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SEN04563-01

10 Structure, function and


maintenance standard
700 Electrical system
1

Electronic control system ................................................................................................................................ 2


Monitor system................................................................................................................. ............................. 33
KOMTRAX system................................................................................................................. ....................... 47
Sensor.........................................................................................................................
.................................. 49

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Electronic control system 1

Machine control system diagram

*1: If equipped

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Engine control function 1

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.

Engine speed control


Upon receipt of a fuel control dial (11) con-
trol signal, engine controller (6) sends a
command current to fuel supply pump (14)
to adjust the fuel injection amount to con-
trol the engine speed.

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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Engine and pump mutual control function 1

1. Battery Input and output signals


2. Battery relay a. CAN signal
3. Fusible link b. PC-EPC valve drive signal
4. Fuse box c. Solenoid valve GND
5. Resistor d. Oil pressure sensor signal
6. Pump controller e. Oil pressure switch signal
7. Engine controller f. Throttle signal
8. Machine monitor g. Fuel supply pump control signal
9. Emergency pump drive switch h. Sensor signals
10. Fuel control dial
11. Fuel supply pump
12. Sensors
13. Pump oil pressure sensor
14. Oil pressure sensor
15. Oil pressure switch
16. Hydraulic pump
16a. Servo
16b. LS valve
16c. PC valve
17. Control valve
17a. Pump merge-divider valve
18. PC-EPC valve

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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 method in each mode

P, E, L, ATT and B mode


Matching point:
Working mode Matching point
41 kW/1,950 rpm
Travel
{55 HP/1,950 rpm}
P, ATT, B
40.7 kW/1,850 rpm
Working
{54.5 HP/1,850 rpm}
32.1 kW/1,630 rpm
E
{43.1 HP/1,630 rpm}
22.2 kW/1,370 rpm
L
{29.8 HP/1,370 rpm}

Pump delivery (Q) is so controlled that engine


speed (N) will be kept near the matching point
set in each mode.
If the load on the pump increases and pump
discharge pressure (P) increases, engine
speed (N) starts decreasing. At the time, the
controller reduces the pump delivery (Q) to
increase the engine speed to the matching
point. If the load on the pump decreases and
pump discharge pressure (P) decreases to the
contrary, pump delivery (Q) is increased until
the engine speed increases to speed (N) near
the matching point.

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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

1. Pump controller Input and output signals


2. Engine controller a. CAN signal
3. Machine monitor b. Oil pressure sensor signal
4. Fuel control dial c. Oil pressure switch signal
5. Fuel supply pump d. Throttle signal
6. Sensors e. Fuel supply pump control signal
7. Oil pressure sensor f. Sensor signals
8. Oil pressure switch
9. Hydraulic pump
10. Control valve
10a. Pump merge-divider valve
11. PPC lock solenoid valve

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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.

When any control lever is operated


With the engine speed at the controlled speed
(approx. 1,175 rpm), when any control lever is
operated, the engine speed increases immedi-
ately to the speed that is set with the fuel con-
trol dial.

A: All work equipment control levers in "NEUTRAL"


B: Work equipment control lever "OPERATED"
C: Fuel control dial set speed
D: Engine controlled speed (approx. 1,175 rpm)
E: 4 sec.
F: Max. 2 sec.
G: Max. 0.2 sec.

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Engine automatic warm-up function 1

1. Battery Input and output signals


2. Battery relay a. CAN signal
3. Fusible link b. PC-EPC valve drive signal
4. Fuse box c. Solenoid valve GND
5. Resistor d. Hydraulic oil temperature signal
6. Pump controller e. Throttle signal
7. Engine controller f. Fuel supply pump control signal
8. Machine monitor g. Sensor signals
9. Emergency pump drive switch
10. Fuel control dial
11. Fuel supply pump
12. Sensors
13. Hydraulic oil temperature sensor
14. Hydraulic pump
14a. Servo
14b. LS valve
14c. PC valve
15. Control valve
15a. Pump merge-divider valve
16. PC-EPC valve

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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

Release conditions (either one required) Release


Coolant temperature: Min. 55°C, and control levers are set to NEUTRAL.
Engine speed: Any
Fuel control dial: Min. 1,300 rpm, and control levers are set to NEUTRAL.

Overheat prevention function 1

See "Engine automatic warm-up function" for system circuit diagram.

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).

Operational conditions Operation and actions taken Release conditions


Engine speed: Remains same
Alarm monitor: ON Coolant temperature: Max. 102°C
• Sends torque control signal to Hydraulic oil temperature: Max. 102°C
Coolant temperature: Min. 102°C • The original conditions are restored if
Hydraulic oil temperature: Min. 102°C lower the pump absorption
above requirements are met (automatic
torque and reduce the engine
restoration).
load.

Operational conditions Operation and actions taken Release conditions


Coolant temperature: Max. 105°C
Hydraulic oil temperature: Max. 105°C
Engine speed: Low idle Fuel control dial: Returns to low idle (MIN)
Coolant temperature: Min. 105°C Alarm monitor: ON position.
Hydraulic oil temperature: Min. 105°C • The original conditions are restored if
Alarm buzzer: Sounds
above requirements are met (manual
restoration).

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Turbocharger protection function 1

See "Engine automatic warm-up function" for system circuit diagram.

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)

*1. Working mode: P mode


Fuel control dial: High idle (MAX) position
Swing lever full operated

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Swing control function 1

1. Battery Input and output signals


2. Battery relay a. Swing holding brake release signal
3. Fusible link b. Swing holding brake solenoid valve drive signal
4. Fuse box c. CAN signal
5. Swing holding brake release switch d. Oil pressure switch signal
6. Pump controller e. Oil pressure sensor signal
7. Machine monitor f. Travel/swing alarm buzzer operation signal
8. Oil pressure switch
9. Oil pressure sensor
10. Travel/swing alarm buzzer
11. Hydraulic pump
12. Control valve
12a. Pump merge-divider valve
13. Swing motor
14. Swing holding brake solenoid valve

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Function

Swing holding brake function Swing holding brake release function


Interlocked with the swing operation, the swing If the controller gets out of order and no swing
holding brake (auto lock) prevents hydraulic is possible because the swing holding brake
drift from occurring after the swing stops. does not work properly, operating swing hold-
Interlocked with the arm retract operation, the ing brake release switch (2) releases the swing
swing holding brake is released to reduce the holding brake and allows swing operation.
load on the swing equipment during excavation a: Release (Emergency)
work. b: Normal
Function Swing holding brake Swing Release Normal
holding brake (when the controller (when the controller
• When the L.H. work equipment control lever release switch is out of order) is in order)
is set to NEUTRAL, the swing holding brake
works in 5 sec. Swing holding
Swing holding
Operation • When the L.H. work equipment control lever Swing brake brake is released.
brake works.
is operated for swing or retracting arm, the (*1)
swing holding brake is released allowing free *1: Hydraulic brake by the safety valve.
swing operation.

When the swing holding brake is released,


only the hydraulic brake with the safety valve is
effective for swing. So, note that, when the
swing stops on a slope, a hydraulic drift may
occur.
Swing holding brake release switch (2) is of the
alternator type. When the switch is turned to
"RELEASE (a)" position, the swing lock moni-
tor in the machine monitor will blink.

A: L.H. work equipment control lever "SWING"


(Swing holding brake "RELEASE")
B: L.H. work equipment control lever "NEUTRAL"
C: Swing holding brake "OPERATED"
D: 5 sec

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Travel control function 1

1. Pump controller Input and output signals


2. Engine controller a. Oil pressure sensor signal
3. Machine monitor b. CAN signal
4. Fuel control dial c. Travel junction/ pump merge-divider solenoid
5. Fuel supply pump valve drive signal
6. Sensors d. 2nd travel speed selector solenoid valve drive
7. Pump oil pressure sensor signal
8. Oil pressure switch e. Oil pressure sensor signal
9. Oil pressure sensor f. Oil pressure switch signal
10. Travel/swing alarm buzzer g. Travel/swing alarm buzzer operation signal
11. Hydraulic pump h. Throttle signal
12. Control valve i. Fuel supply pump control signal
12a. Pump merge-divider valve j. Sensor signals
12b. Travel junction valve
13. Travel motor
14. 2nd travel speed selector solenoid valve
15. Travel junction/ pump merge-divider solenoid
valve

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Function

Travel speed select function


1. Travel speed "Manual" change
Turning the travel speed selector switch
"Hi" and "Lo" changes the motor capacity
and allows the machine to select travel
speed.
Lo Hi
Travel speed selector switch (low speed) (high speed)
Motor capacity (cc/rev.) 54.3 30.5
Travel speed (km/h) 2.9 5.0
Travel motor swash plate angle Max. Min.
A: 13.7 MPa {140 kg/cm2}
B: 25.5 MPa {260 kg/cm2}
2. Travel speed "Automatic" change C: Min. 0.1 sec.
1) Automatic selection corresponding to D: Min. 0.02 sec.
engine speed
When the engine speed is lowered to
below 1,600 rpm with the fuel control
dial, the travel speed changes to "Lo"
automatically.

2) Automatic selection corresponding to


pump discharge pressure
If the travel pressure increases on an
uphill with the travel speed selector
switch in "Hi", and the travel hydraulic
pressure exceeding 25.5 MPa {260
kg/cm2} continues for 0.02 seconds or
more, the travel motor capacity is
switched to low speed (corresponds
to "Lo") automatically (the trave l
speed switch position remains "Hi").
If the travel pressure decreases on a
f l a t o r d o w n h il l w i t h l o w s p e e d
(caused by the automatic gear shift-
ing due to high pressure), and the
travel hydraulic pressure below 13.7
MPa {140 kg/cm 2 } continues for 0.1
seconds or more, the travel motor
capacity is switched back to the set
speed of "Hi" automatically.

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Pump control function during travel


See "Engine and pump mutual control func-
tion" for details.

Travel junction function


When the travel control lever and work equip-
ment control lever are operated, travel junction
function detects the pilot pressure and judges
whether it is for travel/ work equipment com-
pound operation or for travel independent
operation.
For travel/ work equipment compound opera-
tion, the signal to the travel junction/ pump
merge-divider solenoid valve is cut-off, control-
ling the oil flow between the right and left travel
motors to be equal, to prevent travel deviation
and improve straight line stability.
When travel independent operation, a signal is
sent to the travel junction/ pump merge-divider
solenoid valve, separating the oil flow between
the right and left travel motors, to improve
steering stability.

Pump merge-divider function


When the travel control lever and work equipment control lever are operated, pump merge-divider func-
tion detects the pilot pressure and judges whether it is for travel/ work equipment compound operation
or for travel independent operation.
For travel independent operation, a signal is sent to the travel junction/ pump merge-divider solenoid
valve, dividing the pump delivery, to improve travel performance.
Merge-
Pattern Criterion of travel operation Criterion of work equipment operation divider
valve
• Work equipment is not operated
1 Divide
Travel PPC pressure: (Work equipment PPC pressure switch is "OFF").
Min. 1.47 MPa {15 kg/cm2} • Work equipment is operated
2 Merge
(Work equipment PPC pressure switch is "ON").

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PPC lock function 1

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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Oil flow adjuster function for attachment 1

(Machine ready for attachment)

1. Pump controller Input and output signals


2. Engine controller a. Oil flow adjuster EPC valve drive signal for
3. Machine monitor attachment
4. Fuel control dial b. Oil pressure switch signal
5. Fuel supply pump c. CAN signal
6. Sensors d. PC-EPC valve drive signal
7. Emergency pump drive switch e. Solenoid valve GND
8. Oil pressure switch f. Throttle signal
9. Hydraulic pump g. Fuel supply pump control signal
9a. Servo h. Sensor signals
9b. LS valve
9c. PC valve
10. Control valve Function
10a. Pump merge-divider valve The oil flow to the attachment when the attach-
11. PPC lock solenoid valve ment control pedal is depressed fully is con-
12. Oil flow adjuster EPC valve for attachment trolled by selecting ATT mode and setting the
13. PC-EPC valve attachment flow with the machine monitor.
14. Attachment circuit selector valve
15. Attachment

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System components 1

Engine controller

Input and output signals


The following is the list of the symbols used for signal classification in the input/output signal chart.
A: Power supply
B: Input
C: Ground/shield/return
D: Output
E: Communication

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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Input and output signals


AMP-81P [CN-C01]
Pin Signal name Input/output Pin Signal name Input/output
No. signal No. signal
1 Constant power supply (24 V) Input 41 NC —
2 GND Input 42 NC —
3 Window washer Output 43 Starting switch ACC signal Input
4 Constant power supply (24 V) Input 44 GND (pulse signal) Input
5 GND Input 45 CAN_H Input/output
6 NC — 46 GND (analog signal) Input
7 NC — 47 GND (analog signal) Input
8 Potentiometer power supply (5 V) Output 48 NC —
9 Potentiometer power supply (5 V) Output 49 Pump oil pressure sensor Input
10 NC — 50 NC —
11 Arm angle sensor Input 51 NC —
12 NC — 52 Attachment oil pressure switch Input
13 NC — 53 Boom RAISE oil pressure switch Input
14 Boom LOWER oil pressure switch Input 54 NC —
15 Arm OUT oil pressure switch Input 55 Travel oil pressure sensor Input
16 NC — 56 Wiper motor reverse (W) Input
17 Arm IN oil pressure switch Input 57 Cab front window open limit switch Input
18 GND (analog signal) Input 58 Model select 4 Input
19 NC — 59 NC —
20 NC — 60 Starting switch C signal Input
21 Model select 2 Input 61 PPC lock switch Input
22 NC — 62 External start signal Input
23 Air conditioner compressor signal Input 63 NC —
24 Starting switch ACC signal Input 64 CAN_L Input/output
25 NC — 65 NC —
26 NC — 66 NC —
27 NC — 67 Boom angle sensor Input
28 NC — 68 NC —
29 Hydraulic oil temperature sensor Input 69 NC —
30 NC — 70 GND (analog signal) Input
31 Boom cylinder bottom oil pressure sensor Input 71 Blade RAISE oil pressure switch Input
32 NC — 72 NC —
33 Blade LOWER oil pressure switch Input 73 Bucket CURL oil pressure switch Input
34 Bucket DUMP oil pressure switch Input 74 Swing L.H. oil pressure sensor Input
35 NC — 75 Wiper motor stop (P) Input
36 Swing R.H. oil pressure sensor Input 76 Blade specification signal Input
37 GND (digital signal) Input 77 Model select 3 Input
38 Swing holding brake release switch Input 78 Overload alarm enable signal Input
39 Model select 5 Input 79 Starting switch ACC signal Input
40 Model select 1 Input 80 NC —
81 GND (digital signal) Input
AMP-40P [CN-C02]
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
82 NC — 102 NC —
83 NC — 103 NC —
84 NC — 104 NC —
85 NC — 105 NC —
86 NC — 106 NC —
87 2nd travel speed selector sol. Output 107 Travel and swing alarm buzzer Output
88 NC — 108 Battery relay drive Output
89 NC — 109 NC —
90 NC — 110 Travel junction/pump merge-divider sol. Output
91 NC — 111 NC —
92 NC — 112 NC —
93 Arm crane relay drive signal Output 113 NC —
94 Bucket DUMP control lock sol. Output 114 Wiper motor (–) Output
95 NC — 115 GND (solenoid) Input
96 PC-EPC Output 116 Solenoid power supply Input
97 Oil flow adjuster EPC for attachment Output 117 GND (solenoid) Input
98 NC — 118 Solenoid power supply Input
99 NC — 119 Wiper motor (+) Output
100 NC — 120 GND (solenoid) Input
101 Swing holding brake sol. Output 121 Solenoid power supply Input

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Fuel control dial

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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Engine oil pressure switch

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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PPC oil pressure switch

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

1. Machine monitor Outline


2. Battery The monitor system keeps the operator
3. Pump controller informed of all machine conditions, by monitor-
4. Engine controller ing the machine conditions using the sensors
5. Air conditioner controller and switches installed in various parts of the
6. KOMTRAX terminal machine and processing them instantly to dis-
7. Sensors, switches play on the machine monitor.
8. Wiper motor, window washer motor The information displayed on the machine
monitor falls into the following types:
Input and output signals 1. Alarm when an error occurs
a. Power supply 2. Machine status display (coolant tempera-
b. CAN signal ture, hydraulic oil temperature and fuel
c. Sensor and switch signals level)
d. Drive signal The switches on the machine monitor serve to
set operating conditions of the machine.

PC78US-8 10-700 33
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Machine monitor 1

Outline Precautions on the machine monitor display


The machine monitor provides monitor display The LCD panel may have black points (points
function, mode selection function and switch which are not lighted) and bright points (points
function of the electrical equipment etc. Also it which do not go off) for the reason of its char-
provides an alarm buzzer. acteristics. If the number of the bright points
The machine monitor has a CPU (Central Pro- and black points does not exceed 10, it does
cessing Unit) in it to process, display, and out- not indicate a failure or a defect.
put the information. When the engine is started, the battery voltage
The machine monitor consists of display and may drop suddenly depending on ambient
switches: the display is of LCD type, and the temperatures and battery conditions. In this
switches are of flat sheet switch. case, the machine monitor may go off for a
If an error occurs in the machine monitor itself, moment. However, this phenomenon is not a
controllers or wiring circuit between the moni- failure.
tor and controllers, the monitor does not dis- After the machine monitor is used continu-
play properly. ously, blue points (points which do not go off)
may be seen on the black background. This
phenomenon does not indicate a failure or a
defect.
Blue points can never be a problem as the
screen has usually blue or white background.
(White in the LCD is made up of red, green and
blue.)

10-700 34 PC78US-8
SEN04563-01

Input and output signals


070-18P(1) [CN-CM01]
Pin Signal name Input/output Pin Signal name Input/output
No. signal No. signal
1 Constant power supply (24 V) Input 10 Engine coolant temperature Input
2 Constant power supply (24 V) Input 11 Charging level Input
3 GND (constant power supply) — 12 GND (machine analog signal) —
4 GND (constant power supply) — 13 Lamp switch Input
5 Wake-up Input/output 14 Starting switch ACC signal Input
6 Starting motor cut-out relay (for personal code) Output 15 Starting switch C signal Input
7 GND (machine signal) — 16 Preheat Input
8 Hydraulic oil temperature Input 17 USB power supply (5 V) Output
9 Fuel level Input 18 GND (USB power supply) —

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) —

PC78US-8 10-700 35
SEN04563-01

Display 1

A: Normal operation screen


B: All indicators light-up screen
If troubles that turn monitors (14) to (16) ON occur after starting the engine, the corresponding monitors
are displayed from the left top in the order of the occurrence time.
If trouble of monitors (14) to (16) occur during working, the corresponding monitors are displayed in
large size for 2 seconds and then displayed in small size.
If the hydraulic oil temperature goes High or Low while any monitor is displayed at the center portion
(hydraulic oil temperature gauge portion), only hydraulic oil temperature monitor (2b) is displayed.
C: Screen with maintenance interval reminder

10-700 36 PC78US-8
SEN04563-01

No. Classification Display item Description Remarks


Display Temperature Background • Indicates corresponding temperature
location (°C) color range.
• Alarm buzzer sounds when the
W1 105 Red temperature exceeds 105°C.
W2 102 Red • If the monitor background appears
1a Gauge white, warm-up the engine.
(*1) W3 100 Blue
Coolant
temperature W4 85 Blue
W5 60 Blue
W6 30 White
See the "Background color" column of the
1b Caution
gauge.
Display Temperature Background • Indicates corresponding temperature
location (°C) color range.
• Alarm buzzer sounds when the
H1 105 Red temperature exceeds 105°C.
H2 102 Red • If the monitor background appears
2a Gauge white, warm-up the hydraulic
(*1) H3 100 Blue components.
Hydraulic oil
temperature H4 85 Blue
H5 40 Blue
H6 20 White
See the "Background color" column of the
2b Caution
gauge.
Display Background • Indicates corresponding fuel level.
Quantity ( )
location color
F1 96 Blue
F2 78 Blue
3a Gauge
(*1) F3 60 Blue
Fuel level F4 41 Blue
F5 32 Blue
F6 23 Red
See the "Background color" column of the
3b Caution
gauge.
Segment Load level • Indicates average load per minute on
a scale of 1 to 10.
Light to (Indicates when "Default (ECO
Green 1–8
4 ECO gauge medium display setting)" in the service mode
is "ON".)
Orange 9, 10 Heavy

• Indicates accumulated engine


operating hours (the alternator is
Service meter 00000 h – 99999 h
generating).
5 (F4 switch changes for clock display.)
• Displays time.
• 12-hour display (AM/PM)
Clock (F4 switch changes for service meter
• 24-hour display
display.)
*1: If the gauge signal is not available due to disconnection of CAN communication line, the gauge pointer goes off.

PC78US-8 10-700 37
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No. Classification Display item Description Remarks


Background (If KOMTRAX is equipped.)
Status
color • Displays message status.
6 Message (OFF when no message is available.)
Green There is unread message.
Blue There is unsent message.
Air Light ON: ON • Indicates air conditioner and air
7
conditioner Light OFF: OFF blower operating status.
INT: Intermittent • Indicates front glass wiper operating
8 Wiper ON: Continuous status.
Light OFF: Stop
Swing holding brake Monitor • Indicates swing lock operating status.
release switch display
9 Swing lock
OFF OFF
ON Blink
Pilot Elapsed time after turning • Indicates preheat operating status.
Monitor
the starting switch to
display
"HEAT (preheat)".
10 Preheat 0 – 30 sec. ON
30 – 40 sec. Blink
40 sec. or more OFF
Auto- Light ON: ON • Indicates auto-decelerator operating
11
decelerator Light OFF: OFF status.
P: Heavy-duty operation • Displays working mode.
E: Low-fuel consumption operation
Working
12 L: Fine operation
mode
B: Breaker operation
ATT: Double-acting attachment operation
Lo: Low speed • Displays travel speed setting.
13 Travel speed
Hi: High speed
(*2) Light ON: Abnormal range (below the • When an error is detected with the
14 Engine oil specified value) engine stopped, the monitor lights up
pressure Light OFF: Normal range on the screen.
(*2) Light ON: Defective battery charge • When an error is detected with the
15 Battery (Charge voltage < Battery voltage) engine running, the monitor lights up
charge level Light OFF: Normal range on the screen.
Caution Background • The display changes depending on
Status
color the time to/after the maintenance.
• After the starting switch is turned
There is a maintenance item "ON", the monitor turns ON if the
Maintenance
16 Yellow which is 30 hours or less left monitor light-up conditions are met,
interval
before next maintenance. and then turns OFF in 30 seconds.
There is a maintenance
Red
overdue item.
*2: Included in the start-up check. After the staring switch is turned to "ON", the monitor turns ON for 2 seconds, and
changes to a normal operation screen if no error is found.

10-700 38 PC78US-8
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PC78US-8 10-700 39
SEN04563-01

Switches 1

No. Name Function Operation


Turns the auto-decelerator function • When the working mode is in "L", the auto-
Auto-decelerator
ON/OFF. decelerator does not work.
1 switch
Light ON: ON
[Numeric keypad: 1] ON OFF
Light OFF: OFF
P: Heavy-duty operation
(*1)
E: Low-fuel consumption operation
Working mode Displays the working mode selector
2 L: Fine operation
selector switch screen.
B: Breaker operation
[Numeric keypad: 2]
ATT: Double-acting attachment operation
Travel speed selector Changes the travel speed.
3 switch Lo light ON: Low speed Lo (low speed) Hi (high speed)
[Numeric keypad: 3] Hi light ON: High speed
Stops the alarm buzzer. • Stops the alarm buzzer.
Buzzer cancel switch
4 (Some alarm buzzer does not stop even if • The alarm buzzer resumes when another
[Numeric keypad: 4]
the switch is pressed.) error is detected.
Operates the front glass wiper.
(*2) INT ON OFF
INT: Intermittent
5 Wiper switch (Intermittent) (Continuous) (Stop)
ON: Continuous
[Numeric keypad: 5]
Light OFF: Stop
ON: Washer fluid is sprayed and wiper works
continuously.
[When wiper is not working]
(*2)
OFF: Wiper works twice and stops after the
Window washer
6 Sprays washer fluid onto the front glass. switch is released.
switch
[When wiper is working intermittently]
[Numeric keypad: 6]
OFF: Wiper works twice continuously and
returns to intermittent operation after
the switch is released.
*1: When the working mode is changed, the auto-decelerator function turns "ON".
*2: When the front window is open, windshield wiper and washer do not operate even if the switch is pressed.

10-700 40 PC78US-8
SEN04563-01

No. Name Function Operation


Fan switch (Up) Controls the fan speed of the air • The air flow increases and the air
7a
[Numeric keypad: 7] conditioner in 6 levels. conditioner adjustment screen appears.
(Low, Middle 1, Middle 2, Middle 3, Middle • The air flow decreases and the air
7b Fan switch (Down) 4, High) conditioner adjustment screen appears.
Temperature control
• The preset temperature increases and the
8a switch (Up)
air conditioner adjustment screen appears.
[Numeric keypad: 8] Controls the temperature inside the cab.
Temperature control (18.0°C – 32.0°C: Available at every 0.5°C)
• The preset temperature decreases and the
8b switch (Down)
air conditioner adjustment screen appears.
[Numeric keypad: 0]
• Automatically controls the air flow, air vent,
(*3) Auto-runs the air conditioner and air
recirculation/fresh air flow mode according
9 Auto switch blower.
to the temperature setting, and the air
[Numeric keypad: 9] AUTO light ON: Auto run
conditioner adjustment screen appears.
• Switches to the air conditioner adjustment
Turns the air conditioner ON/OFF. screen, and pressing it again switches ON/
(*4)
10 A/C ON lights-up: Manual operation OFF.
Air conditioner switch
Light OFF: Stop
OFF ON
• Switches to the air conditioner adjustment
FRESH/RECIRC screen, and pressing it again switches
11 Changes the FRESH/RECIRC. recirculation/fresh air flow.
selector switch
FRESH RECIRC
• Switches to the air conditioner adjustment
Selects the air vent mode from 5 modes. screen, and pressing it again switches air
1. Front and rear vent mode.
2. Front, rear and foot • Mode 4 and 5 are not available with auto
12 Vent selector switch mode.
3. Foot
4. Foot and defroster 1 2 3 4 5
5. Defroster

Turns the fan and air conditioner OFF.


13 OFF switch • Turns the fan and air conditioner OFF.
Light OFF: OFF

14a Guidance icon


See "Guidance icon and function switch."
14b Function switch

*3: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at "High". Even if the set temperature is
reached, the fan speed remains the same.
*4: When the fan is set at stop, the air conditioner does not start even if the switch is pressed.

PC78US-8 10-700 41
SEN04563-01

Guidance icon and function switch


Functions available with the function switch depend on the guidance icon displayed above the switch.
No function is available if no guidance icon appears above the function switch.
The following is the list of guidance icons and the functions displayed above the function switches.

Guidance
Function switch Item Function
icon

1 Clear Clears selected/displayed item.

Moves selection down one page.


2 Move selection
(To the top page from the bottom page.)

F1 3 Set Sets function.

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.)

3 Clear Clears selected/displayed item.

Moves selection down one item.


1 Move selection (To the top item from the bottom item.)
F3 Cancels hold function in the monitoring.
Moves selection to the left.
2 Move selection
(To the rightmost item from the leftmost item.)
Switching clock/
1 Switches clock/service meter display.
service meter
Moves selection up one item.
F4 2 Move selection (To the bottom item from the top item.)
Starts hold function in the monitoring.
Moves selection to the right.
3 Move selection
(To the leftmost item from the rightmost item.)

10-700 42 PC78US-8
SEN04563-01

Guidance
Function switch Item Function
icon
Selecting maintenance
1 Selects maintenance screen.
screen
F5
2 Return Returns to the previous screen or condition.

Selecting user mode


1 Selects user mode screen.
screen
F6
2 Fix Fixes selected/displayed item.

PC78US-8 10-700 43
SEN04563-01

Operator mode function 1

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:

Category Display order (*2)


Item
(*1) W X Y Z
Display of KOMATSU logo 1 1 1 1
Display of inputting password 2 — — —
Display of start-up check 3 2 2 2
Display of warning after start-up check — — 3 —
A
Display of overdue maintenance — — — 3
Display of check of working mode and travel speed 4 3 4 4
Display of normal operation screen 5 4 5 5
Display of end screen
Selection of auto-decelerator
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
B
Operation to display clock/service meter
Check of maintenance information
Setting and display of user mode
• Breaker/attachment setting
• Display of message (including KOMTRAX messages for user)
• Screen adjustment
• Clock adjustment
• Language setting
• Economy mode adjustment
Display of energy-saving guidance
C Display of caution monitor
Display of user code and failure code
Function of checking display of LCD (Liquid Crystal Display)
D Function of checking service meter
Function of changing attachment/maintenance password
*1: The items available in the operator mode fall into the following categories.
A: Display from the time starting switch is turned to "ON" until the normal operation screen appears. Display after the
starting switch is turned to "OFF".
B: Display when the switch of machine monitor is operated.
C: Display when a certain condition is satisfied.
D: Display when special switch operation is necessary.
*2: For the category A, the order in which items are displayed varies depending on the setting and conditions of the
machine as follows:
W: When the engine start lock is set on.
X: When the engine start lock is set off.
Y: When an error is detected during start-up check.
Z: When a maintenance overdue is detected.
For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Spe-
cial functions of machine monitor" in "Testing and adjusting".
For how to set the engine start lock on/off, see "Password setting/cancel manual".

10-700 44 PC78US-8
SEN04563-01

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

The language used in the machine monitor can


be changed in the "Language setting" of the
user mode.
The available languages are as follows:
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, Turkish,
Indonesian and Thai

PC78US-8 10-700 45
SEN04563-01

Service mode function 1

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".

10-700 46 PC78US-8
SEN04563-01

KOMTRAX system 1

The KOMTRAX system consists of the


KOMTRAX terminal, communication antenna,
machine monitor and GPS antenna.
This system sends various information of the
machine via wireless communication. It allows
operators of the KOMTRAX to obtain the
machine information from the office and to pro-
vide various services with the customers.
The information available from the KOMTRAX
system are as follows:
1. Operation map
2. Service meter
3. Machine location
4. Error record
To provide the services, you need to make an
arrangement for starting the KOMTRAX ser-
vice separately.

PC78US-8 10-700 47
SEN04563-01

KOMTRAX terminal 1

Model: TH300
Satellite wave is used.

1. Communication antenna connection Outline


2. Machine harness connection (AMP-14P) The KOMTRAX terminal sends various
3. Machine harness connection (AMP-10P) machine information based on the network sig-
nals and input signals obtained through the
Input and output signals machine monitor, as well as GPS position
AMP-14P [CN-CK01] d a ta , v ia w i r e le s s c o m m u n ic a t io n . T h e
Pin Input/output KOMTRAX terminal can send information via
Signal name
No. signal communication antenna.
A1 Power supply (5 V) Input Conditions of the KOMTRAX terminal can be
A2 NC — checked with the "Display of KOMTRAX set-
A3 NC — ting" in the service mode of the machine moni-
A4 Selection of power supply voltage Output tor.
A5 NC —
KOMTRAX terminal can be used only in the
countries specified by the communication con-
A6 NC —
tract.
A7 GND Input
A8 GND Input
A9 NC —
A10 NC —
A11 NC —
A12 NC —
A13 NC —
A14 NC —

AMP-10P [CN-CK02]
Pin Input/output
Signal name
No. signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 NC —
B8 NC —
B9 NC —
B10 NC —

10-700 48 PC78US-8
SEN04563-01

Sensor 1

Atmospheric pressure sensor

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.

Boost pressure and temperature sensor

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.

PC78US-8 10-700 49
SEN04563-01

Coolant temperature sensor

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.

Crankshaft speed sensor


Camshaft speed sensor

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.

10-700 50 PC78US-8
SEN04563-01

Common rail pressure sensor

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.

Hydraulic oil temperature sensor

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.

PC78US-8 10-700 51
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Fuel level sensor

1. Connector 4. Body 7. Spacer


2. Float 5. Spring
3. Arm 6. Contact

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.

10-700 52 PC78US-8
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Pump oil pressure sensor


Boom cylinder bottom oil pressure sensor
(For overload alarm)
(EU specification)

1. O-ring Output characteristics


2. Sensor
3. Connector

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.

PC78US-8 10-700 53
SEN04563-01

PPC oil pressure sensor


(For travel and swing operation)

1. O-ring Output characteristics


2. Sensor
3. Connector

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.

10-700 54 PC78US-8
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PC78US-8 10-700 55
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PC78US-8 Hydraulic excavator


Form No. SEN04563-01

©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)

10-700 56

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