.4 ± 0.3 Max. 4.0
Bucket tooth on RAISE (To just before (To just before
ground cushion) cushion)
sec
PC78US-8 20-100 7
100 Standard service value table
SEN04803-00 Standard value table for chassis
Bucket
Blade
RAISE 1.3 ± 0.2 Max. 2.1
Blade on ground
Work equipment
sec
Max. height of LOWER 1.3 ± 0.2 Max. 2.1
blade • Run engine at full throttle.
• Hydraulic oil temperature: 45 – 55°C
Time lag
20-100 8 PC78US-8
100 Standard service value table
Standard value table for chassis SEN04803-00
sec
Bucket 0 Max. 1.0
Work equipment
PC78US-8 20-100 9
100 Standard service value table
SEN04803-00 Standard value table for chassis
20-100 10 PC78US-8
100 Standard service value table
Standard value table for chassis SEN04803-00
PC78US-8 20-100 11
SEN04803-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
20-100 12
SEN04804-01
PC78US-8
SEN04804-01
HYDRAULIC EXCAVATOR
Shop Manual
PC78US-8
PC78US-8 30-4 1
101 Testing and adjusting, Part 1
SEN04804-01 Shop Manual
30-4 2 PC78US-8
101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting SEN04804-01
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Exhaust temperatures R 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
1 799-201-9001 Handy smoke checker 1 Bosch index: 0 – 9
Checking exhaust gas color A Commercially
2 Smoke meter 1
available
Commercially Intake: 0.35 mm
Adjusting valve clearance B Clearance gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression pres-
C 795-502-1370 Adapter 1
sure 2 For 95E-5 engine
6271-11-3880 Gasket 1
Testing blow-by pressure D 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa
799-261-1204 Digital hydraulic tester 1
Testing engine oil pressure E {600 kg/cm2}
Pressure gauge: 1.0 MPa
2 799-401-2320 Gauge 1
{10 kg/cm2}
6732-81-3170 Adapter 1 Size: 10 x 1.0
3
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/cm2}
Pressure gauge: 60 MPa
Testing fuel pressure F 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
795-471-1450 Adapter 1 Size: 8 x 1.25 mm
2
07005-00812 Washer 1
3 799-201-2202 Boost gauge kit 1
1 6151-51-8490 Spacer 1 f14
2 6164-81-5750 Joint 1 f14
3 07042-20108 Plug 1
Commercially
4 Hose 1 Internal dimensions: Approx. 12 mm
available
Testing fuel return rate and
G Commercially
leakage 5 Hose 1 Internal dimensions: Approx. 5 mm
available
Commercially
6 Measuring cylinder 1
available
Commercially
7 Stopwatch 1
available
Testing swing circle bearing Commercially
H Dial gauge 1
clearance available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Testing and adjusting oil
1 {25, 60, 400, 600 kg/cm2}
pressure in work equip-
J Pressure gauge: 60 MPa
ment, swing, and travel cir- 790-261-1204 Digital hydraulic tester 1
cuits {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
Testing and adjusting swing 1 {25, 60, 400, 600 kg/cm2}
and blade circuit oil pres- K Pressure gauge: 60 MPa
sure 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
PC78US-8 30-4 3
101 Testing and adjusting, Part 1
SEN04804-01 Tools for testing, adjusting, and troubleshooting
Sym-
Q'ty
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/cm2}
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/cm2}
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/cm2}
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/cm2}
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/cm2}
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 q Measurement box 1
799-601-4201)
799-601-4130 q T-adapter 1 CAM
Troubleshooting for engine 799-601-4160 q T-adapter 1 Ne sensor
T
controller/sensors/actuators 799-601-4220 q T-adapter 1 Engine controller
799-601-4240 q Socket 1 For ambient pressure sensor
799-601-4190 q Socket 1 Common rail pressure sensor
799-601-4340 q Socket 1 Injector
795-799-5530 q Socket 1 Engine coolant temperature sensor
799-601-4380 Socket 1 Boost pressure sensor
799-601-4260 Socket 1 Engine controller
30-4 4 PC78US-8
101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting SEN04804-01
Sym-
Q'ty
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 q 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 q Measurement box 1
799-601-4100 and 799-601-4201)
799-601-9020 q Adapter for DT 1 For DT2P
For DT3P (Does not include
799-601-9030 q Adapter for DT 1
799-601-4100 and 799-601-4201)
799-601-9040 q Adapter for DT 1
For DT6P (Does not include
799-601-9050 q Adapter for DT 1
799-601-4100 and 799-601-4201)
q 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 q Adapter for AMP 1
799-601-9000 and 799-601-9200)
PC78US-8 30-4 5
101 Testing and adjusting, Part 1
SEN04804-01 Tools for testing, adjusting, and troubleshooting
Sym-
Q'ty
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 q Adapter for X 1
799-601-7000 and 799-601-7100)
799-601-7020 q Adapter for X 1 For X2P
For SW6P (Does not include
799-601-7050 q Adapter for SWP 1
799-601-8000)
For SW6P (Does not include
799-601-7060 q Adapter for SWP 1
799-601-8000)
Troubleshooting for chassis For M1P (Does not include
T 799-601-7080 q Adapter for M 1
sensors/wiring harnesses 799-601-7000 and 799-601-7100)
799-601-7090 q Adapter for M 1 For M2P
799-601-7110 q Adapter for M 1 For M3P
799-601-7130 q Adapter for M For M6P
For S16P (Does not include
799-601-7330 q Adapter for S 1
799-601-7000 and 799-601-7100)
799-601-7500 T-adapter assembly 1
799-601-7520 q Adapter for 070 1 For 070-12P
799-601-7540 q 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 q 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-
a 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".
30-4 6 PC78US-8
101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting SEN04804-01
-:Socket
PC78US-8 30-4 7
101 Testing and adjusting, Part 1
SEN04804-01 Testing engine speed
30-4 8 PC78US-8
101 Testing and adjusting, Part 1
Testing exhaust temperature SEN04804-01
PC78US-8 30-4 9
101 Testing and adjusting, Part 1
SEN04804-01 Checking exhaust gas color
30-4 10 PC78US-8
101 Testing and adjusting, Part 1
Adjusting valve clearance SEN04804-01
PC78US-8 30-4 11
101 Testing and adjusting, Part 1
SEN04804-01 Adjusting valve clearance
5. Adjust the valve clearances marked with q in the 7. After finishing adjustment, remove the adjusting
valve arrangement drawing according to the tools and return the removed parts.
following procedure. 3 Cylinder head cover mounting nut:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
30-4 12 PC78US-8
101 Testing and adjusting, Part 1
Testing compression pressure SEN04804-01
PC78US-8 30-4 13
101 Testing and adjusting, Part 1
SEN04804-01 Testing compression pressure
3. Set the engine in the no-injection cranking mode 3) Connect spill hose connector (6) to injector
with the machine monitor. (1).
q Instead of the above work, you may discon- 4) Install high-pressure pipe (5).
nect the wiring harness connectors from all 3 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}
k 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. a 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).
a Read the pressure when the gauge pointer is a 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.)
a Do not install O-ring (8) to groove "a". 7) Connect wiring harness connector (2) to
injector (1).
30-4 14 PC78US-8
101 Testing and adjusting, Part 1
Testing blow-by pressure SEN04804-01
PC78US-8 30-4 15
101 Testing and adjusting, Part 1
SEN04804-01 Testing engine oil pressure
Testing engine oil pressure 2. Remove oil pressure pickup plug (1) from the
engine block.
a 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
k Stop the machine on a level ground and low-
er the work equipment to the ground.
a Test the engine oil pressure under the following
condition.
q Engine coolant temperature: Within operat-
ing range
1. Remove covers (1) and (2).
30-4 16 PC78US-8
101 Testing and adjusting, Part 1
Handling fuel system parts SEN04804-01
PC78US-8 30-4 17
101 Testing and adjusting, Part 1
SEN04804-01 Testing fuel pressure
30-4 18 PC78US-8
101 Testing and adjusting, Part 1
Testing fuel return rate and fuel leakage SEN04804-01
Testing fuel return rate and fuel 2) Insert spacer G1 on return block (2) side and
leakage tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends of
a 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 a 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 a Bind the connecting part of the test hose
available
Commercially with a wire etc. to prevent it from coming
7 Stopwatch off.
available
a Lay test hose G4 so that it will not slacken
a Prepare an oil pan of about 20 l 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).
PC78US-8 30-4 19
101 Testing and adjusting, Part 1
SEN04804-01 Testing fuel return rate and fuel leakage
2. Testing leakage from pressure limiter 3. Testing return rate from injector
1) Lay test hose G4 so that it will not slacken a 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
a You may test for 20 seconds and judge by cylinder G6.
multiplying the result by 3. a You may test for 20 seconds and judge by
a If the leakage from the pressure limiter is multiplying the result by 3.
in the following standard range, it is nor- a 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 a 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
30-4 20 PC78US-8
101 Testing and adjusting, Part 1
Bleeding air from fuel circuit SEN04804-01
PC78US-8 30-4 21
101 Testing and adjusting, Part 1
SEN04804-01 Bleeding air from fuel circuit
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
30-4 22 PC78US-8
101 Testing and adjusting, Part 1
Checking fuel circuit for leakage SEN04804-01
PC78US-8 30-4 23
101 Testing and adjusting, Part 1
SEN04804-01 Testing and adjusting alternator belt tension
30-4 24 PC78US-8
101 Testing and adjusting, Part 1
Testing and adjusting alternator belt tension SEN04804-01
PC78US-8 30-4 25
101 Testing and adjusting, Part 1
SEN04804-01 Checking and adjusting air conditioner compressor belt tension
30-4 26 PC78US-8
101 Testing and adjusting, Part 1
Testing swing circle bearing clearance SEN04804-01
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.
a Testing tools for swing circle bearing clearance a 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.
a When testing the swing circle bearing clearance a The value indicated by dial gauge H is the
installed to the machine, perform the following clearance of the bearing.
procedure. a For the standard value, see Structure, func-
k Stop the machine on a level ground and low- tion and maintenance standard, "Swing cir-
er the work equipment to the ground. cle".
k Do not put your hands or feet under the un-
dercarriage during test.
PC78US-8 30-4 27
101 Testing and adjusting, Part 1
SEN04804-01 Checking and adjusting track shoe tension
T2P02800
30-4 28 PC78US-8
101 Testing and adjusting, Part 1
Checking and adjusting track shoe tension SEN04804-01
2. Decreasing tension
1) Loosen valve (1) to discharge grease, and
then tighten it.
k 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.
PC78US-8 30-4 29
101 Testing and adjusting, Part 1
SEN04804-01 Testing and adjusting oil pressure in work equipment and travel circuits
Testing and adjusting oil pressure 2) Install nipples J2 and connect oil pressure
in work equipment and travel gauges [1] of hydraulic tester J1.
a Use the oil pressure gauges of 60 MPa
circuits
{600 kg/cm2}.
Testing
a 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").
q Monitoring code: 01100 pump pressure
a Test the oil pressure in the work equipment and
travel circuits under the following condition.
q 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
q (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-
q (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.
a The pressure tested when the unload
valve is unloaded is indicated.
30-4 30 PC78US-8
101 Testing and adjusting, Part 1
Testing and adjusting oil pressure in work equipment and travel circuits SEN04804-01
PC78US-8 30-4 31
101 Testing and adjusting, Part 1
SEN04804-01 Testing and adjusting swing and blade circuit oil pressure (Blade specification)
Testing and adjusting swing and 2) Install nipple K2 and connect oil pressure
blade circuit oil pressure (Blade gauge [1] of hydraulic tester K1
a Use the oil pressure gauge of 60 MPa
specification)
{600 kg/cm2}.
Testing
a 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.
q Monitoring code: 01100 pump pressure 2) While running the engine at high idle, operate
a 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
q Hydraulic oil temperature: Within operating pressure.
range a The swing motor safety valve relief pres-
sure is indicated.
1. Preparation work a 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.
30-4 32 PC78US-8
101 Testing and adjusting, Part 1
Testing and adjusting swing and blade circuit oil pressure (Blade specification) SEN04804-01
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).
k Do not remove the adjustment nut or k Do not remove the adjustment nut or
inside parts will come out. inside parts will come out.
a If the adjustment screw is a If the adjustment screw is
q turned to the right, the set pressure is q turned to the right, the pressure is in-
decreased. creased.
q turned to the left, the set pressure is q turned to the left, the pressure is de-
decreased. creased.
a Amount of adjustment per turn of adjust- a 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).
3 Locknut: 3 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.
PC78US-8 30-4 33
101 Testing and adjusting, Part 1
SEN04804-01 Testing and adjusting swing and blade circuit oil pressure (Blade specification)
30-4 34 PC78US-8
101 Testing and adjusting, Part 1
Testing control circuit basic pressure SEN04804-01
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.
a 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 control, and travel in neutral, and test the oil
799-101-5220 Nipple (10 × 1.25 mm)
2 pressure.
07002-11023 O-ring
k 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".
a Test the control circuit basic pressure under the
following condition.
q Hydraulic oil temperature: Within operating
range
PC78US-8 30-4 35
101 Testing and adjusting, Part 1
SEN04804-01 Testing and adjusting oil pressure in pump PC control circuit
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.
a Use the oil pressure gauges of 60 MPa
a Testing and adjusting tools for oil pressure in
{600 kg/cm2}.
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)
k 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
a 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).
a 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
q Hydraulic oil temperature: Within operating
relieve the arm circuit in the arm IN direction
range and measure the oil pressure.
30-4 36 PC78US-8
101 Testing and adjusting, Part 1
Testing and adjusting oil pressure in pump PC control circuit SEN04804-01
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.
a Use the oil pressure gauges of 6 MPa
{60 kg/cm2}.
PC78US-8 30-4 37
101 Testing and adjusting, Part 1
SEN04804-01 Testing and adjusting oil pressure in pump PC control circuit
3. Adjusting PC valve
a 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.
a Before loosening the locknut, be sure to
make match mark "a".
1) Loosen locknut (3) and rotate adjustment
screw (4) to adjust.
a 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).
3 Locknut: 29.4 – 39.2 {3 – 4 kgm}
30-4 38 PC78US-8
101 Testing and adjusting, Part 1
Testing PC-EPC solenoid output pressure SEN04804-01
PC78US-8 30-4 39
101 Testing and adjusting, Part 1
SEN04804-01 Testing LS differential pressure and adjusting LS valve
30-4 40 PC78US-8
101 Testing and adjusting, Part 1
Testing LS differential pressure and adjusting LS valve SEN04804-01
Adjusting LS valve
a If the LS differential pressure is abnormal, adjust
the LS valve according to the following proce-
dure.
a Before loosening the locknut, be sure to make a
match mark.
1) Loosen locknut (2) and rotate adjustment
screw (3) to adjust.
a If the adjustment screw is
q Turned to the right, the pressure is in-
creased.
q Turned to the left, the pressure is de-
creased.
a Amount of adjustment per turn of adjust-
ment screw: 1.27 MPa {13 kg/cm2}
2) After adjusting, tighten locknut (2).
3 Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}
a After adjusting, measure the LS differen-
tial pressure according to the measure-
ment procedure shown above.
a When loosening or tightening the locknut,
hold adjustment screw (3) with a spanner
to prevent it from being dragged.
PC78US-8 30-4 41
101 Testing and adjusting, Part 1
SEN04804-01 Testing solenoid valve output pressure
Testing solenoid valve output 2. Install adapter P2 and connect the disconnected
pressure hose again.
30-4 42 PC78US-8
101 Testing and adjusting, Part 1
Testing solenoid valve output pressure SEN04804-01
PC78US-8 30-4 43
101 Testing and adjusting, Part 1
SEN04804-01 Testing PPC valve output pressure
30-4 44 PC78US-8
101 Testing and adjusting, Part 1
Testing PPC valve output pressure SEN04804-01
a 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
k 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".
a Before testing the PPC valve output pressure,
ensure that the control circuit basic pressure is
normal.
a Test the solenoid valve output pressure under
the following condition.
q Hydraulic oil temperature: Within operating
range
1. Disconnect the PPC circuit hose to be tested.
a For the host to be disconnected, see "PPC
piping connecting positions".
2. Install adapter Q2 and connect the disconnected a 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
a Use the oil pressure gauge of 6 MPa Stroke end basic pressure (See “Standard
{60 kg/cm2}. value table”)
a 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.
PC78US-8 30-4 45
101 Testing and adjusting, Part 1
SEN04804-01 Adjusting play of work equipment and swing PPC valves
30-4 46 PC78US-8
101 Testing and adjusting, Part 1
Checking parts which cause hydraulic drift of work equipment SEN04804-01
PC78US-8 30-4 47
101 Testing and adjusting, Part 1
SEN04804-01 Checking parts which cause hydraulic drift of work equipment
30-4 48 PC78US-8
101 Testing and adjusting, Part 1
Testing and adjusting travel deviation SEN04804-01
PC78US-8 30-4 49
101 Testing and adjusting, Part 1
SEN04804-01 Testing and adjusting travel deviation
30-4 50 PC78US-8
101 Testing and adjusting, Part 1
Releasing residual pressure from hydraulic circuit SEN04804-01
PC78US-8 30-4 51
101 Testing and adjusting, Part 1
SEN04804-01 Testing oil leakage
30-4 52 PC78US-8
101 Testing and adjusting, Part 1
Testing oil leakage SEN04804-01
PC78US-8 30-4 53
101 Testing and adjusting, Part 1
SEN04804-01 Testing oil leakage
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.
k Put pin [1] between the sprocket and
track frame to lock the travel mecha-
nism securely.
30-4 54 PC78US-8
101 Testing and adjusting, Part 1
Bleeding air from each part SEN04804-01
valve o o
q Removing control valve piping
q Replacing and repairing cylinder
q q o o q
q Removing cylinder piping
q Replacing and repairing swing
motor q o q o q
q Removing swing motor piping
q Replacing and repairing travel
motor q o o q q
q Removing travel motor piping
q Replacing and repairing swivel
joint q o o o q
q Removing swivel joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
PC78US-8 30-4 55
101 Testing and adjusting, Part 1
SEN04804-01 Bleeding air from each part
4. Bleeding air from swing motor 6. Checking oil level and starting work
a 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
a 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.
a 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.
30-4 56 PC78US-8
101 Testing and adjusting, Part 1
Adjusting mirrors SEN04804-01
PC78US-8 30-4 57
SEN04804-01
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
30-4 58
SEN04805-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 30-102 1
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 2 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 3
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
Page Page
t Operator mode (Outline) t Service mode
6p 19p
A Display of KOMATSU logo 6p Monitoring 20p
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
O (Special operation)
30-102 4 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 5
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 6 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 7
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 8 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 9
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 10 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 11
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
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
30-102 12 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 13
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 14 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
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.
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.
PC78US-8 30-102 15
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 16 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
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.
PC78US-8 30-102 17
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 18 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 19
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
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.
30-102 20 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 21
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 22 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 23
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 24 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 25
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" Screen.
30-102 26 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 27
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
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
30-102 28 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
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
PC78US-8 30-102 29
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 30 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 31
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 32 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 33
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
4. Contents of setting of each maintenance item a 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.
30-102 34 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
PC78US-8 30-102 35
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 36 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 37
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 38 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 39
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
1. Selecting menu
Select "Default" on the "Service Menu" screen.
30-102 40 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 41
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 42 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
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.
PC78US-8 30-102 43
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
[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.
30-102 44 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 45
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
2. Starting test
After the screen of "Fuel Consumption" is dis-
played, start test with the function switches.
q [F1]: Start
q [F2]: Clear 4. Finishing test
q [F5]: Return to Service menu screen Press [F1], and test is finished and the data
a 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-
a 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 controller and the
starts. elapsed time are displayed.
30-102 46 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 47
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
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-
necting condition of communication
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
30-102 48 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
PC78US-8 30-102 49
102 Testing and adjusting, Part 2
SEN04805-00 Special functions of machine monitor
30-102 50 PC78US-8
102 Testing and adjusting, Part 2
Special functions of machine monitor SEN04805-00
PC78US-8 30-102 51
SEN04805-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
30-102 52
SEN04806-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 30-103 1
103 Testing and adjusting, Part 3
SEN04806-00 Handling voltage circuit of engine controller
30-103 2 PC78US-8
103 Testing and adjusting, Part 3
Preparation work for troubleshooting of electrical system SEN04806-00
1. Machine monitor
1) Remove 3 mounting bolts and cover (1).
a One of the mounting bolts is installed
in the cover on the right of the sun-
light sensor.
a While removing the mounting bolts,
disconnect connector P31 of the sun-
light sensor.
2. Engine controller
1) Open the engine hood.
a 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).
a Connectors CE01 and CE02 are fixed
with screws. When disconnecting
them, loosen the screws.
a When returning connectors CE01 and
CE02, tighten the screws to the spec-
ified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
2) Remove 1 mounting bolt and duct (2).
PC78US-8 30-103 3
103 Testing and adjusting, Part 3
SEN04806-00 Preparation work for troubleshooting of electrical system
3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove cover (1).
30-103 4 PC78US-8
103 Testing and adjusting, Part 3
Preparation work for troubleshooting of electrical system SEN04806-00
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 a Disconnection and connection of con-
switch) nector
a 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
sens or, e ngine Bk up s peed sens or, 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.
PC78US-8 30-103 5
103 Testing and adjusting, Part 3
SEN04806-00 Preparation work for troubleshooting of electrical system
7. Supply pump IMV solenoid (Fuel regulator) a Precautions for connecting connector
a 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.
30-103 6 PC78US-8
103 Testing and adjusting, Part 3
Preparation work for troubleshooting of electrical system SEN04806-00
PC78US-8 30-103 7
103 Testing and adjusting, Part 3
SEN04806-00 Procedure for testing diodes
30-103 8 PC78US-8
103 Testing and adjusting, Part 3
Pm Clinic service SEN04806-00
Pm Clinic service 1
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 450 mm T( )
Arm T Standard T ( ) T( ) T 600 mm
Bucket T Standard 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
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
PC78US-8 30-103 9
103 Testing and adjusting, Part 3
SEN04806-00 Pm Clinic service
1. Engine
Checking condition
Standard Mea-
Good
Service limit
Bad
No. Check item Fuel Work- Auto- Unit value for new sured
Operation of work value
control ing decel- machine value
equipment
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}
Good
Service limit
Bad
No. Check item Fuel Work- Unit value for new sured
control ing Checking posture, etc. value
machine value
dial mode
1 Boom RAISE Work equipment extended fully sec 3.1 – 3.7 Max. 4.2
2 Arm IN sec 2.9 – 3.6 Max. 4.0
Boom top horizontal
3 Arm OUT sec 3.1 Max. 3.3
Boom top horizontal
4 Bucket CURL sec 2.8 – 3.6 Max. 4.0
MAX P Arm cylinder retracted fully
Work equipment extended fully
5 Swing (5 turns) sec 27 – 33 Max. 35
Swing right and left
One side of track LO STD sec 32 – 40 Max. 43
Travel
6 pushed up and turned
(5 idle turns) HI STD sec 19 – 23 Max. 25
forward and backward
Service limit
Bad
30-103 10 PC78US-8
103 Testing and adjusting, Part 3
Pm Clinic service SEN04806-00
4. Hydraulic circuit
[1] [2] [3] [4] [5] [6]
Checking condition
600K 600K 600K 600K 60K 60K
Good
Bad
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}
Standard value
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)
PC78US-8 30-103 11
103 Testing and adjusting, Part 3
SEN04806-00 Pm Clinic service
* 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
Good
Bad
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
Standard value
30-103 12 PC78US-8
103 Testing and adjusting, Part 3
Pm Clinic service SEN04806-00
PC78US-8 30-103 13
SEN04806-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
30-103 14
SEN04807-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-100 1
100 Failure code table and fuse locations
SEN04807-00 Failure code table
40-100 2 PC78US-8
100 Failure code table and fuse locations
Failure code table SEN04807-00
PC78US-8 40-100 3
100 Failure code table and fuse locations
SEN04807-00 Fuse locations
Fuse locations 1
40-100 4 PC78US-8
100 Failure code table and fuse locations
Fuse locations SEN04807-00
<EU specification>
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
1 10 A Resistor
2 30 A Solenoid valve
F02
Switch power supply 3 15 A Cigarette lighter
(45 A)
4 10 A Windshield washer
5 10 A Horn
6 5A Working lamp relay
7 10 A Beacon (if equipped)
F02
Switch power supply 8 25 A Working lamp
(45 A)
9 10 A Spare
10 5A Air conditioner
11 20 A Air conditioner unit
F02 12 10 A Optional power supply (1)
Switch power supply
(45 A) 13 10 A Optional power supply (2), radio
14 10 A Spare
15 5A Air conditioner
F03 16 10 A Room lamp
Constant power supply
(45 A) 17 20 A Machine monitor, pump controller, starting switch
18 30 A Engine controller
Starting switch 19 5A Engine controller
Switch power supply
ACC 20 5A PPC oil pressure lock solenoid
PC78US-8 40-100 5
100 Failure code table and fuse locations
SEN04807-00 Fuse locations
40-100 6 PC78US-8
100 Failure code table and fuse locations
Fuse locations SEN04807-00
PC78US-8 40-100 7
SEN04807-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-100 8
SEN04808-01
PC78US-8
SEN04808-01
HYDRAULIC EXCAVATOR
Shop Manual
PC78US-8
40 Troubleshooting
200 General Information on troubleshoot-
ing
PC78US-8 40-4 1
200 General Information on troubleshooting
SEN04808-01 Points to remember when troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to 4) Other maintenance items can be checked
disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
after any failure occurs:
q Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or as
q It will become impossible to find the cause of a problem with the method of operation, etc.
the failure. a When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. For this make the problem worse.
reason, when carrying out troubleshooting, it is
necessary to carry out thorough prior investiga- 5. Troubleshooting
tion and to carry out troubleshooting in accor- Use the results of the investigation and inspec-
dance with the fixed procedure. tion in Items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] To start from the simple points.
3) Did the failure occur suddenly, or were there 2] To start from the most likely points.
problems with the machine condition before 3] Inspect other related parts or information.
this?
4) Under what conditions did the failure occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before the Even if the failure is repaired, if the root cause of
failure? When were these repairs carried the failure is not repaired, the same failure will
out? occur again.To prevent this, always investigate
6) Has the same kind of failure occurred why the problem occurred. Then, remove the
before? root cause.
40-4 2 PC78US-8
200 General Information on troubleshooting
Sequence of events in troubleshooting SEN04808-01
PC78US-8 40-4 3
200 General Information on troubleshooting
SEN04808-01 Check before troubleshooting
40-4 4 PC78US-8
200 General Information on troubleshooting
Classification and troubleshooting steps SEN04808-01
1. Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in abnormality
record:
If a user code and a failure code are not displayed on the machine monitor, check a mechanical system
failure code and an electrical system failure code with the abnormality record function of the machine
monitor.
If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see
if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the
abnormality record function, carry out the corresponding troubleshooting in E-mode.
3. When user code and failure code is not displayed and no failure code is recorded in abnormality
record:
If a user code and failure code are not displayed on the machine monitor and no failure code is recorded
in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the
electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode.
PC78US-8 40-4 5
200 General Information on troubleshooting
SEN04808-01 Information in troubleshooting table
40-4 6 PC78US-8
200 General Information on troubleshooting
Information in troubleshooting table SEN04808-01
PC78US-8 40-4 7
200 General Information on troubleshooting
SEN04808-01 Phenomena looking like troubles and troubleshooting Nos.
40-4 8 PC78US-8
200 General Information on troubleshooting
Phenomena looking like troubles and troubleshooting Nos. SEN04808-01
Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
34 Work equipment does not move in its single operation H-10
35 Hydraulic drift of work equipment is large H-11
36 Time lag of work equipment is large H-12
Flow rate in attachment circuit cannot be adjusted (when attachment
37 H-27
is installed)
Phenomena related to compound operation
38 Work equipment loaded more is slower during compound operation H-13
Boom RAISE speed is low in compound operation of swing + boom
39 H-14
RAISE
Travel speed lowers largely during compound operation of work
40 H-15
equipment/swing + travel
Phenomena related to travel
41 Machine deviates during travel H-16
42 Travel speed is low H-17
43 Machine cannot be steered easily or steering power is low H-18
44 Travel speed does not change or it is kept low or high E-16 H-19
45 Track does not move (Only either side) H-20
46 Travel alarm does not sound or does not stop sounding E-20
Phenomena related to swing
47 Machine does not swing H-21
48 Swing acceleration or swing speed is low H-22
49 Excessive overrun when stopping swing H-23
50 When upper structure stops swinging, it makes large shock H-24
51 When upper structure stops swinging, it makes large sound H-25
Swing holding brake does not operate normally
52 E-19 H-26
Hydraulic drift of swing is large
Phenomena related to machine monitor
53 When starting switch is turned ON, machine monitor displays nothing E-1
54 Precaution lights up while engine is running E-6
55 Emergency stop item lights up while engine is running E-7
56 Engine coolant temperature gauge does not indicate normally E-8
57 Hydraulic oil temperature gauge does not indicate normally E-9
58 Fuel level gauge does not indicate normally E-10
Contents of display by machine monitor are different from applicable
59 E-11
machine
60 Machine monitor does not display some items E-12
61 Function switch does not work E-13
62 Alarm buzzer cannot be stopped E-17
63 Windshield wiper and window washer do not operate E-18
Air conditioner does not operate normally (including air conditioner
64 E-21
abnormality record)
65 While starting switch is in OFF position, service meter is not displayed E-22
66 Machine monitor cannot be set in service mode E-23
67 Monitoring function does not display lever control signal normally E-24
PC78US-8 40-4 9
200 General Information on troubleshooting
SEN04808-01 Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
Other phenomena
68 KOMTRAX system does not operate normally E-25
40-4 10 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 11
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 12 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 13
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 14 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 15
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 16 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 17
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 18 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 19
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 20 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 21
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 22 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 23
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 24 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 25
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 26 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 27
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 28 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 29
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 30 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 31
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 32 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 33
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 34 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 35
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 36 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 37
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 38 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 39
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 40 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 41
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 42 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 43
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 44 PC78US-8
200 General Information on troubleshooting
Connection table for connector pin numbers SEN04808-01
PC78US-8 40-4 45
200 General Information on troubleshooting
SEN04808-01 Connection table for connector pin numbers
40-4 46 PC78US-8
200 General Information on troubleshooting
T- branch box and T- branch adapter table SEN04808-01
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
PC78US-8 40-4 47
200 General Information on troubleshooting
SEN04808-01 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
40-4 48 PC78US-8
200 General Information on troubleshooting
T- branch box and T- branch adapter table SEN04808-01
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
PC78US-8 40-4 49
SEN04808-01
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
40-4 50
SEN04809-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-301 1
301 Troubleshooting by failure code, Part 1
SEN04809-00
40-301 2 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [989L00] Engine controller lock caution 1 SEN04809-00
PC78US-8 40-301 3
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [989M00] Engine controller lock caution 2
40-301 4 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [989N00] Engine controller lock caution 3 SEN04809-00
PC78US-8 40-301 5
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [AB00KE] Charge voltage low
40-301 6 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [AB00KE] Charge voltage low SEN04809-00
PC78US-8 40-301 7
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [B@BAZG] Eng oil press. low
40-301 8 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [B@BCNS] Eng coolant overheat SEN04809-00
PC78US-8 40-301 9
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA111] ECM critical internal failure
40-301 10 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA111] ECM critical internal failure SEN04809-00
PC78US-8 40-301 11
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA111] ECM critical internal failure
40-301 12 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA115] Eng. Ne and Bkup speed sensor error SEN04809-00
User code Failure code Eng. Ne and Bkup speed sensor error
Trouble
E10 CA115 (Engine controller system)
Contents of
• Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of
• None in particular.
controller
Problem that
• Engine cannot be started (if engine has been stopped).
appears on
• Engine stops (if engine has been running).
machine
Related
information
PC78US-8 40-301 13
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA122] Charge air press sensor high error
User code Failure code Charge air press sensor high error
Trouble
E11 CA122 (Engine controller system)
Contents of
• High voltage was detected in charge (boost) pressure sensor circuit.
trouble
Action of
• Fixes charge (boost) pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on • Acceleration performance of engine drops.
machine
• Signal voltage of charge (boost) pressure sensor can be checked with monitoring function.
Related
(Code: 36501 Boost pressure sensor voltage).
information
• Method of reproducing failure code: Turn starting switch ON.
40-301 14 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA122] Charge air press sensor high error SEN04809-00
PC78US-8 40-301 15
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA123] Charge air press sensor low error
User code Failure code Charge air press sensor low error
Trouble
E11 CA123 (Engine controller system)
Contents of
• Low voltage was detected in charge (boost) pressure sensor circuit.
trouble
Action of
• Fixes charge pressure (101 kPa {1.02 kg/cm2}) and continues operation.
controller
Problem that
appears on • Acceleration performance of engine drops.
machine
• Signal voltage of charge (boost) pressure sensor can be checked with monitoring function.
Related
(Code: 36501 Boost pressure sensor voltage).
information
• Method of reproducing failure code: Turn starting switch ON.
40-301 16 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA123] Charge air press sensor low error SEN04809-00
PC78US-8 40-301 17
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA131] Throttle sensor high error
40-301 18 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA131] Throttle sensor high error SEN04809-00
PC78US-8 40-301 19
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA132] Throttle sensor low error
40-301 20 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA132] Throttle sensor low error SEN04809-00
PC78US-8 40-301 21
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA144] Coolant temp. sensor high error
40-301 22 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA144] Coolant temp. sensor high error SEN04809-00
PC78US-8 40-301 23
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA145] Coolant temp. sensor low error
40-301 24 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA145] Coolant temp. sensor low error SEN04809-00
PC78US-8 40-301 25
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA153] Charge air temp. sensor high error
User code Failure code Charge air temp. sensor high error
Trouble
E15 CA153 (Engine controller system)
Contents of
• High voltage was detected in charge (boost) temperature sensor circuit.
trouble
Action of
• Fixes charge (boost) temperature (intake air temperature) (70°C) and continues operation.
controller
Problem that
appears on
machine
• Signal voltage of charge (boost) temperature sensor can be checked with monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.
40-301 26 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA153] Charge air temp. sensor high error SEN04809-00
PC78US-8 40-301 27
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA154] Charge air temp. sensor low error
User code Failure code Charge air temp. sensor low error
Trouble
E15 CA154 (Engine controller system)
Contents of
• Low voltage was detected in charge (boost) temperature sensor circuit.
trouble
Action of
• Fixes charge (boost) temperature (intake air temperature) (46°C) and continues operation.
controller
Problem that
appears on
machine
• Signal voltage of charge (boost) temperature sensor can be checked with monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.
40-301 28 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA187] Sensor sup. 2 volt. low error SEN04809-00
PC78US-8 40-301 29
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA221] Ambient air press. sensor high error
User code Failure code Ambient air press. sensor high error
Trouble
E11 CA221 (Engine controller system)
Contents of
• High voltage was detected in ambient pressure sensor circuit.
trouble
Action of • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues opera-
controller tion.
Problem that
appears on • Output drops.
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37401 Ambient pressure sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.
40-301 30 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA221] Ambient air press. sensor high error SEN04809-00
PC78US-8 40-301 31
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA222] Ambient air press. sensor low error
User code Failure code Ambient air press. sensor low error
Trouble
E11 CA222 (Engine controller system)
Contents of
• Low voltage was detected in ambient pressure sensor circuit.
trouble
Action of
• Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
appears on • Output drops.
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37401 Ambient pressure sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.
40-301 32 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA227] Sensor sup. 2 volt. high error SEN04809-00
PC78US-8 40-301 33
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA234] Eng. overspeed
40-301 34 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA234] Eng. overspeed SEN04809-00
PC78US-8 40-301 35
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA238] Ne speed sensor sup. volt. error
40-301 36 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA238] Ne speed sensor sup. volt. error SEN04809-00
PC78US-8 40-301 37
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA271] IMV/PCV1 short error
40-301 38 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA272] IMV/PCV1 open error SEN04809-00
PC78US-8 40-301 39
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA322] Injector #1 (L #1) system open/short error
40-301 40 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA322] Injector #1 (L #1) system open/short error SEN04809-00
PC78US-8 40-301 41
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA324] Injector #3 (L #3) system open/short error
40-301 42 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA324] Injector #3 (L #3) system open/short error SEN04809-00
PC78US-8 40-301 43
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA331] Injector #2 (L #2) system open/short error
40-301 44 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA331] Injector #2 (L #2) system open/short error SEN04809-00
PC78US-8 40-301 45
301 Troubleshooting by failure code, Part 1
SEN04809-00 Failure code [CA332] Injector #4 (L #4) system open/short error
40-301 46 PC78US-8
301 Troubleshooting by failure code, Part 1
Failure code [CA332] Injector #4 (L #4) system open/short error SEN04809-00
PC78US-8 40-301 47
SEN04809-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-301 48
SEN04810-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-302 1
302 Troubleshooting by failure code, Part 2
SEN04810-00
40-302 2 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA351] Inj. drive circuit error SEN04810-00
PC78US-8 40-302 3
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA351] Inj. drive circuit error
40-302 4 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA351] Inj. drive circuit error SEN04810-00
PC78US-8 40-302 5
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA352] Sensor sup. 1 volt. low error
40-302 6 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA352] Sensor sup. 1 volt. low error SEN04810-00
PC78US-8 40-302 7
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA386] Sensor sup. 1 volt. high error
40-302 8 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA386] Sensor sup. 1 volt. high error SEN04810-00
PC78US-8 40-302 9
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA435] Abnormality in engine oil pressure switch
40-302 10 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA441] Battery voltage low error SEN04810-00
PC78US-8 40-302 11
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA442] Battery voltage high error
40-302 12 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA449] Rail press. very high error SEN04810-00
PC78US-8 40-302 13
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA451] Rail press. sensor high error
40-302 14 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA451] Rail press. sensor high error SEN04810-00
PC78US-8 40-302 15
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA452] Rail press. sensor low error
40-302 16 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA488] Chg air temp high torque derate SEN04810-00
User code Failure code Charge air temperature high torque derate
Trouble
E11 CA488 (Engine controller system)
Contents of • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature
trouble limit.
Action of
• Limits output and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related • Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
information • Method of reproducing failure code: Start engine.
PC78US-8 40-302 17
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA553] Rail press. high error
40-302 18 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA559] Rail press. low error SEN04810-00
PC78US-8 40-302 19
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA559] Rail press. low error
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
40-302 20 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA559] Rail press. low error SEN04810-00
*1 – *10:
See Testing and adjusting, "Special functions of machine monitor", Monitoring items table.
*: A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)".
Rating or equivalent:
Relieve the circuit under the following condition.
1) Engine: Full throttle
2) Mode: P
3) Boom: Raise
PC78US-8 40-302 21
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA689] Eng. Ne speed sensor error
Related
• Method of reproducing failure code: Start engine.
information
40-302 22 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA689] Eng. Ne speed sensor error SEN04810-00
PC78US-8 40-302 23
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA731] Eng. Bkup speed sensor phase error
User code Failure code Eng. Bkup speed sensor phase error
Trouble
E15 CA731 (Engine controller system)
Contents of
• Engine Bkup speed sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
machine • Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
• Method of reproducing failure code: Start engine.
information
40-302 24 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA757] All persistent data lost error SEN04810-00
PC78US-8 40-302 25
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA778] Eng. Bkup speed sensor error
Related
• Method of reproducing failure code: Start engine.
information
40-302 26 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA778] Eng. Bkup speed sensor error SEN04810-00
PC78US-8 40-302 27
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA1633] KOMNET datalink timeout error
40-302 28 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA1633] KOMNET datalink timeout error SEN04810-00
PC78US-8 40-302 29
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA2185] Throttle sens. sup. volt. high error
User code Failure code Throttle Sens. sup. volt. high error
Trouble
E14 CA2185 (Engine controller system)
Contents of
• High voltage was detected in throttle sensor power supply (5 V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-302 30 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA2185] Throttle sens. sup. volt. high error SEN04810-00
PC78US-8 40-302 31
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [CA2186] Throttle sens. sup. volt. low error
User code Failure code Throttle sens. sup. volt. low error
Trouble
E14 CA2186 (Engine controller system)
Contents of
• Low voltage was detected in throttle sensor power supply (5 V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-302 32 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [CA2311] Abnormality in IMV solenoid SEN04810-00
PC78US-8 40-302 33
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [D110KB] Battery relay drive short
40-302 34 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [D110KB] Battery relay drive short SEN04810-00
PC78US-8 40-302 35
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [D19JKZ] Personal code relay abnormality
40-302 36 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [D19JKZ] Personal code relay abnormality SEN04810-00
PC78US-8 40-302 37
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [D862KA] GPS antenna discon
Configuration drawing
40-302 38 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [D862KA] GPS antenna discon SEN04810-00
PC78US-8 40-302 39
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [DA22KK] Pump solenoid power low error
40-302 40 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [DA22KK] Pump solenoid power low error SEN04810-00
PC78US-8 40-302 41
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [DA25KP] 5V sensor 1 power abnormality
40-302 42 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [DA25KP] 5V sensor 1 power abnormality SEN04810-00
PC78US-8 40-302 43
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [DA26KP] 5V sensor 2 power abnormality
40-302 44 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [DA26KP] 5V sensor 2 power abnormality SEN04810-00
PC78US-8 40-302 45
302 Troubleshooting by failure code, Part 2
SEN04810-00 Failure code [DA29KQ] Model selection abnormality
40-302 46 PC78US-8
302 Troubleshooting by failure code, Part 2
Failure code [DA29KQ] Model selection abnormality SEN04810-00
PC78US-8 40-302 47
SEN04810-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-302 48
SEN04811-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-303 1
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DA2RMC] CAN discon (Pump controller detected)
40-303 2 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DA2RMC] CAN discon (Pump controller detected) SEN04811-00
PC78US-8 40-303 3
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DAFGMC] GPS module error
40-303 4 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DAFGMC] GPS module error SEN04811-00
PC78US-8 40-303 5
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DAFRMC] CAN discon (Monitor detected)
40-303 6 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DAFRMC] CAN discon (Monitor detected) SEN04811-00
PC78US-8 40-303 7
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DGH2KB] Hydr oil sensor short
40-303 8 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DGH2KB] Hydr oil sensor short SEN04811-00
PC78US-8 40-303 9
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DHPAMA] Pump press sensor abnormality
40-303 10 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DHPAMA] Pump press sensor abnormality SEN04811-00
PC78US-8 40-303 11
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DHS5KX] Travel PPC press sensor abnormality
40-303 12 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DHS5KX] Travel PPC press sensor abnormality SEN04811-00
PC78US-8 40-303 13
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DHSAMA] Swing right PPC press sensor abnormality
User code Failure code Swing right PPC pressure sensor abnormality
Trouble
E20 DHSAMA (Pump controller system)
Contents of
• Signal voltage of swing right PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes swing right PPC pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
• Automatic decelerator cannot be reset.
appears on
• Swing right performance lowers.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related
• Swing right PPC pressure can be checked with monitoring function.
information
(Code: 09002 Swing right PPC pressure)
• Method of reproducing failure code: Turn starting switch ON or start engine.
40-303 14 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DHSAMA] Swing right PPC press sensor abnormality SEN04811-00
PC78US-8 40-303 15
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DHSBMA] Swing left PPC press sensor abnormality
User code Failure code Swing left PPC pressure sensor abnormality
Trouble
E20 DHSBMA (Pump controller system)
Contents of
• Signal voltage of swing left PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes swing left PPC pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
• Automatic decelerator cannot be reset.
appears on
• Swing left performance lowers.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related
• Swing left PPC pressure can be checked with monitoring function.
information
(Code: 09001 Swing left PPC pressure)
• Method of reproducing failure code: Turn starting switch ON or start engine.
40-303 16 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DHSBMA] Swing left PPC press sensor abnormality SEN04811-00
PC78US-8 40-303 17
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DHX1MA] Overload sensor abnormality (Analog)
40-303 18 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DV20KB] Travel alarm S/C SEN04811-00
PC78US-8 40-303 19
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DW43KA] Travel speed sol discon
40-303 20 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DW43KB] Travel speed sol short SEN04811-00
PC78US-8 40-303 21
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DW45KA] Swing brake sol discon
User code Failure code Swing holding brake solenoid system disconnection
Trouble
E03 DW45KA (Pump controller system)
Contents of • When output to swing holding brake solenoid was turned OFF, disconnection was detected in cir-
trouble cuit.
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Machine cannot swing (Swing holding brake is not reset).
machine
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).
Related • Keep swing lock switch in OFF position and swing holding brake release switch in release position
information during troubleshooting.
• Operating condition of swing holding brake solenoid can be checked with monitoring function.
(Code: 02300 Solenoid 1)
• Method of reproducing failure code: Turn starting switch ON.
40-303 22 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DW45KA] Swing brake sol discon SEN04811-00
PC78US-8 40-303 23
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DW45KB] Swing brake sol short
User code Failure code Swing holding brake solenoid system short
Trouble
E03 DW45KB (Pump controller system)
Contents of
• When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to swing holding brake solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Machine cannot swing (Swing holding brake is not reset).
machine
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).
Related
• Keep swing holding brake release switch in release position during troubleshooting.
information
• Operating condition of swing holding brake solenoid can be checked with monitoring function.
(Code: 02300 Solenoid 1)
• Method of reproducing failure code: Start engine + Swing with left work equipment control lever.
40-303 24 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DW45KB] Swing brake sol short SEN04811-00
PC78US-8 40-303 25
303 Troubleshooting by failure code, Part 3
SEN04811-00 Failure code [DWJ0KA] Merge-divider sol discon
40-303 26 PC78US-8
303 Troubleshooting by failure code, Part 3
Failure code [DWJ0KB] Merge-divider sol short SEN04811-00
PC78US-8 40-303 27
SEN04811-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-303 28
SEN04812-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-304 1
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DXA8KA] PC-EPC sol discon
40-304 2 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DXA8KA] PC-EPC sol discon SEN04812-00
PC78US-8 40-304 3
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DXA8KB] PC-EPC sol short
40-304 4 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DXA8KB] PC-EPC sol short SEN04812-00
PC78US-8 40-304 5
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DXE4KA] Service current EPC discon
40-304 6 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DXE4KB] Service current EPC short SEN04812-00
PC78US-8 40-304 7
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DY20KA] Wiper working abnormality
40-304 8 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DY20KA] Wiper working abnormality SEN04812-00
PC78US-8 40-304 9
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DY20MA] Wiper parking abnormality
40-304 10 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DY20MA] Wiper parking abnormality SEN04812-00
PC78US-8 40-304 11
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DY2CKA] Washer drive discon
40-304 12 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DY2CKA] Washer drive discon SEN04812-00
PC78US-8 40-304 13
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DY2CKB] Washer drive short
40-304 14 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DY2CKB] Washer drive short SEN04812-00
PC78US-8 40-304 15
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DY2DKB] Wiper drive (for) short
User code Failure code Wiper motor drive forward system short
Trouble
— DY2DKB (Pump controller system)
Contents of
• When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive forward side OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
information
40-304 16 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DY2DKB] Wiper drive (for) short SEN04812-00
PC78US-8 40-304 17
304 Troubleshooting by failure code, Part 4
SEN04812-00 Failure code [DY2EKB] Wiper drive (rev) short
User code Failure code Wiper motor drive reverse system short
Trouble
— DY2EKB (Pump controller system)
Contents of
• When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive reverse side OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
information
40-304 18 PC78US-8
304 Troubleshooting by failure code, Part 4
Failure code [DY2EKB] Wiper drive (rev) short SEN04812-00
PC78US-8 40-304 19
SEN04812-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-304 20
SEN04813-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-400 1
400 Troubleshooting of electrical system (E-mode)
SEN04813-00
E-20 Travel alarm does not sound or does not stop sounding...................................................................... 42
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) .................... 43
E-22 While starting switch is in OFF position, service meter is not displayed .............................................. 56
E-23 Machine monitor cannot be set in service mode .................................................................................. 57
E-24 Monitoring function does not display lever control signal normally....................................................... 58
E-25 KOMTRAX system does not operate normally..................................................................................... 74
40-400 2 PC78US-8
400 Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system SEN04813-00
PC78US-8 40-400 3
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 Before carrying out troubleshooting of electrical system
<EU specification>
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
1 10 A Resistor
2 30 A Solenoid valve
F02
Switch power supply 3 15 A Cigarette lighter
(45 A)
4 10 A Windshield washer
5 10 A Horn
6 5A Working lamp relay
7 10 A Beacon (if equipped)
F02
Switch power supply 8 25 A Working lamp
(45 A)
9 10 A Spare
10 5A Air conditioner
11 20 A Air conditioner unit
F02 12 10 A Optional power supply (1)
Switch power supply
(45 A) 13 10 A Optional power supply (2), radio
14 10 A Spare
15 5A Air conditioner
F03 16 10 A Room lamp
Constant power supply
(45 A) 17 20 A Machine monitor, pump controller, starting switch
18 30 A Engine controller
Starting switch 19 5A Engine controller
Switch power supply
ACC 20 5A PPC oil pressure lock solenoid
40-400 4 PC78US-8
400 Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system SEN04813-00
PC78US-8 40-400 5
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 Information in troubleshooting table
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine
Related
Information related to detected trouble or troubleshooting
information
40-400 6 PC78US-8
400 Troubleshooting of electrical system (E-mode)
Information in troubleshooting table SEN04813-00
PC78US-8 40-400 7
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-1 When starting switch is turned ON, machine monitor displays nothing
E-1 When starting switch is turned ON, machine monitor displays nothing1
Trouble • When starting switch is turned ON, machine monitor displays nothing.
• When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen to check breaker mode (if set), screen of check before starting, screen to check
Related
working mode and travel speed, and ordinary screen in order.
information
• When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery.
40-400 8 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-1 When starting switch is turned ON, machine monitor displays nothing SEN04813-00
PC78US-8 40-400 9
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-2 Engine does not start (Engine does not turn)
40-400 10 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-2 Engine does not start (Engine does not turn) SEN04813-00
PC78US-8 40-400 11
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-2 Engine does not start (Engine does not turn)
40-400 12 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-2 Engine does not start (Engine does not turn) SEN04813-00
PC78US-8 40-400 13
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-3 Preheater does not operate
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash.
• Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 sec-
onds after to notify completion of preheating (It stops flashing about 10 seconds after).
Related • If engine coolant temperature is below 20°C, automatic warm-up system operates and preheating
information monitor lights up for up to 30 seconds.
• Condition of starting switch (preheating) signal can be checked with the monitoring function.
(Code: 04500 Monitor input 1)
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related • Check that engine can be turned with starting motor (If engine cannot be turned, carry out trouble-
information shooting for E-1 Engine does not start (Engine does not turn)).
40-400 14 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-3 Preheater does not operate SEN04813-00
PC78US-8 40-400 15
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-4 Automatic warm-up system does not operate (in cold season)
E-4 Automatic warm-up system does not operate (in cold season) 1
Trouble • Automatic warm-up system does not operate (in cold season).
• When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed
to 1,300 rpm.
• If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after
Related
engine is started, automatic warm-up system is turned OFF. (Automatic warm-up system stops
information
automatically after operating for 10 minutes.)
• If engine coolant temperature is below 10°C, turbocharger protection function operates to keep the
engine speed at low idle.
40-400 16 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-4 Automatic warm-up system does not operate (in cold season) SEN04813-00
PC78US-8 40-400 17
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked
E-5 All work equipment, swing, and travel mechanism do not move or
cannot be locked 1
Trouble (1) All work equipment, swing, and travel mechanism do not move.
Related
information
40-400 18 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked SEN04813-00
Trouble (2) All work equipment, swing, and travel mechanism cannot be locked.
Related
information
PC78US-8 40-400 19
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-6 Precaution lights up while engine is running
40-400 20 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-6 Precaution lights up while engine is running SEN04813-00
PC78US-8 40-400 21
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-6 Precaution lights up while engine is running
40-400 22 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-7 Emergency stop item lights up while engine is running SEN04813-00
PC78US-8 40-400 23
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-8 Engine coolant temperature gauge does not indicate normally
(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
40-400 24 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate normally SEN04813-00
PC78US-8 40-400 25
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-9 Hydraulic oil temperature gauge does not indicate normally
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to
Related machine monitor through communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)
40-400 26 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-9 Hydraulic oil temperature gauge does not indicate normally SEN04813-00
PC78US-8 40-400 27
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-9 Hydraulic oil temperature gauge does not indicate normally
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to
Related machine monitor through communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)
40-400 28 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-10 Fuel level gauge does not indicate normally SEN04813-00
(1) While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
(2) While fuel level is low, fuel level gauge does not lower from green range top (F).
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel level sensor voltage)
PC78US-8 40-400 29
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-10 Fuel level gauge does not indicate normally
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel level sensor voltage)
40-400 30 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-11 Contents of display by machine monitor are different from applicable machine SEN04813-00
Trouble Contents of display by machine monitor are different from applicable machine.
Related
information
PC78US-8 40-400 31
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-14 Auto-decelerator does not operate normally
(1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not
Trouble
go off.
Related • Condition of signal of auto-decelerator switch can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
40-400 32 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-15 Working mode does not change SEN04813-00
Trouble (1) When working mode switch is operated, working mode selection screen is not displayed.
Related • Condition of signal of working mode switch can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
Trouble (2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related
information
PC78US-8 40-400 33
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-16 Travel speed does not change
Trouble (1) When travel speed switch is operated, travel speed monitor does not change.
Related • Condition of signal of travel speed switch can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
Trouble (2) When travel speed is shifted, actual travel speed does not change.
Related
• If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo.
information
40-400 34 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-17 Alarm buzzer cannot be stopped SEN04813-00
PC78US-8 40-400 35
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-18 Windshield wiper and window washer do not operate
Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off.
Related • Condition of wiper switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
Trouble (2) When wiper switch is operated, wiper does not operate.
Related • Condition of window rear limit switch signal can be checked with monitoring function.
information (Code: 02204 Switch input 5)
40-400 36 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-18 Windshield wiper and window washer do not operate SEN04813-00
PC78US-8 40-400 37
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-18 Windshield wiper and window washer do not operate
Trouble (3) When window washer switch is operated, window washer does not operate.
Related • Condition of window washer switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
40-400 38 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-18 Windshield wiper and window washer do not operate SEN04813-00
PC78US-8 40-400 39
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-19 Swing holding brake does not operate normally
Trouble When swing holding brake release switch is set to FREE position, machine cannot swing.
Related • Signal state of swing holding brake release switch can be checked with monitoring function.
information (Code: 02200 Switch input 1)
40-400 40 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-19 Swing holding brake does not operate normally SEN04813-00
PC78US-8 40-400 41
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-20 Travel alarm does not sound or does not stop sounding
E-20 Travel alarm does not sound or does not stop sounding 1
40-400 42 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) SEN04813-00
Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related • Condition of air conditioner switch signal can be checked with monitoring function.
information (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch)
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information
PC78US-8 40-400 43
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-21 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble (3) Air does not come out (Air flow is insufficient).
Related
information
40-400 44 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) SEN04813-00
PC78US-8 40-400 45
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-21 Air conditioner does not operate normally (including air conditioner abnormality record)
40-400 46 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) SEN04813-00
(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communica-
Trouble
tion condition “Abnormal”
• While abnormality in communication is being detected, “CAN disconnection” is displayed.
• If abnormality in communication has been detected and reset, “Abnormality” is displayed.
Related
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, condition of other items is not displayed.
• Method of reproducing abnormality record: Turn starting switch ON.
PC78US-8 40-400 47
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-21 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble (7) Air conditioner abnormality record: Internal air sensor “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
40-400 48 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) SEN04813-00
PC78US-8 40-400 49
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-21 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble (9) Air conditioner abnormality record: Air flow sensor “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
40-400 50 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) SEN04813-00
PC78US-8 40-400 51
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-21 Air conditioner does not operate normally (including air conditioner abnormality record)
Trouble (11) Air conditioner abnormality record: Air outlet damper “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
40-400 52 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) SEN04813-00
PC78US-8 40-400 53
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-21 Air conditioner does not operate normally (including air conditioner abnormality record)
40-400 54 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-21 Air conditioner does not operate normally (including air conditioner abnormality record) SEN04813-00
PC78US-8 40-400 55
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-22 While starting switch is in OFF position, service meter is not displayed
E-22 While starting switch is in OFF position, service meter is not displayed1
Trouble • When starting switch is turned OFF, service meter is not displayed.
• While starting switch is at OFF position, if following switches are operated, service meter is dis-
Related
played at top center of screen.
information
Operation of switches: [4] + [1] (Press simultaneously)
40-400 56 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-23 Machine monitor cannot be set in service mode SEN04813-00
PC78US-8 40-400 57
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
E-24 Monitoring function does not display lever control signal normally 1
Trouble (1) Boom RAISE operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
40-400 58 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 59
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
Trouble (2) Arm DIGGING operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
40-400 60 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 61
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
Trouble (3) Bucket DIGGING operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01901 Pressure switch 2
information
40-400 62 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 63
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
Trouble (4) Bucket DUMP operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01901 Pressure switch 2
information
40-400 64 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 65
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
Trouble (5) Boom LOWER operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
40-400 66 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 67
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
Trouble (6) Arm DUMP operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
40-400 68 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 69
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
40-400 70 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 71
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-24 Monitoring function does not display lever control signal normally
Trouble (9) Blade DOWN operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01902 Pressure switch 3
information
40-400 72 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-24 Monitoring function does not display lever control signal normally SEN04813-00
PC78US-8 40-400 73
400 Troubleshooting of electrical system (E-mode)
SEN04813-00 E-25 KOMTRAX system does not operate normally
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from
KOMTRAX setting” in the service menu of the “12 Display of KOMTRAX setting” in the ser-
machine monitor. vice menu of the machine monitor.
40-400 74 PC78US-8
400 Troubleshooting of electrical system (E-mode)
E-25 KOMTRAX system does not operate normally SEN04813-00
PC78US-8 40-400 75
SEN04813-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-400 76
SEN04814-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-500 1
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00
40-500 2 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
Information contained in troubleshooting table SEN04814-00
a Troubleshooting table collectively carry the following information. Carry out troubleshooting work after
fully grasping their contents.
Trouble Phenomena occurring on machine
Related
Information on occurred failures and troubleshooting
information
2
Possible causes Cause for presumed
and standard failure <Contents>
value in normal (The attached No. for • The standard values in normalcy by which to judge "good"
3
state filing and reference or "no good" about presumed causes.
purpose only. It does not • References for making judgement of "good" or "no good"
stand for any priority)
4
PC78US-8 40-500 3
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 System chart for hydraulic and mechanical systems
40-500 4 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
System chart for hydraulic and mechanical systems SEN04814-00
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as
a reference material when troubleshooting the hydraulic and mechanical systems.
PC78US-8 40-500 5
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-1 Speed or power of all work equipment, swing, and travel are low
H-1 Speed or power of all work equipment, swing, and travel are low 1
Trouble • Speed or power of all work equipment, swing, and travel are low.
• Conduct the troubleshooting in working mode P.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
40-500 6 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-2 Engine speed sharply drops or engine stalls SEN04814-00
PC78US-8 40-500 7
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-3 No work equipment, travel and swing move
Possible causes It is presumed that the breather in the cap of hydraulic tank is
Hydraulic tank cap breather
and standard 3 clogged, thereby causing negative pressure inside the tank. Make
clogged
value in normal a visual check.
state It is presumed that the strainer in the hydraulic tank is clogged,
Hydraulic tank strainer
4 thereby causing negative pressure in the suction circuit. Make a
clogged
visual check.
The piston pump is suspected of an internal failure. Check the
5 Defective piston pump
pump itself.
40-500 8 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-5 Fine control performance or response of work equipment and travel is low SEN04814-00
Trouble • Fine control performance or response of work equipment and travel is low.
• Set the working mode at P mode for the troubleshooting.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
PC78US-8 40-500 9
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-6 Speed or power of boom is low
Possible causes Malfunction of pump merge- The pump merge-divider valve of the control valve may have a
3
and standard divider valve malfunction. Check it directly.
value in normal Malfunction of boom control The spool of the boom control valve may have a malfunction.
4
state valve (spool) Check it directly.
Malfunction of boom control
The pressure compensation valve of the boom control valve may
5 valve (pressure compensa-
have a malfunction. Check it directly.
tion valve)
Malfunction of boom control The lock valve of the boom control valve may have a malfunction.
6
valve (lock valve) Check it directly.
Malfunction or defective The suction valve of the boom control valve (on the bottom side
7 sealing of boom control valve and head side) may have a malfunction or its sealing may be
(suction valve) defective. Check it directly.
Malfunction or defective
The centralized safety-suction valve of the control valve may have
8 sealing of centralized safety-
a malfunction or its sealing may be defective. Check it directly.
suction valve
a Keep the engine stopped for the preparations, and keep it
running at high idle during the troubleshooting.
9 Defective boom cylinder
Boom cylinder Leakage from cylinder
Relieved in RAISE direction 7.5 cc/min
40-500 10 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Speed or power of arm is low SEN04814-00
PC78US-8 40-500 11
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-8 Speed or power of bucket is low
40-500 12 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-9 Speed or power of blade is low SEN04814-00
Failure
• Speed or power of blade is low.
information
• Set the working mode to P mode and carry out the troubleshooting.
Relative
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
PC78US-8 40-500 13
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-10 Work equipment does not move in its single operation
40-500 14 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-11 Hydraulic drift of work equipment is large SEN04814-00
Trouble • Hydraulic drift of work equipment is large. (1) Hydraulic drift of boom is large.
• Conduct the troubleshooting in working mode P.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Trouble • Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large.
• Conduct the troubleshooting in working mode P.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Trouble • Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large.
• Conduct the troubleshooting in working mode P.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
PC78US-8 40-500 15
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-11 Hydraulic drift of work equipment is large
Trouble • Hydraulic drift of work equipment is large. (4) Hydraulic drift of blade is large.
• Set the working mode to P mode and carry out the troubleshooting.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
40-500 16 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-12 Time lag of work equipment is large SEN04814-00
Trouble • Boom RAISE speed is low in compound operation of swing + boom RAISE.
• If the speed of single operation of the boom RAISE speed is slow, conduct troubleshooting for H-7
Related first.
information • Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
PC78US-8 40-500 17
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel
Trouble • Travel speed lowers largely during compound operation of work equipment/swing + travel.
• Conduct the troubleshooting in working mode P.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
40-500 18 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-16 Machine deviates during travel SEN04814-00
PC78US-8 40-500 19
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-17 Travel speed is low
40-500 20 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-18 Machine cannot be steered easily or steering power is low SEN04814-00
PC78US-8 40-500 21
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-19 Travel speed does not change or it is kept low or high
40-500 22 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-21 Machine does not swing SEN04814-00
Trouble • Machine does not swing. (1) Machine does not swing in either direction.
• Conduct the troubleshooting in working mode P.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Trouble • Machine does not swing. (2) Machine does not swing in only one direction.
• Conduct the troubleshooting in working mode P.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
PC78US-8 40-500 23
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-22 Swing acceleration, swing speed and swing power are low
H-22 Swing acceleration, swing speed and swing power are low 1
• Swing acceleration, swing speed and (1) Swing acceleration, swing speed and swing power
Trouble
swing power are low. are low in both directions.
• Set the working mode to P mode and carry out the troubleshooting.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
40-500 24 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-22 Swing acceleration, swing speed and swing power are low SEN04814-00
• Swing acceleration, swing speed and (2) Swing acceleration, swing speed and swing power
Trouble
swing power are low. are low in only either direction.
• Set the working mode to P mode and carry out the troubleshooting.
Related
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
information
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
PC78US-8 40-500 25
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-23 Excessive overrun when stopping swing
40-500 26 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-24 When upper structure stops swinging, it makes large shock SEN04814-00
PC78US-8 40-500 27
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04814-00 H-26 Hydraulic drift of swing is large
Trouble • Hydraulic drift of swing is large. (1) When swing holding brake is operated
• If the swing holding brake release switch is in the normal position, the swing holding brake operates
and the disc brake holds the upper structure.
Related
• Conduct the troubleshooting in working mode P.
information
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
Trouble • Hydraulic drift of swing is large. (2) When swing holding brake is released
• If the swing holding brake release is in the emergency position, the swing holding brake is released
and the upper structure is held with only hydraulic pressure.
Related
• Conduct the troubleshooting in working mode P.
information
• Before starting troubleshooting, check that the oil level in the hydraulic tank is proper.
• When starting troubleshooting, warm up the hydraulic oil to 45 – 55°C.
40-500 28 PC78US-8
500 Troubleshooting of hydraulic and mechanical system (H-mode)
H-27 Flow rate in attachment circuit cannot be adjusted SEN04814-00
PC78US-8 40-500 29
SEN04814-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-500 30
SEN04815-00
HYDRAULIC EXCAVATOR
PC78US-8
40 Troubleshooting 40
PC78US-8 40-600 1
600 Troubleshooting of engine (S-mode)
SEN04815-00 Method of using troubleshooting chart
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The
items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on
the right.
Causes
Items to be narrowed from the questions and check items. The serviceman narrows down the probable
causes from A, B, and C.
Troubleshooting
Items used to find out the true cause by verifying the narrowed causes finally in order from the most
probable one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
40-600 2 PC78US-8
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart SEN04815-00
PC78US-8 40-600 3
600 Troubleshooting of engine (S-mode)
SEN04815-00 Method of using troubleshooting chart
40-600 4 PC78US-8
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart SEN04815-00
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in
the [Causes] section.
The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is
explained according to Step 1 – Step 3 shown below.
PC78US-8 40-600 5
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-1 Starting performance is poor
Defective injector
nomenon does not indicate a trouble, however.
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated
q
by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
40-600 6 PC78US-8
600 Troubleshooting of engine (S-mode)
S-2 Engine does not start SEN04815-00
on E-mode
When terminal B and terminal C of starting switch are connected, q
engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are
connect cord, and carry out q
connected, engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are
q
connected, engine does not start
When terminal at safety switch and terminal B at starting motor are
q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
PC78US-8 40-600 7
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-2 Engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
40-600 8 PC78US-8
600 Troubleshooting of engine (S-mode)
S-2 Engine does not start SEN04815-00
c) Exhaust smoke comes out but engine does not start Causes
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
PC78US-8 40-600 9
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-3 Engine does not pick up smoothly
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
40-600 10 PC78US-8
600 Troubleshooting of engine (S-mode)
S-4 Engine stops during operations SEN04815-00
w Q Q
Questions
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Add
Remedy
PC78US-8 40-600 11
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-5 Engine does not rotate smoothly
Remedy
40-600 12 PC78US-8
600 Troubleshooting of engine (S-mode)
S-6 Engine lacks output (or lacks power) SEN04815-00
(air leakage)
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Suddenly Q w Q Q Q Q
Questions
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy
PC78US-8 40-600 13
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-7 Exhaust smoke is black (incomplete combustion)
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)”
q
indicated by code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
40-600 14 PC78US-8
600 Troubleshooting of engine (S-mode)
S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN04815-00
Turbocharger
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC78US-8 40-600 15
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-9 Oil becomes contaminated quickly
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
—
Remedy
40-600 16 PC78US-8
600 Troubleshooting of engine (S-mode)
S-10 Fuel consumption is excessive SEN04815-00
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated
by code q
Remedy
PC78US-8 40-600 17
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Replace
Replace
Replace
Replace
Remedy
40-600 18 PC78US-8
600 Troubleshooting of engine (S-mode)
S-12 Oil pressure drops SEN04815-00
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Add
—
Remedy
PC78US-8 40-600 19
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-13 Oil level rises (Entry of coolant or fuel)
Remedy
40-600 20 PC78US-8
600 Troubleshooting of engine (S-mode)
S-14 Coolant temperature becomes too high (overheating) SEN04815-00
Sudden overheated Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Rises quickly Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
w
Check items
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard side are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Hydraulic oil temperature enters red range faster than engine coolant w
temperature
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
PC78US-8 40-600 21
600 Troubleshooting of engine (S-mode)
SEN04815-00 S-15 Abnormal noise is made
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
40-600 22 PC78US-8
600 Troubleshooting of engine (S-mode)
S-16 Vibration is excessive SEN04815-00
Replace
Replace
Replace
Remedy
PC78US-8 40-600 23
SEN04815-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-600 24
SEN04833-01
PC78US-8
SEN04833-01
HYDRAULIC EXCAVATOR
Shop Manual
PC78US-8
PC78US-8 50-4 1
100 General information on disassembly and assembly
SEN04833-01 How to read this manual
50-4 2 PC78US-8
100 General information on disassembly and assembly
How to read this manual SEN04833-01
3) Circle mark Q in sketch column: are described as [1], [2]•••etc. and their part
q The sketch of the special tool is present-
names, part numbers and quantities are not de-
ed in the section of “Sketches of special scribed.
q The meanings of the symbols used in
tools”.
“Assembly” section are as follows.
k : Precautions related to safety in execution of
q This mark means part No. of special tools
starting with 79*T-***-**** and that they
can not be supplied from Komatsu in Ja- the work
pan (i.e. locally made parts). a : This mark gives guidance or precautions when
doing the procedure.
2 : Type of coating material
a General tools that are necessary for removal
3 : Tightening torque
5 : Quantity of oil or coolant to be added
or installation are described as [1],[2]•••etc.
and their part names, part numbers and
quantities are not described.
Sketches of special tools
q Various special tools are illustrated for the con-
venience of local manufacture.
PC78US-8 50-4 3
100 General information on disassembly and assembly
SEN04833-01 Coating materials list
Polyethylene
LT-4 790-129-9040 250 g q Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
q Quick-setting adhesive.
ThreeBond Polyethylene q Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Used mainly to stick metals, rubbers, plastics,
and woods.
q Quick-setting adhesive.
q Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
q Used mainly to stick rubbers, plastics, and met-
als.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Used for fitted portions used at high tempera-
648-50 container
tures.
q Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
q Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container q Used to seal tapered plugs, elbows, and nipples
of hydraulic piping.
Gasket sealant
50-4 4 PC78US-8
100 General information on disassembly and assembly
Coating materials list SEN04833-01
Categ-
Komatsu code Part number Q'ty Container Main features and applications
ory
q Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
Gasket sealant
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A
q Feature: Lithium grease with extreme pressure
G0-LI SYG2-160LI
Various Various lubrication performance.
*: For cold dis- SYGA-160CNLI
q General purpose type.
trict SYG0-400LI-A (*)
SYG0-160CNLI
(*)
q Used for parts under heavy load.
Caution:
Bel-
Molybdenum SYG2-400M 400 g × 10 q Do not apply grease to rolling bearings like
lows-type
disulfide grease SYG2-400M-A 400 g × 20 swing circle bearings, etc. and spline.
container
LM-G (G2-M) SYGA-16CNM 16 kg q The grease should be applied to work equip-
Can
ment pins at their assembly only, not applied
for greasing afterwards.
Hyper White SYG2-400T-A q Seizure resistance, heat resistance and water
Bel-
Grease SYG2-16CNT resistance higher than molybdenum disulfide
Grease
400 g lows-type
G2-T, SYG0-400T-A grease.
16 kg container
G0-T (*) (*) SYG0-16CNT q Not conspicuous on machine since color is
Can
*: For cold district (*) white.
Biogrease SYG2-400B
Bel-
G2-B, G2-BT(*) SYGA-16CNB q Since this grease is decomposed by natural
400 g lows-type
*: For use at high SYG2-400BT (*) bacteria in short period, it has less effects on
16 kg container
temperature and SYGA-16CNBT microorganisms, animals, and plants.
Can
under high load (*)
q Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond - 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
q Used for oil seals of the transmission, etc.
q Feature: Urea (organic system) grease with
heat resistance and long life. Enclosed type.
G2-U-S
427-12-11871 2 kg Can q Used for rubber, bearing and oil seal in damp-
ENS grease
er.
Caution: Do not mix with lithium grease.
PC78US-8 50-4 5
100 General information on disassembly and assembly
SEN04833-01 Coating materials list
Categ-
Komatsu code Part number Q'ty Container Main features and applications
ory
SUNSTAR q Used as primer for cab side.
Glass con-
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
tainer
580 SUPER facture)
SUNSTAR 417-926-3910
q Used as primer for glass side.
GLASS Glass con-
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 tainer
“W” facture)
Polyethyl- q Used as adhesive for glass.
Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
Adhesive for cab glass
Sikaflex 256HV
tainer facture)
SUNSTAR Ecocart q Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- q Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
Caulking material
50-4 6 PC78US-8
100 General information on disassembly and assembly
Special tool list SEN04833-01
New/remodel
Necessity
Sym-
Component Part No. Part name Nature of work, remarks
Sketch
bol
Q'ty
1 795T-221-1010 Push tool t 1 N Q Press fitting of front oil seal
2 795-931-1100 Seal puller assembly q 1 Pulling out of rear oil seal
Removal and installation
A 795T-221-1020 Plate t 1 R Q
of engine oil seal
3 790-101-5421 Grip t 1 Press fitting of rear oil seal
01010-51240 Bolt t 1
Removal and installation 1 796-460-1210 Oil stopper q 1
of hydraulic pump
Oil stopper of hydraulic
assembly and engine D
and hydraulic pump 2 796T-460-1240 Rod t 1 Q tank
assembly
Removal, installation of
1 796T-226-1120 Push tool q 1 Q
spacer
790-101-3400 Bearing puller q 1 Removal of bearing outer
2
790-101-3220 Screw q 1 race
790-101-5201 Push tool kit q 1
790-101-5281 q Plate 1
3 Installation of oil seal
790-101-5221 q Grip 1
01010-51225 q Bolt 1
790-101-5201 Push tool kit q 1
Disassembly and assem-
bly of swing machinery F 790-101-5331 q Plate 1 Press fitting of sub bearing
4
assembly 790-101-5221 q Grip 1 outer race
01010-51225 q Bolt 1
790-101-5401 Push tool kit q 1
790-101-5431 q Plate 1 Press fitting of main bear-
5
790-101-5421 q Grip 1 ing outer race
01010-51240 q Bolt 1
Press fitting of main bear-
6 796T-221-1010 Push tool t 1 Q
ing inner race
Press fitting of sub bearing
7 792T-413-1120 Push tool t 1 Q
inner race
Press fitting of bushing
1 796T-416-1010 Push tool t 1 Q
Disassembly and assem- (inside)
Press fitting of bushing
bly of travel PPC valve H 2 796T-416-1030 Push tool t 1 Q
assembly (outside)
3 796T-416-1020 Push tool t 1 Q Insertion of pin
PC78US-8 50-4 7
100 General information on disassembly and assembly
SEN04833-01 Special tool list
New/remodel
Necessity
Sym-
Component Part No. Part name Nature of work, remarks
Sketch
bol
Q'ty
790-101-5001 Push tool kit q 1
790-101-5141 q Plate 1
Disassembly and assem- 1 Press fitting of bushing
790-101-5021 q Grip 1
bly of idler assembly
01010-50816 q Bolt 1
2 796-230-1110 Installer t 1 Installation of floating seal
L 790-101-5001 Push tool kit q 1
790-101-5111 q Plate 1
3 Press fitting of bushing
Disassembly and assem- 790-101-5021 q Grip 1
bly of track roller assem-
bly 01010-50816 q Bolt 1
4 796T-230-1210 Installer t 1 Q Installation of floating seal
5 791-601-1000 Oil pump q 1 Charging with oil
50-4 8 PC78US-8
100 General information on disassembly and assembly
Special tool list SEN04833-01
New/remodel
Necessity
Sym-
Component Part No. Part name Nature of work, remarks
Sketch
bol
Q'ty
790-101-2501 Push puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
790-101-2540 q Washer 1
Disassembly and assem-
Disconnection of rotor and
bly of center swivel joint T 791-112-1180 q Nut 1
shaft
assembly
790-101-2630 q Leg 2
790-101-2570 q Washer 4
790-101-2560 q Nut 2
790-121-2650 q Adapter 2
790-502-1003 Repair stand t 1 Disassembly and assembly
1 of hydraulic cylinder
790-101-1102 Hydraulic pump t 1 assembly
Boom,
boom Removal and
790-102-3802 Wrench assembly t 1
swing, installation of
2
blade cylinder head
Arm, assembly
790-330-1100 Wrench assembly t 1
bucket
Boom,
Socket (Width across
790-102-1320 t 1 boom
flats: 70 mm)
swing
Removal and
Socket (Width across
790-102-1330 t 1 Blade installation of
3 flats: 75 mm)
piston nylon
Socket (Width across
790-302-1290 t 1 Bucket nut
flats: 60 mm)
Socket (Width across
790-302-1310 t 1 Arm
flats: 65 mm)
4 790-720-1000 Expander q 1 Expansion of piston ring
796-720-1650 Band q 1
Bucket
Disassembly and assem- 07281-01029 Clamp q 1
bly of hydraulic cylinder U 796-720-1660 Band q 1 Installation of
assembly 5 Boom, arm
07281-01159 Clamp q 1 piston ring
796-720-1670 Band q 1 Boom
swing,
07281-01279 Clamp q 1 blade
790-201-1702 Push tool kit q 1
790-101-5021 q Grip 1 Boom,
01010-50816 q Bolt 1 blade
790-201-1791 q Push tool 1
790-201-1702 Push tool kit q 1
790-101-5021 q Grip 1 Press fitting of
Arm, boom
6 cylinder head
01010-50816 q Bolt 1 swing
bushing
790-201-1781 q Push tool 1
790-201-1702 Push tool kit q 1
790-101-5021 q Grip 1
Bucket
01010-50816 q Bolt 1
790-201-1771 q Push tool 1
PC78US-8 50-4 9
100 General information on disassembly and assembly
SEN04833-01 Special tool list
New/remodel
Necessity
Sym-
Component Part No. Part name Nature of work, remarks
Sketch
bol
Q'ty
790-201-1500 Push tool kit q 1
790-201-1610 q Plate 1 Boom,
790-101-5021 q Grip 1 blade
01010-50816 q Bolt 1
790-201-1500 Push tool kit q 1
Disassembly and assem- 790-201-1590 q Plate 1 Press fitting of
Arm, boom
bly of hydraulic cylinder U 7 cylinder head
790-101-5021 q Grip 1 swing
assembly dust seal
01010-50816 q Bolt 1
790-201-1500 Push tool kit q 1
790-201-1580 q Plate 1
Bucket
790-101-5021 q Grip 1
01010-50816 q Bolt 1
790-441-1802 q Remover t 1
790-441-1810 q Sleeve 1
792-900-1530 q Screw 1
Removal and installation 796-270-1110 q Adapter 1 Removal of work equip-
of work equipment V 1
01803-13034 q Nut 1 ment assembly
assembly
01643-33080 q Washer 1
790-101-4000 Puller 1
790-101-1102 Pump 1
Removal and installation 1 793-498-1210 Lifter (Suction cup) t 2 Removal and installation of
of operator’s cab glass X operator’s cab glass
(stuck glass) 2 20Y-54-13180 Adapter t 2 (stuck glass)
Commercially
Impact wrench q 1
available
Removal and install of
— Socket wrench
counterweight assenbly Commercially
(Width across flats:41 q 1
available
mm)
50-4 10 PC78US-8
100 General information on disassembly and assembly
Sketches of special tools SEN04833-01
A3 Plate
PC78US-8 50-4 11
100 General information on disassembly and assembly
SEN04833-01 Sketches of special tools
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2 Rod
F1 Push tool
50-4 12 PC78US-8
100 General information on disassembly and assembly
Sketches of special tools SEN04833-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
F7 Push tool
H1 Push tool
PC78US-8 50-4 13
100 General information on disassembly and assembly
SEN04833-01 Sketches of special tools
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H2 Push tool
H3 Push tool
50-4 14 PC78US-8
100 General information on disassembly and assembly
Sketches of special tools SEN04833-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
L4 Installer
PC78US-8 50-4 15
SEN04833-01
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
50-4 16
SEN04834-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 50-200 1
200 Engine and cooling system
SEN04834-00 Removal and installation of fuel supply pump assembly
Removal
50-200 2 PC78US-8
200 Engine and cooling system
Removal and installation of fuel supply pump assembly SEN04834-00
2) Remove belt protection cover (13) and fan 8. Disconnect connector PREG (20).
guard (14).
3) Loosen the mounting bolts of air condi- 9. Remove the pin and disconnect spill hose (21).
tioner compressor (15) and remove belt
(16). [*1] 10. Loosen sleeve nuts (22) and (23) and remove
high-pressure pipe (24). [*4]
PC78US-8 50-200 3
200 Engine and cooling system
SEN04834-00 Removal and installation of fuel supply pump assembly
14. Fully loosen temporary fixing bolt (33) from the 2) Remove 3 nuts (38) and remove fuel sup-
fuel supply pump and remove fuel supply ply pump (34) from pump holder (39). [*9]
pump assembly (34). [*6] a After the pump holder is removed, the
a Temporary fixing bolt (33) cannot be temporary fixing bolt can be removed.
removed from the pump holder at this
time.
15. Remove fuel hose (18) and joint bolt (35) from
fuel supply pump (34) and remove fuel tube
(31). [*7]
a Check the installed direction of the fuel Installation
tube. q Carry out installation in the reverse order to
removal.
[*1]
q Adjust the belt tension. For details, see Testing
and adjusting, “Checking and adjusting air con-
ditioner compressor belt tension”.
[*2]
3 Fuel hose joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*3]
q When installing the boots, set their slits in the
directions checked when removed.
16. Remove the supply pump holder according to q The boot is designed with fire safety to prevent
the following procedure. fuel from splashing onto the hot engine if fuel
1) Loosen nut (36) and pull out fuel supply leaks.
pump gear (37) with gear puller [1]. [*8]
50-200 4 PC78US-8
200 Engine and cooling system
Removal and installation of fuel supply pump assembly SEN04834-00
[*4] [*7]
k Never bend a high-pressure pipe for the 3 Fuel tube joint bolt (35):
convenience sake. 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
k Be sure to install the boot to the sleeve nut
after installing the high-pressure pipe. [*8]
a Before installing a high-pressure pipe, confirm 3 Pump gear mounting nut (36):
the following points. If any abnormality was 65 – 75 Nm {6.6 – 7.6 kgm}
found, replace it with new one. Otherwise,
leakage of fuel can result. [*9]
q No visible striations (b) or patchy dents (c) in q When installing the pump holder, install the
the taper seal portion of the connection ((a) temporarily fixing bolt without fail.
portion: area 2 mm inside the tip).
q No deformation in portion (d) (at the end of the
taper seal portion: 2 mm inside the tip).
[*5]
3 Joint bolts (28) and (29):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*6]
q Temporarily fix the fuel supply pump with tem-
porary fixing bolt (33) and then tighten the 4
mounting bolts from the gear case side.
PC78US-8 50-200 5
200 Engine and cooling system
SEN04834-00 Removal and installation of fuel injector assembly
Removal and installation of fuel 4. Remove clamp (4) and 3 bolts to remove
injector assembly 1
bracket (5).
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
50-200 6 PC78US-8
200 Engine and cooling system
Removal and installation of fuel injector assembly SEN04834-00
8. Remove 2 high-pressure pipe fixing clamps a Store the high-pressure pipe, taking care
(10). [*3] that taper seal portion “a” of its joint will
not be scratched.
11. Pull out pin (14) and disconnect spill hose (15).
PC78US-8 50-200 7
200 Engine and cooling system
SEN04834-00 Removal and installation of fuel injector assembly
[*1]
3 Oil filler hose clamp:
5.9 ± 0.49 Nm {60 ± 5 kgcm}
[*2]
q Adjust the belt tension. For details, see Testing
and adjusting, “Checking and adjusting air con-
ditioner compressor belt”.
[*3]
k The clamp used for fixing a high-pressure
a Remove aftercooler hose (22) and tube pipe must be a gunuine Komatsu part and it
(23) from fuel injector No. 4. must be tightened to the specified torque.
[*4]
q When installing the boot, set its slit in the direc-
tion checked when it was removed.
q The boot is designed with fire safety to prevent
fuel from splashing onto the hot engine if fuel
leaks.
3 Sleeve nut: 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
[*5]
q When installing the boot, set its slit in the direc-
tion checked when it was removed.
k Never bend a high-pressure pipe for the
convenience sake.
k Be sure to install the boot to the sleeve nut
after installing the high-pressure pipe.
a Before installing a high-pressure pipe, confirm
the following points. If any abnormality was
found, replace it with new one. Otherwise,
leakage of fuel can result.
q No visible striations (b) or patchy dents (c) in
the taper seal portion of the connection ((a)
portion: area 2 mm inside the tip).
q No deformation in portion (d) (at the end of the
taper seal portion: 2 mm inside the tip).
50-200 8 PC78US-8
200 Engine and cooling system
Removal and installation of fuel injector assembly SEN04834-00
[*6]
3 Holder mounting bolt:
27 – 30 Nm {2.8 – 3.1 kgm}
[*7]
q When reusing the injector, replace O-ring (24)
and gasket (25) with new ones.
PC78US-8 50-200 9
200 Engine and cooling system
SEN04834-00 Removal and installation of engine front seal
New/Remodel
that the crankshaft end corners and front
Necessity
Sym- oil seal lip sliding surfaces are free from
Part No. Part name
Sketch
bol flaw, burr, fin, rust, etc.
Q'ty
a Charge the space between the front oil
t 1 N Q seal lips with 2 cc of lithium grease.
2 Front oil seal: grease (G2-LI)
A 1 795T-221-1010 Push tool
Removal a Install the front oil seal flush with the front
side.
1. Remove the engine and hydraulic pump
assembly. For details, see “Removal and
installation of engine and hydraulic pump
assembly”.
[*1]
3 Crankshaft pulley mounting bolt (1):
343 – 402 Nm {35 – 41 kgm}
50-200 10 PC78US-8
200 Engine and cooling system
Removal and installation of engine rear seal SEN04834-00
Removal and installation of 4. Install 2 guide bolts [1], remove remaining fly-
engine rear seal 1
wheel mounting bolt (4), and lift off flywheel
(3). [*3]
4
Special tools
Flywheel: 25 kg
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
2 795-931-1100 Seal puller assem- q 1
bly
A 795T-221-1020 Plate t 1 R Q
3 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Removal
PC78US-8 50-200 11
200 Engine and cooling system
SEN04834-00 Removal and installation of engine rear seal
Installation
[*3]
q Measuring radial runout of flywheel
1) Install dial gauge [3] to the flywheel hous-
ing.
2) Set the probe of the dial gauge at right
angles to the spigot joint (a) or the outer
periphery of the flywheel.
3) Rotate the crankshaft one full turn and
q Carry out installation in the reverse order to measure the difference of the maximum
removal. values of runout of the needle.
a Check that the position of needle
[*1] remains in its original position after
3 Coupling mounting bolt: the flywheel is rotated one full turn.
98 – 123 Nm (10 – 12.5 kgm) Radial runout: Max. 0.3 mm
50-200 12 PC78US-8
200 Engine and cooling system
Removal and installation of cylinder head assembly SEN04834-00
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Disconnect the cable from the negative (–)
terminal of the battery.
PC78US-8 50-200 13
200 Engine and cooling system
SEN04834-00 Removal and installation of cylinder head assembly
50-200 14 PC78US-8
200 Engine and cooling system
Removal and installation of cylinder head assembly SEN04834-00
4) Loosen alternator mounting bolts and 1] Lock spacer (22) with bar [1] and
remove fan belt (20). [*4] loosen the mounting bolts. [*6]
a Loosen the mounting bolts of alterna- 2] Remove the mounting bolts, taking
tor (21) through the hole of the parti- care that spacer (22) and pulley (23)
tion cover removed in step 2). will not fall.
5) Remove the 6 mounting bolts through the 6) Remove 4 mounting bolts (24) and water
hole of the slung fan and remove spacer pump assembly (25). [*7]
(22) and pulley (23) from the water pump.
[*5]
PC78US-8 50-200 15
200 Engine and cooling system
SEN04834-00 Removal and installation of cylinder head assembly
14. Disconnect 2 fuel hoses (26) and (27) and 20. Disconnect 4 connectors (39) from the fuel
remove fuel main filter (28) and bracket (29) injector.
together. [*8] q No. 1 cylinder: CN1
q No. 2 cylinder: CN2
q No. 3 cylinder: CN3
q No. 4 cylinder: CN4
17. Remove bracket (32) and oil filler (34) 22. Remove 8 boots (41) from the high-pressure
together. pipes. [*10]
a Check the directions of the slits of the
respective boots on the fuel injection side
and common rail side.
23. Pull out pin (42) and disconnect spill hose (43)
from the fuel injector.
50-200 16 PC78US-8
200 Engine and cooling system
Removal and installation of cylinder head assembly SEN04834-00
25. Remove 2 clamps (45) and remove 4 high- 27. Remove the fuel injector according to the fol-
pressure pipes (46). [*11] lowing procedure.
1) Remove fuel injector holder mounting bolt
(49) and holder (50). [*13]
2) Remove 4 fuel injectors (51). [*14]
PC78US-8 50-200 17
200 Engine and cooling system
SEN04834-00 Removal and installation of cylinder head assembly
50-200 18 PC78US-8
200 Engine and cooling system
Removal and installation of cylinder head assembly SEN04834-00
[*2]
q When connecting the radiator hose, apply
TB1208E (ThreeBond) to the adapter up to
about 30 mm from its end.
q When connecting the radiator hose, check that
it is free of a crack etc. and normal.
q Check the inside of the insertion portion of the
hose, too, for breakage etc.
3 Clamps of radiator hoses (12) and (13):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
q Adjust the fan belt tension. For details, see
3) Lift off cylinder head assembly (79). Testing and adjusting, “Testing and adjusting
4 Cylinder head assembly: 30 kg alternator belt tension”.
[*5]
q Before installing the spacer and pulley, check
that there is the slug fan.
PC78US-8 50-200 19
200 Engine and cooling system
SEN04834-00 Removal and installation of cylinder head assembly
[*6] [*9]
q Lock spacer (22) with bar [1] and tighten the 3 Oil filler hose clamp (35):
mounting bolts. 5.9 ± 0.49 Nm {60 ± 5 kgcm}
[*10]
q When installing the boots on the fuel injector
side and common rail side, set their slits in the
directions checked when removed.
q The boot is designed with fire safety to prevent
fuel from splashing onto the hot engine if fuel
leaks.
[*11]
a Precautions when installing high-pressure pip-
ing.
k Never bend a high-pressure pipe for the
convenience sake.
[*7] k The clamp used for fixing a high-pressure
q Since there are 2 lengths of the mounting pipe must be a genuine Komatsu part and it
bolts, take care when installing them. must be tightened to the specified torque.
Part (a): L = 55 mm (3 bolts), Part (b): L = 50 k Be sure to install the boot to the sleeve nut
[*8]
3 Joint bolt of fuel hose (26):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Tighten harness clamp (80) and bracket (29)
together.
50-200 20 PC78US-8
200 Engine and cooling system
Removal and installation of cylinder head assembly SEN04834-00
[*12]
q When installing the air intake manifold, apply
gasket sealant to it.
q Apply a string of gasket sealant about 1 mm in
diameter (f).
2 Air intake manifold mounting face:
Gasket sealant (LG-7)
[*15]
3 Cylinder head cover mounting nut (55):
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
[*16]
3 Nut (58) on turbocharger side:
27 – 34 Nm {2.8 – 3.5 kgm}
q Since there are 2 lengths of the mounting
bolts, take care when installing them. [*17]
Part (a): L = 75 mm (6 bolts), Part (b): L = 65 3 Fixing nut of U-bolt (59):
mm (2 bolts) 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*18]
3 Clamp of air intake hose (64):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*19]
3 Clamp (65) (turbocharger side):
5.88 – 7.8 Nm {0.6 – 0.8 kgm}
3 Clamp (66) (air intake hose side):
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*20]
q Install turbocharger lubrication tubes (68) and
(69) as shown in the photo.
[*13], [*14]
q Installation procedure of fuel injector
1) Install new O-ring (81) and copper gasket
(82) to fuel injector (51).
2) Insert fuel injector (51) in the cylinder
head.
3) Install holder (50) to the fuel injector and
tighten mounting bolt (49).
a Ensure that holder (50) is fitted to
groove “a” of fuel injector (51)
securely and then tighten mounting
bolt (49).
3 Holder mounting bolt:
27 – 30 Nm {2.8 – 3.1 kgm}
PC78US-8 50-200 21
200 Engine and cooling system
SEN04834-00 Removal and installation of cylinder head assembly
[*24]
a Tightening procedure of cylinder head mount-
ing bolts
1) Clean the threaded holes of the cylinder
block.
2) Apply molybdenum disulfide lubricant
(LM-P) to all surfaces of the threaded por-
tions and seats of the cylinder head
mounting bolts and the seats of the cylin-
der head holes.
3) Screw each cylinder head mounting bolt
into the threaded hole of the cylinder head
with the fingers in the order shown in the
figure by 2 – 3 turns.
3 Joint bolt of turbocharger lubrication inlet 4) Tighten the cylinder head bolts in the
tube (68) (turbocharger side): order shown in the figure.
9.8 – 12.7 Nm {1.0 – 1.3 kgm} 3 1st time: 68.6 ± 9.8 Nm {7 ± 1 kgm}
tube (68) (cylinder block side): 107.8 ± 4.9 Nm {11.0 ± 0.5 kgm}
24.5 – 34.3 Nm {2.5 – 3.5 kgm} 3 3rd time: Make a mark on the cylinder
head mounting bolt head and cylinder
[*21] head seat and tighten the cylinder head
q Installation procedure of exhaust manifold and mounting bolt by 90° (+ 30/0°).
turbocharger assembly
1) Install the guide bolt and set the gasket.
2) Install exhaust manifold and turbocharger
assembly to the guide bolt and tighten the
mounting bolts.
3 Exhaust manifold and turbocharger
assembly:
34.3 – 53.9 Nm {3.5 – 5.5 kgm}
[*22], [*23]
q Before installing rocker arm assembly (76),
loosen locknut (73) and fully loosen adjustment
screw (74).
q When installing rocker arm assembly (76),
ensure that the adjustment screw ball is fitted (“F” in the figure indicates the front side of
to the push rod socket and tighten the mount- the engine and “R” indicates the rear
ing bolts alternately. side.)
3 Rocker arm mounting bolt (75):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
q For valve clearance adjustment, see Testing
and adjusting, “Adjusting valve clearance”.
50-200 22 PC78US-8
200 Engine and cooling system
Removal and installation of cylinder head assembly SEN04834-00
PC78US-8 50-200 23
200 Engine and cooling system
SEN04834-00 Removal and installation of radiator assembly
Removal and installation of 6. Remove 4 wing screws (6) to remove net (7).
radiator assembly 1
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Disconnect the cable from the negative (–)
terminal of the battery.
2. Open radiator coolant drain valve (1) to drain 7. Remove partition plate (5) and plate (8).
the coolant. a Pull the partition plate out of tube (9).
6 Coolant: 10 l
8. Remove receiver tank fixing clamps (10) and 2
clamps (11) to remove receiver tank (12).
5. Disconnect radiator overflow hose (4) and pull 9. Remove condenser assembly (13).
it out of partition plate (5). a Move the condenser assembly aside so
that its tubes will not be deformed or bro-
ken.
50-200 24 PC78US-8
200 Engine and cooling system
Removal and installation of radiator assembly SEN04834-00
10. Disconnect radiator lower hose (14). [*3] 13. Lift up and remove aftercooler assembly (18).
11. Disconnect aftercooler lower tube (15) and 14. While moving radiator assembly (19) toward
remove cover (16). the removed aftercooler, lift up and remove it.
PC78US-8 50-200 25
200 Engine and cooling system
SEN04834-00 Removal and installation of radiator assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Clamp of aftercooler upper hose (2):
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*2], [*3]
q When connecting the radiator hose, apply
TB1208E (ThreeBond) to the adapter up to
about 30 mm from its end.
q When connecting the radiator hose, check that
it is free of a crack etc. and normal.
q Check the inside of the insertion portion of the
hose, too, for breakage etc.
3 Clamp of radiator upper hose (3):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Clamp of radiator lower hose (14):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
50-200 26 PC78US-8
200 Engine and cooling system
Removal and installation of aftercooler assembly SEN04834-00
Removal and installation of 4. Remove 4 wing screws (5) to remove net (6).
aftercooler assembly 1
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
PC78US-8 50-200 27
200 Engine and cooling system
SEN04834-00 Removal and installation of aftercooler assembly
7. Remove condenser (12). 10. Pull out and remove aftercooler assembly (16).
a Place the condenser on a stand so that its [*2]
tubes will not be deformed or broken.
[*1]
3 Aftercooler upper hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*2]
q When installing, set convex parts (“a” and “b”)
at the bottom of the aftercooler to the concave
parts (“a” and “b”) of the machine.
50-200 28 PC78US-8
200 Engine and cooling system
Removal and installation of hydraulic oil cooler assembly SEN04834-00
Removal and installation of 5. Remove hydraulic oil cooler net rail (3).
hydraulic oil cooler assembly 1
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Loosen the hydraulic tank cap gradually to
release the pressure inside the hydraulic
tank.
PC78US-8 50-200 29
200 Engine and cooling system
SEN04834-00 Removal and installation of hydraulic oil cooler assembly
7. Remove clamp (6) and disconnect hydraulic oil 10. Raise and remove hydraulic oil cooler assem-
cooler upper hose (7). bly (11). [*3]
50-200 30 PC78US-8
200 Engine and cooling system
Removal and installation of hydraulic oil cooler assembly SEN04834-00
PC78US-8 50-200 31
200 Engine and cooling system
SEN04834-00 Removal and installation of engine and hydraulic pump assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 796-460-1210 Oil stopper q 1
D
2 796T-460-1240 Rod t 1 Q
3. Remove the counterweight. For details, see
Removal “Removal and installation of counterweight
k Park the machine on a level ground, lower assembly”.
the work equipment to the ground, stop the
engine, and set the lock lever in the lock 4. Remove undercovers (2) and (3).
position.
k Loosen the hydraulic tank cap to release
the pressure inside the hydraulic tank.
k Disconnect the cable from the negative (–)
terminal of the battery.
a Record the positions of the disconnected pip-
ings, wirings, and connectors to prevent a mis-
take in reconnecting them.
50-200 32 PC78US-8
200 Engine and cooling system
Removal and installation of engine and hydraulic pump assembly SEN04834-00
PC78US-8 50-200 33
200 Engine and cooling system
SEN04834-00 Removal and installation of engine and hydraulic pump assembly
9. Disconnect hydraulic oil temperature sensor 14. Remove fan guard (22).
connector P22 (16).
50-200 34 PC78US-8
200 Engine and cooling system
Removal and installation of engine and hydraulic pump assembly SEN04834-00
PC78US-8 50-200 35
200 Engine and cooling system
SEN04834-00 Removal and installation of engine and hydraulic pump assembly
24. Remove belt protection cover (42), fan belt 28. Disconnect electrical intake air heater terminal
(43) and air conditioner compressor belt (44). E01 (50).
[*7], [*8]
a Loosen the alternator and air conditioner 29. Remove clamps (51) and (52).
compressor mounting bolts and remove
the belt. 30. Disconnect connector (53).
a To disconnect starting motor terminal C 34. Disconnect aftercooler upper hose (59). [*10]
E10 (47), remove cap (49) and loosen the
screw with a cross-head screwdriver. 35. Disconnect radiator overflow hose (60).
50-200 36 PC78US-8
200 Engine and cooling system
Removal and installation of engine and hydraulic pump assembly SEN04834-00
36. Disconnect radiator upper hose (61). [*11] 43. Remove air conditioner compressor assembly
(70).
37. Disconnect air conditioner heater outlet hose
(62).
PC78US-8 50-200 37
200 Engine and cooling system
SEN04834-00 Removal and installation of engine and hydraulic pump assembly
46. Remove the fan according to the following pro- 4) Remove 6 mounting bolts (80) from the
cedure. aftercooler side and remove fan (81). [*15]
1) Disconnect aftercooler lower tube (76)
and remove cover (77).
50-200 38 PC78US-8
200 Engine and cooling system
Removal and installation of engine and hydraulic pump assembly SEN04834-00
[*1]
3 Hydraulic tank drain plug:
58.8 – 78.4 Nm {6 – 8 kgm}
[*2]
3 Clamp of suction hose (24):
10.8 ± 0.5 Nm {110 ± 5 kgcm}
[*3]
q Fit spacer (85) and install ground wire terminal
(21).
[*4]
q Fit spacer (86) and install clamp (24) to plate
(25).
PC78US-8 50-200 39
200 Engine and cooling system
SEN04834-00 Removal and installation of engine and hydraulic pump assembly
[*5] [*11]
3 Joint bolt of fuel hose (35): q When connecting the radiator hose, apply
24.5 – 34.3 Nm {2.5 – 3.5 kgm} TB1208E (ThreeBond) to the adapter up to
about 30 mm from its end.
[*6] q When connecting the radiator hose, check that
q When connecting the radiator hose, apply it is free of a crack etc. and normal.
TB1208E (ThreeBond) to the adapter up to q Check the inside of the insertion portion of the
about 30 mm from its end. hose, too, for breakage etc.
q When connecting the radiator hose, check that 3 Clamp of radiator upper hose:
it is free of a crack etc. and normal. 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
q Check the inside of the insertion portion of the
hose, too, for breakage etc. [*12]
3 Clamp of radiator lower hose: 3 Clamp (76): 8.3 – 8.8 Nm {0.85 – 0.9 kgm}
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*13]
[*7] 3 Clamp (79): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
q Adjust the fan belt tension. For details, see
Testing and adjusting, “Testing and adjusting [*14]
alternator belt tension”. q When installing, set convex parts (“a” and “b”)
at the bottom of the aftercooler to the concave
[*8] parts (“a” and “b”) of the machine.
q Adjust the belt tension. For details, see Testing
and adjusting, “Checking and adjusting air con-
ditioner compressor belt tension”.
[*9]
q Install wiring clamp (87) to muffler drain tube
(54).
[*10]
3 Aftercooler upper hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
50-200 40 PC78US-8
200 Engine and cooling system
Removal and installation of engine and hydraulic pump assembly SEN04834-00
q Bleeding air
[*16] Bleed air. For details, see Testing and adjust-
q The right rear of the engine and hydraulic ing, “Bleeding air from each part”.
pump assembly mount is different from the
other portions. Take care when installing.
3 Engine and hydraulic pump assembly
mounting bolt:
249 – 309 Nm {25.0 – 31.5 kgm}
PC78US-8 50-200 41
200 Engine and cooling system
SEN04834-00 Removal and installation of fuel tank assembly
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Disconnect the cable from the negative (–)
terminal of the battery.
50-200 42 PC78US-8
200 Engine and cooling system
Removal and installation of fuel tank assembly SEN04834-00
5. Remove fuel tank under cover (8). 8. Lift off fuel tank assembly (12).
4 Fuel tank assembly: 50 kg
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Fuel tank mounting bolt: Adhesive (LT-2)
PC78US-8 50-200 43
SEN04834-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
50-200 44
SEN04835-01
PC78US-8
SEN04835-01
HYDRAULIC EXCAVATOR
Shop Manual
PC78US-8
Removal and installation of travel motor and final drive assembly ............................................................. 2
Removal and installation of swing motor and swing machinery assembly ................................................. 4
Disassembly and assembly of swing machinery......................................................................................... 6
Removal and installation of swing circle assembly ..................................................................................... 13
PC78US-8 50-4 1
300 Power train
SEN04835-01 Removal and installation of travel motor and final drive assembly
50-4 2 PC78US-8
300 Power train
Removal and installation of travel motor and final drive assembly SEN04835-01
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
2 Thread of travel motor mounting bolt:
Thread tightener (LT-2)
3 Sprocket mounting bolt:
186.3 – 225.6 Nm {19 – 23 kgm}
[*2]
2 Thread of travel motor and final drive assem-
bly mounting bolt:
Thread tightener (LT-2)
3 Travel motor and final drive assembly mount-
ing bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
a Bleed the air from the travel motor. For details,
see Testing and adjusting, "Bleeding air from
each part".
PC78US-8 50-4 3
300 Power train
SEN04835-01 Removal and installation of swing motor and swing machinery assembly
50-4 4 PC78US-8
300 Power train
Removal and installation of swing motor and swing machinery assembly SEN04835-01
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
q When installing the swing motor and swing ma-
chinery assembly, position it to dowel pin (9).
2 Mating face of swing machinery case:
Gasket sealant (LG-6)
3 Swing motor and swing machinery assembly
mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
q Bleeding air
Bleed air. For details, see Testing and adjusting,
"Bleeding air from each part".
PC78US-8 50-4 5
300 Power train
SEN04835-01 Disassembly and assembly of swing machinery
New/Remodel
Necessity
Sym-
Part No. Part name 2. Swing motor assembly
Sketch
bol
1) Remove swing motor mounting bolts (4).
Q'ty
2) Separate swing motor assembly (1) by tight-
1 796T-226-1120 Push tool q 1 Q
ening a forcing screw into tapped hole "a"
790-101-3400 Bearing puller q 1
2 and lift it off.
790-101-3220 Screw q 1
790-101-5201 Push tool kit q 1 a Before disassembling, make match
790-101-5281 q Plate 1 marks between swing motor assembly (1)
3 and ring gear (2)and between ring gear
790-101-5221 q Grip 1
01010-51225 q Bolt 1 (2) and machinery case (3) with paint to
790-101-5201 Push tool kit q 1 position these parts accurately when as-
F 790-101-5331 q Plate 1 sembling.
4
790-101-5221 q Grip 1
01010-51225 q Bolt 1
790-101-5401 Push tool kit q 1
790-101-5431 q Plate 1
5
790-101-5421 q Grip 1
01010-51240 q Bolt 1
6 795T-221-1010 Push tool t 1 Q
7 792T-413-1120 Push tool t 1 Q
50-4 6 PC78US-8
300 Power train
Disassembly and assembly of swing machinery SEN04835-01
PC78US-8 50-4 7
300 Power train
SEN04835-01 Disassembly and assembly of swing machinery
7. Collar
1) Set the shaft and case assembly to a press 9. Oil seal and bearing outer race
and push sub bearing (28) with tool F1. 1) Remove oil seal (33) from case (3).
a Operate the press slowly and push the
bearing until the 2-piece collar can be re-
moved.
2) Remove 2-piece collar (29).
8. Shaft assembly
1) Set block [1] to shaft and case assembly (3).
Using push tool [2] and the press, remove
shaft assembly (29).
2) Remove sub bearing (28).
50-4 8 PC78US-8
300 Power train
Disassembly and assembly of swing machinery SEN04835-01
4. Shaft assembly
1) Install seal (36) to shaft (32).
a Install the seal so that the lip may face up-
a Coat on the lip to be free from swelling of oil side.
seal. Fill 40 - 60? % of the space "a" between
2) Using tool F6 and the press, press fit main
oil seal and dust seal.
2 The lip of oil seal: Grease (G2-LI)
bearing (35).
a Press fitting force:
12.0 – 34.2 kN {1.3 – 3.5 tons}
PC78US-8 50-4 9
300 Power train
SEN04835-01 Disassembly and assembly of swing machinery
50-4 10 PC78US-8
300 Power train
Disassembly and assembly of swing machinery SEN04835-01
6. Ring gear
Install ring gear (2).
a Apply gasket sealant to the hatched part "d"
in the figure.
2 Fitting face of ring gear:
Gasket sealant (LG-6)
PC78US-8 50-4 11
300 Power train
SEN04835-01 Disassembly and assembly of swing machinery
50-4 12 PC78US-8
300 Power train
Removal and installation of swing circle assembly SEN04835-01
PC78US-8 50-4 13
SEN04835-01
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
50-4 14
SEN04836-01
PC78US-8
SEN04836-01
HYDRAULIC EXCAVATOR
Shop Manual
PC78US-8
PC78US-8 50-4 1
4 400 Undercarriage and frame
SEN04836-01 Disassembly and assembly of track roller assembly
Disassembly and assembly of 4. Remove O-ring (7) from shaft and collar
track roller assembly assembly (6).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-5001 Push tool kit t 1
790-101-5111 q Plate 1
3
790-101-5021 q Grip 1
L 01010-50816 q Bolt 1
4 796T-230-1210 Installer t 1 Q
5 791-601-1000 Oil pump q 1
50-4 2 PC78US-8
4 400 Undercarriage and frame
Disassembly and assembly of track roller assembly SEN04836-01
7. Remove bushings (10) and (11) from roller (5). a The metallic faces of the floating seal which are
in contact with each other must be free from dirt.
a Thoroughly clean the parts to be in contact with
the supplied oil. After cleaning them, the dirt re-
maining on these parts of 1 roller assembly must
be below 25 mg and the size of the dirt must be
below 0.3.
a Set plug (2) on the outside of the machine body.
Assembly
PC78US-8 50-4 3
4 400 Undercarriage and frame
SEN04836-01 Disassembly and assembly of track roller assembly
2. Using tool L4, press fit floating seal (9b) to shaft 7. Install O-ring (7) to shaft and collar assembly (6).
(6).
9. Using tool L5, fill the roller with oil and tighten
plug (12).
5 Track roller: 145 – 155 cc (GO140)
4. Install shaft and collar assembly (8) to roller (5).
50-4 4 PC78US-8
4 400 Undercarriage and frame
Disassembly and assembly of idler assembly SEN04836-01
Disassembly and assembly of 4. Remove floating seal (6) on the opposite side
idler assembly from idler (4), shaft (5) and support assembly (7).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-5001 Push tool kit q 1
790-101-5141 q Plate 1
1
L 790-101-5021 q Grip 1
01010-50816 q Bolt 1
2 796-230-1110 Installer t 1
Disassembly
5. Remove dowel pin (8) to remove support (7)
1. Remove dowel pin (1) and then support (2). from shaft (5).
2. Remove floating seal (3) form support (2) and 6. Remove bushings (9) and (10) from idler (4).
idler (4).
PC78US-8 50-4 5
4 400 Undercarriage and frame
SEN04836-01 Disassembly and assembly of idler assembly
50-4 6 PC78US-8
4 400 Undercarriage and frame
Disassembly and assembly of idler assembly SEN04836-01
PC78US-8 50-4 7
4 400 Undercarriage and frame
SEN04836-01 Disassembly and assembly of recoil spring assembly
New/Remodel
47.3 kN {4,826 kg} (Steel shoe)
Necessity
Sym-
Part No. Part name 68.5 kN {6,985 kg} (Rubber shoe)
Sketch
bol
Q'ty
791-685-8006 Compressor (B) t 1
790-201-2860 Spacer t 1
791-635-3160 Extension t 1
M
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
790-101-1102 Hydraulic pump t 1
Disassembly
50-4 8 PC78US-8
4 400 Undercarriage and frame
Disassembly and assembly of recoil spring assembly S E N 0 4 8 3 6 -0 1
PC78US-8 50-4 9
4 400 Undercarriage and frame
SEN04836-01 Spreading and installation of track shoe assembly
Spreading and installation of track 2. Move machine forward so that position of master
shoe assembly pin is at front of idler, and set block [1] in position.
New/Remodel
4. Remove tool R, pull out temporary pin, and
remove dust seal, then drive machine in reverse
Necessity
Sym-
Part No. Part name to lay out track (2). [*3]
Sketch
bol
Q'ty
791-620-3000 Remover and installer t 1
791-635-3110 q Frame 1
791-635-3120 q Support 1
791-635-3130 q Nut 1
791-635-3140 q Screw 1
791-635-3150 q Hook 1
791-635-3160 q Extension 1
791-635-3170 q Nut 4
R 791-635-3180 q Screw 2
791-635-3190 q Screw (For fixing) 1
791-635-3210 q Pilot 1
791-620-3220 q Adapter 1
791-615-7161 Pin pusher t 1
791-615-7170 Guide t 1
Cylinder
790-101-1300 t 1
(980 kN {100 ton})
790-707-1102 Hydraulic pump t 1
Spreading
50-4 10 PC78US-8
4 400 Undercarriage and frame
Spreading and installation of track shoe assembly SEN04836-01
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
a Adjust the track tension.
For details, see Testing and adjusting, "Testing
and adjusting track tension".
[*2]
a Use tool R and press fit the master pin so that
the protrusion of the master pin is dimension (a).
Protrusion (a) of master pin: 3 ± 2 mm
[*3]
a When assembling the dust seal, coat the bush-
ing contact surface with grease (G2-LI).
a If the rubber of the road liner (rubber pad type)
becomes worn or broken and the head of the
mounting bolt becomes damaged, replace the
shoe with a new part immediately. If the head of
the mounting bolt becomes flattened, it will be
impossible to remove it.
PC78US-8 50-4 11
4 400 Undercarriage and frame
SEN04836-01 Removal and installation of sprocket
50-4 12 PC78US-8
4 400 Undercarriage and frame
Removal and installation of revolving frame assembly SEN04836-01
Removal and installation of 5. Remove the operator cab assembly. For details,
revolving frame assembly see “Removal and installation of operator cab
assembly”.
Removal
k Loosen the hydraulic tank cap to release the
6. Disconnect the hoses from the center swivel
pressure inside the hydraulic tank.
k Release the residual pressure in the hydrau-
joint.
(6): Drain hose (Band color: White/Blue)
lic circuit. For details, see Testing and adjust- (7): Travel right reverse hose
ing, “Releasing residual pressure from (Band color: Green/Yellow)
hydraulic circuit”.
k Disconnect the cable from the negative (–)
(8): Travel left reverse hose
(Band color: Orange/Yellow)
terminal of the battery. (9): Blade raise hose
(Band color: Yellow/Blue)
1. Remove the work equipment assembly. For (10): Travel 2nd travel speed selection hose
details, see “Removal and installation of work (Band color: Yellow/Yellow)
equipment assembly”.
PC78US-8 50-4 13
4 400 Undercarriage and frame
SEN04836-01 Removal and installation of revolving frame assembly
[*1]
2 Sliding surface of mounting pin (When as-
sembling): Hyper white grease (G2-T)
2 Mounting pin (Greasing after assembly):
Hyper white grease (G2-T)
k When aligning the pin holes, never insert
your fingers in them.
q Adjust the shim so that clearances “(a), (b)” be-
tween boom foot pin (17) and boom bracket (18)
will be 1.0 mm or less.
Clearance (a): t = 1.0 mm
Clearance (b): t = 1.0 mm, t = 1.5 mm
9. Sling revolving frame assembly (16) and remove
the remaining mounting bolts. [*3]
a Sling the revolving frame assembly so that it
can be balanced in each direction.
k Never use the tap hole at the top of the
counterweight.
[*2], [*3]
2 Revolving frame mounting bolt:
Adhesive (LT-2)
3 Revolving frame mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
q Bleeding air
Bleed air. For details, see Testing and adjusting,
“Bleeding air from each part”.
50-4 14 PC78US-8
4 400 Undercarriage and frame
Removal and installation of counterweight assembly SEN04836-01
Removal and installation of coun- 2. Lift off engine hood assembly (4).
terweight assembly 4 Engine hood assembly: 30 kg
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Commercially
Impact wrench q 1
available
- Socket wrench
Commercially
(Width across q 1
available
flats: 41 mm)
a Use the impact wrench and socket wrench appli-
cable for the tight ening torque for the counter-
weight mounting bolts. 3. Remove 2 mounting bolts (6) of engine controller
3 Counterweight mounting bolt:
rubber cover (5).
1,150 –1,440 Nm {118 – 147 kgm}
4. Remove engine hood fixing bracket (7).
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock po-
sition.
k Disconnect the cable from the negative (–)
terminal of the battery.
PC78US-8 50-4 15
4 400 Undercarriage and frame
SEN04836-01 Removal and installation of counterweight assembly
5. Disconnect connectors CE01(8), CE02(9) and 7. Remove damper case breather bracket (14).
CE03 (10) from engine controller (11).
a Use a 4-mm hexagonal wrench to loosen 10. Install 2 eyebolts [1] to the eyebolt holes and
screws (13) of connectors CE01 and CE02. sling counterweight (18).
[*1]
50-4 16 PC78US-8
4 400 Undercarriage and frame
Removal and installation of counterweight assembly SEN04836-01
[*2]
q For the installation procedure of the engine
controller assembly, see “Removal and in-
stallation of engine controller assembly”
q .
[*3]
2 Counterweight mounting bolt:
Adhesive (LT-2)
3 Counterweight mounting bolt:
1,150 – 1,440 Nm {118 – 147 kgm}
12. Lift off counterweight assembly (18). [*4] [*4]
a When slinging the counterweight, move it to- q When installing the counterweight, raise en-
ward the rear horizontally so that it will not in- gine controller rubber cover (5).
terfere with the machine body.
4 Counterweight assembly: 830 kg
PC78US-8 50-4 17
SEN04836-01
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
50-4 18
SEN04837-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 50-500 1
500 Hydraulic system
SEN04837-00 Removal and installation of center swivel joint assembly
Removal and installation of center 3. Disconnect hoses (10) – (19) from the under-
swivel joint assembly 1
side of the swivel joint.
50-500 2 PC78US-8
500 Hydraulic system
Removal and installation of center swivel joint assembly SEN04837-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Center swivel joint mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
q Bleeding air
Bleed air. For details, see Testing and adjust-
ing, "Bleeding air from each part".
PC78US-8 50-500 3
500 Hydraulic system
SEN04837-00 Disassembly and assembly of center swivel joint assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
T 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Washer 4
790-101-2560 • Nut 2
791-112-2650 • Adapter 2
Disassembly
50-500 4 PC78US-8
500 Hydraulic system
Disassembly and assembly of center swivel joint assembly SEN04837-00
Assembly
PC78US-8 50-500 5
500 Hydraulic system
SEN04837-00 Removal and installation of hydraulic tank assembly
50-500 6 PC78US-8
500 Hydraulic system
Removal and installation of hydraulic tank assembly SEN04837-00
6. Remove fuel hose clamp (11) from the hydrau- 9. Remove bolt (19) and clamp (20).
lic tank.
10. Remove wiring clamp (21).
7. Disconnect the 6 hoses from the hydraulic a Wiring clamp (21) is of insert type.
tank.
(12): Main valve seal drain (Ts) hose
(13): T-block drain hose
(Band color: Black/Green)
(14): Swing motor drain hose
(Band color: White/Green)
(15): Solenoid drain hose
(Band color: Black/Blue)
(16): Swivel joint drain hose
(Band color: White/Blue)
(17): Boom cylinder hydraulic drift prevention
valve drain hose (Machine with boom
hydraulic drift prevention valve)
PC78US-8 50-500 7
500 Hydraulic system
SEN04837-00 Removal and installation of hydraulic tank assembly
[*1]
3 Hydraulic tank drain plug:
58.8 – 78.4 Nm {6 – 8 kgm}
[*2]
3 Suction hose clamp:
10.8 ± 0.5 Nm {110 ± 5 kgcm}
[*3]
q If hydraulic pump drain hose (24) was discon-
nected from the hydraulic tank, connect it to
the hydraulic tank when installing the hydraulic
a Remove clamp (26) to remove the mount- tank.
ing bolt at the left rear of the hydraulic
tank.
[*4]
2 Hydraulic tank mounting bolt:
14. Lift off hydraulic tank assembly (27). Adhesive (LT-2)
a While pulling out suction hose (22), 3 Hydraulic tank mounting bolt:
remove the hydraulic tank assembly. 98 – 123 Nm {10.0 – 12.5 kgm}
4 Hydraulic tank assembly: 75 kg
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic tank:
56 l (Specified oil quantity: 102 l)
q Bleeding air
Bleed air. For details, see Testing and adjust-
ing, "Bleeding air from each part".
50-500 8 PC78US-8
500 Hydraulic system
Removal and installation of hydraulic pump assembly SEN04837-00
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 796-460-1210 Oil stopper q 1
D
2 796T-460-1240 Rod t 1 Q
Removal
k Park the machine on a level ground, lower 4. Loosen drain plug (3) to drain the oil from the
the work equipment to the ground, stop the flywheel case.
engine, and set the lock lever in the lock
position.
k Loosen the hydraulic tank cap to release
the pressure inside the hydraulic tank.
k Disconnect the cable from the negative (–)
terminal of the battery.
PC78US-8 50-500 9
500 Hydraulic system
SEN04837-00 Removal and installation of hydraulic pump assembly
6. Remove the muffler according to the following 8. Disconnect the hoses from the hydraulic pump.
procedure. q (10): Port P4 hose
1) Remove 4 mounting bolts (6) and clamp
(7).
2) Pull out the muffler (8) with muffler mount-
ing bracket.
50-500 10 PC78US-8
500 Hydraulic system
Removal and installation of hydraulic pump assembly SEN04837-00
11. Disconnect hydraulic oil temperature sensor 16. Sling hydraulic pump assembly (24) and
connector P22 (18). remove the 12 mounting bolts.
12. Remove clamps (19) and (20). 17. Lift off hydraulic pump assembly (24). [*5]
a Pull out the flange section of the hydraulic
pump to near the frame. Then, while rais-
ing the flange section a little and lowering
the gear pump side a little, lift off the
hydraulic pump assembly.
4 Hydraulic pump assembly: 67 kg
PC78US-8 50-500 11
500 Hydraulic system
SEN04837-00 Removal and installation of hydraulic pump assembly
[*2]
q Install wiring clamp (16) to muffler drain tube q Bleeding air
(25). Bleed air. For details, see Testing and adjust-
ing, "Bleeding air from each part".
[*3]
3 Clamp of suction hose (22):
10.8 ± 0.5 Nm {110 ± 5 kgcm}
[*4]
q Fit spacer (26) and install ground wire terminal
(23).
[*5]
2 All around flywheel case mating face:
Gasket sealant (LG-6)
50-500 12 PC78US-8
500 Hydraulic system
Removal and installation of control valve assembly SEN04837-00
Removal and installation of 3. Remove the washer tank and radiator reservoir
control valve assembly 1
tank.
1) Disconnect vinyl tube (4) from the washer
Removal tank.
k Park the machine on a level ground, lower 2) Disconnect washer motor connector M06
the work equipment to the ground, stop the (5).
engine, and set the lock lever in the lock 3) Remove washer tank (6), radiator reser-
position. voir tank (7) and bracket (8) together.
k Loosen the hydraulic tank cap to release
the pressure inside the hydraulic tank.
k Release the residual pressure in the
hydraulic circuit. For details, see Testing
and adjusting, "Releasing residual pres-
sure in the hydraulic circuit".
k Disconnect the cable from the negative (–)
terminal of the battery.
a Record the positions of the disconnected pip-
ings and wiring connectors to prevent a mis-
take in reconnecting them.
PC78US-8 50-500 13
500 Hydraulic system
SEN04837-00 Removal and installation of control valve assembly
50-500 14 PC78US-8
500 Hydraulic system
Removal and installation of control valve assembly SEN04837-00
7. Disconnect the connectors on the rear side of 9. Remove clamps (32) and remove wiring (33)
the control valve. from the control valve.
(25): Spare for service valve (If equipped)
(26): P04 (Bucket curl pressure switch)
(27): P05 (Arm in pressure switch)
(28): P06 (Boom lower pressure switch)
PC78US-8 50-500 15
500 Hydraulic system
SEN04837-00 Removal and installation of control valve assembly
11. Disconnect the PPC hoses on the front side of 12. Disconnect the PPC hoses on the rear side of
the control valve the control valve.
(39): Port PA8 PPC hose (Service valve) (49): Port PB8 PPC hose (Service valve)
(If equipped) (Band color: White/Brown) (If equipped) (Band color: White/Orange)
(40): Port PA7 PPC hose (Band color: Red) (50): Port PB7 PPC hose (Band color: Blue)
(41): Port PA6 PPC hose (Band color: Orange) (51): Port PB6 PPC hose: (Band color: Green)
(42): Port PA5 PPC hose (Band color: Yellow) (52): Port PB5 PPC hose: (Band color: Black)
a Do not disconnect hose (43).
50-500 16 PC78US-8
500 Hydraulic system
Removal and installation of control valve assembly SEN04837-00
13. Disconnect the hoses and joints on the left side (70): Port A4 hose (Band color: Green/Yellow)
of the control valve. (71): Port B4 hose (Band color: Black/Yellow)
(59): Service valve A8 port (If equipped) (72): Port A3 hose
(60): Service valve B8 port (If equipped) (Band color: Orange/Yellow)
(61): Port A7 hose (Band color: Red) (73): Port B3 hose (Band color: Brown/Yellow)
(62): Port B7 hose (Band color: Blue) (74): Port A2 hose (Band color: Brown)
(63): Port A6 hose (Band color: Orange) (75): Port B2 hose (Band color: White)
(64): Port B6 hose (Band color: Green)
(65): Port A5 hose
a The hoses of ports A8 (59) and B8 (60)
were disconnected when the ATT selector
valve assembly was removed.
PC78US-8 50-500 17
500 Hydraulic system
SEN04837-00 Removal and installation of control valve assembly
50-500 18 PC78US-8
500 Hydraulic system
Removal and installation of control valve assembly SEN04837-00
Installation
q Carry out installation in the reverse order to removal.
a Do not mistake the installed position of each hose.
PC78US-8 50-500 19
500 Hydraulic system
SEN04837-00 Removal and installation of control valve assembly
[*1]
3 Hydraulic tank drain plug:
58.8 – 78.4 Nm {6 – 8 kgm}
q Bleeding air
Bleed air. For details, see Testing and adjust-
ing, "Bleeding air from each part".
50-500 20 PC78US-8
500 Hydraulic system
Disassembly and assembly of control valve assembly SEN04837-00
Assembly
In this section, only the precautions for assembling
the 8-spool valve are described.
a Only the related items are shown in the figure.
a For the figures not shown here, see Structure,
function and maintenance standard, "Control
valve".
PC78US-8 50-500 21
500 Hydraulic system
SEN04837-00 Disassembly and assembly of control valve assembly
50-500 22 PC78US-8
500 Hydraulic system
Disassembly and assembly of control valve assembly SEN04837-00
PC78US-8 50-500 23
500 Hydraulic system
SEN04837-00 Disassembly and assembly of work equipment PPC valve assembly
Disassembly Assembly
a Spring (6) and spring (7) consists of each one a Plugs (2) and (3) cannot be replenished.
of two types of springs with different installed a The head of plug (3) must not be projected
loads in four places, so check the mounting from the body (1) surface.
position (oil pressure port) and mark with tags 3 Plug (3): 6 – 11 Nm {0.6 – 1.1 kgm}
to prevent mistakes when installing. a When installing piston (8), apply grease (G2-
LI) to its outside and the inside of the body (1)
hole.
a Install spring (5) with its small diameter side on
the shim (4) side.
q Diameter of spring (Inside diameter)
Small diameter side: Ø4.9 mm
Large diameter side: Ø5.55 mm
a When installing springs (6) and (7), note that
they are different and they must be installed to
different hydraulic ports.
q Installed height: 32 mm (Common to both
springs)
q Installed load:
Spring (6) (P1, P2): 35 N {3.57 kg}
Spring (7) (P3, P4): 21.77 N {2.22 kg}
3 Bolt (11):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
50-500 24 PC78US-8
500 Hydraulic system
Disassembly and assembly of work equipment PPC valve assembly SEN04837-00
PC78US-8 50-500 25
500 Hydraulic system
SEN04837-00 Disassembly and assembly of travel PPC valve assembly
Special tool
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
2 796T-416-1010 Push tool t 1 Q
H 3 796T-416-1030 Push tool t 1 Q
4 796T-416-1020 Push tool t 1 Q
Disassembly
1. Remove screw (20) and damper assembly 5. Remove piston (7) to remove retainer (6),
(19). springs (5) and (4) and shim (3).
a Store shim (3) after checking the thickness
2. Remove mounting bolt (17) to remove case and the number of shims at each mount-
(16), shaft (15) and lever (13) assembly. ing position.
3. Remove mounting bolt (11) to remove plate 6. Remove valve (2) from body (1).
(10).
a Check the thickness and the mounting
position of washer (12).
a Remove pin (22) from body (1).
50-500 26 PC78US-8
500 Hydraulic system
Disassembly and assembly of travel PPC valve assembly SEN04837-00
Assembly
Only the precautions for assembling the travel PPC
valve assembly are described.
PC78US-8 50-500 27
500 Hydraulic system
SEN04837-00 Disassembly and assembly of hydraulic cylinder assembly
New/Remodel
bly (2).
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-502-1003 Repair stand t 1
1
790-101-1102 Hydraulic pump t 1
790-102-3802 Wrench assembly t 1
2
790-330-1100 Wrench assembly t 1
Socket (Width
790-102-1320 across flats: 70 mm) t 1
50-500 28 PC78US-8
500 Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly SEN04837-00
PC78US-8 50-500 29
500 Hydraulic system
SEN04837-00 Disassembly and assembly of hydraulic cylinder assembly
50-500 30 PC78US-8
500 Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly SEN04837-00
3. Piston rod assembly 4) Set piston rod assembly (3) to tool U1.
1) Set plunger (8) to the piston rod and install 5) Using tool U3, tighten nut (4).
9 balls (7) and secure them with cap (6). 2 Nut: Liquid adhesive
a Check that there is some play at the (Equivalent to LOCTITE 262)
plunger tip. 3 Nut:
q Perform this work for only arm cylin- Cylinder
der. Tightening torque
name
Boom 2.60 ± 0.26 kNm {265 ± 26.5 kgm}
Arm 2.65 ± 0.26 kNm {270 ± 27 kgm}
Bucket 2.16 ± 0.22 kNm {220 ± 22 kgm}
Blade 3.14 ± 0.31 kNm {320 ± 32 kgm}
4. Cylinder assembly
1) Set the cylinder to tool U1.
2) Install piston rod assembly (3).
a Push in the piston rod to the end.
PC78US-8 50-500 31
500 Hydraulic system
SEN04837-00 Disassembly and assembly of hydraulic cylinder assembly
Cylinder
Tightening torque
name
Boom 961 ± 96.1 Nm {98 ± 9.8 kgm}
Arm 785 ± 78.5 Nm {80 ± 8 kgm}
1st time:
Tighten to 1,176 – 1,372 Nm {120 –
140 kgm}.
2nd time:
Loosen to 0 Nm {0 kgm}.
Bucket 3rd time:
Tighten to 392 Nm {40 kgm}
4th time:
Apply angle tightening
(Tighten periphery of cylinder head
by 3.5 – 4.5 mm).
Blade 1.03 ± 0.10 kNm {105 ± 10.5 kgm}
50-500 32 PC78US-8
500 Hydraulic system
Disassembly and assembly of hydraulic cylinder assembly SEN04837-00
PC78US-8 50-500 33
SEN04837-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
50-500 34
SEN04838-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 50-600 1
600 Work equipment
SEN04838-00 Removal and installation of work equipment assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-441-1802 Remover t 1
790-441-1810 Sleeve 1
792-900-1530 Screw 1
796-900-1240 Adapter 1 3. Remove cover (10).
V 1
01803-13034 Nut 1
01643-33080 Washer 1
790-101-4000 Puller 1
790-101-1102 Pump 1
Removal
k Extend the arm and bucket fully, lower the
work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Loosen the hydraulic tank cap to release
the pressure inside the hydraulic tank.
k Release the residual pressure in the
hydraulic circuit. For details, see Testing 4. Disconnect connector (11).
and adjusting, “Releasing residual pres- (If arm crane is equipped.)
sure from hydraulic circuit”.
k Disconnect the cable from the negative (–)
terminal of the battery.
50-600 2 PC78US-8
600 Work equipment
Removal and installation of work equipment assembly SEN04838-00
6. Remove lock plate (13) on the head side, and 9. Disconnect connector (14) and remove mount-
pull out pin (14). [*1] ing bolt (16) on the potentiometer mounting
a Check the quantity and positions of the plate (15). (If arm crane is equipped.)
inserted shims.
10. Remove plate (15) and pull out lock pin.
PC78US-8 50-600 3
600 Work equipment
SEN04838-00 Removal and installation of work equipment assembly
[*1]
2 Sliding surface of mounting pin (When
assembling): Hyper white grease (G2-T)
2 Mounting pin (Greasing after assembly):
Hyper white grease (G2-T)
k When aligning the pin holes, never insert
your fingers in them.
q Adjust the shim so that clearances “a, b”
between boom (19) and bracket (20) will be 1.0
mm or less.
q Clearance “a” shim thickness: t = 1.0 mm
q Clearance “b” shim thickness: t = 1.0 mm,
t = 1.5 mm
q Bleeding air
Bleed air. For details, see Testing and adjust-
ing, “Bleeding air from each part”.
50-600 4 PC78US-8
600 Work equipment
Removal and installation of blade assembly SEN04838-00
Removal and installation of blade 4. Remove right and left lock plates (5) and
assembly 1
remove blade and frame mounting pin (6). [*2]
PC78US-8 50-600 5
600 Work equipment
SEN04838-00 Removal and installation of blade assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Mounting pin: Grease (G1-T)
k When aligning the pin holes, never insert
your fingers in them.
q Adjust the shim so that clearance “a” between
blade (4) and blade cylinder piston rod (7) will
be 1.0 mm or less.
a Shim thickness: t = 1.0 mm
[*2]
2 Mounting pin: Grease (G1-T)
k When aligning the pin holes, never insert
your fingers in them.
q Adjust the shim so that clearance “b” between
blade (4) and frame (8) will be 1.0 mm or less.
a Shim thickness: t = 1.0 mm
q Bleeding air
Bleed air. For details, see Testing and adjust-
ing, “Bleeding air from each part”.
50-600 6 PC78US-8
600 Work equipment
Removal and installation of blade assembly SEN04838-00
PC78US-8 50-600 7
SEN04838-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
50-600 8
SEN04839-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 50-700 1
700 Cab and its attachments
SEN04839-00 Removal and installation of operator cab assembly
Removal and installation of 4. Remove cover (6) and ducts (7), (8) and (9).
operator cab assembly 1
[*1]
a Remove wiper motor wiring connector
Removal M05 on the reverse of cover (6), too.
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Disconnect the cable from the negative (–)
terminal of the battery.
a Record the locations of the disconnected wir-
ings and connectors to prevent a mistake in
reconnecting them.
50-700 2 PC78US-8
700 Cab and its attachments
Removal and installation of operator cab assembly SEN04839-00
PC78US-8 50-700 3
700 Cab and its attachments
SEN04839-00 Removal and installation of operator cab assembly
16. Remove 2 bolts (33) and clip (34) to remove 19. Disconnect connectors H09 (43), H16 (44) and
duct (35) at the left rear. H08 (45).
50-700 4 PC78US-8
700 Cab and its attachments
Removal and installation of operator cab assembly SEN04839-00
23. Remove 2 mounting nuts (50) and 3 mounting 25. Lift off operator cab assembly (54).
bolts (51) at the left front and rear of the opera- a Lift up and remove the operator cab
tor cab. [*2] assembly little by little, while checking for
a Mounting nuts (50) are used to install the an undisconnected wiring, etc.
4
floor frame, too.
Operator cab assembly: 330 kg
a The photo shows the left rear.
PC78US-8 50-700 5
700 Cab and its attachments
SEN04839-00 Removal and installation of operator cab assembly
[*1]
q Insert 2 ducts (8) and (9) to the base of duct
(55) in advance and pull up and insert them in
ducts (56) after installing the machine monitor.
[*3]
3 Mounting bolt (52):
235 – 309 Nm {24 – 31.5 kgm}
(Right front mounting bolt)
3 Mounting bolt (58):
[*2] 319 – 608 Nm {32.5 – 62 kgm}
q Bolts (57) of mounting nuts (50) are used to (Right rear mounting bolt)
install the front frame from underside, too.
When tightening the nuts, hold the bolts so that
they will not be dragged.
3 Mounting nut (50):
235 – 309 Nm {24 – 31.5 kgm}
3 Mounting bolt (57):
235 – 309 Nm {24 – 31.5 kgm}
50-700 6 PC78US-8
700 Cab and its attachments
Removal and installation of operator's cab glass (Stuck glass) SEN04839-00
a Among the panes of window glass on the 4 (1) :Right side window glass
sides of the operator's cab, 5 panes (1) – (5) (2) :Left side rear window glass
are stuck. (3) :Door upper window glass
In this section, the procedure for replacing the (4) :Door lower window glass
stuck glass is explained. (5) :Front window glass
When replacing front window glass (5), remove (6) :Front window assembly
front window assembly (6). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (7) : Double-sided adhesive tape
front window assembly is installed to the oper- (16) : Center trim seal
ator's cab.)
For the procedure for replacing the front win-
dow assembly, see “Removal and installation
of front window assembly”.
PC78US-8 50-700 7
700 Cab and its attachments
SEN04839-00 Removal and installation of operator's cab glass (Stuck glass)
New/Remodel
driver.
a Widening the cut with a screwdriver, cut
Necessity
Sym-
Part No. Part name the adhesive and double-sided adhesive
Sketch
bol
tape with knife [4].
Q'ty
(The figure shows the operator's cab of a
1 793-498-1210 Lifter (Suction cup) t 2 wheel loader.)
X
2 20Y-54-13180 Adapter t 2
Removal
a Remove the window glass to be replaced
according to the following procedure.
Installation
1. Using a knife and scraper [5], remove the
remaining adhesive and double-sided adhe-
a If a seal cutter is not available, make holes sive tape from the metal sheets (glass sticking
on the adhesive and double-sided adhe- surfaces) of the operator's cab.
sive tape with a drill and pass a fine wire a Remove the adhesive and double-sided
(piano wire, etc.) [2] through the holes. adhesive tape to a degree that they will
Grip the both ends of the wire with pliers not affect adhesion of the new adhesive.
[3], etc. (or hold them by winding them Take care not to scratch the painted sur-
onto something) and move the wire to the faces.
right and left to cut the adhesive and dou- (If the painted surfaces are scratched,
ble-sided adhesive tape. Since the wire adhesion will be lowered.)
may be broken by the frictional heat, apply (The figure shows the operator's cab of a
lubricant to it. wheel loader.)
(The figure shows the operator's cab of a
wheel loader.)
50-700 8 PC78US-8
700 Cab and its attachments
Removal and installation of operator's cab glass (Stuck glass) SEN04839-00
2. Remove oil, dust, dirt, etc. from the sticking 3. Apply primer (10).
surfaces of cab (8) and window glass (9) with a The using limit of primer (10) is 4 months
white gasoline. after the date of manufacture. Do not use
a If the sticking surfaces are not cleaned primer (10) after this limit.
well, the glass may not be stuck perfectly. a Use the primer within 2 hours after
a Clean the all black part on the back side of unpacking it.
the window glass. a Even if the primer is packed again just
a After cleaning the sticking surfaces, leave after it is unpacked, use it within 24 hours
them for at least 5 minutes to dry. after it is unpacked for the first time.
(Discard the primer 24 hours after it is
packed.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it.
(If the primer is unpacked just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
PC78US-8 50-700 9
700 Cab and its attachments
SEN04839-00 Removal and installation of operator's cab glass (Stuck glass)
3) Evenly apply paint primer to the surfaces a As for right side window glass (1),
to stick double-sided adhesive tapes and apply the primer to only the surfaces
the surfaces out of those surfaces on to stick double-sided adhesive tapes
operator's cab (8) which will be coated and the surfaces out of those sur-
with the adhesive. faces.
2 Paint primer: q Part (b)
SUNSTAR PAINT PRIMER 580 SUPER a After applying the primer, leave it for
or equivalent at least 5 minutes (within 8 hours) to
a Do not apply the primer more than 2 dry.
times. (If it is applied more than 2 a Never apply wrong primer. If the glass
times, its performance will be low- primer is applied by mistake, wipe it
ered.) off with white gasoline.
a Parts to be coated with primer: Apply 4) Evenly apply glass primer to the sticking
the primer all over dimension (a). surfaces of window glass (9).
q Dimension to apply primer (a): 2 Glass primer:
25 mm SUNSTAR GLASS PRIMER 580 SUPER
or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be low-
ered.)
50-700 10 PC78US-8
700 Cab and its attachments
Removal and installation of operator's cab glass (Stuck glass) SEN04839-00
a Parts to be coated with primer: Apply a When sticking double-sided adhesive tape
the primer to the sticking surfaces of (7) around a frame, do not lap its finishing
window glass (9) and all over dimen- end over the starting end but make clear-
sion (d) which will be on double-sided ance (e) of about 5 mm between them.
adhesive tape (7) and operator's cab 1) Stick double-sided adhesive tape (7) for
(8). right side window glass (1) as shown in
a Do not apply the primer to the the figure.
boarder about 5 mm wide between
the black part and transparent part of
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it
off with white gasoline.
PC78US-8 50-700 11
700 Cab and its attachments
SEN04839-00 Removal and installation of operator's cab glass (Stuck glass)
2) Stick double-sided adhesive tape (7) for 4) Stick double-sided adhesive tape (7) for
left side rear window glass (2) as shown in front window glass (5) as shown in the fig-
the figure. ure.
a Double-sided adhesive tape: 1,004
mm × 2 pieces
50-700 12 PC78US-8
700 Cab and its attachments
Removal and installation of operator's cab glass (Stuck glass) SEN04839-00
5. Position the new window glass. a When positioning front window glass
1) Check the clearance between the window (5), set its horizontal and vertical posi-
glass and the operator's cab on the right, tions as shown below.
left, upper, and lower sides, and then Part (m) (Right side):
adjust it evenly. Project by “3.8 mm” from the
2) Stick tapes [6] between window glass (9) frame end.
and operator's cab (8) and draw position- Part (o) (Upper side):
ing line (n). Retract by “3.0 mm” from the
a Stick tapes [6] to the right, left, and frame end.
lower parts of the right side window
glass, left side rear window glass, and
door lower window glass for accurate
positioning.
3) Cut the tape between window glass (9)
and operator's cab (8) with a knife, and
then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
6. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer): SUNSTAR PEN-
GUINE SEAL 580 SUPER “S”
2 Adhesive (Winter): SUNSTAR PEN-
GUINE SEAL 580 SUPER “W”
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
PC78US-8 50-700 13
700 Cab and its attachments
SEN04839-00 Removal and installation of operator's cab glass (Stuck glass)
1) Break aluminum seal (13) of the outlet of 5) Apply adhesive (15) to the outside of dou-
adhesive cartridge (12) and install the ble-sided adhesive tape (7) of the opera-
nozzle. tor's cab.
2) Cut the tip of the adhesive nozzle (14) so a Apply adhesive (15) to dimensions (s)
that dimensions (q) and (r) will be as fol- and (t) of double-sided adhesive tape
lows. (7) of operator's cab (8).
q Dimension (q): 10 mm q Dimension (s): 10 mm
q Dimension (r): 15 mm q Dimension (t): 15 mm
a Apply adhesive (15) thicker than dou-
ble-sided adhesive tape (7).
a Apply the adhesive evenly.
50-700 14 PC78US-8
700 Cab and its attachments
Removal and installation of operator's cab glass (Stuck glass) SEN04839-00
7. Install the window glass. a After installing front window glass (5),
1) Install window glass (9), matching it to the install the center trim seal to its bot-
lines of the positioning tapes drawn in step tom. Then, apply caulking material all
5. a r o u n d t h e g l a s s t o f i l l pa r t ( u )
a Since the window glass cannot be between the glass and center trim
removed and stuck again, stick it very seal.
carefully. a When caulking, neatly arrange the
a Stick the glass within 5 minutes after form of the adhesive at the right and
applying the adhesive. left ends with a rubber spatula.
2) After sticking window glass (9), press all 2 Adhesive: Sikaflex 256HV manu-
around it until it is stuck to the double- factured by Sika Japan
sided adhesive tape.
a Press the corners of the window glass
firmly.
PC78US-8 50-700 15
700 Cab and its attachments
SEN04839-00 Removal and installation of operator's cab glass (Stuck glass)
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to primer and adhesive from the operator's cab
the operator's cab, insert stopper rubbers and window glass.
X2 to 2 places (v) at the bottom of the a Using white gasoline, wipe off the adhe-
glass to fix the glass. sive before it is dried up.
(The figure shows the operator's cab of a When cleaning the glass, do not give an
PC200-7.) impact to it.
50-700 16 PC78US-8
700 Cab and its attachments
Removal and installation of front window assembly SEN04839-00
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
PC78US-8 50-700 17
700 Cab and its attachments
SEN04839-00 Removal and installation of floor frame assembly
Removal and installation of floor 3. Open radiator coolant drain valve (2) to drain
frame assembly 1
the coolant.
6 Coolant: 10 l
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Loosen the hydraulic tank cap gradually to
release the pressure inside the hydraulic
tank.
k Disconnect the cable from the negative (–)
terminal of the battery.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose. 4. Remove air cleaner assembly (3). [*1]
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
a Record the locations of the disconnected pip- 5. Remove exhaust temperature sensor P32 (4).
ings, wirings and connectors to prevent a mis-
take in reconnecting them.
50-700 18 PC78US-8
700 Cab and its attachments
Removal and installation of floor frame assembly SEN04839-00
6. Remove fusible links F02 (5) and F03 (6) and 9. Remove 2 clamps (14) and (15).
fuse holder (7).
PC78US-8 50-700 19
700 Cab and its attachments
SEN04839-00 Removal and installation of floor frame assembly
13. Disconnect horn connector M07 (25). 17. Remove ground wire terminal (36).
50-700 20 PC78US-8
700 Cab and its attachments
Removal and installation of floor frame assembly SEN04839-00
20. Remove air conditioner high and low pressure 26. Disconnect starting motor safety relay interme-
switch connectors P17 (50) and disconnect air diate connector R17 (60).
conditioner refrigerant hoses (51) and (52)
from the air conditioner unit. [*1]
PC78US-8 50-700 21
700 Cab and its attachments
SEN04839-00 Removal and installation of floor frame assembly
28. Pull out wiring lock pad (63) and draw out wir- 31. Remove 2 mounting bolts (70) at the left front
ing (64). and rear of the floor frame from underside. [*2]
29. Remove T-block (29). 32. Lift off floor frame assembly (71).
a Place the removed T-block on the floor a Lift up and remove the floor frame assem-
frame. bly little by little while checking for an
undisconnected wiring etc.
4 Floor frame assembly: 220 kg
50-700 22 PC78US-8
700 Cab and its attachments
Removal and installation of floor frame assembly SEN04839-00
PC78US-8 50-700 23
SEN04839-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
50-700 24
SEN04840-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 50-800 1
800 Electrical system
SEN04840-00 Removal and installation of air conditioner unit assembly
Removal and installation of air 2. Remove covers (2) on the front side and left
conditioner unit assembly 1
side of the machine.
Removal
k Park the machine on a level ground, lower
the work equipment to the ground, stop the
engine, and set the lock lever in the lock
position.
k Loosen the hydraulic tank cap gradually to
release the pressure inside the hydraulic
tank.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose. 3. Disconnect connectors V04 (3), V03 (4), V02
k Collect the air conditioner refrigerant (5) and V01 (6) and remove the wiring and
(R134a) from air conditioner circuit in toolbox (7).
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
50-800 2 PC78US-8
800 Electrical system
Removal and installation of air conditioner unit assembly SEN04840-00
6. Remove floor mat (13) and cover (14). a Use a 4-mm hexagonal wrench to remove
1 right bolt (22) of cover (18).
7. Remove machine monitor (15). For details, see a Remove 2 clips (23) to disconnect ducts
“Removal and installation of machine monitor (20) and (21).
assembly”.
9. Remove cover (18) and ducts (19), (20) and 11. Remove duct (26) at the left rear.
(21). [*2]
a Remove wiper motor wiring connector 12. Disconnect connectors N10 (27) and AC01
M05 on the reverse of cover (18), too. (28) and connectors (29) and (30) from air con-
ditioner controller (31) and unclamp and
remove wiring (32).
PC78US-8 50-800 3
800 Electrical system
SEN04840-00 Removal and installation of air conditioner unit assembly
13. Remove right duct (33). 17. Remove 3 mounting bolts (40) of seat mount-
ing bracket (39) on each of the right and left
sides.
50-800 4 PC78US-8
800 Electrical system
Removal and installation of air conditioner unit assembly SEN04840-00
Installation
q Carry out installation in the reverse order to
removal.
a When installing the air conditioner circuit
hoses, take care that dirt, dust, water, etc. will
not enter them.
[*1]
q When installing each air conditioner refrigerant
hose joint, check that the O-ring is fitted to it.
q Check that the O-ring is not damaged or deteri-
orated.
q When connecting each air conditioner refriger-
ant hose, apply compressor oil (DENSO: ND-
20. Install 1 guide bolt [2] on each of the right and O I L 8 , VA L E O T H E R M A L S Y S T E M S :
left sides, tighten the right and left forcing ZXL100PG (equivalent to PAG46)) for refriger-
screws [1] evenly to lift up the bracket, and ant (R134a) to the O-ring.
remove air conditioner unit assembly (43).
a Tighten the forcing screws until the [*2]
bracket is lifted up 90 mm. q Insert 2 ducts (20) and (21) to the base of duct
(38) in advance and pull up and insert them in
ducts (44) after installing the machine monitor.
PC78US-8 50-800 5
800 Electrical system
SEN04840-00 Removal and installation of machine monitor assembly
Removal and installation of 3. Remove 1 mounting bolt (6) and remove duct
machine monitor assembly 1
(7).
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
Installation
q Carry out installation in the reverse order to
removal.
50-800 6 PC78US-8
800 Electrical system
Removal and installation of pump controller assembly SEN04840-00
Removal and installation of pump 4. Remove 4 mounting bolts (5) to remove pump
controller assembly 1
controller assembly (6).
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
Installation
q Carry out installation in the reverse order to
removal.
PC78US-8 50-800 7
800 Electrical system
SEN04840-00 Removal and installation of engine controller assembly
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
50-800 8 PC78US-8
800 Electrical system
Removal and installation of engine controller assembly SEN04840-00
[*1]
3 Screw: 2.55 – 3.11 Nm {0.26 – 0.32 kgm}
PC78US-8 50-800 9
800 Electrical system
SEN04840-00 Removal and installation of KOMTRAX terminal assembly
50-800 10 PC78US-8
800 Electrical system
Removal and installation of KOMTRAX terminal assembly SEN04840-00
PC78US-8 50-800 11
SEN04840-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
50-800 12
SEN04564-00
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 90-100 1
100 Hydraulic diagrams and drawings
SEN04564-00
90-100 2 PC78US-8
Hydraulic circuit diagram
Hydraulic circuit diagram PC78US-8 (Blade specification)
1
SEN04564-00
PC78US-8
90-100 3
Hydraulic circuit diagram
Hydraulic circuit diagram 1
PC78US-8 (Bladeless specification)
PC78US-8 (Bladeless specification)
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04564-00
PC78US-8
90-100 5
Hydraulic circuit diagram
Hydraulic circuit diagram PC78US-8 (EU specification)
1
SEN04564-00
PC78US-8
90-100 7
100 Hydraulic diagrams and drawings
Actuator attachment hydraulic circuit diagram SEN04564-00
PC78US-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC78US-8 90-100 9
100 Hydraulic diagrams and drawings
SEN04564-00
PC78US-8 90-100 11
SEN04564-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
90-100 12
SEN04565-01
HYDRAULIC EXCAVATOR
PC78US-8
PC78US-8 90-200 1
200 Electrical diagrams and drawings
SEN04565-01
90-200 2 PC78US-8
Electrical circuit diagram (1/6)
Electrical circuit diagram (1/6) PC78US-8
1
PC78US-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04565-01
PC78US-8
90-200 3
Electrical circuit diagram (2/6)
Electrical circuit diagram (2/6) PC78US-8
1
PC78US-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04565-01
PC78US-8
90-200 5
Electrical circuit diagram (3/6)
Electrical circuit diagram (3/6) PC78US-8
1
PC78US-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04565-01
PC78US-8
90-200 7
Electrical circuit diagram (4/6)
Electrical circuit diagram (4/6) PC78US-8
1
PC78US-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04565-01
PC78US-8
90-200 9
Electrical circuit diagram (5/6)
Electrical circuit diagram (5/6) PC78US-8
1
PC78US-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04565-01
PC78US-8
90-200 11
Electrical circuit diagram (6/6)
Electrical circuit diagram (6/6) PC78US-8
1
PC78US-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
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PC78US-8
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Electrical circuit diagram (1/6)
Electrical circuit diagram (1/6) PC78US-8 (EU specification)
1
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PC78US-8
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Electrical circuit diagram (2/6)
Electrical circuit diagram (2/6) PC78US-8 (EU specification)
1
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PC78US-8
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Electrical circuit diagram (3/6)
Electrical circuit diagram (3/6) PC78US-8 (EU specification)
1
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PC78US-8
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Electrical circuit diagram (4/6)
Electrical circuit diagram (4/6) PC78US-8 (EU specification)
1
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PC78US-8
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Electrical circuit diagram (5/6)
Electrical circuit diagram (5/6) PC78US-8 (EU specification)
1
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PC78US-8
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Electrical circuit diagram (6/6)
Electrical circuit diagram (6/6) PC78US-8 (EU specification)
1
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PC78US-8
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Air conditioner unit electrical circuit diagram
Air conditioner unit electrical circuit diagram PC78US-8
1
PC78US-8
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PC78US-8
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Connector list and stereogram
PC78US-8
Connector list and stereogram PC78US-8
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©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
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