PC78US-8 Testing and Adjusting

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HYDRAULIC EXCAVATOR
PC78US-8
SEN04804-01
PC78US-8
Shop Manual
PC78US-8 15001 and up
30 Testing and adjusting

101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting ........................................................................................ 3

Testing engine speed.................................................................................................................................. 8
Testing exhaust temperature ...................................................................................................................... 9
Checking exhaust gas color........................................................................................................................ 10
Adjusting valve clearance ........................................................................................................................... 11
Testing compression pressure .................................................................................................................... 13
Testing blow-by pressure ............................................................................................................................ 15
Testing engine oil pressure ......................................................................................................................... 16
Handling fuel system parts.......................................................................................................................... 17
Releasing residual pressure from fuel system ............................................................................................ 17
Testing fuel pressure .................................................................................................................................. 18
Testing fuel return rate and fuel leakage .................................................................................................... 19
Bleeding air from fuel circuit........................................................................................................................ 21
Checking fuel circuit for leakage ................................................................................................................. 23
Testing and adjusting alternator belt tension .............................................................................................. 24
Checking and adjusting air conditioner compressor belt tension ................................................................ 26
Testing swing circle bearing clearance ....................................................................................................... 27
Checking and adjusting track shoe tension ................................................................................................ 28
Testing and adjusting oil pressure in work equipment and travel circuits ................................................... 30
Testing and adjusting swing and blade circuit oil pres sure (Blade specification) ....................................... 32
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Testing control circuit basic pressure.......................................................................................................... 35

Testing and adjusting oil pressure in pump PC control circuit .................................................................... 36
Testing PC-EPC solenoid output pressure ................................................................................................. 39
Testing LS differential pressure and adjusting LS valve ............................................................................. 40
Testing solenoid valve output pressure....................................................................................................... 42
Testing PPC valve output pressure............................................................................................................. 44
Adjusting play of work equipment and swing PPC valves........................................................................... 46
Checking parts which cause hydraulic drift of work equipment................................................................... 47
Testing and adjusting travel deviation......................................................................................................... 49
Releasing residual pressure from hydraulic circuit...................................................................................... 51
Testing oil leakage ...................................................................................................................................... 52
Bleeding air from each part ......................................................................................................................... 55
Adjusting mirrors ......................................................................................................................................... 57
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Tools for testing, adjusting, and troubleshooting

Sym-
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/cm 2}
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 mmH 2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm 2}
Pressure gauge: 60 MPa
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:
1 {25, 60, 400, 600 kg/cm 2}
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 14
2 6164-81-5750 Joint 1 14
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:
Testing and adjusting oil
1 {25, 60, 400, 600 kg/cm 2}
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:
Testing and adjusting swing 1 {25, 60, 400, 600 kg/cm 2}
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
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Sym-
bol
Pressure gauge:
1 {25, 60, 400, 600 kg/cm 2}
Testing basic pressure of
L Pressure gauge: 60 MPa
control circuit 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm 2}
Testing and adjusting oil
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:
1 {25, 60, 400, 600 kg/cm 2}
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:
Testing solenoid valve out- 1 {25, 60, 400, 600 kg/cm 2}
P
put pressure Pressure gauge: 60 MPa
{600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Pressure gauge:
Testing PPC valve output 1 {25, 60, 400, 600 kg/cm 2}
Q
pressure Pressure gauge: 60 MPa
{600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Commercially
Testing oil leakage S Measuring cylinder 1
available
799-601-4101
or T-adapter assembly 1
799-601-4201
For DRC60, Econo (Does not include
799-601-4350 Measurement box 1
799-601-4201)
799-601-4130 T-adapter 1 CAM
Troubleshooting for engine 799-601-4160 T-adapter 1 Ne sensor
T
controller/sensors/actuators 799-601-4220 T-adapter 1 Engine controller
799-601-4240 Socket 1 For ambient pressure sensor
799-601-4190 Socket 1 Common rail pressure sensor
799-601-4340 Socket 1 Injector
795-799-5530 Socket 1 Engine coolant temperature sensor
799-601-4380 Socket 1 Boost pressure sensor
799-601-4260 Socket 1 Engine controller
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Sym-
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
799-601-2700)
799-601-4101
Troubleshooting for chassis or
U
sensors/wiring harnesses 799-601-4201
799-601-9000
or
799-601-9200
For DT, HD (Does not include
799-601-4100 and 799-601-4201)
799-601-9020 Adapter for DT 1 For DT2P
For DT3P (Does not include
799-601-9030 Adapter for DT 1
799-601-4100 and 799-601-4201)
For DT6P (Does not include
799-601-4100 and 799-601-4201)
Adapter for DT For DT12P (Does not include
799-601-9110 1
(Gray) 799-601-4100 and 799-601-4201)
For AMP3P (Does not include
799-601-9420 Adapter for AMP 1
799-601-9000 and 799-601-9200)
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Sym-
bol
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For X1P (Does not include
799-601-7010 Adapter for X 1
799-601-7000 and 799-601-7100)
799-601-7020 Adapter for X 1 For X2P
For SW6P (Does not include
799-601-7050 Adapter for SWP 1
799-601-8000)
For SW6P (Does not include
799-601-7060 Adapter for SWP 1
799-601-8000)
Troubleshooting for chassis For M1P (Does not include
T 799-601-7080 Adapter for M 1
sensors/wiring harnesses 799-601-7000 and 799-601-7100)
799-601-7090 Adapter for M 1 For M2P
799-601-7130 Adapter for M For M6P
For S16P (Does not include
799-601-7330 Adapter for S 1
799-601-7000 and 799-601-7100)
799-601-7500 T-adapter assembly 1
799-601-7520 Adapter for 070 1 For 070-12P
799-601-7540 Adapter for 070 1 For 070-18P
799-601-9890 Multi-adapter 1 For DT-2, 3, 4/DTM-2P
Box for controller
799-601-4280 1
(PUMP)
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7370 Adapter for relay 1 For REL-6P
Testing coolant tempera-
799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
ture and oil temperature
Testing operating effort and 79A-264-0021 Push-pull scale 1
depressing force 79A-264-0091 Push-pull scale 1
Testing stroke and hydraulic Commercially
Ruler 1
drift available
Testing work equipment Commercially
Stopwatch 1
speed available
Testing voltage and resis- Commercially
Circuit tester 1
tance available
27 mm deep socket (hexagonal),
Removal and installation of Commercially
Deep socket 1 Inside diameter: 24.5 (Equivalent to
engine oil pressure switch available
TONE 4A-27L)
Removel and installation of
coolant temperature sensor
Commercially 21 mm deep socket
(6261-81-6900) Deep socket 1
available (MITOLOY 4ML-21 or equivalent)
Engine serial
No.500001-502653
Removel and installation of
coolant temperature sensor 19 mm deep socket
Deep socket 1
(6261-81-6901) 795T-981-1010 (MITOLOY 4ML-19 or equivalent)
Engine serial No.502654-
For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the ma-
chine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Trouble-
shooting (General information on troubleshooting), List of T-boxes and T-adapters".
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-:Socket
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Testing engine speed 4. Testing pump relief speed

1) Start the engine and operate the arm cylinder
Test the engine speed with the monitoring func-
to the IN stroke end.
tion of the machine monitor.
Test the engine speed under the following condi- 2) Set the fuel control dial in the high idle (MAX)
tion. position and set the working mode in the
Engine coolant temperature: Within operat- power mode (P).
ing range 3) Operate the left work equipment control lever
Hydraulic oil temperature: Within operating to relieve the arm circuit at the IN stroke end
range and test the engine speed.
1. Preparation work 5. Testing auto-deceleration speed

Operate the machine monitor so that the engine 1) Start the engine, set the fuel control dial in
speed can be monitored. the high idle position (MAX), and turn the
For the operating method of the machine auto-decelerator ON.
monitor, see “Special functions of machine 2) Set all the levers and pedals for work equip-
monitor”. ment control, swing control, and travel in
Monitoring code: 01002 Engine speed neutral and test the engine speed when the
auto-decelerator operates.
The engine speed lowers to a certain level
about 5 seconds after all the levers and ped-
als are set in neutral. This level is the au-
to-deceleration speed.
2. Testing low idle speed

1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
2) Set all the levers and pedals for work equip-
ment control, swing control, and travel in
neutral and test the engine speed.
3. Testing high idle speed

1) Start the engine and set the fuel control dial
in the high idle (MAX) position.
2) Set the working mode in the power mode (P)
and turn the auto-decelerator OFF.
3) Set all the levers and pedals for work equip-
ment control, swing control, and travel in
neutral and test the engine speed.
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Testing exhaust temperature

Testing tools for exhaust temperature 3. Install sensor [1] of digital thermometer R and
Symbol Part No. Part name connect it to thermometer [2].
R 799-101-1502 Digital thermometer
Install or remove the testing instrument after
the exhaust manifold temperature has low-
ered.
1. Remove covers (1) and (2).
4. Run the engine and test the exhaust tempera-

ture over the speed range.
5. After finishing test, remove the testing instru-

ment and return the removed parts.
2. Remove exhaust temperature pickup plug (3)

from the side of the center of the exhaust mani-
fold.
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Checking exhaust gas color

Checking tools for exhaust gas color
Symbol Part No. Part name
1 799-210-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
Stop the machine on a level ground and low-
er the work equipment to the ground.
Be careful not to touch any hot part when re-
moving or installing the checking tools.
Check the exhaust gas color under the following
condition.
Engine coolant temperature: Within operat-
ing range
If an air source and an electric power source are 2) Connect the probe hose, receptacle of the
not available in the field, use handy smoke accelerator switch, and air hose to smoke
checker A1. When recording official data, use meter A2.
smoke meter A2. Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2}.
1. Testing with handy smoke checker A1 3) Connect the power cable to an AC recep-
1) Stick a sheet of filter paper to smoke checker tacle.
A1. Before connecting the cable, check that
2) Insert the exhaust gas intake pipe in exhaust the power switch of the smoke meter is
pipe (1). turned OFF.
3) Start the engine and accelerate it suddenly or 4) Loosen the cap nut of the suction pump and
run it at high idle and operate the handle of fit the filter paper.
smoke checker A1 so that the filter paper will Fit the filter paper securely so that the ex-
absorb the exhaust gas. haust gas will not leak.
Absorbing time: 1.4 ± 0.2 sec 5) Turn on the power switch of smoke meter A2.
6) Start the engine and accelerate it suddenly or

4) Remove the filter paper and compare it with run it at high idle and depress the accelerator
the attached scale. pedal of smoke meter A2 and collect the
5) After finishing checking, remove the testing exhaust gas into the filter paper.
tools and return the removed parts. 7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
2. Checking with smoke meter A2 filter paper holder and read the indicated
1) Insert probe [1] of smoke meter A2 in the value.
outlet of the exhaust pipe (1) and fix it to the 8) After finishing checking, remove the
exhaust pipe with a clip. checking tools and return the removed parts.
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Adjusting valve clearance

Adjusting tools for valve clearance 3. Remove undercover (5) and rotate the crank-
Symbol Part No. Part name shaft through the opening under the crankshaft
Commercially pulley.
B Clearance gauge
available
Adjust the valve clearance under the following
condition.
Engine coolant temperature: Normal temper-
ature
1. Remove the engine hood, engine oil feed hose

(1), air conditioner compressor hose clamp (2)
and air intake elbow (3).
4. Rotate the crankshaft forward (clockwise seen

from the front) and set wide notch (a) (Width: 25
mm) of signal plate (1) at the rear of the crank-
shaft pulley to embossed letters "1.4TOP" (b) of
front cover (2).
Reference: All of the other notches of the signal
plate are 5 mm in width.
Rotate the crankshaft with the crankshaft pul-
ley bolt (3) (Width: across flats: 27 mm).
Always rotate the crankshaft pulley bolt for-
ward to prevent it from being loosened.
2. Remove cylinder head cover (4).
When the No. 1 cylinder is at the compres-

sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not at
the compression top dead center. In this
case, rotate the crankshaft one more turn.
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5. Adjust the valve clearances marked with in the 7. After finishing adjustment, remove the adjusting
valve arrangement drawing according to the tools and return the removed parts.
following procedure. Cylinder head cover mounting nut:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
1) While fixing adjustment screw (1), loosen

locknut (2).
2) Insert clearance gauge B in the clearance
between rocker arm (3) and valve stem (4)
and adjust the valve clearance with adjust-
ment screw (1).
With the clearance gauge inserted, turn

the adjustment screw to a degree that you
can move the clearance gauge lightly.
Valve clearance
Intake valve: 0.35 ± 0.02 mm
Exhaust valve: 0.50 ± 0.02 mm
3) While fixing adjustment screw (1), tighten
locknut (2).
Locknut: 39 – 49 Nm {4 – 5 kgm}
After tightening the locknut, check the
valve clearance again.
6. Rotate the crankshaft forward 1 turn according

to step 4 to set the No. 4 cylinder to the compres-
sion top dead center and adjust the valve clear-
ances marked with in the valve arrangement
drawing similarly to those marked with .
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Testing compression pressure 6) Remove holder (7) and injector (1).

If the injector is stuck and is not removed
easily, pass a wire under the fuel inlet and
1 795-502-1590 Compression gauge
C 795-502-1370 Adapter
pull it up to remove the injector.
2 Do not apply an external force to the ter-
6271-11-3880 Gasket
minal at the injector top.
When testing the compression pressure,
take care not to burn yourself on the exhaust
manifold or muffler or get caught in a rotating
part.
Test the compression pressure after the engine
is warmed up.
(Engine oil temperature: 40 – 60 °C)
1. Remove the injector of the cylinder to be tested

according to the following procedure.
Test of the No. 1 cylinder is explained below
as an example.
1) Remove the heater hose clamp.
2) Remove wiring harness connector (2) from
2. Install adapter C2 to the injector mounting part
injector (1).
with holder (7) and connect compression gauge
3) Move fuel scatter prevention cover (3) from C1.
the joint. Fit the gasket to the adapter end without fail.
4) Remove clamp (4) and high-pressure pipe Holder mounting bolt:
(5). 27 – 30 Nm {2.8 – 3.1 kgm}
5) Pull spill hose connector (6) out of injector Tighten the mounting bolt after the fulcrum of
(1). the holder is seated perfectly.
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3. Set the engine in the no-injection cranking mode 3) Connect spill hose connector (6) to injector
with the machine monitor. (1).
Instead of the above work, you may discon- 4) Install high-pressure pipe (5).
nect the wiring harness connectors from all High-pressure pipe flare nut (Both
the injectors so that fuel will not be injected at ends):
all. 25.5 – 29.4 Nm {2.6 – 3.0 kgm}
Since starting of engine is dangerous, be 5) Install fuel scatter prevention cover (3) to the
sure to set the injectors so that they will joint of high-pressure pipe (5).
not inject fuel before starting the check. Install fuel scatter prevention cover (3)
with the slit down (on both injector side
4. Crank the engine with the starting motor and and common rail side).
measure the compression pressure. 6) Install clamp (4) to high-pressure pipe (5).
Read the pressure when the gauge pointer is Install the clamp to the position from
stabilized. which it was removed. (The mounting
bolt goes through the clamp and enters
5. After finishing measurement, remove the the bolt hole of the air intake manifold.
measuring instruments and return the removed Accordingly, if the mounting bolt is in-
parts according to the following procedure. stalled normally, the clamp is installed to
1) Install O-ring (8) and gasket (9) to injector (1). its original position.)
Do not install O-ring (8) to groove "a". 7) Connect wiring harness connector (2) to
injector (1).
2) Insert injector (1) in the cylinder head and fix

it with holder (7).
Holder mounting bolt:
27 – 30 Nm {2.8 – 3.1 kgm}
Seat the fulcrum of the holder perfectly
before tightening the mounting bolts.
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Testing blow-by pressure
Testing tools for blow-by pressure

Symbol Part No. Part No.
D 799-201-1504 Blow-by checker
Test the blow-by pressure under the following
condition.
ing range
Hydraulic oil temperature: Within operating
range
5. After finishing test, remove the testing tools and
return the removed parts.
1. Remove the undercover of the hydraulic pump.
2. Install tool and adapter [1] of blow-by checker D

to breather hose (1) and connect gauge [2].
3. Start the engine, set the working mode in the

power mode (P), and turn the swing lock switch
ON.
4. While running the engine at high idle, relieve the

arm circuit and test the blow-by pressure.
Read the gauge when the pointer is stabi-
lized.
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Testing engine oil pressure 2. Remove oil pressure pickup plug (1) from the
engine block.
Testing tools for engine oil pressure
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
Test the engine oil pressure under the following
condition.
ing range
3. Install nipple [1] of hydraulic tester E1 and

adapter E3 and connect gauge E2.
4. Start the engine and turn the auto-decelerator

OFF.
5. Test the oil pressure during low idle and high
idle.

Oil pressure pickup plug:
20 – 22 Nm {2.0 – 2.2 kgm}
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Handling fuel system parts Releasing residual pressure from

Precautions for checking and maintaining fuel system fuel system
The common rail fuel injection system (CRI) Pressure is generated in the low-pressure circuit
consists of more precise parts than the conven- and high-pressure circuit of the fuel system while
tional fuel injection pump and nozzle. If foreign the engine is running.
matter enters this system, it can cause a trouble. Low-pressure circuit:
When checking and maintaining the fuel system, Feed pump – Fuel main filter – Supply pump
take care more than the past. If dust, etc. sticks High-pressure circuit:
to any part, wash that part thoroughly with clean Supply pump – Common rail – Injector
fuel. The pressure in both low-pressure circuit and
Precautions for replacing fuel filter cartridge high-pressure circuit lowers to a safety level au-
Be sure to use the Komatsu genuine fuel filter tomatically 30 seconds after the engine is
cartridge. stopped.
Since the common rail fuel injection system Before the fuel circuit is checked and its parts
(CRI) consists of more precise parts than the are removed, the residual pressure in the fuel
conventional fuel injection pump and nozzle, it circuit must be released completely. According-
employs a high-efficiency special filter to prevent ly, observe the following.
foreign matter from entering it. If a filter other Before checking the fuel system or removing its
than the genuine one is used, the fuel system parts, wait at least 30 seconds after stopping the
may have a trouble. Accordingly, never use such engine until the residual pressure in the fuel cir-
a filter. cuit is released. (Do not start the work just after
stopping the engine since there is residual pres-
sure.)
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Testing fuel pressure 2) Install adapter F2 and nipple [1] of the

hydraulic tester F1 and connect them to
Testing tools for fuel pressure
gauge of boost gauge kit F3.
Use the oil pressure gauges of 2.5 MPa
1 {25 kg/cm2}.
F 795-471-1450 Adapter (8 × 1.25 mm)
2
07005-00812 O-ring
3 799-201-2202 Boost gauge kit
Test only the fuel pressure in the low-pressure
circuit from the priming pump through the fuel
main filter to the supply pump, and the return cir-
cuit from the supply pump/common rail/injector
to fuel tank.
Since the pressure in the high-pressure cir-
cuit from the supply pump through the com-
mon rail to the injector is very high, it cannot
be tested.
3) Run the engine at high idle and test the pres-
1. Testing pressure in fuel low-pressure circuit sure in the fuel low-pressure circuit.
1) Open the engine hood and remove fuel pres- If the pressure in the fuel low-pressure cir-
sure pickup plug (1) from the fuel main filter. cuit is in the following range, it is normal.
Reference: Negative pressure is indi-
cated.
Engine speed Fuel pressure
-49 – 0 kPa
At high idle
{-0.5 – 0 kg/cm 2}
4) After finishing test, remove the testing tools

and return the removed parts.
Fuel pressure pickup plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
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Testing fuel return rate and fuel 2) Insert spacer G1 on return block (2) side and
leakage tighten the removed joint bolt again.
Be sure to fit the gaskets to both ends of
Testing tools for fuel return rate and fuel leakage the spacer.
Symbol Part No. Part name 3) Insert joint G2 on common rail (1) side and
1 6151-51-8490 Spacer
tighten the removed joint bolt again.
2 6164-81-5750 Joint
3 07042-20108 Plug Be sure to fit the gaskets to both ends of
Commercially the joint.
4 Hose
available 4) Connect test hose G4 to the end of joint G2.
G Commercially 5) Connect test hose G5 to connector (6) side of
5 Hose
available spill hose (4).
Commercially
6 Measuring cylinder Bind the connecting part of the test hose
available
Commercially with a wire etc. to prevent it from coming
7 Stopwatch off.
available
Lay test hose G4 so that it will not slacken
Prepare an oil pan of about 20 to receive the and put its end in the oil pan.
fuel flowing out during the test.
1. Preparation work
1) Remove tube (3) and spill hose (4) between
common rail (1) and return block (2).
6) Remove spill hose connector joint (5) and

install plug G3.
The above is the preparation work for test

of the leakage from the pressure limiter
and return rate from the injector.
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2. Testing leakage from pressure limiter 3. Testing return rate from injector
1) Lay test hose G4 so that it will not slacken While testing the return rate from the injector,
and put its end in the oil pan. keep the test hose on the pressure limiter
2) Start the engine and keep its speed at 1,600 side connected and keep its end in the oil
rpm with no load. pan.
3) After the engine speed is stabilized, test the 1) Run the engine at the rated output.
leakage in 1 minute with measuring cylinder 2) After the engine speed is stabilized, test the
G6. return rate in 1 minute with measuring
You may test for 20 seconds and judge by cylinder G6.
multiplying the result by 3. You may test for 20 seconds and judge by
If the leakage from the pressure limiter is multiplying the result by 3.
in the following standard range, it is nor- If the supply pump pressure is low, the
mal. engine speed may not rise.
Engine speed Leakage In this case, record the engine speed, too,
(rpm) (cc/min) during the test.
At rated output Max. 20 If the return rate (spill) from the injector is
in the following standard range, it is nor-
mal.
Rated output Limit of return rate
speed (rpm) (spill) (cc/min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230
4) After finishing test, stop the engine.
3) After finishing test, stop the engine.

Joint bolt: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
30-4 20 PC78US-8
SEN04804-01
Bleeding air from fuel circuit

If fuel is used up or if a fuel circuit part is removed
and installed, bleed air from the fuel circuit ac-
cording to the following procedure.
1. Fill fuel in the fuel tank to full.

Add fuel until float of the sight gauge reaches
to the maximum rising position.
2. Open the engine hood.
3. Loosen knob (1) of the feed pump and pull it out,

and then operate it forward and backward.
Move the knob until it becomes heavy.
The plug at the top of the fuel main filter does
not need to be removed.
4. After bleeding air, push in and tighten knob (1).
PC78US-8 30-4 21
SEN04804-01
Air bleeding route of fuel circuit

Fuel tank Pre-filter Main filter Feed pump Metering unit Fuel tank
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
SEN04804-01
Checking fuel circuit for leakage

Very high pressure is generated in the
high-pressure circuit of the fuel system. If
fuel leaks while the engine is running, it is
dangerous since it can catch fire.
After checking the fuel system or removing its
parts, check it for fuel leakage according to the
following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Start the engine, keep its speed at low idle, and

stop it when its speed is stabilized.
3. Check the fuel piping and devices for fuel

leakage.
Check mainly around the high-pressure cir-
cuit parts coated with the color checker for
fuel leakage.
If any fuel leakage is detected, repair it and
check again from step 2.
4. Run the engine at high idle.

leakage.
Check around the high-pressure circuit parts
coated with the color checker for fuel leak-
age.
6. Run the engine at high idle and load it.

Relieve the arm circuit at the IN stroke end.

leakage.
Check mainly around the high-pressure cir-
cuit parts coated with the color checker for
fuel leakage.
If no fuel leakage is detected, check is com-
pleted.
PC78US-8 30-4 23
SEN04804-01
Testing and adjusting alternator Adjusting

belt tension If the deflection is out of the standard range, ad-
just the belt tension according to the following
Testing procedure.
1. Remove undercover (1).
Press the middle point of the belt between the

alternator pulley and crankshaft pulley with a
finger and measure deflection (a).
Pressing force: Approx. 60 Nm {Approx. 6.1
kg}
Deflection (a): 6 – 10 mm
2. Loosen alternator fixing bolts (1) and (2).
30-4 24 PC78US-8
SEN04804-01
3. Loosen locknut (3) and rotate adjustment bolt (4)

to adjust the tension of alternator belt (5).
Reference: If adjustment bolt (4) is tightened
(turned to the right), the alternator belt (5) is loos-
ened. If the former is turned to the left, the latter
is tightened.
4. After adjusting the belt tension, tighten alternator

fixing bolts (1) and (2) and locknut (3).
5. Check again that the tension of alternator belt (5)

is in the standard range.
PC78US-8 30-4 25
SEN04804-01
Checking and adjusting air condi- Adjusting

tioner compressor belt tension If the belt deflection is abnormal, adjust it accord-
ing to the following procedure.
er the work equipment to the ground. 1. Loosen bolts (1) and (2).
Checking 2. Move compressor (3) and bracket (4) together to

1. Open the engine hood, press the middle point of adjust the belt tension.
the belt between compressor pulley (2) and
crankshaft pulley (3) with a finger, and measure 3. After positioning compressor (3), tighten bolts
deflection (a). (1) and (2).
Belt pressing force: 60 N {6.1 kg} Check each pulley for breakage, wear of the
Deflection (a):12 - 15 mm V-groove, and contact of the V-belt and
V-groove.
If the V-belt is so lengthened that the adjust-
ment allowance is eliminated or it has a cut or
a crack, replace it.
If the belt is replaced, adjust their tension
again after operating the machine for 1 hour.
After tightening the bolts, check the belt ten-
sion again according the above procedure.
4. After finishing test, return the removed parts.
30-4 26 PC78US-8
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.
Testing tools for swing circle bearing clearance At this time the front of the upper structureris-
Symbol Part No. Part name es and the rear lowers.
Commercially
H Dial gauge
available
5. Under this condition, read dial gauge H.
When testing the swing circle bearing clearance The value indicated by dial gauge H is the
installed to the machine, perform the following clearance of the bearing.
procedure. For the standard value, see Structure, func-
Stop the machine on a level ground and low- tion and maintenance standard, "Swing cir-
er the work equipment to the ground. cle".
Do not put your hands or feet under the un-
dercarriage during test.
1. Fix dial gauge H to the track frame and apply the

probe to the lower end of the outer race.
6. Return the machine to the condition of step 2

and check that dial gauge H indicates 0.
If the dial gauge does not indicate 0, repeat
steps 2 through 5.
2. Set the work equipment to the maximum reach

position and set the bucket tip to the height of the
underside of the revolving frame.
At this time the front of the upper structure
lowers and the rear rises.
3. Set dial gauge H to the 0 point.
PC78US-8 30-4 27
SEN04804-01
Checking and adjusting track Adjusting

shoe tension If the track shoe tension is abnormal, adjust it ac-
cording to the following procedure.
Checking
1. Run the engine at low idle and drive the machine 1. Increasing tension
forward by the length of track on ground, and 1) Add grease through grease fitting (2) with a
then stop slowly. grease gun.
2) To check that the tension is normal, run the
2. Place square bar [3] longer than the distance engine at low idle and move the machine
between idler (1) and carrier roller (2) on the forward by the length of track on ground, then
track shoe. stop slowly.
As the square bar [3], use an angle steel, etc. 3) After adjusting, check the track shoe tension
which will be deflected less. again according to the above procedure.
3. Test maximum clearance (a) between square

bar [3] and track shoe.
Standard max. clear-
Specification
ance (a)
Road liner, steel shoe 10 – 30 mm
Rubber shoe 1 – 3 mm
You may add grease until dimension (b)

between the idler guide and track frame
end becomes 0 mm. If the tension is still
low, the pins and bushings are worn
much. In this case, reverse or replace the
pins and bushings.
30-4 28 PC78US-8
SEN04804-01
2. Decreasing tension
1) Loosen valve (1) to discharge grease, and
then tighten it.
Do not loosen the valve more than 1
turn. If it is loosened more, it may
jump out because of the high-pressure
grease in it.
2) To check that the tension is normal, run the
engine at low idle and move the machine
forward by the length of track on ground, then
stop slowly.
3) After adjusting, check the track shoe tension
again according to the above procedure.
PC78US-8 30-4 29
SEN04804-01
Testing and adjusting oil pressure 2) Install nipples J2 and connect oil pressure
in work equipment and travel gauges [1] of hydraulic tester J1.
circuits Use the oil pressure gauges of 60 MPa
{600 kg/cm 2}.
Testing and adjusting tools for oil pressure in

work equipment and travel circuits
1
J
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
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
The oil pressure in the work equipment and trav-
el circuits (pump discharge pressure) can be
checked with monitoring function of the machine
monitor, too (For details, see "Special functions
of machine monitor").
Monitoring code: 01100 pump pressure
Test the oil pressure in the work equipment and
travel circuits under the following condition.
range
1. Preparation work
1) Open the sand cover and remove oil pres-
sure pickup plugs (1) and (2). 2. Testing unload pressure
(1): Pump discharge pressure port (1) 1) Start the engine, set the working mode in the
check plug power mode (P), and turn the auto-deceler-
(2): Pump discharge pressure port (2) ator OFF.
check plug 2) Run the engine at high idle, set all the levers
and pedals for work equipment control and
travel in neutral, and test the oil pressure.
The pressure tested when the unload
valve is unloaded is indicated.
3. Testing work equipment relief pressure

1) Start the engine and move the cylinder to be
tested to the stroke end.
2) Set the working mode in the power mode (P).
3) Run the engine at high idle, operate the right
and left work equipment control levers to
relieve the cylinder, and test the oil pressure.
The pressure tested when the main relief
valve is relieved is indicated.
30-4 30 PC78US-8
SEN04804-01
4. Testing travel relief pressure Adjusting

1) Run the engine and lock the travel mecha- The unload valve cannot be adjusted.
nism.
Put pin [2] between the sprocket and 1. Adjusting work equipment and travel relief
track frame to lock the travel mecha- pressure
nism securely. If the relief pressure of the work equipment
circuit and travel circuit is abnormal, adjust
main relief valves (3) according to the follow-
ing procedure.
(3): Main relief valve
When adjusting the main relief valve, open
the sand cover.
2) Set the working mode in the power mode (P).

3) Run the engine at high idle, operate the travel
lever and pedal to relieve the travel motor,
and test the oil pressure.
Before operating the travel lever and
pedal, check the position and locking 1) Loosen locknut (4) of relief value (6) and turn
direction of the locked sprocket again. adjustment screw (3).
Do not remove the adjustment nut or
5. Work after finishing test inside parts will come out.
After finishing test, remove the testing tools and The adjustment screw is
return the removed parts. Turned to the right, the set pressure is
Oil pressure pickup plug: increased.
20 – 27 Nm {2.0 – 2.8 kgm} Turned to the left, the set pressure is
decreased.
Amount of adjustment per turn of adjust-
ment screw:
Approx. 19.6 MPa {Approx.
200 kg/cm2}
2) While holding adjustment nut (7), tighten
locknut (8).
Locknut: 39 – 49 Nm {4 – 5 kgm}
3) Referring to the section of measuring, check
the relief pressure again.
PC78US-8 30-4 31
SEN04804-01
Testing and adjusting swing and 2) Install nipple K2 and connect oil pressure
blade circuit oil pressure (Blade gauge [1] of hydraulic tester K1
specification) Use the oil pressure gauge of 60 MPa
{600 kg/cm 2}.
Testing and adjusting tools for swing and blade

circuit oil pressure (Blade specification)
1
K
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Stop the machine on a flat ground, lower the
work equipment to the ground, and release
the residual pressure, referring to "Releasing
residual pressure in hydraulic circuit".
Testing
The oil pressure in the work equipment, swing,
and travel circuits (pump discharge pressure) 2. Testing swing relief pressure
can be checked with monitoring function of the 1) Start the engine, set the working mode to
machine monitor, too (For details, see “Special power mode (P), and turn the swing lock
functions of machine monitor”). switch ON.
Monitoring code: 01100 pump pressure 2) While running the engine at high idle, operate
Test the swing and blade circuit oil pressure un- the left work equipment control lever to
der the following condition. (Blade specification) relieve the swing motor, and measure the oil
Hydraulic oil temperature: Within operating pressure.
range The swing motor safety valve relief pres-
sure is indicated.
1. Preparation work The swing relief pressure is lower than
1) Open the right exterior inspection window the main relief pressure.
and remove oil pressure pickup plug (1).
3. Testing blade (lower) relief pressure
1) Start the engine and set the working mode to
power mode (P).
2) While running the engine at high idle, operate
the blade control lever in the lowering direc-
tion to relieve, and measure the oil pressure.
4. Testing blade (raise) 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 raising direction
to relieve, and measure the oil pressure.
5. Work after finishing testing

After finishing testing, remove the testing tools
Oil pressure pickup plug:
20 – 27 Nm {2.0 – 2.8 kgm}
30-4 32 PC78US-8
SEN04804-01
6. Adjusting swing relief pressure 7. Adjusting blade (lower) relief pressure

If the swing relief pressure is abnormal, ad- If the blade (lower) relief pressure is abnor-
just swing motor safety valve (2) according to mal, adjust main relief valve (6) according to
the following procedure. the following procedure.
1) Loosen locknut (5) of safety valve (2) and 1) Loosen locknut (9) of main relief valve (6)
turn adjustment screw (3). and turn adjustment screw (7).
Do not remove the adjustment nut or Do not remove the adjustment nut or
inside parts will come out. inside parts will come out.
If the adjustment screw is If the adjustment screw is
turned to the right, the set pressure is turned to the right, the pressure is in-
decreased. creased.
turned to the left, the set pressure is turned to the left, the pressure is de-
decreased. creased.
Amount of adjustment per turn of adjust- Amount of adjustment per turn of adjust-
ment screw: ment screw:
4.8 MPa {49.3 kg/cm2} 19.6 MPa {200 kg/cm2}
2) After adjusting, tighten locknut (5). 2) After adjusting, tighten locknut (9).
Locknut: Locknut: 39 – 49 Nm {4 – 5 kgm}
93.2 – 117.7 Nm {9.5 – 12 kgm} 3) Referring to the section of measuring, check
3) Referring to the section of measuring, check the relief pressure again.
the relief pressure again.
PC78US-8 30-4 33
SEN04804-01
8. Adjusting blade (raise) relief pressure

If the blade (raise) relief pressure is abnor-
mal, adjust suction safety valve (blade) (10)
according to the following procedure.
1) Loosen locknut (13) of suction safety valve

(blade) (10) and turn adjustment screw (11).
Do not remove the adjustment nut or
inside parts will come out.
If the adjustment screw is
turned to the right, the pressure is in-
creased.
turned to the left, the pressure is de-
creased.
ment screw:
19.6 MPa {200 kg/cm 2}
2) After adjusting, tighten locknut (13).
Locknut: 39 – 49 Nm {4 – 5 kgm}
3) Referring to the section of measuring,
chenck the relief pressure again.
30-4 34 PC78US-8
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.
Testing tools for control circuit basic pressure
Symbol Part No. Part name 4. Run the engine at high idle, set all the levers and
1 pedals for work equipment control, swing
L
799-101-5220 Nipple (10 × 1.25 mm) control, and travel in neutral, and test the oil
2 pressure.
07002-11023 O-ring
Test the control circuit basic pressure under the
following condition.
range
1. Open the left front inspection cover and remove

oil pressure pickup plug (1).

Do not adjust the relief valve for control circuit

basic pressure.
2. Install nipple L2 and connect oil pressure gauge

[1] of hydraulic tester L1.
Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
PC78US-8 30-4 35
SEN04804-01
Testing and adjusting oil pressure 2) Install nipple M2 and connect it to oil pres-
in pump PC control circuit sure gauge [1] of hydraulic tester M1.
Use the oil pressure gauges of 60 MPa
{600 kg/cm 2}.
pump PC control circuit
1
M 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-3300 Adapter (Size: 03)
Testing
Before testing the oil pressure in the PC control
circuit, check that the oil pressure in the work 3) Start the engine and operate the arm cylinder
equipment, swing, and travel circuits and the ba- to the arm IN stroke end.
sic pressure of the control circuit are normal. 4) Set the working mode in the power mode (P).
Test the oil pressure in the pump PC control cir- 5) While running the engine at high idle, operate
cuit under the following condition. the right work equipment control lever to
Hydraulic oil temperature: Within operating relieve the arm circuit in the arm IN direction
range and measure the oil pressure.
1. Testing PC valve output pressure (servo

piston inlet pressure)
Test the PC valve output pressure (servo pis-
ton inlet pressure) and pump discharge pres-
sure simultaneously and compare them.
1) Open the engine hood and remove oil pres-
sure pickup plug (1).
(1): PC valve output pressure pickup plug
Testing condition and method of judg-

ment: If the pressures are in the following
ratio, the PC valve is normal.
Tested oil Operation of Ratio of oil
pressure lever pressures
Pump discharge
1
pressure
Arm IN relief
PC valve output Approx. 0.6
pressure (Approx. 3/5)
If the PC valve or the servo piston is ab-
normal, the PC valve output pressure
(servo piston inlet pressure) is "the same
as the pump discharge pressure" or "al-
most 0".
30-4 36 PC78US-8
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.
Use the oil pressure gauges of 6 MPa
{60 kg/cm2}.
Testing condition and judgment method:

If the basic pressure is as shown in the ta-
ble, the PC-EPC valve is normal.
Operation of
Engine Output pressure
lever
All control Approx. 2.9 MPa
Low idle
levers and {Approx. 30 kg/cm 2}
pedals in Approx. 3.4 MPa
High idle
neutral {Approx. 35 kg/cm 2}
6) After finishing test, remove the testing tools

PC78US-8 30-4 37
SEN04804-01
3. Adjusting PC valve
When "the engine speed decreases" or "the
engine speed is normal but the work equip-
ment speed decreases" as the load increas-
es, if the pump discharge pressure and LS
differential pressure are normal, adjust the
pump PC valve according to the following
procedure.
Before loosening the locknut, be sure to
make match mark "a".
1) Loosen locknut (3) and rotate adjustment
screw (4) to adjust.
Since the PC valve is eccentric type, in
which direction to rotate it to increase the
torque is unknown. Accordingly, adjust
while monitoring the engine speed.
2) After finishing measurement, tighten locknut
(1).
Locknut: 29.4 – 39.2 {3 – 4 kgm}
30-4 38 PC78US-8
SEN04804-01
Testing PC-EPC solenoid output pressure

pump PC control circuit
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Testing
Oil temperature for test: 45 – 55 °C
1) Remove the pump oil pressure pickup plug
(5) (10 mm, P = 1.25).
3) Start the engine, select P mode, and

measure the oil pressure under the following
condition.
Measured
Measure- pressure Monitor
Engine
ment con- MPa output cur-
speed
dition rent
{kg/cm2}
Approx. Approx.
Full Neutral
1.14 {11.18} 525 mA
Arm IN Approx. Approx.
Full
relief 0.51 {5.00} 360 mA
Approx. Approx.
2) Install nipple M2 and connect it to oil pres- Slow Neutral
2.80 {27.5} 930 mA
sure gauge [1] of hydraulic tester M1.
Use the oil pressure gauge of 60 MPa
{600 kg/cm 2}.
PC78US-8 30-4 39
SEN04804-01
Testing LS differential pressure 5) Install nipple [1] of hydraulic tester N1 and

and adjusting LS valve connect it to differential pressure gauge N2
(low pressure side) or oil pressure gauge [1]
Testing and adjusting tools for LS valve of hydraulic tester N1.
1
2 799-401-2701 Differential pressure gauge
N
799-101-5220 Nipple (10 × 1.25 mm)
3
07002-11023 O-ring
4 799-401-3300 Adapter (Size: 03)
Stop the machine on a flat ground, lower the
To obtain the LS differential pressure, measure

the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously and cal- Differential
Fuel con-
culate their differential pressure. Operation pressure
trol dial
(MPa {kg/cm2})
Testing LS differential pressure Full Lever in neutral
2.5 – 4.4
1. Testing with main relief differential pressure {25 – 45}
Bucket CURL
gauge Approx. 2.11
Full (Lever at stroke
1) Remove oil pressure pickup plug (1). end)
{21.5}
2) Install nipple N3 and connect it to differential
pressure gauge N2 (high pressure side) or oil
pressure gauge [1] of hydraulic tester N1.
3) Disconnect LS oil pressure pickup hose (1).

4) Install adapter N4 and connect the discon-
nected hose again.
30-4 40 PC78US-8
SEN04804-01
Adjusting LS valve
If the LS differential pressure is abnormal, adjust
the LS valve according to the following proce-
dure.
Before loosening the locknut, be sure to make a
match mark.
1) Loosen locknut (2) and rotate adjustment
screw (3) to adjust.
If the adjustment screw is
Turned to the right, the pressure is in-
creased.
Turned to the left, the pressure is de-
creased.
ment screw: 1.27 MPa {13 kg/cm2}
2) After adjusting, tighten locknut (2).
Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}
After adjusting, measure the LS differen-
tial pressure according to the measure-
ment procedure shown above.
When loosening or tightening the locknut,
hold adjustment screw (3) with a spanner
to prevent it from being dragged.
PC78US-8 30-4 41
SEN04804-01
Testing solenoid valve output 2. Install adapter P2 and connect the disconnected
pressure hose again.
Testing tools for solenoid valve output pressure

1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (Size: 02)
Lower the work equipment to the ground and
stop the engine. Operate the control lever
several times to release the residual pres-
sure from the piping, and then loosen the oil
filler cap of the hydraulic tank slowly to re-
lease the residual pressure from the tank.
Before testing the solenoid valve output pres-
sure, check that the control circuit basic pres-
sure is normal.
3. Install nipple [1] of hydraulic tester P1 and
Test the solenoid valve output pressure under connect it to oil pressure gauge [2].
the following condition. Use the oil pressure gauge of 6 MPa
Hydraulic oil temperature: Within operating {60 kg/cm2}.
range The figure shows the testing tools installed to
travel shift solenoid valve outlet hose (2).
1. Open the left side cover and disconnect solenoid
valve outlet hoses (1) – (4).
No. Solenoid valve to be tested
1 PPC lock solenoid valve
2 Travel speed selector solenoid valve
3 Swing holding brake solenoid valve
4 Pump merge-divider solenoid valve
4. Start the engine.
5. While running the engine at high idle, operate

each control lever and each switch to turn each
solenoid valve ON and OFF and measure the
output pressure.
For the condition for turning ON and OFF,
see the operation table of each solenoid
valve.
The operating condition of each solenoid
valve can be checked with the monitoring
function of the machine monitor (For details,
see "Special functions of machine monitor").
Monitoring code: 02300 Solenoid 1
30-4 42 PC78US-8
SEN04804-01
If the output pressure is as follows, the sole-

noid valve is normal.
Solenoid valve Output pressure
OFF (De-energized) 0 MPa {0 kg/cm2}
ON (Energized) 2.9 MPa {30 kg/cm 2}
6. The PPC lock solenoid valve output pressure

can be tested similarly to the control circuit basic
pressure.
7. After finishing testing, remove the testing instru-

ments and return the removed parts.
PC78US-8 30-4 43
SEN04804-01
Testing PPC valve output pressure
PPC piping connecting positions
The above figure shows the connecting posi-

tions of the PPC piping of the 1-attachment
specification.
The colors in ( ) are the colors of the bands
installed for piping distinction.
30-4 44 PC78US-8
SEN04804-01
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).
1
Q 790-261-1204 Digital hydraulic tester
5. While running the engine at high idle, measure
2 799-401-3100 Adapter (Size: 02)
the oil pressure with the control lever in neutral
Stop the machine on a flat ground, lower the and at the stroke end.
Before testing the PPC valve output pressure,
ensure that the control circuit basic pressure is
normal.
Test the solenoid valve output pressure under
the following condition.
range
1. Disconnect the PPC circuit hose to be tested.
For the host to be disconnected, see "PPC
piping connecting positions".
2. Install adapter Q2 and connect the disconnected If the output pressure is as follows, the PPC
hose again. valve is normal.
Lever operation Output pressure
3. Install nipple [1] of hydraulic tester Q1 and Neutral 0 MPa {0 kg/cm2}
connect it to oil pressure gauge [2]. Almost same as control circuit
Use the oil pressure gauge of 6 MPa Stroke end basic pressure (See “Standard
{60 kg/cm2}. value table”)
The figure shows the testing tools installed to
the bucket dump PPC circuit.
6. After finishing testing, remove the testing instru-
ments and return the removed parts.
PC78US-8 30-4 45
SEN04804-01
Adjusting play of work equipment

and swing PPC valves
If the right and left work equipment levers have
large play, adjust them according to the following
procedure.
The play of the lever terminal must be 0.5 – 3
mm at a position of 200 mm from the center of le-
ver rotation.
1. Remove the work equipment and swing PPC

valve assembly.
2. Remove bellows (1).
3. Loosen locknut (2) and tighten disc (3) until it

touches the heads of 4 pistons (4).
4. Fix disc (3) and tighten locknut (2) to the speci-

fied torque.
Locknut: 69 – 88 Nm {7 – 9 kgm}
5. Install bellows (1).
6. Install the work equipment and swing PPC valve

assembly.
30-4 46 PC78US-8
SEN04804-01
Checking parts which cause 2. Checking arm cylinder

hydraulic drift of work equipment 1) Stop the arm cylinder about 100 mm before
the IN stroke end and stop the engine.
If the work equipment (cylinder) drifts hydrauli-
cally, check to see if the cause is on the cylinder
packing side or control valve side according to
the following procedure.
1. Checking boom cylinder and bucket cylinder

1) Set the machine in the position for testing
hydraulic drift and stop the engine.
Fill the bucket with a rated load or with dirt
and sand.
2) Operate the arm control lever in the IN posi-

tion.
If the lowering speed is increased at this
time, the cylinder packing is defective.
If the lowering speed does not change at
this time, the control valve is defective.
Operate the control lever while the start-
ing switch is in the ON position.
If the pressure in the accumulator is lost,
run the engine for about 5 seconds to
2) When checking the boom cylinder, set the heighten the pressure in the accumulator.
boom control lever in the RAISE position. [Reference] Reason why the lowering speed
When checking the bucket cylinder, set the is increased by the above operation when the
bucket control lever in the CURL position. cylinder packing is the cause of the hydraulic
If the lowering speed is increased at this drift:
time, the cylinder packing is defective. 1] If the machine is set in the above position
If the lowering speed does not change at (where the holding pressure is applied to
this time, the control valve is defective. the bottom side), the oil leaks from the
Operate the control lever while the start- bottom side to the head side. Since the
ing switch is in the ON position. volume on the head side is less than that
If the pressure in the accumulator is lost, on the bottom side by the volume of the
run the engine for about 5 seconds to rod, the pressure in the head side is
heighten the pressure in the accumulator. increased by the oil flowing in from the
bottom side.
2] As the pressure in the head side is
increased, it is balanced at a certain level
(which depends on the leakage), and
then the lowering speed is lowered.
3] If the circuit on the head side is opened to
the drain circuit by the above operation of
the lever (the bottom side is closed by the
check valve at this time), the oil on the
head side flows in the drain circuit. As a
result, the pressure is unbalanced and
the lowering speed is increased.
PC78US-8 30-4 47
SEN04804-01
3. Checking PPC valve

While the pressure in the accumulator is high,
set the lock lever in the LOCK/FREE position
and test the lowering distance.
Operate the control lever while the starting
switch is in the ON position.
If the pressure in the accumulator is lost, run
the engine for about 5 seconds to heighten
the pressure in the accumulator.
If there is a difference in the lowering dis-
tance between the LOCK position and FREE
position, the PPC valve is defective (it has an
internal defect).
30-4 48 PC78US-8
SEN04804-01
Testing and adjusting travel deviation
Inspection Install an oil pressure gauge and check that

1. Run the engine and heighten the hydraulic oil the P1 and P2 discharge pressures of the hy-
temperature to the operating range and set the draulic pump are even.
machine in the travel posture.
To set the machine in the travel posture, ex-
tract the bucket cylinder and arm cylinder ful-
ly and set the boom angle to 45 °.
2. Set the working mode to P and travel speed to

Lo.
3. Run up for 10 m with the engine speed at high

idle and continue travel under the same condi-
tion for 20 m and test the deviation (a).
PC78US-8 30-4 49
SEN04804-01
Adjusting 2. Insert hexagonal wrench (1) (Width across flats:

Travel deviation can be corrected by draining a 4 mm) in adjustment plug (1) or (2).
part of the oil discharged from the pump which Insert the hexagonal wrench securely.
discharges more oil with the adjustment plugs. 3. Loosen locknut (3), leaving the hexagonal
If the travel deviation is corrected by this method, wrench inserted.
however, the travel speed, work equipment Before adjusting, mark the position of the
speed in the compound operation, and relief locknut with paint.
pressure lower since the pump discharge is Loosen the locknut, securing the hexagonal
reduced. wrench.
The following is the method of correcting devia- Loosening angle of locknut: Approx. 90 –
tion applied when the machine deviates to the 180 °
right (left) in both travel directions.
Travel deviation can be corrected by the follow-
ing method only when it is 200 mm or less.
If the adjustment plug is loosened more than

the adjustment limit, high pressure oil spurts
out. Take care extremely.
Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal
pressure of the hydraulic tank.
1. Check the position of each adjustment plug of

the main pump.
When the machine deviates to the right:
Loosen adjustment plug (1). 4. Correct the travel deviation by loosening adjust-
When the machine deviates to the left: Loos- ment plug (1) or (2).
en adjustment plug (2). Quantity of correction of travel deviation per
Loosen only either plug. Do not loosen both turn of adjustment plug: 150 mm (For refer-
plugs at the same time. ence)
When the machine is shipped, the adjust-
ment plugs are tightened fully. Adjust the cor-
rection angle by the loosening angle of the
adjustment plugs.
If the adjustment plug is dragged when the
locknut is loosened, tighten it again.
The adjustable range of each adjustment
plug is 2 turns / 720° from the tightened po-
sition.
5. Tighten locknut (3).
Locknut: 2.94 – 4.9 Nm {0.3 – 0.5 kgm}
6. Check for travel deviation again. If the machine

still deviates, adjust again according to the
above procedure.
Do not loosen the adjustment plugs more
than the adjustable range (2 turns / 720 °).
30-4 50 PC78US-8
SEN04804-01
Releasing residual pressure from 4) Repeat steps 2) and 3) above 2 – 3 times,

hydraulic circuit and the residual pressure in the piping is
released completely.
1. Releasing residual pressure from hydraulic
tank 3. Releasing residual pressure from swing
Since the hydraulic tank is enclosed and motor circuit
pressurized, release the residual pres- The residual pressure in the swing motor circuit
sure from it when removing a hose or a can be released by performing the operation for
plug connected to it. "Releasing residual pressure from hydraulic
1) Lower the work equipment to the ground in a cylinder circuit" (Operate the lever in the swing
stable position and stop the engine. direction only, however).
2) Remove upper plate (1) of the oil filler cap.
3) Loosen oil filler cap (2) of the hydraulic tank 4. Releasing residual pressure from travel
gradually to release the air in the tank. motor circuit
Since the control valve spool of the travel motor
circuit is open, the pressure in this circuit can be
released by performing "Releasing residual
pressure from hydraulic tank".
2. Releasing residual pressure from hydraulic

cylinder circuit
When disconnecting a pipe between a hy-
draulic cylinder and the control valve, re-
lease the residual pressure from the
piping according to the following proce-
dure.
1) Lower the work equipment and release the
residual pressure from the hydraulic tank.
For details, see "Releasing residual pressure
from hydraulic tank".
Keep the oil filler cap of the hydraulic tank
removed.
2) Turn the starting switch ON and set the lock
lever in the FREE position, and then operate
the right and left work equipment control
levers forward, backward, to the right, and to
the left.
The control valve is operated by the pres-
sure in the accumulator. The pressure in
the accumulator is used up, however, af-
ter the control valve is operated 2 – 3
times.
3) Run the engine at low idle for 5 seconds to
heighten the pressure in the accumulator.
The engine does not start until the lock le-
ver is set in the LOCK position once.
PC78US-8 30-4 51
SEN04804-01
Testing oil leakage

Testing tools for oil leakage 2. Testing oil leakage from arm cylinder
Symbol Part No. Part name 1) Move the arm cylinder to the IN stroke end
Commercially and stop the engine.
S Measuring cylinder
available Release the residual pressure from the
Test the oil leakage under the following condi- piping on the arm cylinder head side.
tion. For details, see Releasing residual
Hydraulic oil temperature: Within operating pressure from hydraulic circuit (Oper-
range ate the lever in the arm IN direction on-
ly, however).
1. Testing oil leakage from boom cylinder 2) Disconnect hose (2) on the cylinder head
1) Move the boom cylinder to the RAISE stroke side and block it with a plug.
end and stop the engine. Take care not to disconnect the hose
Release the residual pressure from the on the cylinder bottom side.
piping on the boom cylinder head side. Use the following part to block the hose
For details, see "Releasing residual side.
pressure from hydraulic circuit" (Op- 07376-70522 (Plug #05)
erate the lever in the boom RAISE di-
rection only, however).
2) Disconnect hose (1) on the cylinder head
side and block it with a plug.
Take care not to disconnect the hose
on the cylinder bottom side.
Use the following part to block the hose
side.
07376-70422 (Plug #04)
3) Run the engine at high idle and relieve the

arm circuit by moving the arm IN.
Take care not to "move the arm OUT".
4) Start testing the oil leakage 30 seconds after
relieving is started and test for 1 minute.
5) After finishing test, return the removed parts.

boom circuit by raising the boom.
Take care not to "lower the boom".
4) Start testing the oil leakage 30 seconds after
relieving is started and test for 1 minute.
30-4 52 PC78US-8
SEN04804-01
3. Testing oil leakage from bucket cylinder

1) Move the bucket cylinder to the CURL stroke
end and stop the engine.
Release the residual pressure from the
piping on the bucket cylinder head
side. For details, see “Releasing resid-
ual pressure from hydraulic circuit”
(Operate the lever in the bucket CURL
direction only, however).
2) Disconnect hose (3) on the cylinder head
side and block it with a plug.
Take care not to disconnect the hose
on the cylinder bottom side.
side. 2) Disconnect drain hoses (6) and block the
07376-70422 (Plug #04) hose side with plugs.
Use the following parts to block the hose
side.
07376-70315 (Plug #03)

bucket circuit by curling the bucket.
Take care not to "dump the bucket".
4) Start testing the oil leakage 30 seconds after 3) Turn the swing lock switch ON.
relieving is started and test for 1 minute. 4) Run the engine at high idle and relieve the
5) After finishing test, return the removed parts. swing circuit by swinging.
Start testing the oil leakage 30 seconds
4. Testing oil leakage from swing motor after relieving is started and test for 1 min-
1) Remove covers (4) and (5). ute.
After testing 1 time, swing 180 °, and then
test again.
PC78US-8 30-4 53
SEN04804-01
5. Testing oil leakage from travel motor 5) After finishing test, return the removed parts.
1) Remove the travel motor cover.
2) Run the engine, lock the travel mechanism,
and stop the engine.
Put pin [1] between the sprocket and
track frame to lock the travel mecha-
nism securely.
3) Disconnect drain hose (7) of the travel motor

and block the hose side with a plug.
side.
07376-70315 (Plug #03)
4) Run the engine at high idle, relieve the travel

circuit, and test the oil leakage.
Before operating the travel lever,
check the position and locking direc-
tion of the locked sprocket again.
Wrong operation of the lever can
cause an accident. Accordingly, make
signs and checks securely.
Start testing the oil leakage 30 seconds
after relieving is started and test for 1 min-
ute.
Test several times, moving the motor a lit-
tle (changing the position of the valve
plate and cylinder and that of the cylinder
and piston) each time.
30-4 54 PC78US-8
SEN04804-01
Bleeding air from each part

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

1) Loosen air bleeder (1) and check that oil When running the engine after performing step
oozes out through the air bleeder. 1, keep its speed at low idle for 10 minutes.
2) After the oil oozes out, tighten air bleeder (1). If the engine coolant temperature is low and
Air bleeder: the automatic warm-up operation is started,
7.8 – 9.8 Nm {0.8 – 1.0 kgm} stop the engine temporarily and reset the au-
Do not use an impact wrench to tighten tomatic warm-up operation with the fuel con-
the air bleeder. trol dial (Set the starting switch in the ON
position and hold the fuel control dial in the
MAX position for 3 seconds, and the auto-
matic warm-up operation is reset).
3. Bleeding air from cylinder

If a cylinder is replaced, bleed air from it be-
fore connecting the work equipment. In par-
ticular, the boom cylinder does not move to
the lowering stroke end, if it is installed to the
work equipment.
1) Run the engine at low idle for about 5
minutes.
2) While running the engine at low idle, raise
and lower the boom 4 – 5 times.
Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
PC78US-8 30-4 55
SEN04804-01
4. Bleeding air from swing motor 6. Checking oil level and starting work
Carry out this step only when the oil in the 1) Run the engine, retract the arm cylinder and
swing motor case was drained. bucket cylinder to the stroke ends, lower the
If the engine is operated without bleeding air work equipment to the ground, and stop the
from the swing motor, the motor bearing may engine.
be broken.
1) While running the engine at low idle, loosen
the drain hose (2) and tighten it when the oil
flows out.
Do not swing while working.
2) While running the engine at low idle, swing
evenly to the right and left at least 2 turns
each.
2) Check the oil level by sight gauge (4) on the

rear side of the hydraulic tank.
If the oil level is below line L, it is insuffi-
cient. Add oil.
The oil level changes according to the oil
temperature. Add oil when the oil level is
out of the following standard ranges.
When oil temperature is 10 – 30 °C:
Between line H and line L
5. Bleeding air from travel motor When oil temperature is 50 – 80 °C:
1) Remove the travel motor cover and discon- Near line H
nect motor drain hose (3).
2) Run the engine at low idle and check that oil
flows out of nipple (4).
30-4 56 PC78US-8
SEN04804-01
Adjusting mirrors Adjusting mirror (B)

Adjust the mirror so that the operator can see per-
Adjusting mirror (A) sons at 1 m around the machine.
Loosen mirror bolt (2) and adjust the mirror so that (J): 1 m
the operator can see the right and left rear views
best which are blind spots from the operator seat.
If the mirror is hard to adjust, loosen mirror bolt

(4).
Install the mirror as shown in the following figure. Bolt (4): 15.7 – 19.6 Nm {1.6 – 2.0 kgm}
(E): 170 mm
Fix mirror stay (1) at the outermost position.
If the mirror is hard to adjust, loosen mirror bolt
(2) and stay mounting bolt (3).
Bolt (2): 15.7 – 19.6 Nm {1.6 – 2.0 kgm}
Adjust the mirror so that the side of the machine

will be reflected in it as shown below.
Adjust the mirror so that the side of the machine

will be reflected in it as shown below.
PC78US-8 30-4 57
SEN04804-01
PC78US-8 Hydraulic excavator
Form No. SEN04804-01
©2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
30-4 58
SEN04805-00

30
Special functions of machine monitor ............................................................................................................. 2
PC78US-8 30-102 1
SEN04805-00
Special functions of machine monitor 1
Air conditioner specification
30-102 2 PC78US-8
SEN04805-00
Upper section of machine monitor (Display sec-

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

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

tion)
[1]: Numeral 1 input switch/Auto-decelerator
switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed shifting
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner or
heater switch
heater switch
heater switch
heater switch
Switch having no numerals: Air conditioner or
heater switch
Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display.
PC78US-8 30-102 3
SEN04805-00
Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
Operator mode (Outline) 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
A Display of end screen 8p Unit 37p
B Selection of auto-deceleration 9p Default With/Without Attachment 38p
B Selection of working mode 9p Attachment/Maintenance Password 39p
B Selection of travel speed 10p ECO Display 40p
B Operation to stop alarm buzzer 10p Pump Absorption Torque 41p
B Operation of windshield wiper 10p Attachment Flow Adjustment 42p
B Operation of window washer 10p ATT EPC1 current adjustment 42p
Adjustment
B Operation of air conditioner/heater 11p ATT EPC2 current adjustment 42p
B Operation to display clock and service meter 11p ATT EPC3 current adjustment 42p
B Check of maintenance information 12p ATT EPC4 current adjustment 42p
Setting and display of user mode Cylinder Cut-Out 43p
B 12p
(Including KOMTRAX messages for user)
No Injection 44p
C Display of energy-saving guidance 13p
Fuel Consumption 46p
C Display of caution monitor 14p
Terminal Status 47p
C Display of user code and failure code 14p KOMTRAX
GPS & Communication Status 48p
Settings
(Special operation)
MODEM S/N (TH300) 49p
Function of checking display of LCD
D 16p Service Message 50p
(Liquid Crystal Display)
D Function of checking service meter 16p
Function of changing attachment/maintenance
D 17p
password
30-102 4 PC78US-8
SEN04805-00
Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
PC78US-8 30-102 5
SEN04805-00
Operator mode (Outline) Display pattern of operator mode

Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/opera- starting switch is turned ON to time when
tion of each function/display, see the “Struc- screen changes to ordinary screen depends on
ture, function and maintenance standard”, or the setting and condition of the machine.
Operation and Maintenance Manual. A : When engine start lock is set effective
The following are the displays or functions of B : When engine start lock is set ineffective
the operator mode explained in this section C : When working mode at start is set to
(including some items which need special breaker mode (B)
operations). D : When there is abnormal item in check-
before-starting items
Display pattern E : When there is maintenance item which is
A B C D E not maintained after specified interval
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 — — — —
Display of check of breaker mode — — 2 — —
Display of KOMATSU logo
Display of check before starting 3 2 3 2 2
W h e n th e s tar t i n g s w it c h i s tu rn e d ON , t h e
Display of warning after check
— — — 3 — KOMATSU logo is displayed for 2 seconds.
before starting
After the KOMATSU logo is displayed for 2
Display of ending of maintenance
— — — — 3 seconds, the screen changes to "Display of
interval
inputting password", or "Display of check
Display of check of working mode
4 3 4 4 4 before starting".
and travel speed
Display of ordinary screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode (including The following screen may be displayed instead
KOMTRAX messages for user) of the above “Display of inputting password
Display of energy-saving guidance screen”.
Display of caution monitor If this screen is displayed, call the person
Display of user code and failure code responsible to operation of KOMTRAX in your
Komatsu distributor and ask for remedy.
(Special operation)
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing attachment/maintenance pass-
word
30-102 6 PC78US-8
SEN04805-00
Display of inputting password Display of check before starting

After the KOMATSU logo is displayed, the screen When the screen changes to the check-before-
to input the engine start lock password is displayed. starting screen, the check before starting is carried
This screen is displayed only when the engine out for 2 seconds.
start lock function is set effective. If any abnormality is detected by the check
If the password is input normally, the screen before starting, the screen changes to "Display
changes to "Display of check before starting". of warning after check before starting" or "Dis-
The machine monitor has some password play of ending of maintenance interval".
functions other than the engine start lock. If no abnormality is detected by the check
Those functions are independent from one before starting, the screen changes to "Display
another. of check of working mode and travel speed".
The monitors (2 pieces) displayed on the screen
are the items under the check before starting.
Display of check of breaker mode

When the starting switch is turned ON, if the work-
ing mode is set to the breaker mode [B], a message Display of warning after check before starting
to inform the operator of starting in the breaker If any abnormality is detected by the check before
mode is displayed on the screen. starting, the warning monitor is displayed on the
If an attachment other than the breaker is screen.
used while the working mode is set to the The following figure shows that the engine oil
breaker mode [B], the machine may move level monitor (a) is warning of low of engine oil
unexpectedly or may not operate normally level.
or the hydraulic components may be dam-
aged.
After operation to check of the breaker mode is
finished, the screen changes to "Display of check
before starting".
If No is selected: Working mode is set to econ-
omy mode [E].
If Yes is selected: Working mode is set to breaker
mode [B].
PC78US-8 30-102 7
SEN04805-00
Display of ending of maintenance interval Display of ordinary screen

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

When the starting switch is turned OFF, the end
screen is displayed for 5 seconds.
Another message may be displayed on the
end screen, depending on the message dis-
play function of KOMTRAX.
Display of check of working mode and travel
speed
If the check before starting is finished normally, the
screen to check the working mode and travel speed
is displayed for 2 seconds.
After display of check of the working mode and
travel speed is finished, the screen changes to
"Display of ordinary screen".
30-102 8 PC78US-8
SEN04805-00
Selection of auto-deceleration [F4]: Move to upper working mode

While the ordinary screen is displayed, if the auto- [F5]: Cancel selection and return to ordi-
deceleration switch is pressed, large auto-deceler- nary screen
ation monitor (a) is displayed for 2 seconds and the [F6]: Confirm selection and return to ordi-
setting of the auto-deceleration is changed. nary screen
Each time the auto-deceleration switch is Working mode selector switch
pressed, the auto-deceleration is turned ON Press: Move to lower working mode
and OFF alternately. Hold down:Confirm selection and return to
If the auto-deceleration is turned ON, large ordinary screen
monitor (a) and auto-deceleration monitor (b) If you do not touch any of the function
are displayed simultaneously. switche s and working mode selector
If the auto-deceleration is turned OFF, auto- switch for 5 seconds, the selection is con-
deceleration monitor (b) goes off. firmed and the screen changes to the ordi-
nary screen.
3. When the ordinary screen is displayed again,

Selection of working mode large working mode monitor (a) is displayed for
Select a working mode according to the following 2 seconds, and then the setting of the working
procedure. mode is changed.
1. While the ordinary screen is displayed, press When large monitor (a) is displayed, the
the working mode selector switch, and the display of working mode monitor (b) is
working mode selection screen is displayed. changed, too.
The following figure is the working mode
selection screen displayed when "With
attachment" is set (If "With attachment" is
not set in the service mode, the attach-
ment mode [ATT] is not displayed).
<Precautions for selecting breaker mode [B]>

If breaker mode [B] is selected, both of the
control of the hydraulic pump and the setting of
the hydraulic circuit are changed.
2. Operate the function switches or working mode If an attachment other than the breaker is
selector switch to select and confirm the work- used, the machine may move unexpectedly or
ing mode which you will use. may not operate normally or the hydraulic
Function switches components may be damaged.
[F3]: Move to lower working mode
PC78US-8 30-102 9
SEN04805-00
Selection of travel speed Operation of windshield wiper

While the ordinary screen is displayed, if the travel While the ordinary screen is displayed, if the wiper
speed shifting switch is pressed, large travel speed switch is pressed, large wiper monitor (a) is dis-
monitor (a) is displayed for 2 seconds and the set- played for 2 seconds and the windshield wiper
ting of the travel speed is changed. starts or stops.
Each time the travel speed shifting switch is Each time the wiper switch is pressed, the
pressed, the travel speed is changed to Lo, Hi, windshield wiper setting is changed to INT,
and Lo again in order. ON, OFF, and INT again in order.
When large monitor (a) is displayed, the dis- When large monitor (a) is displayed, the dis-
play of travel speed monitor (b) is changed, play of wiper monitor (b) is changed or turned
too. OFF, too.
If the windshield wiper is turned OFF, large
monitor (a) is not displayed.
Operation to stop alarm buzzer

While the alarm buzzer is sounding, if the alarm
buzzer cancel switch is pressed, the alarm buzzer Operation of window washer
stops. While the ordinary screen is displayed, if the win-
Even if the alarm buzzer cancel switch is dow washer switch is pressed, the washing liquid is
pressed, the screen does not change. splashed only while the switch is held down.
Even if the window washer switch is pressed,
the screen does not change.
30-102 10 PC78US-8
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Operation of air conditioner/heater Operation to display clock and service meter

While the ordinary screen is displayed, press the air While the ordinary screen is displayed, press [F4],
conditioner switch and the air conditioner adjust- and section (a) changes to the service meter and
ment screen is displayed. clock alternately.
While the air conditioner adjustment screen is When the clock is selected, adjust the time, set
displayed, if you do not touch any switch for 5 12-hour or 24-hour display, and set the sum-
seconds, the screen changes to the ordinary mer time with the user mode function.
screen.
Air conditioner specification
PC78US-8 30-102 11
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Check of maintenance information Setting and display of user mode

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

played only when "With attachment" is set in
the service mode.
30-102 12 PC78US-8
SEN04805-00
[KOMTRAX message] Display of energy-saving guidance

There are 2 types of KOMTRAX message; 1 is When the machine is set in a certain operating con-
for the user and the other is for the service. dition, the energy-saving guidance screen is dis-
For user: played automatically to urge the operator to the
A message transmitted from the KOMTRAX energy-saving operation.
base station for the user. If it is received, the The energy-saving guidance is displayed when
message monitor is displayed on the ordinary the following condition is satisfied while the
screen. To see the contents of the message, display setting is set effective in the service
operate "User Message" in the above user mode.
menu. Condition for display:
For service: Engine is running + All levers have been in
A message transmitted from the KOMTRAX neutral for 5 minutes + Caution (Note) or user
base station for the service. Even if it is code is not generated (Note).
received, nothing is displayed on the ordinary Note: Excluding hydraulic oil low temperature
screen. To see the contents of the message, caution.
operate "KOMTRAX message" display in the If any lever or pedal is operated, or [F5] is
service menu. pressed, the screen returns to the ordinary
screen.
PC78US-8 30-102 13
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Display of caution monitor Display of user code and failure code

If an abnormality which displays a caution monitor If an abnormality which displays a user code and a
occurs on the ordinary screen or camera mode failure code occurs on the ordinary screen, all the
screen, the caution monitor is displayed large for a information of the abnormality is displayed.
moment and then displayed at (a) in the screen. (a): User code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone mark
(d): Telephone No.
This screen is displayed only when an abnor-
mality (failure code) for which a user code is
set occurs.
The telephone mark and telephone No. are
displayed only when the telephone No. is reg-
istered in the service mode.
If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
Since the information of the displayed failure
code is recorded in the abnormality record in
the service mode, check the details in the ser-
vice mode.
When the caution monitor is also displayed,

the telephone mark is not displayed.
30-102 14 PC78US-8
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Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried
E11
Output reduced to protect engine out immediately.
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Operations are possible, but have inspection carried out
E20 Abnormality in travel system
immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error
out immediately.
PC78US-8 30-102 15
SEN04805-00
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. Operation of switches (simultaneous): [4] + [1]
Operation of switches (simultaneous): [4] + [F2] Since there is some time lag in start of the
When finishing the operation of the switches, LCD, hold down the switches until the LCD dis-
release [F2] first. plays normally.
If there is a display error in the LCD, only that After the machine monitor is used continu-
part is indicated in black. ously, blue points (points which do not go off)
The LCD panel sometimes has black points may be seen on this screen. This phenomenon
(points which are not lighted) and bright points does not indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
To return to the former screen, press the func-
tion switch.
30-102 16 PC78US-8
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- Set a new password of 4 – 6 digits (If it
dures. has only 3 or less digits or has 7 or more
1. While the ordinary screen is displayed, perform digits, it is not accepted).
the following operation with the numeral input [F5]: Reset input numeral/Return to ordi-
switches. nary screen
Operation of switches (While pressing [4], [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] [5] [5]
This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
4. After the New password input screen is dis-

played again, input a new password again with
the numeral input switches and confirm it with
the function switch.
[F5]: Reset input numeral/Return to ordi-
2. After the Attachment/Maintenance PASS- nary screen
WORD screen is displayed, input the current [F6]: Confirm input numeral
password with the numeral input switches and If a password different from the password
confirm it with the function switch. input before is input, the message to input
[F5]: Reset input numeral/Return to ordi- again is displayed.
nary screen
[F6]: Confirm input numeral
Default password: [000000]
If the input password is correct, the screen
changes to the next screen.
If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
PC78US-8 30-102 17
SEN04805-00
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is dis-
played, the password is changed successfully.
30-102 18 PC78US-8
SEN04805-00
Service mode The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows (including
perform the following operation. some items which need special opera-
This operation is always required when you use the tions).
service mode. 01 Monitoring
Mechanical Systems
1. Check of display of screen and operation of 02 Abnormality
switches Electrical Systems
Record
While the ordinary screen is displayed, perform Air-conditioning System
the following operation with the numeral input 03 Maintenance Record
switches.
04 Maintenance Mode Change
Operation of switches (While pressing [4],
perform the operation in order): 05 Phone Number Entry
[4] + [1] [2] [3] Key-on Mode
This operation of the switches is accepted Unit
only while the ordinary screen is displayed.
With/Without Attachment
06 Default
Attachment/Maintenance
Password
ECO Display
Pump Absorption Torque
07 Adjustment
Attachment Flow Adjustment
08 Cylinder Cut-Out
09 No Injection
10 Fuel Consumption
Terminal Status
11 KOMTRAX
GPS & Communication Status
Settings
MODEM S/N (TH300)
12 Service Massage
2. Selection of service menu
When the Service menu screen is displayed,
the service mode is selected. Select a service
menu you use with the function switches or
numeral input switches.
[F3]: Move to lower menu
[F4]: Move to upper menu
[F5]: Return to ordinary screen (operator
mode)
[F6]: Confirm selection
You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].
PC78US-8 30-102 19
SEN04805-00
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select "Monitorin g" on the service menu
screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
Execution with function switch: Double-
click or hold down [F6] (about 2 seconds).
Execution with numeral input switch: Input
[99999] and press [F6].
When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
2. Selecting monitoring items monitoring is executed.
After the "Monitoring selection menu screen" is If monitoring items are selected up to the
displayed, select items to be monitored with limit number, monitoring is executed auto-
t h e f u n c t i o n s w it c h e s o r n u m e r a l in p u t matically.
switches.
[F1]: Move to next page (screen)
[F2]: Move to previous page (screen)
[F3]: Move to lower item
[F4]: Move to upper item
[F5]: Reset input numeral/Return to ser-
vice menu screen
Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that item
with [F6].
If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.
30-102 20 PC78US-8
SEN04805-00
4. Executing monitoring 6. Changing machine setting mode

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

The monitoring information can be held and
reset with the function switches.
[F3]: Reset holding
[F4]: Hold information (displayed data)
[F5]: Return to monitoring selection menu
screen
PC78US-8 30-102 21
SEN04805-00
Monitoring items table

Unit (Initial setting: ISO) Com-
Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
00200 Controller model select — Pump
00201 Machine ID — ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd eng. speed command r/min rpm rpm PUMP
01100 Pump pressure MPa kg/cm2 psi PUMP
07101 Travel PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant temperature °C °C °F ENG
04401 Hyd oil temperature °C °C °F PUMP
01300 PC-EPC sol current mA mA mA PUMP
01700 Attachment sol current mA mA mA PUMP
03200 Battery voltage V V V PUMP
03203 Battery power supply V V V ENG
04300 Battery charge vol. V V V MON
36400 Rail pressure MPa kg/cm2 psi ENG
37400 Ambient pressure kPa kg/cm2 psi ENG
18500 Charge temperature °C °C °F ENG
All items (including the
ambient pressure) are
36500 Boost Pressure kPa kg/cm2 psi ENG
indicated by absolute
values.
36700 Engine torque ratio % % % ENG
18700 Engine output torque Nm kgm lbft ENG
03000 Fuel dial pos sens volt V V V ENG
04200 Fuel level sensor volt V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sensor Vol. V V V PUMP
37401 Ambient press sens volt V V V ENG
18501 Charge temp sens volt V V V ENG
36501 Charge press sens volt V V V ENG
36401 Rail pressure sens volt V V V ENG
17500 Engine power mode — ENG
31701 Throttle position % % % ENG
31706 Final throttle position % % % ENG
18600 Inject fueling command mg/st mg/st mg/st ENG
36200 Rail press command MPa kg/cm 2 psi ENG
36300 Injection timing command CA CA CA ENG
37300 Fuel rate (Note 1) /h /h gal/h ENG
01602 2nd eng. speed command % % % PUMP
13113 Main pump absorb torque Nm kgm lbft PUMP
15900 Boom bottom pressure MPa kg/cm2 psi PUMP
Boom lower ON, OFF PUMP
Boom raise ON, OFF PUMP
01900 Pressure switch 1
Arm curl (IN) ON, OFF PUMP
Arm dump (OUT) ON, OFF PUMP
Bucket curl ON, OFF PUMP
01901 Pressure switch 2 Bucket dump ON, OFF PUMP
Service ON, OFF PUMP
30-102 22 PC78US-8
SEN04805-00

Code ponent
charge
Blade Up ON, OFF PUMP
01902 Pressure switch 3
Blade Down ON, OFF PUMP
Swing Brake ON, OFF PUMP
02300 Solenoid valve 1 Merge-divider ON, OFF PUMP
Travel speed ON, OFF PUMP
02200 Switch input 1 Swing Release Sw ON, OFF PUMP
Blade Spec ON, OFF PUMP
02201 Switch input 2
Overload Alarm ON, OFF PUMP
02202 Switch input 3 Key Switch (ACC) ON, OFF PUMP
Aircon SW ON, OFF PUMP
02203 Switch input 4
Lock Lever Sw ON, OFF PUMP
Window Limit SW. ON, OFF PUMP
02204 Switch input 5 P Limit SW. ON, OFF PUMP
W Limit SW. ON, OFF PUMP
03701 Controller output 2 Travel Alarm ON, OFF PUMP
Key switch ON, OFF MON
Start ON, OFF MON
04500 Monitor input Preheat ON, OFF MON
Light ON, OFF MON
Rad. Level ON, OFF MON
04501 Monitor input 2 Battery charge ON, OFF MON
F1 ON, OFF MON
F2 ON, OFF MON
Monitor function F3 ON, OFF MON
04503
switches F4 ON, OFF MON
F5 ON, OFF MON
F6 ON, OFF MON
SW1 ON, OFF MON
SW2 ON, OFF MON
Monitor 1st & 2nd SW3 ON, OFF MON
04504
row switches SW4 ON, OFF MON
SW5 ON, OFF MON
SW6 ON, OFF MON
SW7 ON, OFF MON
SW8 ON, OFF MON
Monitor 3rd & 4th SW9 ON, OFF MON
04505
row switches SW10 ON, OFF MON
SW11 ON, OFF MON
SW12 ON, OFF MON
SW13 ON, OFF MON
Monitor 5th row
04506 SW14 ON, OFF MON
switches
SW15 ON, OFF MON
20216 ECM build version — ENG
20217 ECM calibration data ver — ENG
18900 ECM internal temp °C °C °F ENG
20400 ECM serial No — ENG
20227 Monitor ass'y P/N — MON
20402 Monitor serial No — MON
20228 Monitor prog. P/N — MON
20229 Pump con ass'y P/N — PUMP
PC78US-8 30-102 23
SEN04805-00

Code ponent
charge
20403 Pump con serial No — PUMP
20230 Pump con. prog P/N — PUMP
Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
Unit
The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in Initialization of the
service menu).
CA in the display unit is an abbreviation for crankshaft angle.
mg/st in the display unit is an abbreviation for milligram/stroke.
Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
Note 1: The momentary fuel consumption (Code No.: 37300) means the theoretical fuel consumption (Since
it is a theoretical value, it is a little different from the actual fuel consumption).
30-102 24 PC78US-8
SEN04805-00
Abnormality Record (Mechanical Systems) 3. Information displayed on "Abnormality Record"

The machine monitor classifies and records the screen
abnormalities which occurred in the past or which On the "Mechanical Systems" screen, the fol-
are occurring at present into the mechanical sys- lowing information is displayed.
tems, electrical systems, and air-conditioning sys- (a) : Occurrence order of abnormalities from
tem or heater system. latest one/Total number of records
To check the mechanical system abnormality (b) : Failure code
record, perform the following procedures. (c) : Contents of trouble
(d) : Number of occurrence time (Displayable
1. Selecting menu range: 0 – 65,535 times)
Select "Abnormality Record" on the "Service (e) : Service meter reading at first occurrence
Menu" screen. (f) : Service meter reach at last occurrence
[F1]: Move to next page (screen) (if dis-
played)
[F2]: Move to previous page (screen) (if
displayed)
[F5]: Return to abnormality record screen
If no abnormality record is recorded, "No
abnormality record" is displayed.
If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
For all the failure codes that the machine
2. Selecting sub menu monitor can record, see the Failure code
After the "Abnormality Record" screen is dis- table in "Abnormality Record (Electrical
played, select "Mechanical Systems" with the Systems)".
function switches or numeral input switches.
[F5]: Return to service menu screen
numeral input switches to select the record
The following figure shows the display of
the air conditioner specification. The
heater specification and heaterless speci-
fication are different from each other in the
display of "03 Air-conditioning System",
which may not be displayed in the heater-
less specification.
4. Resetting abnormality record
The contents of the mechanical system abnor-
mality record cannot be reset.
PC78US-8 30-102 25
SEN04805-00
Abnormality Record (Electrical Systems)

The machine monitor classifies and records the
abnormalities which occurred in the past or which
are occurring at present into the mechanical sys-
tems, electrical systems, and air-conditioning
system.
To check the electrical system abnormality record,
perform the following procedures.
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" Screen.
3. Information displayed on "Abnormality Record"

screen
On the "Electrical Systems" screen, the follow-
ing information is displayed.
(a) : Occurrence order of abnormalities from
latest one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
[F1]: Move to next page (screen) (if dis-
2. Selecting sub menu played)
After the "Abnormality Record" screen is dis- [F2]: Move to previous page (screen) (if
played, select "Electrical Systems" with the displayed)
function switches or numeral input switches. [F3]: Move to lower item
[F3]: Move to lower item [F4]: Move to upper item
[F4]: Move to upper item [F5]: Return to "Abnormality Record" screen
[F5]: Return to service menu screen If no Abnormality Record is recorded, "No
[F6]: Confirm selection abnormality record" is displayed.
You may enter a 2-digit code with the If the number of occurrence time is 1 (first
numeral input switches to select the occurrence), the service meter reading at
record of that code and confirm it with the first occurrence and that at the last
[F6]. occurrence are the same.
The following figure shows the display of If [E] is displayed on the left of a failure
the air conditioner specification. The code, the abnormality is still occurring or
heater specification and heaterless speci- resetting of it has not been confirmed.
fication are different from each other in the For all the failure codes that the machine
display of "03 Air-conditioning System", monitor can record, see the “Failure code
which may not be displayed in the heater- table”.
less specification.
30-102 26 PC78US-8
SEN04805-00
4. Resetting abnormality record 3) After the "Electrical Sys. Error Reset"

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

mode, and then reset the items one by
one or together with the function switches.
If the screen is set in the reset mode,
[CLEAR] graphic mark is indicated at 4) If the screen to notify completion of reset
[F2]. is displayed and then the "Electrical Sys-
[F2]: Reset all items tems" (reset mode) screen is displayed,
[F3]: Move to lower item the reset of the abnormality record is com-
[F4]: Move to upper item pleted.
[F5]: Return to abnormality record After a while, the screen returns to
screen the "Electrical Systems" screen.
[F6]: Reset selected item
To reset items one by one: Select the
item to be reset with [F3] or [F4] and
press [F6].
To reset all items together: Press [F2],
and all the items are reset, regardless
of selection of the items.
If [E] is displayed on the left of a fail-
ure code, the resetting operation is
accepted but the information is not
reset.
PC78US-8 30-102 27
SEN04805-00
Failure code table
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
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
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
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Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
User code
Attached : If the failure code is detected, the user, failure code, and telephone No. (if registered) are
displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.
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Abnormality Record (Air-conditioning System) 3. Information displayed on "Abnormality Record"

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

After the "Abnormality Record" screen is dis-
played, select "Air-conditioning System" or
"Heater System" with the function switches or
numeral input switches. 4. Resetting abnormality record
[F3]: Move to lower item While the "Abnormality Record" screen is dis-
[F4]: Move to upper item played, press [F2], and the number of occur-
[F5]: Return to service menu screen rence time of abnormality is reset. If it is
[F6]: Confirm selection confirmed at this time that the abnormality has
You may enter a 2-digit code with the been reset, the display changes to Normal.
numeral input switches to select the
record of that code and confirm it with
[F6].
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Maintenance Record The following items can be selected in the

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

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

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

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

Off”
After selecting "Maintenance Mode On/Off", if
the screen is displayed, set ON or OFF with
the function switches.
ON: Functions of all maintenance items
are set effective in operator mode
2. Selecting sub menu OFF: Functions of all maintenance items
After the "Maintenance Mode Change" screen are set ineffective in operator mode
is displayed, select an item to change the set- [F3]: Move to lower item
ting with the function switches or numeral input [F4]: Move to upper item
switches. [F5]: Cancel selection and return to
[F1]: Move to next page (screen) “Maintenance Mode Change” screen
[F2]: Move to previous page (screen) [F6]: Confirm selection and return to
[F3]: Move to lower item “Maintenance Mode Change” screen
[F4]: Move to upper item Even if ON/OFF of each item has been
[F5]: Return to service menu screen set, if the above setting is changed, it is
You may enter a 2-digit code with the applied.
numeral input switches to select the item
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4. Contents of setting of each maintenance item If the set value of an item set to "ON" is
After selecting each maintenance item, if the changed after 1 or more operating hours
screen is displayed, set the item with the func- since the start of setting, the change is
tion switches. recognized as a resetting operation.
Initial value: Maintenance interval set in

machine monitor (Recommended by man- 5. Function of initializing all items
ufacturer and not changeable). After selecting "All Default Value", if the screen
Set value: Maintenance interval which can is displayed, set with the function switches.
be set freely. Maintenance functions in
operator mode operate on basis of this set
time (which is increased or decreased by
50 hours).
ON: Maintenance function of this item is
set effective in operator mode.
OFF: Maintenance function of this item is
set ineffective in operator mode.
[F3]: Select Reduce set value (Upper) or
OFF (Lower).
[F4]: Select Increase set value (Upper) or
ON (Lower).
[F5]: Cancel setting before confirmation
and return to “Maintenance Mode
If this operation is executed, the set val-
Change” screen.
ues of all the maintenance items are ini-
[F6]: Confirm setting of upper or lower line.
tialized.
After the setting of the upper and lower
[F5]: Return to “Maintenance Mode
lines is confirmed with [F6] and the screen
Change” screen
ch a n g e s t o t h e “ M a in t e n a n ce M o d e
[F6]: Execute initialization
Change” screen with [F5], the setting is
A while after [F6] is pressed, the initializa-
effective.
tion completion screen is displayed. Then,
if the "Maintenance Mode Change" screen
is displayed, initialization is completed.
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Phone Number Entry If [F6] is pressed without inputting a digit,

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

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

Input nothing in the surplus positions.
If one of the input digits is wrong, move to
that digit (orange background) and over-
write it with the correct digit.
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Default (Key-on Mode) 3. Selecting mode

Check or change various settings related to the After the "Key-on Mode" screen is displayed,
machine monitor and machine by "Default". select the mode to be set with the function
The function of working mode with key ON is used switches.
to set the working mode displayed on the machine Power Mode: [P] is displayed when key is
monitor when the starting switch is turned ON. ON
Economy Mode: [E] is displayed when key
1. Selecting menu is ON
Select "Default" on the "Service Menu" screen. Lifting Mode: [L] is displayed when key is
ON
Breaker Mode: [B] is displayed when key
is ON
Attachment Mode: [ATT] is displayed
when key is ON
Mode at Previous Key-off: Final mode in
previous operation is displayed when key
is ON
[F5]: Cancel selection and return to
"Default" screen
[F6]: Confirm selection and return to
"Default" screen
When the machine is delivered, "Mode at
2. Selecting sub menu Previous Key-off" is set.
After the "Default" screen is displayed, select If "With attachment" is not set, the attach-
"Key-on Mode" with the function switches or ment mode cannot be selected.
numeral input switches. While Attachment mode [ATT] is selected,
Select this item similarly to an item on the if "Without attachment" is set, Power
"Service Menu" screen. mode [P] is displayed when the key is
turned ON.
If the engine is stopped while breaker
mode [B] is selected in the operator mode,
Breaker mode [B] is always displayed,
regardless of the above setting.
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Default (Unit) 3. Selecting unit

Check or change various settings related to the After the "Unit" screen is displayed, select the
machine monitor and machine by "Default". unit to be set with the function switches.
The unit selecting function is used to select the unit [F3]: Move to lower unit
of the data displayed for monitoring, etc. [F4]: Move to upper unit
[F5]: Cancel selection and return to
1. Selecting menu "Default" screen
Select "Default" on the "Service Menu" screen. [F6]: Confirm selection and return to
"Default" screen
When the machine is delivered, the “SI
Unit” system is set.

After the "Default" screen is displayed, select
"Unit" with the function switches or numeral
input switches.
Select this item similarly to an item on the
"Service Menu" screen.
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Default (With/Without Attachment) 3. Selecting With/Without

Check or change various settings related to the After the "With/Without Attachment" screen is
machine monitor and machine by "Default". displayed, select the setting with the function
The "With/Without Attachment" function is used to switches.
set an installed or a remove attachment. Without Attachment:
When attachment is not installed
1. Selecting menu With 1 Attachment:
Select "Default" on the "Service Menu" screen. When attachment 1 is installed
With 2 Attachment:
When attachments 1 and 2 are
installed
[F3] : Move to lower item
[F4] : Move to upper item
[F5] : Cancel selection and return to
Default screen
[F6] : Confirm selection and return to
Default screen
When an attachment is installed, if this

setting is not carried out normally, the
attachment cannot be set in the operator
mode. As a result, the attachment may not
work normally or the hydraulic compo-
2. Selecting sub menu nents may have trouble.
"With/Without Attachment" with the function
switches or numeral input switches.
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Default (Attachment/Maintenance Password) 3. Selecting Disable/Enable

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

"Attachment/Maintenance Password" with the 4. Displaying “Attachment/Maintenance Pass-
function switches or numeral input switches. word” screen
Select this item similarly to an item on the When the following operation is performed, the
"Service Menu" screen. password screen is displayed in the operator
mode.
Maintenance mode: The Maintenance
table screen is changed to the Mainte-
nance interval reset screen.
User mode: On the User menu screen, the
B reak er/A ttac hm ent s etting me nu is
selected and the screen is changed to the
Attachment setting menu screen.
5. Changing attachment/maintenance password

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

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

"ECO Display" with the function switches or
numeral input switches.
Display of energy saving guidance
3. Selecting display setting

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

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

After the "Adjustment" screen is displayed,
select "Pump Absorption Torque" with the func- Relationship between set value and
tion switches or numeral input switches. torque adjustment value
Select this item similarly to an item on the Set
"Service Menu" screen. Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}
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Adjustment (Attachment Flow Adjustment) 3. Selecting distribution of oil flow

The operator can adjust various items related to the After the screen of "Attachment Flow Adjust-
machine with the machine monitor. ment" is displayed, select a set value on the
The function of "Attachment Flow Adjustment" is right side with the function switches.
used to finely adjust the oil flow to the attachment in [F3]: Increase set value
compound operation. [F4]: Decrease set value
1. Selecting menu [F6]: Confirm setting and return to Adjust-
Select "Adjustment" on the "Service Menu" ment menu screen
screen. The 3 digits on the left side do not vary
since they are the code of this function.

After the "Adjustment" screen is displayed, Relationship between set value and distri-
select "Attachment Flow Adjustment" with the bution of flow to attachment
function switches or numeral input switches. Set Distribution of flow to
Select this item similarly to an item on the Code
value attachment
"Service Menu" screen. 000 50 %
001 70 %
037
002 100 %
003 40 %
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Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" oper-
ation with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1. Selecting menu
Select "Cylinder Cut-Out" on the "Service
Menu" screen.
3. Resetting Cut-Out cylinder

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

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

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

After completing the no injection cranking
operation, press [F6], and finish of no injection
cranking is displayed and the screen returns to
the "Service Menu" screen automatically.
PC78US-8 30-102 45
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Fuel Consumption 3. Display and function during test

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

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

The setting condition and operating condition of On the "Terminal Status" screen, the following
K O MT R A X c a n b e c h e c k e d w i th D is p la y o f items are displayed.
KOMTRAX setting. Terminal type: Model name of KOMTRAX
Setting condition of terminal is used to check the communication MODEM
setting condition of the KOMTRAX terminal. KOMTRAX communication: Executing con-
dition of station opening inspection
1. Selecting menu GMT time: Greenwich Mean Time
Select "KOMTRAX Settings" on the "Service [F5]: Return to KOMTRAX settings screen
Menu" screen.

After the "KOMTRAX Settings" screen is dis-
played, select "Terminal Status" with the func-
tion switches or numeral input switches.
Service menu screen.
The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200/TH201 is installed, "03 IP Address"
is displayed.
PC78US-8 30-102 47
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KOMTRAX Settings (GPS & Communication Status) 3. Contents of display of “GPS & Communication
The setting condition and operating condition of Status”
KOMTRAX can be checked with "KOMTRAX Set- On the screen of "GPS & Communication Sta-
tings". tus", the following items are displayed.
GPS & communication status is used to check the Positioning: Positioning condition of GPS
condition of positioning and communication of the Communication: Communication environ-
KOMTRAX terminal. ment of communication MODEM and con-
ne c t i n g co n d itio n o f c o mmu n i c a t io n
1. Selecting menu MODEM
Select "KOMTRAX Settings" on the "Service Number of message not yet sent: Number
Menu" screen. of mails which are saved in machine mon-
itor and not transmitted yet
[F5]: Return to KOMTRAX settings screen

played, select “GPS & Communication Status”
with the function switches or numeral input
switches.
The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200/TH201 is installed, "03 IP Address" is
displayed.
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KOMTRAX Setting (MODEM S/N: TH300) 3. Contents of display of Modem S/N

The setting condition and operating condition of The serial No. of TH300 Modem is displayed.
KOMTRAX can be checked with display of [F5]: Return to KOMTRAX settings screen
"KOMTRAX Settings".
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.
1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.

played, select "Modem S/N" with the function
switches or numeral input switches.
PC78US-8 30-102 49
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Service Message 3. Display of message (with return mail function)

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

If there is a message, its contents are dis-
played. If there is not a message, "No mes-
sage" is displayed.
This message is different from a message
transmitted to the operator in the operator
mode.
Since this message is special for the ser-
viceman, the message monitor is not dis-
play ed w hen it is receive d as in th e
operator mode.
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PC78US-8 30-102 51
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©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
30-102 52
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30
Handling voltage circuit of engine controller ................................................................................................... 2

Preparation work for troubleshooting of electrical system .............................................................................. 3
Procedure for testing diodes ........................................................................................................................... 8
Pm Clinic service ............................................................................................................................................ 9
PC78US-8 30-103 1
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Handling voltage circuit of engine

controller 1
1. Before disconnecting or connecting a connec-

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

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30-103 2 PC78US-8
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Preparation work for 3) Insert or connect troubleshooting T-adapt-

troubleshooting of electrical ers in or to connectors CM01, CM02, and
system 1
CM03 of machine monitor (3).
Connectors CM02 and CM03 are of
When carrying out troubleshooting of an elec- the same type. When returning them,
tric circuit related to the machine monitor, check the mark plates of the mount-
e n g i n e c o n t r o l l e r, p u m p c o n t r o l l e r, o r ing brackets and take care not to
KOMTRAX communication MODEM, expose make a wrong connection.
the related connectors according to the follow-
ing procedure.
Disconnect and connect the connectors having
special locking mechanisms according to the
procedure shown below.
1. Machine monitor
1) Remove 3 mounting bolts and cover (1).
One of the mounting bolts is installed
in the cover on the right of the sun-
light sensor.
While removing the mounting bolts,
disconnect connector P31 of the sun-
light sensor.
2. Engine controller
1) Open the engine hood.
The engine controller is installed to
the counterweight.
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors CE01, CE02, and
CE03 of engine controller (4).
Connectors CE01 and CE02 are fixed
with screws. When disconnecting
them, loosen the screws.
When returning connectors CE01 and
CE02, tighten the screws to the spec-
ified torque.
Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
2) Remove 1 mounting bolt and duct (2).
PC78US-8 30-103 3
SEN04806-00
3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove cover (1).
4. KOMTRAX communication module

1) Slide the operator's seat and seat stand to
the forward end.
2) Remove cover (1).
3) Connect the troubleshooting adapters to
connectors C01 and C02 of pump control-
ler.
Install the adapters to only the wiring
harness side.
3) Connect troubleshooting T-adapters to con-

nectors CK01 and CK02 of KOMTRAX
communication module (2).
Cable (3) is for the communication
antenna.
The pump controller connector has a
special locking mechanism. Discon-
nect it according to procedures (a) –
( c ) s h o w n b e lo w a n d co n n e c t i t
according to procedures (d) – (f).
Disconnection: (a) Unlock – (b)
Slide lever – (c) Disconnect connec-
tor.
Connection: (d) Position connector –
(e) Slide lever – (f) Lock.
30-103 4 PC78US-8
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 Disconnection and connection of con-
switch) nector
Disconnection and connection of con- The connector of the boost pressure and
nectors temperature sensor has a special locking
The connectors of the engine Ne speed mechanism. Disconnect it according to
se n s o r, e n g i n e B k u p s p e e d s e n s o r, steps (a) – (b) and connect it according to
engine oil pressure switch have a special steps (c) – (d) as shown below.
locking mechanism. Disconnect them Disconnection: (a) Unlock – (b) Discon-
according to steps (a) – (c) and connect nect connector.
them according to steps (d) – (f) as shown Connection: (c) Connect connector – (d)
below. Lock.
Disconnection: (a) Slide lever – (b)
Unlock – (c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
Removal and installation of sensor

A torque wrench is necessary for removal
and installation of the boost pressure and
temperature sensor. See "Tools for test-
Removal and installation of sensor ing, adjusting, and troubleshooting".
A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See "Tools for testing, adjusting,
and troubleshooting".
PC78US-8 30-103 5
SEN04806-00
7. Supply pump IMV solenoid (Fuel regulator) Precautions for connecting connector
Disconnection and connection of con- Take care not to connect the connector
nector reversely.
The connector of the supply pump IMV Engage lock (e) on the wiring harness side
solenoid has a special locking mecha- with triangular notch (f) on the sensor side
nism. Disconnect it according to steps (a) (Do not engage lock (e) with square guide
– (b) and connect it according to steps (c) (g) on the opposite side of triangular notch
– (d) as shown below. (f)).
Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
8. Common rail pressure sensor (Fuel rail

press)
Disconnection and connection of con-
nector
Precautions for disconnecting connector The connector of the common rail pres-
The direction of the lock of the connector sure sensor has a special locking mecha-
varies with the tightened position of the nism. Disconnect it according to steps (a)
sensor and the lock may be in a direction – (b) and connect it according to steps (c)
in which it is difficult to reset (on the under- – (d) as shown below.
side or engine side). Disconnection: (a) Unlock – (b) Discon-
In this case, pinch the lock in direction (a) nect connector.
with bent-nose nippers [1] (commercially Connection: (c) Connect connector – (d)
available), and the lock is reset. Lock.
Since the lock clicks when it is reset, dis-
connect the connector after a click is heard.
30-103 6 PC78US-8
SEN04806-00
9. Engine coolant temperature sensor (Cool-

ant temp)
Disconnection and connection of con-
nector
The connector of the engine coolant tem-
perature sensor has a special locking
mechanism. Disconnect it according to
steps (a) – (b) and connect it according to
steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine coolant tem-
perature sensor. See "Tools for testing,
adjusting, and troubleshooting".
PC78US-8 30-103 7
SEN04806-00
Procedure for testing diodes 1
Test the assembled-type diode (8-pin) and the

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

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to
The conductive direction of the single diode is the anode (P) side of the diode and
indicated on the surface of the diode. apply the black (–) lead to the cath-
ode (N) side.
ii) Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Judge the condition of the diode by the
movement of the pointer.
The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends
on the type and selected range of the
tester, however).
The pointer moves in both i) and ii):
The diode is defective (Internal short
circuit).
1. When using digital circuit tester The pointer moves in neither of i) and
1) Set the tester in the diode range and ii): The diode is defective (Internal
check the indicated value. disconnection).
When an ordinary circuit tester is
used, the voltage of the internal bat-
tery is indicated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black (–) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the
indicated value.
The indicated value does not change:
The diode does not have conductivity
(Defective).
The indicated value changes:
The diode has conductivity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is indi-
cated.
30-103 8 PC78US-8
SEN04806-00
Pm Clinic service 1
Model name Serial No. Service meter

PC78US-8 h
User's name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom Standard ( ) Breaker 450 mm ( )
Arm Standard ( ) ( ) 600 mm
Bucket Standard ( ) ( )
Check of oil/coolant level
Radiator coolant When necessary
Machinery case oil
Engine oil Damper case oil
( )
Hydraulic oil Final drive case oil
Ambient temperature Altitude
°C m
Operator's opinion
Result of visual inspection
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
SEN04806-00
Check sheet (PC78US-8)

Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Checking condition
Standard Mea-
Fuel Work- Auto- Service limit
No. Check item Operation of work Unit value for new sured
control ing decel- value
equipment machine value
dial mode eration
1 Engine speed rpm 1,900 – 2,000 1,900 – 2,000
Engine oil MAX All levers in neutral MPa 0.34 – 0.59 0.25
2
pressure {kg/cm2} {3.5 – 6.0} {2.5}
P OFF
3 Engine speed rpm 1,150 – 1,200 1,150 – 1,200
Engine oil MIN All levers in neutral MPa Min. 0.18 0.15
4
pressure {kg/cm2} {Min. 1.8} {1.5}
2. Work equipment speed

Checking condition
Standard Mea-
Fuel Work- Service limit
No. Check item 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
3. Hydraulic drift of work equipment

Checking condition Standard Mea-
Service limit
No. Check item Unit value for new sured
Checking posture, etc. value
machine value
Boom top horizontal
Hydraulic drift of
1 Engine stopped Arm cylinder retracted fully mm/5 min. Max. 350 Max. 600
bucket tip
Bucket loaded
30-103 10 PC78US-8
SEN04806-00
4. Hydraulic circuit
[1] [2] [3] [4] [5] [6]
Checking condition
600K 600K 600K 600K 60K 60K
No. Checked part
Fuel Work- Pump for
Operation of work Pump Pump main Pump Pump
control ing Control swing and
equipment main 1 2 LS 1 LS 2
dial mode blade
A
1 Pilot relief valve All lever in neutral — — — — —
B
2 Main relief valve Arm OUT relief — — — — —
C
3 Unload valve All levers in neutral — — — — —
D1 D2
4 LS valve Bucket CURL full — — — —
MAX P
E E
(Bladeless (Blade
Right swing relief — — — —
specifica- specifica-
Swing motor tion) tion)
5
safety valve E E
(Bladeless (Blade
Left swing relief — — — —
specifica- specifica-
tion) tion)
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 3.14 ± 0.3 {32 ± 3} 3.14 ± 0.5 {32 ± 3}
B (Work equipment relief pressure) 26.5 ± 1 {270 ± 10} 26.5 ± 1.5 {270 ± 15}
C (Unload pressure) 2.45 – 4.41 {25 – 45} 2.45 – 4.41 {25 – 45}
D (LS differential pressure when
Approx. 2.11 {Approx. 21.5} Approx. 2.11 {Approx. 21.5}
bucket control lever operated) MPa
{kg/cm2}
Blade
20.6 ± 1 {210 ± 10} 20.6 ± 1.5 {210 ± 15}
specification
E (Swing relief pressure)
Bladeless
22.6 ± 1 {230 ± 10} 22.6 ± 1.5 {230 ± 15}
specification
F (Travel relief pressure) 26.5 ± 1 {270 ± 10} 26.5 ± 1.5 {270 ± 15}
* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5] [6]
Checking condition
600K 600K 600K 600K 60K 60K
No. Check item
Fuel Work- Pump for
Pump Pump Pump Pump
control ing Operation of work equipment Control swing
main 1 main 2 LS 1 LS 2
dial mode and blade
H1 H1 H2 H2
6 Servo piston MAX P Arm OUT relief — —
H1 : H2 = 1 : 0.25
H (Servo control pressure) —
(Oil pressure ratio)
PC78US-8 30-103 11
SEN04806-00
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Checking condition
600K 600K 60K 60K 60K
No. Check item
Fuel Work-
Pump Pump Pump Pump
control ing Operation of work equipment Control
main 1 main 2 LS 1 LS 2
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
7 PC-EPC valve All levers in neutral
J3 J3
MAX E — — —
J4 J4
L — — —
J1 (PC-EPC valve output pressure 1) Approx. 2.8 {Approx. 29}
J2 (PC-EPC valve output pressure 2) MPa Approx. 1.1 {Approx. 12}
J3 (PC-EPC valve output pressure 3) {kg/cm2} Approx. 2.3 {Approx. 24}
J4 (PC-EPC valve output pressure 4) Approx. 1.4 {Approx. 14}
30-103 12 PC78US-8
SEN04806-00
PC78US-8 30-103 13
SEN04806-00

©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
30-103 14

PC78US-8 Testing and Adjusting

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SEN04804-01

PC78US-8 15001 and up

30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ........................................................................................ 3

Testing control circuit basic pressure.......................................................................................................... 35

Tools for testing, adjusting, and troubleshooting

Testing engine speed 4. Testing pump relief speed

1. Preparation work 5. Testing auto-deceleration speed

2. Testing low idle speed

3. Testing high idle speed

Testing exhaust temperature

1. Remove covers (1) and (2).

4. Run the engine and test the exhaust tempera-

5. After finishing test, remove the testing instru-

2. Remove exhaust temperature pickup plug (3)

Checking exhaust gas color

6) Start the engine and accelerate it suddenly or

Adjusting valve clearance

1. Remove the engine hood, engine oil feed hose

4. Rotate the crankshaft forward (clockwise seen

When the No. 1 cylinder is at the compres-

1) While fixing adjustment screw (1), loosen

With the clearance gauge inserted, turn

6. Rotate the crankshaft forward 1 turn according

Testing compression pressure 6) Remove holder (7) and injector (1).

1. Remove the injector of the cylinder to be tested

2) Insert injector (1) in the cylinder head and fix

Testing blow-by pressure

Testing tools for blow-by pressure

2. Install tool and adapter [1] of blow-by checker D

3. Start the engine, set the working mode in the

4. While running the engine at high idle, relieve the

3. Install nipple [1] of hydraulic tester E1 and

4. Start the engine and turn the auto-decelerator

6. After finishing test, remove the testing tools and

Handling fuel system parts Releasing residual pressure from

Testing fuel pressure 2) Install adapter F2 and nipple [1] of the

4) After finishing test, remove the testing tools

6) Remove spill hose connector joint (5) and

The above is the preparation work for test

4) After finishing test, stop the engine.

3) After finishing test, stop the engine.

4. After finishing test, remove the testing tools and

Bleeding air from fuel circuit

1. Fill fuel in the fuel tank to full.

2. Open the engine hood.

3. Loosen knob (1) of the feed pump and pull it out,

4. After bleeding air, push in and tighten knob (1).

Air bleeding route of fuel circuit

Checking fuel circuit for leakage

1. Spray color checker (developer) over the fuel

2. Start the engine, keep its speed at low idle, and

3. Check the fuel piping and devices for fuel

4. Run the engine at high idle.

5. Check the fuel piping and devices for fuel

6. Run the engine at high idle and load it.

7. Check the fuel piping and devices for fuel

Testing and adjusting alternator Adjusting

Press the middle point of the belt between the

2. Loosen alternator fixing bolts (1) and (2).

3. Loosen locknut (3) and rotate adjustment bolt (4)

4. After adjusting the belt tension, tighten alternator

5. Check again that the tension of alternator belt (5)

Checking and adjusting air condi- Adjusting