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*1: If equipped
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1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Fusible link secure safety when the engine is started.
4. Fuse box The engine does not start until the lock
5. Starting switch lever is set in the "LOCK" position.
6. Engine controller
7. Lock lever 2. The KOMTRAX engine cut circuit is employed
8. PPC lock switch to disable the engine from starting when the
9. Starting motor cut-out relay (for PPC lock) KOMTRAX terminal receives an engine cut
10. Starting motor cut-out relay (for personal code) command issued through external operation.
11. Fuel control dial
12. Safety relay
13. Starting motor
14. Fuel supply pump
15. Sensors
16. Engine controller power cut-off relay A
17. Engine controller power cut-off relay B
18. Machine monitor
19. KOMTRAX terminal
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Starting engine
When starting switch (5) is turned to "ON"
position, engine controller (6) sends com-
mand current to fuel supply pump (14).
For this reason, a fail-safe mechanism is
provided with the electrical system to stop
the engine when an electrical failure
occurs.
When starting switch (5) is turned to
"START" with lock lever (7) set in the
"LOCK" position, a starting current is sup-
plied to starting motor (13) causing the
engine to start.
However, as the neutral safety mecha-
nism is provided, the engine will not start if
lock lever (7) is set in the "FREE" position
at this time; starting motor cut-out relay (9)
cuts off the starting current to starting
motor (13).
Upon receipt of the engine cut-off com-
mand from the external source,
KOMTRAX terminal (19) sends the signal
to machine monitor (18).
Machine monitor (18) causes starting
motor cut-out relay (10) to cut off the start-
ing current to starting motor (13), therefore
the engine does not start.
Stopping engine
When starting switch (5) is turned to
"OFF" position, the current from the ACC
terminal of starting switch (5) to engine
controller (6) is cut off, and consequently
the command current to fuel supply pump
(14) is cut off.
Fuel supply pump (14) stops fuel feed,
causing the engine speed to go down and
the engine stops.
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Function
This function is turned ON when 1 of the 5
work modes of P, E, L, ATT and B is selected
with the work mode selector switch of the
machine monitor. The most suitable combina-
tion of engine torque (T) and pump absorption
torque can be selected for the contents of
work. If "Without" is selected for the attach-
ment on the initialization menu of the service
mode, 1 of the 3 modes of P, E and L is select-
able.
According to the pump absorption torque set at
each mode, based on the engine governor set
speed with the fuel control dial and the actual
engine speed, the controller controls pump
delivery (Q) so that the pump will absorb all
torque at each engine output point.
When the engine speed (N) is lowered, the
controller prevents the engine from stopping by
throttling the pump absorption torque.
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Control function during travel Control function with emergency pump drive
In P, ATT or B mode, engine speed (N) at the switch "ON"
matching point is set higher during travel than If the controller gets out of order and no work is
during working. possible because the hydraulic pump does not
In E or L mode, engine speed (N) and pump work properly, operating emergency pump
absorption torque are kept constant during drive switch (1) temporarily enables to main-
travel and working. tain functions of the machine with absorption
torques quite similar to those in the E mode.
In this case, a constant current flows from the
battery to the PC-EPC valve, thus the hydrau-
lic pump is not controlled by the controller.
a: Emergency
b: Normal
Emergency pump drive switch (1) is of the
alternative type. If the machine is operated
after the switch is set to "Emergency (a)" even
though the machine is normal, the user code
"E02" will be shown on the display.
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Auto-deceleration function 1
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Function
When all the control levers are set to NEU-
TRAL for waiting for a dump truck or work, the
engine speed is automatically reduced to a
controlled speed, and fuel consumption and
noise are lowered.
When any control lever is operated, the engine
speed returns immediately to the speed that is
set with the fuel control dial.
Operation
When control levers are set in neutral
If all the control levers are kept in neutral for 4
seconds with the engine speed higher than
ap pro x. 1 ,1 75 rp m, th e en gine sp ee d is
decreased to the controlled speed (approx.
1,175 rpm) and held until any control lever is
operated.
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Function
Raises the engine speed automatically to warm up the engine if the coolant temperature is low after
start-up of the engine.
Operational conditions (all required) Operation
Coolant temperature: Max. 55°C
Fuel control dial: Max. 1,300 rpm Engine speed: 1,300 rpm
Control levers: NEUTRAL
Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil tem-
perature becomes too high.
Operational conditions Operation and actions taken Release conditions
Engine speed: Remains same Coolant temperature: Max. 95°C
• Sends torque control signal to Hydraulic oil temperature: Max. 95°C
Coolant temperature: Min. 95°C lower the pump absorption • The original conditions are restored if
Hydraulic oil temperature: Min. 95°C
torque and reduce the engine above requirements are met (automatic
load. restoration).
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When the engine is started at low temperatures and the engine speed is increased sharply, the turbo-
charger may be seized. Controlling the engine speed prevents this problem.
The turbocharger protection time is controlled according to the coolant temperature.
Operational conditions Operating
Turbocharger protection
Engine oil pressure: Max. 50 kPa {0.51 kg/cm 2}
(See the following figure)
A: Start engine
B: Duration of turbocharger protection
(approx. 0 – 20 sec)
C: Modulating time (approx. 1.5 sec)
D: 500 rpm
E: 1,175 rpm
F: 2,050 rpm (*1)
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Function
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Function
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1. Battery Function
2. Battery relay Interlocked with the lock lever, the PPC lock
3. Fusible link switch is turned "OFF" when operating the lock
4. Fuse box lever to "LOCK" position.
5. Starting switch When the PPC lock switch is turned "OFF", the
6. Lock lever current to the PPC lock solenoid valve is cut-
7. PPC lock switch off, causing neither the work equipment nor
8. Hydraulic pump machine moves even if levers or pedal are
9. Control valve operated.
9a. Pump merge-divider valve
10. PPC lock solenoid valve
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System components 1
Engine controller
DTP-4P [CN-CE03]
Signal
Pin No. Signal name
classification
1 GND C
2 NC —
3 Constant power supply (24 V) A
4 NC —
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DRC-60P(1) [CN-CE01]
Pin Signal Pin Signal
Signal name Signal name
No. classification No. classification
1 NC — 31 NC —
2 NC — 32 Engine oil pressure switch B
3 NC — 33 NC —
4 NC — 34 NC —
5 NC — 35 NC —
6 NC — 36 Sensor power supply (5 V) A
7 NC — 37 Camshaft speed sensor B
8 NC — 38 NC —
9 NC — 39 NC —
10 Fuel supply pump regulator (+) B 40 NC —
11 Boost temperature sensor B 41 NC —
12 NC — 42 Crankshaft speed sensor B
13 NC — 43 NC —
14 Fuel supply pump regulator (–) C 44 Crankshaft speed sensor GND C
15 NC — 45 Injector #2 (+) D
16 NC — 46 NC —
17 NC — 47 Coolant temperature sensor GND C
18 NC — 48 Sensor GND C
19 Boost pressure sensor B 49 Coolant temperature sensor D
20 Ambient pressure sensor B 50 NC —
21 NC — 51 Injector #4 (–) C
22 NC — 52 NC —
23 NC — 53 Injector #1 (–) C
24 NC — 54 NC —
25 NC — 55 Injector #3 (+) D
26 Crankshaft speed sensor (5 V) A 56 Injector #4 (+) D
27 NC — 57 Injector #1 (+) D
28 NC — 58 Injector #2 (–) C
29 Common rail pressure sensor B 59 Injector #3 (–) C
30 NC — 60 NC —
DRC-60P(2) [CN-CE02]
Pin Signal Pin Signal
Signal name Signal name
No. classification No. classification
1 CAN(+) E 31 NC —
2 NC — 32 C
3 NC — 33 NC —
4 NC — 34 NC —
5 NC — 35 Fuel control dial (+) B
6 NC — 36 NC —
7 NC — 37 NC —
8 NC — 38 NC —
9 NC — 39 NC —
10 NC — 40 NC —
11 NC — 41 NC —
12 NC — 42 NC —
13 NC — 43 NC —
14 NC — 44 NC —
15 NC — 45 Starting switch ACC signal B
16 NC — 46 NC —
17 NC — 47 NC —
18 NC — 48 NC —
19 NC — 49 NC —
20 NC — 50 NC —
21 CAN (–) E 51 NC —
22 NC — 52 NC —
23 NC — 53 NC —
24 NC — 54 NC —
25 NC — 55 Engine controller power cut-off relay D
26 NC — 56 NC —
27 Fuel control dial (5 V) A 57 NC —
28 Fuel control dial (–) C 58 NC —
29 NC — 59 NC —
30 NC — 60 NC —
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Pump controller
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1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
This dial is installed in the right console box.
Potentiometer (5) is installed inside knob (1).
Turning knob (1) causes potentiometer (5)
shaft to rotate.
This rotation changes the resistance of the
variable resistor within potentiometer (5), and a
throttle signal is sent to the controller.
The hatched areas in the graph are error
detection areas. If the throttle voltage is within
the area, the engine speed drops down to low
idle.
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Resistor
1. Resistor
2. Connector
Specifications
For PC-EPC valve: 30
Function
This resistor sends an appropriate electric cur-
rent to each EPC valve, when the emergency
pump drive switch is turned to "ON".
No electric current flows in the normal condi-
tion.
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1. Connector
2. Sensor
3. O-ring
Specifications
Contact type: Normal close
Function
This oil pressure switch is installed in the cylin-
der block. It detects engine oil pressure, and
turns the switch "ON" when the pressure goes
below the specified value.
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1. Plug
2. Switch
3. Connector
Specifications
Contact type: Normal open
Operating pressure to make contact point ON:
490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Operating pressure to break contact point OFF:
294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function
This oil pressure switch is installed (8 places)
in the control valve. It detects the PPC oil pres-
sure when each actuator is operated, and
turns the switch "ON" when the pressure
exceeds the specified value.
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Monitor system 1
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Machine monitor 1
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070-12P(1) [CN-CM02]
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Engine oil pressure sensor Input 7 GND (machine signal) —
2 Engine oil level sensor Input 8 CAN terminal signal —
3 Radiator coolant level sensor Input 9 CAN_H Input/output
4 Air cleaner clogging sensor Input 10 CAN_L Input/output
5 Swing lock switch Input 11 USB data (–) Input/output
6 Spare Input 12 USB data (+) Input/output
070-18P(2) [CN-CM03]
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 For communication terminal, RS232C CD Input 10 For communication terminal, RS232C CTS Input
2 For communication terminal, RS232C RXD Input 11 For communication terminal, RS232C RI Input
3 For communication terminal, RS232C SG — 12 GND (communication terminal power supply) —
4 GND (communication terminal control signal) — 13 Communication terminal status signal CH1 Input
5 Communication terminal selection signal Input 14 Output
6 For communication terminal, RS232C RTS Output 15 Communication terminal control signal CH1 Output
7 For communication terminal, RS232C TXD Output 16 Communication terminal control signal CH2 Output
8 For communication terminal, RS232C DTR Output 17 Communication terminal status signal CH2 Input
9 For communication terminal, RS232C DSR Input 18 Communication terminal power supply (12 V) Output
070-12P(2) [CN-CM04]
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 GND (peripheral equipment power supply) — 7 Reserved —
2 Peripheral equipment control signal Output 8 Reserved —
3 GND (for peripheral equipment, RS232C) — 9 Reserved —
4 For peripheral equipment, RS232C TXD Output 10 Reserved —
5 For peripheral equipment, RS232C RXD Input 11 Reserved —
6 Reserved — 12 Peripheral equipment power supply (12 V) Output
B60-8P [CN-CM05]
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply) —
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1) —
3 Camera NTSC signal 2 Input 7 GND (Camera signal 2) —
4 Camera NTSC signal 3 Input 8 GND (Camera signal 3) —
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Display 1
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Switches 1
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*3: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at "High". Even if the set temperature is
reached, the fan speed remains the same.
*4: When the fan is set at stop, the air conditioner does not start even if the switch is pressed.
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Guidance
Function switch Item Function
icon
Starts function.
4 Start
(Used for starting measurement of split fuel consumption.)
Stops function.
5 Stop
(Used for stopping measurement of split fuel consumption.)
Sets selected item back to default.
1 Default
(Used for screen adjustment.)
Moves selection up one page.
F2 2 Move selection
(To the bottom page from the top page.)
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Guidance
Function switch Item Function
icon
Selecting maintenance
1 Selects maintenance screen.
screen
F5
2 Return Returns to the previous screen or condition.
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The functions in this mode are displayed in normal operation. Display and setting of these functions are
available from the operator's switch operations.
Display and setting of some functions require special operation of the switch.
Items available in the operator mode are as follows:
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Oil flow setting for breaker Oil flow setting for attachment
Oil flow for the breaker can be changed in the Oil flow for the double-acting attachment can
"Breaker/attachment setting" of the user mode. be changed in the "Breaker/attachment set-
Oil flow level can be set as follows: ting" of the user mode.
Oil flow level can be set as follows:
Oil flow level Quantity ( /min) Remarks
1 45 Oil flow level Quantity ( /min) Remarks
2 50 1 20
3 55 2 35
4 60 3 50
5 65 4 65
6 70 5 80
7 75 6 95
8 80 Default 7 110
9 85 8 125 Default
10 90
11 95
Language setting
12 100
13 105
14 110
15 115
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The functions in this mode are not accessible from the normal operation screen. Display and setting of
these functions are available by the serviceman's special operations of the switch.
This mode is used for special setting, testing, adjusting or troubleshooting.
Items available in the service mode are as follows:
Monitoring
Mechanical Systems
Abnormality Record Electrical Systems
Air-conditioning System
Maintenance Record
Maintenance Mode Change
Phone Number Entry
Key-on Mode
Unit
Default With/Without attachment
Attachment/Maintenance Password
ECO Display
Pump Absorption Torque
Adjustment
Attachment Flow Adjustment
Cylinder Cut-Out
No Injection
Fuel Consumption
Terminal Status
GPS & Communication Status
KOMTRAX Settings
Modem IP Address (Model TH201)
Modem S/N (Model TH300)
Display of KOMTRAX message
For how to operate the service mode functions, see "Special functions of machine monitor" in "Testing
and adjusting".
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KOMTRAX system 1
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KOMTRAX terminal 1
Model: TH300
Satellite wave is used.
AMP-10P [CN-CK02]
Pin Input/output
Signal name
No. signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 NC —
B8 NC —
B9 NC —
B10 NC —
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Sensor 1
1. Connector
2. Pressure inlet port
Function
This sensor is installed in the bracket on the side face of the cylinder block.
This sensor senses the atmospheric pressure and converts it into an electric signal and then outputs
that signal.
1. Connector
2. Sensor
3. O-ring
Function
This sensor is installed in the intake manifold.
This sensor senses the boost pressure and boost temperature and converts them into electric signals
and then outputs those signals.
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1. Connector
2. Sensor
3. O-ring
Function
This sensor is installed in the water pump.
This sensor senses the coolant temperature and converts it into an electric signal and then outputs that
signal.
1. Connector
2. Sensor
3. O-ring
Function
The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is
installed in the gear of the camshaft.
These sensors sense the gear rotations and convert them into pulse signals and then output those sig-
nals.
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1. Common rail
2. Sensor
3. Connector
Function
This sensor is installed in the common rail.
This sensor senses the fuel pressure and converts it into an electric signal and then outputs that signal.
1. Connector
2. Plug
3. Thermistor
Function
This sensor is installed in the suction pipe of the hydraulic pump.
This sensor senses the hydraulic temperature and converts it into an electric signal and then outputs
that signal.
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Function
This sensor is installed on the side face of the fuel tank.
This sensor senses the fuel level and converts it into an electric signal and then outputs that signal.
The float moves up and down according to the fuel level.
The movement of the float operates the variable resistor through the arm.
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Function
The pump oil pressure sensor is installed in the
control valve, and the boom cylinder bottom oil
pressure sensor is installed in the boom cylin-
der bottom piping.
The pump pressure sensor senses the pump
discharge pressure and converts it into an
electric signal and then outputs that signal.
The boom cylinder bottom pressure sensor
senses the cylinder circuit pressure and con-
verts it into an electric signal and then outputs
that signal.
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Function
This sensor is installed in the control valve
connecting part of the pilot circuit for travel and
swing operation.
This sensor senses the pilot pressure and con-
verts it into an electric signal and then outputs
that signal.
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©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)
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