PC78US-8 Structure, Function and Maintenance Standard

SEN04555-01
HYDRAULIC EXCAVATOR
PC78US-8
Machine model Serial number

PC78US-8 15001 and up
10 Structure, function and

maintenance standard 1
100 Engine and cooling system

Engine mount.................................................................................................................................................. 2
PTO................................................................................................................................................................. 3
Cooling system ............................................................................................................................................... 4
PC78US-8 10-100 1
SEN04555-01 Engine mount
Engine mount 1
10-100 2 PC78US-8
PTO SEN04555-01
PTO 1
a PTO: Abbreviation for Power Take Off
1. Breather combined with oil filler plug

2. Drain plug
3. Flywheel
4. Hydraulic pump case
5. Coupling
6. Hydraulic pump shaft
7. Oil level plug
PC78US-8 10-100 3
SEN04555-01 Cooling system
Cooling system 1
10-100 4 PC78US-8
Cooling system SEN04555-01
1. Reservoir tank 12. Fuel cooler inlet

2. Aftercooler outlet hose 13. Oil cooler outlet
3. Aftercooler inlet tube 14. Radiator
4. Radiator inlet hose 15. Radiator cap
5. Radiator outlet hose 16. Radiator inlet
6. Fan guard 17. Aftercooler outlet
7. Oil cooler inlet 18. Aftercooler
8. Net (if equipped) 19. Oil cooler
9. Drain plug 20. Shroud
10. Fuel cooler 21. Aftercooler inlet
11. Fuel cooler outlet 22. Radiator outlet
Specifications
Radiator Oil cooler Aftercooler Fuel cooler

4-array aluminum Aluminum mesh
Core type CF40 Drawn cup
mesh core core
Fin pitch (mm) 3.5/2 3.5/2 4.0/2 4.0/2
Total heat dissipation surface
16.44 4.12 x 2 6.17 0.59
(m2)
Pressure valve cracking 49.0 ± 14.7
— — —
pressure (kPa {kg/cm2}) {0.5 ± 0.15}
Vacuum valve cracking pressure –4.9 – 0
— — —
(kPa {kg/cm2}) {–0.05 – 0}
PC78US-8 10-100 5
SEN04555-01
PC78US-8 Hydraulic excavator

Form No. SEN04555-01
©2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (01)
10-100 6
SEN04556-00
HYDRAULIC EXCAVATOR
PC78US-8


200 Power train

Power train...................................................................................................................................................... 3
Swing circle..................................................................................................................................................... 4
Swing machinery............................................................................................................................................. 6
PC78US-8 10-200 1
200 Power train
SEN04556-00
10-200 2 PC78US-8
200 Power train
Power train SEN04556-00
Power train 1
1. Idler 10. Engine

2. Control valve 11. Center swivel joint
3. Travel junction valve 12. PPC lock solenoid valve
4. Pump merge-divider valve 13. 2nd travel speed selector solenoid valve
5. Swing motor 14. Swing holding brake solenoid valve
6. Travel motor 15. Travel junction/ pump merge-divider sole-
7. Hydraulic pump (for pilot) noid valve
8. Hydraulic pump (for swing and blade) 16. Swing machinery
[installed to only blade specification] 17. Swing circle
9. Hydraulic pump
(Blade specification: for work equipment
and travel)
(Bladeless specification: for work equip-
ment, travel and swing)
PC78US-8 10-200 3
200 Power train
SEN04556-00 Swing circle
Swing circle 1
10-200 4 PC78US-8
200 Power train
Swing circle SEN04556-00
Unit: mm
No. Item Criteria Remedy
Standard clearance Clearance limit
1 Bearing clearance Replace
0.3 – 1.2 2.0
2. Swing circle pinion grease filler port

3. Swing circle bearing grease fitting
4. Swing pinion bearing grease fitting
5. Outer race
6. Ball
7. Seal
8. Inner race (Number of teeth: 80)
a. Inner race soft zone position

b. Outer race soft zone position
Specifications
Reduction ratio 80/10 = 8.0
Grease G2-LI
Grease quantity (l) 5.5
PC78US-8 10-200 5
200 Power train
SEN04556-00 Swing machinery
Swing machinery 1
1. Swing pinion (Number of teeth: 10) Specifications

2. Swing machinery case
3. No. 2 sun gear (Number of teeth: 14) Reduction ratio (14 + 58)/14 x (14 + 58)/14 = 26.45
4. Ring gear (Number of teeth: 58) Swing reduction
26.45 x 8.0 = 211.59
5. No. 1 planetary carrier ratio
6. No. 1 sun gear (Number of teeth: 14) Swing speed
10.0
7. Swing motor (rpm)
8. Oil filler pipe
9. Level gauge
10. No. 1 planetary gear (Number of teeth: 22)
11. No. 2 planetary gear (Number of teeth: 22)
12. No. 2 planetary carrier
13. Drain plug
10-200 6 PC78US-8
200 Power train
Swing machinery SEN04556-00
Unit: mm
Backlash between swing motor
1 shaft and No. 1 sun gear 0.03 – 0.11 —
Backlash between No. 1 sun gear
2 and No. 1 planetary gear
0.10 – 0.27 0.6
Backlash between No. 1 planetary
3 gear and ring gear
0.12 – 0.38 0.6
4 Backlash between No. 1 planetary

carrier and No. 2 sun gear 0.10 – 0.26 —
Replace
Backlash between No. 2 sun gear
5 and No. 2 planetary gear 0.10 – 0.27 0.6
6 gear and ring gear 0.12 – 0.38 0.6
7 carrier and swing pinion 0.07 – 0.21 —
Backlash between swing pinion
8 and swing circle 0.27 – 0.83 2.0
Outside diameter of oil seal Standard size Tolerance Repair limit Repair by hard
9 contacting surface on swing 0 chrome-plating or
pinion collar 75 74.8 replace
–0.074
PC78US-8 10-200 7
SEN04556-00

©2008 KOMATSU
All Rights Reserved
10-200 8
SEN04557-00
HYDRAULIC EXCAVATOR
PC78US-8


300 Undercarriage and frame

Track frame ..................................................................................................................................................... 2
Idler cushion.................................................................................................................................................... 3
Idler ................................................................................................................................................................. 4
Track roller ...................................................................................................................................................... 5
Carrier roller .................................................................................................................................................... 6
Sprocket .......................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
PC78US-8 10-300 1
SEN04557-00 Track frame
Track frame 1
Unit: mm
Standard size Repair limit
Track Rebuild
74 78
1 Length at idler guide frame
Idler 73 69 Rebuild or replace
support
Track 158 162 Rebuild
frame
2 Width at idler guide
Idler 156 152 Rebuild or replace
support
3. Idler 9. Track shoe

4. Track frame 10. Track roller guard (if equipped)
5. Carrier roller 11. Idler cushion
6. Travel motor 12. Idler guard (steel shoe, road liner)
7. Sprocket 13. Bracket to secure machine body for transpor-
8. Track roller tation (North America specification)
10-300 2 PC78US-8
Idler cushion SEN04557-00
Idler cushion 1
Unit: mm
Installed Installed Installed
Free length Free length
length load load
1 Recoil spring Steel shoe, 47.3 kN 42.1 kN Replace
Road liner 412.3 323 402
{4,826 kg} {4,295 kg}
Rubber 68.5 kN 61.0 kN
crawler 412.3 283 402
{6,985 kg} {6,217 kg}
2. Idler Specifications
3. Support Grease G2-LI
4. Rod
5. Cylinder Grease quantity (cc)
• Steel shoe, Road liner 84
6. Recoil spring • Rubber crawler 208
7. U-packing
8. Collar
9. Nut
10. Valve
11. Grease fitting
PC78US-8 10-300 3
SEN04557-00 Idler
Idler 1
Unit: mm
1 Outside diameter of projection
460 —
2 Outside diameter of tread 415 407
3 Tread depth 22.5 26.5 Rebuild or replace

4 Width of projection 43 —
5 Overall width 100 —
6 Tread width 28.5 —
Standard Tolerance Standard Clearance

Clearance between idler shaft size Shaft Hole clearance limit
7 and bushing
44 –0.250 +0.062 0.250 – —
–0.290 0 0.352
Standard Tolerance Standard Interference
Interference between bushing size Shaft Hole interference limit Replace
8 and idler +0.117 +0.025 0.062 –
50 —
+0.087 0 0.117
Side clearance of idler
9 (each side) 0.190 – 0.395 —

10 Tread thickness
(at tread center)
Rebuild or replace
13.8 9.8
— Oil capacity 60 cc (engine oil: SAE30CD) —
10-300 4 PC78US-8
Track roller SEN04557-00
Track roller 1
Unit: mm
1 Outside diameter of projection
139 —
Rebuild or replace
2 Outside diameter of tread 110 103
3 Flange width 43 —
4 Overall width 136.6 — —
5 Tread width 46.8 — Rebuild or replace

Clearance between shaft and size Shaft Hole clearance limit
6 bushing –0.250 +0.165 0.230 –
40 –0.270 –0.020 0.435 —

Interference between roller and size Shaft Hole interference limit Replace
7 bushing
44 +0.150 +0.025 0.075 – —
+0.100 –0.020 0.170
Side clearance of track roller
8 (each side) 0.26 – 0.445 —
Tread thickness
9 (at tread center)
Rebuild or replace
33 29.5
— Oil capacity 160 – 180 cc (gear oil: GO140) —
PC78US-8 10-300 5
SEN04557-00 Carrier roller
Carrier roller 1
Unit: mm
1 Outside diameter of tread Rebuild or replace
82 72
2 Tread width 100 — —

Interference between shaft and size Shaft Hole interference limit
3 bearing +0.009 0 –0.004 – Replace
30 —
–0.004 –0.010 0.019
Interference between roller and 0 +0.018 –0.031 –
4 bearing
62
–0.013 –0.012 0.012
—
5 Tread thickness Rebuild or replace
10 5
— Oil capacity 51 – 56 cc (grease: Alvania EP-2) —
10-300 6 PC78US-8
Sprocket SEN04557-00
Sprocket 1
Unit: mm
Standard size Tolerance Repair limit
1 Wear on tooth bottom diameter +1.0
433.004 421
–2.0
2 Wear on tooth tip diameter 483.7 ±2.0 472
Rebuild or replace
3 Wear on tooth tip width 28 — 23
4 Wear on tooth bottom width 38 +0.5 33

–2.5
+0.475
5 Thickness at tooth bottom 84.002
–1.150
78
PC78US-8 10-300 7
SEN04557-00 Track shoe
Track shoe 1
City pad shoe, road liner, triple grouser shoe
*1. City pad shoe

Triple grouser shoe (if equipped)
*2. Road liner (if equipped)
a Part P is the link on the bushing press-fitting side.
10-300 8 PC78US-8
Track shoe SEN04557-00
Unit: mm
1 Link pitch
154.3 157.3 Reverse or
replace
2 Bushing external diameter 41.3 37.3
3 Link height 74 70
Repair or replace
Link thickness
4 (bushing press fitting part)
20 16
5 89
6 Shoe bolt pitch 73 Replace
7 57
8 Internal width 45
9 Link Overall width 30 Repair or replace
10 Tread width 26.3
11 Pin projection 3
12 Regular bushing projection 3.15
13 Pin overall length 131
14 Bushing overall length

(master bushing)
74.6 Adjust or replace

15 Bushing thickness
8.4 4.4
16 Spacer thickness —
17 Bushing 49.0 – 62.8 kN {5 – 6.4 ton}
18 Press-fit force Regular pin 49.0 – 117.7 kN {5 – 12 ton} —

(*)
Master pin 39.2 – 78.5 kN {4 – 8 ton}
19
Retightening angle
Tightening torque (Nm {kgm})
(degree)
a. • City pad 117.7 ± 19.6
90 ± 10
Regular link • Triple grouser {12 ± 2}
117.7 ± 19.6
Shoe bolt • Road liner {12 ± 2}
60 ± 10 Retighten
20
Tightening torque Retightening angle Torque lower limit
b. (Nm {kgm}) (degree) (Nm {kgm})
Master link
— — —
Number of shoes (each side) 39 —
Items marked with * are for the dry track.
PC78US-8 10-300 9
Unit: mm
Tolerance Standard
Standard size interference
21 Interference
and link
between bushing Shaft Hole
+0.314 +0.042
41 0.232 – 0.334
+0.274 –0.020
22 Interference
and link
between regular pin
24
+0.150
0
–0.198
–0.250
0.198 – 0.400
Tolerance Standard
Standard size clearance
23 Clearance between regular pin
and bushing
Shaft Hole
+0.150 +0.830
24 0 +0.330 0.180 – 0.830 Adjust or replace
Tolerance Standard
Standard size
(*) Interference between master pin Shaft Hole interference
24 and link +0.020 –0.198
24 –0.020 –0.250 0.178 – 0.270
Tolerance Standard
Standard size
(*) Clearance between master pin Shaft Hole clearance
25 and bushing –0.150 +0.630
24 0.380 – 0.880
–0.250 +0.230
26 Grouser height a. Replace
42 19
Road liner
Items marked with * are for the dry track.
10-300 10 PC78US-8
City pad shoe, triple grouser shoe
Unit: mm
1 Grouser height
20 12
2 Shoe overall height 26 18
3 Plate thickness 6 Rebuild or replace

4 14
5 Grouser tip length 10
6 12
PC78US-8 10-300 11
Rubber crawler
(If equipped)
Unit: mm
1 Wear of lug height
30 5
2 Wear of roller guide 42 58 Replace

Standard size Tolerance Repair limit
Wear of part meshing with
3 sprocket 22.5 ±0.5 27
10-300 12 PC78US-8
PC78US-8 10-300 13
SEN04557-00

©2008 KOMATSU
All Rights Reserved
10-300 14
SEN04558-00
HYDRAULIC EXCAVATOR
PC78US-8


401 Hydraulic system, Part 1

Hydraulic component layout drawing .............................................................................................................. 2
Valve control ................................................................................................................................................... 4
Hydraulic tank and filter .................................................................................................................................. 6
Hydraulic pump ............................................................................................................................................... 8
PC78US-8 10-401 1
SEN04558-00 Hydraulic component layout drawing
Hydraulic component layout drawing 1
10-401 2 PC78US-8
Hydraulic component layout drawing SEN04558-00
1. Bucket cylinder
2. Arm cylinder
3. Arm anti-drop valve (*3, *4)
4. Boom cylinder
5. Boom anti-drop valve (*2, *4)
6. Attachment selector valve
(machine ready for attachment)
7. Control valve
8. Swing motor
9. Accumulator (for breaker)
10. Hydraulic pump
11. Oil filter
12. R.H. work equipment PPC valve
13. L.H. work equipment PPC valve
14. Oil cooler
15. Travel motor
16. Blade PPC valve
17. Accumulator (for PPC circuit)
18. 4-spool solenoid valve
19. Multi-control valve (*1, *4)
20. Travel PPC valve
21. Attachment PPC valve
22. Center swivel joint
23. Blade cylinder
24. Hydraulic tank
*1: North America specification

*2: EU specification
*3: EU specification (if equipped)
*4: Except North America and EU (if equipped)
PC78US-8 10-401 3
SEN04558-00 Valve control
Valve control 1
1. Blade control lever 11. Attachment PPC valve

2. Blade PPC valve (machine ready for attachment)
3. L.H. work equipment control lever 12. Attachment control pedal
(for arm and swing control) (machine ready for attachment)
4. L.H. work equipment PPC valve 13. Travel lever
5. Lock lever 14. R.H. work equipment PPC valve
6. Accumulator (for PPC circuit) 15. R.H. work equipment control lever
7. 4-spool solenoid valve (for boom and bucket control)
8. Multi-control valve (*1, *2) 16. Control valve
9. Travel PPC valve 17. Lock pin
10. Travel pedal (machine ready for attachment)
*1: North America specification

*2: Except North America and EU (if equipped)
10-401 4 PC78US-8
Valve control SEN04558-00
PC78US-8 10-401 5
SEN04558-00 Hydraulic tank and filter
Hydraulic tank and filter 1
1. Hydraulic tank Specifications

2. Sight gauge Hydraulic tank capacity (l) 70
3. Suction strainer
4. Drain plug Oil level in hydraulic tank (l) 56
5. Oil filler cap combined with breather Bypass valve set pressure 0.15 ± 0.03
6. Filter element (MPa {kg/cm2}) {1.5 ± 0.3}
7. Bypass valve
10-401 6 PC78US-8
Hydraulic tank and filter SEN04558-00
Breather
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

q The hydraulic tank is enclosed and pressur-
ized. When the oil level in the hydraulic tank
drops, negative pressure is generated in the
tank.
To prevent this negative pressure generation,
seam valve (4) is opened to draw the atmo-
sphere to the tank.
(Vacuum valve cracking pressure:
0 – 4.9 kPa {0 – 0.05 kg/cm2})
Prevention of pressure rise in tank

q When the hydraulic circuit is operating, the
pressure in the hydraulic tank increases as the
hydraulic cylinder operates and the oil level
and temperature increase in the tank.
If the pressure in the tank rises above the set
value, bottom plate (2) is pushed up to release
the pressure in the tank.
(Pressure valve cracking pressure:
38.2 ± 14.7 kPa {0.39 ± 0.15 kg/cm2})
PC78US-8 10-401 7
SEN04558-00 Hydraulic pump
Hydraulic pump 1
Blade specification
Model: LPD45+45
10-401 8 PC78US-8
Hydraulic pump SEN04558-00
Outline
q This pump consists of a variable displacement
swash plate type piston pump, a double gear
pump (1 unit for blade and swinging and the
other for pilot pump) and a servo valve.
Features of double pump system

q The common single pump system makes
much loss in the pressure compensation valve.
Accordingly, the machine travel speed is
reduced much when the machine is steered.
q The double pump system does not make much
loss in the pressure compensation valve, since
the right and left travel circuits are independent
from each other. Accordingly, the machine
travel speed is less reduced when the machine
is steered.
q The double pump has simpler structure than
the tandem pump.
P1: Pump discharge port

P1T: Travel deviation control orifice
P3: Gear pump discharge port
P4: Pilot pump discharge port
P5: Gear pump pressure pickup port
PD: Drain port
PD2: Pump drain port (plug)
PEN: Control pressure pickup port
PEPC: EPC basic pressure pickup port
PGS: Gear pump suction port
PLS: LS pressure input port
(from control valve port LS)
PM: PC mode selector pressure pickup port
PPLS: Pump pressure input port
(from control valve port PP)
PPT: PTO oil filler port
PS1: Main pump suction port
1. Main pump
2. Servo valve
3. Double gear pump
4. EPC valve
5. Bleeder
PC78US-8 10-401 9
10-401 10 PC78US-8
P3: Gear pump pressure input port

PAV: Pump average pressure port
PDE: EPC drain port
PEN: Control pressure input port
PEPC: EPC basic pressure input port
PH: Pump shuttle port
T: Drain port
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
PC78US-8 10-401 11
Bladeless specification
Model: LPD45+45
10-401 12 PC78US-8
Outline
q This pump consists of a variable displacement
swash plate type piston pump, a double gear
pump (1 unit for blade and swinging and the
other for pilot pump) and a servo valve.
Features of double pump system

q The common single pump system makes
much loss in the pressure compensation valve.
Accordingly, the machine travel speed is
reduced much when the machine is steered.
q The double pump system does not make much
loss in the pressure compensation valve, since
the right and left travel circuits are independent
from each other. Accordingly, the machine
travel speed is less reduced when the machine
is steered.
q The double pump has simpler structure than
the tandem pump.

P3: Gear pump discharge port
PD: Drain port
PD2: Pump drain port (plug)
PEN: Control pressure pickup port
PEPC: EPC basic pressure pickup port
(from control valve port LS)
PM: PC mode selector pressure pickup port
PPLS: Pump pressure input port
(from control valve port PP)
PPT: PTO oil filler port
PS1: Main pump suction port
1. Main pump
2. Servo valve
3. Gear pump
4. EPC valve
5. Bleeder
PC78US-8 10-401 13
10-401 14 PC78US-8

PAV: Pump average pressure port
PDE: EPC drain port
PEN: Control pressure input port
PH: Pump shuttle port
T: Drain port
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
PC78US-8 10-401 15
Function Structure
q The pump converts the engine rotation and q Cylinder block (7) is supported on shaft (1)
torque transmitted to its shaft to oil pressure through spline (a). Shaft (1) is supported on
and delivers pressurized oil corresponding to the front and rear bearings.
the load. q The tip of piston (6) is shaped to a concave ball
q It is possible to change the delivery by chang- and integrated with caulked shoe (5). Piston
ing the swash plate angle. (6) and shoe (5) form a spherical bearing.
q There are 2 discharge ports, which can supply q Rocker cam (4) has flat surface (A), and shoe
pressurized oil independently. (5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) is supported on flange (2) and
ball (12) which are fixed to case (3).
q Shoe (5) leads high-pressure oil to flat surface
(A) of rocker cam (4) to form a static pressure
bearing for its sliding.
q Piston (6) in each cylinder chamber of cylinder
block (7) moves relatively in the axial direction.
q Cylinder block (7) rotates relatively to valve
plate (8) while sealing the pressurized oil so
that an appropriate oil pressure balance is
maintained on this surface.
q The oil in the respective cylinder chambers of
cylinder block (7) is sucked and discharged
through valve plate (8).
10-401 16 PC78US-8
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q Rocker cam (4) leans around ball (12), and plate angle (a) = 0), the difference between
accordingly angle (a) between center line (X) volumes (E) and (F) inside cylinder block (7)
of rocker cam (4) and the axial direction of cyl- becomes 0.
inder block (7) changes. q Suction and discharge of pressurized oil is not
q (a) is named the swash plate angle. carried out in this state. Namely pumping
action is not performed. (actually, however, the
swash plate angle is not set to 0)
q Swash plate angle (a) is in proportion to the
pump delivery.
q There are an even number (10) of holes on cyl-
inder block and they match the 2 grooves of
valve plate (8) alternately. Oil of quantity for 5
pistons is discharged respectively through
pump discharge ports (P1) and (P2).
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) suctions and discharges the
oil by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
PC78US-8 10-401 17
Servo valve
10-401 18 PC78US-8
IM: PC mode selector current connector

PAV: Pump average pressure input port
PDE: EPC drain port
PE: Control piston pressure port
PH: Pump shuttle pressure port
PM: PC mode selector pressure input port
PMI: PC mode selector pressure pickup port
PPLS: LS pump pressure input port
T: Drain port
1. Lever
2. Spool
3. Plug
4. Seat
5. Piston
6. Sleeve
7. Plug
8. Locknut
9. Spring
10. PC-EPC valve
11. Spool
12. Ball
13. Plug
14. LS valve
15. PC valve
PC78US-8 10-401 19
Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
be co m es l ar g er an d p ump de liv e ry (Q )
increases.
q Servo piston (11) is used for changing swash
plate angle (a).
q Servo piston (11) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This straight motion is transmitted to rocker
cam (4).
q Rocker cam (4) supported on flange (2) by ball
(12) carries out rotary motion.
10-401 20 PC78US-8
Function
LS valve PC valve
q The LS valve controls the pump delivery q The PC valve is an equal horsepower control
according to the stroke of the control lever, or valve, which limits the oil flow rate to a certain
the demand flow for the actuator. level (according to the discharge pressure)
q The LS valve senses the flow rate demanded regardless of the control valve stroke so that
by the actuator from differential pressure the pump absorption horsepower will not
(dPLS) between inlet pressure (PPLS) and exceed the engine horsepower when pump
output pressure (PLS) of the control valve and discharge pressure (PP) is high.
controls pump delivery (Q). [(PPLS) is called q If the load during the operation becomes larger
the LS pump pressure, (PLS) the LS pressure, and the pump discharge pressure rises, it
and (dPLS) the LS differential pressure] reduces the pump delivery; and if the pump
q In other words, the pressure loss caused by discharge pressure drops, it increases the
flow of oil through the open area of the control pump delivery.
valve spool (= LS differential pressure (dPLS)) q This pump has 2 discharge ports and the aver-
is detected, and then pump delivery (Q) is con- age of their respective discharge pressures
trolled to keep that pressure loss constant and (P1) and (P2) is sensed.
supply the pump delivery according to the q The average pressure of (P1) and (P2) is
demand flow for the actuator. called (PAVE) and the relationship between it
q Pump discharge pressure (PP), LS pump pres- and the pump delivery [the total deliveries of
sure (PPLS) and LS pressure (PLS) are lead to (P1) and (P2)] is as follows.
the LS valve. The relationship between LS dif-
ferential pressure (dPLS) and pump delivery
(Q) changes as shown in the figure below.
PC78US-8 10-401 21
Operation
Action of spring When swing gear pump pressure increases or

q The spring load of spring (2) at the PC valve is decreases
decided by the position of the swash plate. q The pressing force of spool (4) changes and
q If servo piston (6) moves to the right, spring (2) the pump delivery changes as in the case
is compressed through lever (1) and the spring when (PAVE) increases or decreases.
load changes. The spring constant of this
spring changes to 2 stages, depending on its When PC-EPC valve operates
length. q The PC-EPC valve changes the output pres-
sure with the input current from the controller
When pump pressure (PAVE) is low and the pressing force of spool (5) changes as
q The pressing force of spool (4) is reduced and in t he c a s e w h en ( PAV E) in c re as es o r
spool (3) is off to the right. At this time, ports decreases.
(C) and (D) are connected and the pressure
entering the LS valve becomes drain pressure
(PT). (Fig. 1)
q If port (F) and port (G) of the LS valve are con-
nected, the pressure in port (J) becomes drain
pressure (PT) and servo piston (6) moves to
the left.
q The pump delivery increases.
q If lever (1) moves to the left according to the
movement of servo piston (6) to extend spring
(2) and decrease its force, spool (3) moves to
the left to disconnect ports (C) and (D) and
connect pump discharge ports (B) and (C).
q Since the pressure in port (C) increases and
the piston pressure increases, servo piston (6)
stops moving to the left.
When pump pressure (PAVE) is high

q The pressing force of spool (4) is increased
and spool (3) is off to the left. At this time, ports
(C) and (B) are connected and the pressure
entering the LS valve becomes pump pressure
(PP). (Fig. 2)
q If port (F) and port (G) of the LS valve are con-
nected, the pressure in port (J) becomes pump
pressure (PP) and servo piston (6) moves to
the right.
q The pump delivery decreases.
q If lever (1) moves to the right according to the
movement of servo piston (6) to compress
spring (2) and increase its force, spool (3)
moves to the right to disconnect ports (C) and
(B) and connect drain pressure ports (D) and
(C).
q Since the pressure in port (C) decreases and
the piston pressure decreases, servo piston (6)
stops moving to the right.
q The stopping position of servo piston (6) (=
pump delivery) depends on the position at
which the pressing force generated by pres-
sure (PAVE) applied to spool (4) is balanced
with the force of spring (2). (Fig. 3)
10-401 22 PC78US-8
When load is light
When load is heavy
PC78US-8 10-401 23
When balanced
10-401 24 PC78US-8
PC78US-8 10-401 25
SEN04558-00

©2008 KOMATSU
All Rights Reserved
10-401 26
SEN04559-00
HYDRAULIC EXCAVATOR
PC78US-8



Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 14
Functions and operation by valve ................................................................................................................. 18
PC78US-8 10-402 1
SEN04559-00 Control valve
Control valve 1
Outline
The control valves of the following types are set.
q 7-spool valve (with blade, without service valve)
q 7-spool valve (without blade, with 1 service valve)
Outside view and shape of each control valve

q The general view and sectional view show the 7-spool valve (with blade, without service valve).
q Compared to the control valve as shown, the blade valve located on the block is removed but the ser-
vice valve is added between the cover and the bucket valve for the control valve of the 7-spool valve
(without blade, with 1 service valve).
Since each service valve is add-on type, its later addition or removal is available.
A1: To blade cylinder P3: From pump discharge port
A2: To swing motor PA1: From blade RAISE PPC valve
A3: To left travel motor PA2: From swing RIGHT PPC valve
A4: To right travel motor PA3: From left travel REVERSE PPC valve
A5: To boom cylinder PA4: From right travel REVERSE PPC valve
A6: To arm cylinder PA5: From boom RAISE PPC valve
A7: To bucket cylinder PA6: From arm OUT PPC valve
B1: To blade cylinder PA7: From bucket DUMP PPC valve
B2: To swing motor PB1: From blade LOWER PPC valve
B3: To left travel motor PB2: From swing LEFT PPC valve
B4: To right travel motor PB3: From left travel FORWARD PPC valve
B5: To boom cylinder PB4: From right travel FORWARD PPC valve
B6: To arm cylinder PB5: From boom LOWER PPC valve
B7: To bucket cylinder PB6: From arm IN PPC valve
BP: From boom RAISE PPC valve PB7: From bucket CURL PPC valve
LS: To pump LS valve (LS pressure input) PP: To pump LS valve (LS pressure input)
LS1I: LS1 pressure pickup port PT: From pump merge-divider selector solenoid
LS2I: LS2 pressure pickup port PTSW: Pump pressure sensor mounting port
P1: From pump discharge port TB: To tank through bypass check valve
P1I: P1 pressure pickup port TC: To tank through bypass check valve
P2: From pump discharge port TS: To tank
P2I: P2 pressure pickup port TSW: To swing motor
1. Block
2. Blade valve
3. Swing valve
4. Left travel valve
5. Right travel valve
3. Pump merge-divider valve block
7. Boom valve
8. Arm valve
9. Bucket valve
10. Cover
11. LS bypass valve
12. Travel junction valve + LS bypass valve
13. Boom hydraulic drift prevention valve
14. Cooler bypass valve
10-402 2 PC78US-8
Control valve SEN04559-00
7-spool valve 1
(Blade specification, without service valve)

General view
PC78US-8 10-402 3
Sectional view
(1/5)
10-402 4 PC78US-8
1. Suction safety valve (blade) 13. Suction valve (left travel)

2. Suction valve (left travel) 14. Suction valve (blade)
3. Suction valve (right travel) 15. Main relief valve
4. Main relief valve 16. Spool (assistant valve)
5. Suction valve (boom) 17. Spool (blade)
6. Suction valve (arm) 18. Spool (swing)
7. Suction valve (bucket) 19. Spool (left travel)
8. Suction safety valve 20. Spool (right travel)
9. Suction valve (bucket) 21. Spool (boom)
10. Suction valve (arm) 22. Spool (arm)
11. Suction valve (boom) 23. Spool (bucket)
12. Suction valve (right travel) 24. Unload valve
Unit: mm
No. Check item Criteria Remedy
Free length x
Installed
Outside Installed load Free length Installed load
25 Suction valve spring diameter
length
5.1 N 4.12 N
39.2 x 4.45 33.5 —
{0.52 kg} {0.42 kg}
2.65 N 2.06 N
26 Suction valve spring 36.3 x 4.45 33.3
{0.27 kg}
—
{0.21 kg}
89.2 N 71.4 N
27 Spool return spring 29.01 x 18.3 27.5
{9.1 kg}
—
{7.28 kg}
173 N 138 N
28 Spool return spring 29.03 x 18.4 26
{17.66 kg}
—
{14.1 kg}
181 N 144 N If damaged or
29 Spool return spring 29 x 17.5 25
{18.42 kg}
—
{14.7 kg} deformed, replace
spring.
136 N 109 N
{13.82 kg}
—
{11.1 kg}
34.3 N 27.5 N
{3.5 kg}
—
{2.8 kg}
104 N 83.2 N
{10.6 kg}
—
{8.48 kg}
136 N 109 N
{13.91 kg}
—
{11.1 kg}
184 N 147 N
34 Spool return spring 41.28 x 15 33.5
{18.74 kg}
—
{15.0 kg}
317 N 253 N
35 Spool return spring 42.4 x 19 34.5
{32.3 kg}
—
{25.8 kg}
PC78US-8 10-402 5
(2/5)
10-402 6 PC78US-8
1. Pressure compensation valve R (left travel)

2. Pressure compensation valve R (right travel)
3. Pump merge-divider valve spool
4. Pressure compensation valve R (boom)
5. Pressure compensation valve R (arm)
6. Pressure compensation valve R (bucket)
7. Pressure compensation valve F (bucket)
8. Pressure compensation valve F (arm)
9. Pressure compensation valve F (boom)
10. Pressure compensation valve F (right travel)
11. Pressure compensation valve F (left travel)
F: Flow control valve

R: Pressure reducing valve
Unit: mm
Free length x
Installed
12 Spool return spring diameter length
164 N 131 N
45.38 x 14 37.5 —
{16.74 kg} {13.4 kg}
13 Pressure
spring
compensation valve
30.85 x 5.2 27
9.81 N
{1.0 kg}
—
7.85 N
{0.8 kg}
14 Pressure
spring
compensation valve
33.4 x 14.4 21.5
55.9 N
{5.7 kg}
—
44.7 N
{4.56 kg}
If damaged or
15 Pressure
spring
compensation valve
28.0 x 14.4 14.5
13.7 N
{1.4 kg}
—
11.0 N
spring.
16 Pressure
spring
compensation valve
20 x 8.4 12
6.86 N
{0.7 kg}
—
5.49 N
{0.56 kg}
1.96 N 1.57 N
17 Check valve spring 13.0 x 6.5 9.5
{0.2 kg}
—
{0.16 kg}
3.92 N 3.14 N
18 Check valve spring 27.2 x 6.9 22
{0.4 kg}
—
{0.32 kg}
3.92 N 3.14 N
{0.4 kg}
—
{0.32 kg}
1.96 N 1.57 N
20 Check valve spring 21.9 x 5 15.8
{0.2 kg}
—
{0.16 kg}
PC78US-8 10-402 7
(3/5)
10-402 8 PC78US-8
Block
1. Spool (assistant valve)
2. Main relief valve
Blade valve
3. Suction safety valve
4. Suction valve
5. Spool
6. Check valve
Swing valve
7. Spool
8. Check valve
L.H. travel valve

9. Pressure compensation valve F
10. Suction valve
11. Suction valve
12. Spool
13. Pressure compensation valve R
14. LS bypass valve

Unit: mm
Free length x If damaged or
Installed
15 Check valve spring diameter
length deformed, replace
spring.
1.96 N 1.57 N
21.9 x 5 15.8 —
{0.2 kg} {0.16 kg}
PC78US-8 10-402 9
(4/5)
10-402 10 PC78US-8
R.H. travel valve

2. Suction valve
3. Suction valve
4. Spool
6. Travel junction valve + LS bypass valve
Pump merge-divider valve block

7. Pump merge-divider valve spool
8. Unload valve
9. Check valve
10. Cooler bypass valve
11. Unload valve
12. Main relief valve
13. Check valve
Boom valve
15. Suction valve
16. Hydraulic drift prevention valve
17. Suction valve
18. Spool

Unit: mm
Free length x
Installed
20 Spool return spring diameter
length
15.7 N 12.6 N
19.26 x 7.5 14 —
{1.6 kg} {1.28 kg}
1.96 N 1.57 N If damaged or
21 Check valve spring 21.9 x 5 15.8
{0.2 kg}
—
spring.
73.5 N 58.8 N
22 Valve return spring 34.5 x 17.7 25
{7.5 kg}
—
{6.0 kg}
11.2 N 9.02 N
23 Valve return spring 16.6 x 13 13
{1.14 kg}
—
{0.92 kg}
10.8 N 8.63 N
24 Piston return spring 13 x 8.8 7.5
{1.1 kg}
—
{0.88 kg}
PC78US-8 10-402 11
(5/5)
10-402 12 PC78US-8
Arm valve
2. Suction valve
3. Suction valve
4. Spool
Bucket valve
7. Suction valve
8. Suction valve
9. Spool
Cover
11. Suction safety valve
12. Check valve

Unit: mm
Free length x If damaged or
Installed
length deformed, replace
spring.
3.92 N 3.14 N
27.2 x 6.9 22 {0.4 kg} — {0.32 kg}
PC78US-8 10-402 13
SEN04559-00 CLSS
CLSS 1
a CLSS: Abbreviation for Closed center Load Sensing System
Outline of CLSS 1
Features Composition
q Fine control not influenced by load q CLSS consists of a variable capacity piston
q Controllability enabling digging even under the pump, control valves, and respective actua-
fine control tors.
q Ease of compound operation ensured by flow q The hydraulic pump is configured with pump
divider function using the open area of spool body, PC valve and LS valve.
during compound operations
q Energy saving using variable pump control
10-402 14 PC78US-8
CLSS SEN04559-00
Basic principle 1
Pump swash plate angle control

q The pump swash plate angle (pump delivery) q The pump swash plate angle shifts toward the
is controlled so that LS differential pressure maximum position if LS differential pressure
(dPLS) (the difference between pump pressure (dPLS) is lower than the set pressure of the LS
(PP) and control valve outlet port LS pressure valve (when the actuator load pressure is
(PLS)) (load pressure of actuator) is constant. high).
q [LS differential pressure (dPLS) = Pump dis- q If it becomes higher than the set pressure
charge pressure (PP) – LS pressure (PLS)] (when the actuator load pressure is low), the
pump swash plate angle shifts toward the mini-
mum position.
LS differential pressure ( d PLS) and pump swash

plate angle
a For details of functions, see the "Hydraulic

pump" paragraph.
PC78US-8 10-402 15
SEN04559-00 CLSS
Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve to bal-
ance the load.
q When actuators are operated simultaneously,
the pressure difference (dP) between the
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless of the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve.
10-402 16 PC78US-8
CLSS SEN04559-00
PC78US-8 10-402 17
SEN04559-00 Functions and operation by valve
Functions and operation by valve 1
Hydraulic circuit diagram and the name of valves 1
a The hydraulic circuit diagram shows the 7-spool valve (with blade, without service valve).
10-402 18 PC78US-8
Functions and operation by valve SEN04559-00
1. Block 18. Arm spool

2. Blade valve 19. Bucket spool
3. Swing valve 20. Pressure compensation valve
4. Left travel valve 21. Suction valve
5. Right travel valve 22. LS check valve
6. Pump merge-divider valve block 23. Travel junction valve + LS check valve
7. Boom valve 24. Boom hydraulic drift prevention valve
8. Arm valve 25. Cooler bypass valve
9. Bucket valve 26. Suction safety valve
10. Cover Set pressure: 9.8 MPa {100 kg/cm2}
11. Assistant valve 27. Suction safety valve
12. Blade spool Set pressure: 27.9 MPa {285 kg/cm2}
13. Swing spool 28. Main relief valve
14. Left travel spool Set pressure: 21.1 MPa {215 kg/cm2}
15. Right travel spool 29. Main relief valve
16. Pump merge-divider valve Set pressure: 26.5 MPa {270 kg/cm2}
17. Boom spool 30. Unload valve
PC78US-8 10-402 19
Unload valve 1
When control valve is at HOLD
Function Operation
q When the control valve is at HOLD, pump q Pump discharge pressures (PP1) and (PP2)
delivery (Q) discharged by the minimum swash are applied to the right side of unload spool (1),
plate angle is drained to the tank circuit. and LS pressures (PLS1) and (PLS2) are
q Pump discharge pressures (PP1) and (PP2) applied to the left side. (PP1 = PP2, PLS1 =
are set to 2.45 MPa {25.0 kg/cm2} by spring (2) PLS2)
in the valve. [LS pressures (PLS1) and (PLS2) q When the control valve is at HOLD, LS pres-
are 0 MPa {0 kg/cm2}] sures (PLS1) and (PLS2) are 0 MPa {0 kg/cm2}
q Since the pump merge-divider spool is at the and only pump discharge pressures (PP1) and
merge position, pump discharge pressures (PP2) are applied.
(PP1) and (PP2) are merged. q (PP1) and (PP2) are set with only the installa-
q LS pressures (PLS1), (PLS2), and (PLS3) are tion load of spring (2).
merged. q Pump discharge pressures (PP1) and (PP2)
increase to 2.45 MPa {25.0 kg/cm 2} which is
the installation load of spring (2).
q Spool (1) moves to the left.
q Pump circuits (PP1) and (PP2) are connected
to tank circuit (T) through the notch of spool
(1).
q Pump discharge pressures (PP1) and (PP2)
are set to 2.45 MPa {25.0 kg/cm2}.
10-402 20 PC78US-8
During work equipment fine control

Work equipment: Swing, boom, arm, bucket, attachment
Function Operation
q When the actuator demand flow is less than q If the work equipment is controlled finely, LS
the pump discharge at the minimum swash pressures (PLS1) and (PLS2) are generated
plate angle during work equipment fine control. and applied to the left side of spool (1). (PP1 =
q Pump discharge pressure (PP1) [(PP2)] is set PP2, PLS1 = PLS2)
to LS pressure (PLS1) [(PLS2)] + 2.45 MPa q Since the open area of the work equipment
{25.0 kg/cm2}. valve spool is narrow, LS pressures (PLS1)
q The differential pressure between pump dis- and (PLS2) are very different from pump dis-
charge pressure (PP1) or (PP2) and LS pres- charge pressures (PP1) and (PP2).
sure (PLS1) or (PLS2) becomes 2.45 MPa q The differential pressure between pump dis-
{25.0 kg/cm 2} which is the installation load of charge pressure (PP1) or (PP2) and LS pres-
spring (2). sure (PLS1) or (PLS2) reaches 2.45 MPa {25.0
q Unload spool (1) opens. kg/cm2} by the installation load of spring (2).
q LS differential pressure (dPLS) becomes 2.45 q Spool (1) moves to the left.
MPa {25.0 kg/cm2}. q Pump circuits (PP1) and (PP2) are connected
q Since the pump merge-divider spool is at the to tank circuit (T).
merge position, pump discharge pressures q Pump discharge pressure (PP1) [(PP2)] is set
(PP1) and (PP2) are merged. to the force of spring (2) (2.45 MPa {25.0 kg/
q LS pressures (PLS1), (PLS2), and (PLS3) are cm2}) + LS pressure (PLS1) [(PLS2)].
merged. q LS differential pressure (dPLS) becomes 2.45
MPa {25.0 kg/cm2}.
PC78US-8 10-402 21
During fine control of both travel valves
Function Operation
q When the demand flow is less than the maxi- q If the both travel valves are controlled finely,
mum pump delivery during fine control of both LS pressures (PLS1) and (PLS2) are gener-
travel valves. ated and applied to the left side of spool (1)
q Pump discharge pressure (PP1) [(PP2)] is set [(PP1), (PP2), (PLS1) and (PLS2) are divided].
to LS pressure (PLS1) [(PLS2)] + 2.45 MPa q Since the open areas of the both travel valve
{25.0 kg/cm2}. spools are narrow, LS pressures (PLS1) and
q The differential pressure between pump dis- (PLS2) are very different from pump discharge
charge pressure (PP1) or (PP2) and LS pres- pressures (PP1) and (PP2).
sure (PLS1) or (PLS2) becomes 2.45 MPa q The differential pressure between pump dis-
{25.0 kg/cm2} by the installation load of spring charge pressure (PP1) or (PP2) and LS pres-
(2). sure (PLS1) or (PLS2) reaches 2.45 MPa {25.0
q Unload spool (1) opens. kg/cm2} by the installation load of spring (2).
q The excessive oil (maximum pump delivery – q Spool (1) moves to the left.
demand flow) flows to the tank circuit. q Pump circuits (PP1) and (PP2) are connected
q Since the pump merge-divider spool is at the to tank circuit (T).
divider position, pump discharge pressures q The excessive oil (maximum pump delivery –
(PP1) and (PP2) are divided. demand flow) above the strokes of both travel
q LS pressures (PLS1) and (PLS2) are divided. valve spools is drained to tank circuit (T).
q The pump swash plate angle becomes maxi-
mum and the pump delivery becomes maxi-
mum. (for details, see "Pump merge-divider
valve")
10-402 22 PC78US-8
When both travel valves are operated
Function Operation
q During operation of both travel valves, when q If the both travel valves are operated to the
the demand flow becomes maximum, draining maximum, LS pressures (PLS1) and (PLS2)
to tank circuit (T) is cut off, and all of pump are generated and applied to the left side of
delivery (Q) flows to both travel circuits. spool (1). [(PP1) and (PP2), and (PLS1) and
q Since the pump merge-divider spool is at the (PLS2) are divided respectively]
divider position, pump discharge pressures q Since the open areas of the both travel valve
(PP1) and (PP2) are divided. spools are wide, LS pressures (PLS1) and
q LS pressures (PLS1) and (PLS2) are divided. (PLS2) are not much different from pump dis-
q The pump swash plate angle becomes maxi- charge pressures (PP1) and (PP2).
mum and the pump delivery becomes maxi- q The differential pressure between pump dis-
mum. (For details, see "Pump merge-divider charge pressure (PP1) or (PP2) and LS pres-
valve".) sure (PLS1) or (PLS2) will not reach 2.45 MPa
{25.0 kg/cm2 } which is the installation load of
spring (2).
q Spring (2) pushes spool (1) to the right.
q Pump circuits (PP1) and (PP2) are discon-
nected from tank circuit (T), and all pump deliv-
ery (Q) flows to the actuator circuit.
PC78US-8 10-402 23
When either travel valve is operated
Function q Since the open area of the left travel valve

q When either travel valve is operated, the travel spool is wide, LS pressure (PLS1) is not much
valve demand flow is supplied to the travel cir- different from pump discharge pressure (PP1).
cuit according to the travel valve stroke. q The differential pressure between pump dis-
q All the pump delivery on the non-operated charge pressure (PP 1) and LS pressure
travel valve side is drained to the tank circuit. (PLS1) will not reach 2.45 MPa {25.0 kg/cm 2}
q Since the pump merge-divider spool is at the which is the installation load of spring (2).
divider position, pump discharge pressures q Spring (2) pushes spool (1) to the right.
(PP1) and (PP2) are divided. q Pump circuit (PP1) is disconnected from tank
q LS pressures (PLS1) and (PLS2) are divided. circuit (T), and all pump delivery (Q) on the
q The pump swash plate angle becomes maxi- (PP1) side flows to the left travel circuit.
mum and the pump delivery becomes maxi- q Since the right travel valve is at HOLD, LS
mum. (for details, see "Pump merge-divider pressure (PLS2) is not generated.
valve") q Only pump discharge pressure (PP2) is
applied.
Operation q Pump discharge pressure (PP2) reaches 2.45
MPa {25.0 kg/cm2 } by the installation load of
When left travel valve is operated to stroke end spring (4). Spool (3) moves to the left.
and right one is at HOLD. q All of pump delivery (Q) on the (PP2) side is
q If the left travel valve is operated to the maxi- drained to tank circuit (T).
mum stroke, LS pressure (PLS1) is generated.
q LS pressure (PLS1) is applied to the left side of
unload spool (1).
10-402 24 PC78US-8
PC78US-8 10-402 25
Merge-divider valve 1
When control valve is at HOLD and work equipment is operated (including compound operation of
work equipment + travel)
Function Operation
q Pump discharge pressures (PP1) and (PP2) q When the control valve is at HOLD, the right
are merged in pump merge-divider spool (3). and left travel PPC pressure switches and the
LS pressures (PLS1), (PLS2), and (PLS3) are work equipment PPC pressure switch output
also merged. no signals.
q The controller generates no output signals and
the pump merge-divider solenoid valve gener-
ates no output pressure.
q When the work equipment is operated, the
right and left PPC pressure switches do not
output signals and only the work equipment
PPC pressure switch outputs signals.
q The controller generates no output signals and
the pump merge-divider solenoid valve gener-
ates no output pressure.
are merged and LS pressures (PLS1), (PLS2)
and (PLS3) are also merged (PP1 = PP2,
PLS1 = PLS2 = PLS3).
10-402 26 PC78US-8
When both travel valves are operated (including operation of either travel valve)
Function Operation
q Pump discharge pressures (PP1) and (PP2) q If only right and left travel valves are operated,
are divided in pump merge-divider spool (3). the right and left travel PPC pressure switches
LS pressures (PLS1), (PLS2), and (PLS3) are output signals but the work equipment PPC
also divided. pressure switch does not output signals.
q The higher one of pump discharge pressures q The controller generates output signals and
(PP1) and (PP2) is output as the LS pressure. the pump merge-divider solenoid valve gener-
ates output pressure.
q If the output pressure reaches 1.47 MPa {15
kg/cm2} which is the installation load of spring
(4), spool (3) is pushed to the left.
are divided and LS pressures (PLS1), (PLS2),
and (PLS3) are also divided.
q (PP1) and (PLS1) are supplied to the left travel
circuit and (PP2) and (PLS2) are supplied to
the right travel circuit.
q The higher one of pump discharge pressures
(PP1) and (PP2) is output as the LS pressure.
q The pump swash plate angle becomes maxi-
mum and the pump delivery becomes maxi-
mum.
PC78US-8 10-402 27
Introduction of LS pressure 1
Work equipment valve: Swing, boom, arm, bucket, attachment
Function q LS circuit (PLS) is connected to tank circuit (T)

q LS pressure means the actuator load pressure from LS bypass valve (4). (see "LS bypass
on the outlet side of the control valve. valve")
q Practically, pump pressure (PP) is reduced by q The areas at both ends of pressure reducing
pressure reducing valve (3) of the pressure valve (3) are the same [(SA) = (SLS)], and
compensation valve to the same pressure as actuator circuit pressure (PA) acts on the (SA)
actuator circuit pressure (A), and is sent to LS end. The reduced pump discharge pressure
circuit (PLS). (PP) acts on (SLS) at the other end.
q In the travel valve, actuator circuit pressure (A) q Pressure reducing valve (3) is balanced at a
is directly introduced to LS circuit (PLS). position where actuator circuit pressure (PA)
and the pressure of spring chamber (PLSS)
Operation are the same. Pump discharge pressure (PP)
q If spool (1) is operated, pump discharge pres- reduced at notch (c) becomes actuator pres-
sure (PP) flows from flow control valve (2) sure (A) and is introduced to LS circuit (PLS).
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit (A).
q Since pressure reducing valve (3) moves to
the right, pump discharge pressure (PP) is
reduced by the pressure loss at notch (c) and
supplied to LS circuit (PLS). Then, it goes to
spring chamber (PLSS).
10-402 28 PC78US-8
Travel valve
Operation
q When spool (1) is operated, pump discharge
pressure (PP) flows from flow control valve (2)
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit (A).
q Pressure reducing valve (3) is moved to the
right by actuator circuit pressure (PA) and
notches (c) and (d) are connected to travel
junction circuit (e) and LS circuit (PLS) respec-
tively.
q Actuator circuit pressure (PA) [(A)] is intro-
duced to LS circuit (PLS) through notch (c),
internal check valve and notch (d).
PC78US-8 10-402 29
LS bypass valve 1
Function
q The LS bypass valve releases the remaining
pressure of LS pressure (PLS).
q While moderating increasing rate of LS pres-
sure (PLS), this valve generates pressure loss
in the throttle function with this discarded throt-
tle flow, decreasing the effective LS differential
pressure and enhancing stability.
When work equipment valve is operated (including compound operation of work equipment + travel)
Operation
q Since pump merge-divider spool (1) is at the
merge position, the hydraulic oil in LS circuits
(PLS1), (PLS2), and (PLS3) is drained from tip
filter (a) of LS bypass valve (2) on the (P2) side
through orifice (b) to tank circuit (T).
10-402 30 PC78US-8
When both travel valves are operated (including operation of either travel valve)
Operation
q Since spool (1) is at the divider position, LS cir-
cuits (PLS1) and (PLS2) are divided.
q Hydraulic oil (PLS1) is drained from tip filter (a)
of LS bypass valve (3) on the (P1) side through
orifice (b) to tank circuit (T).
q Hydraulic oil (PLS2) is drained from tip filter (a)
of LS bypass valve (2) on the (P2) side through
orifice (b) to tank circuit (T).
PC78US-8 10-402 31
LS select valve 1
Function
q At the time of simultaneous operation of swing
+ boom RAISE, this valve prevents high swing
LS pressure from entering the LS circuit (PLS)
so that the pump flow to the boom cylinder is
secured when the machine starts swinging,
and also prevents the boom RAISE speed
from reducing.
During normal operation
Operation
q The pilot pressure is not generally applied to
the pilot port (BP) except for boom RAISE
operation.
q In this state, pump pressure (PP) is led through
the internal passage of spool (1) to pressure
reducing valve (3) of the swing valve. At the
time of swing operation, there occurs LS pres-
sure (PLS) suitable for the load pressure, and
the pressure is led to the pump LS valve.
10-402 32 PC78US-8
At simultaneous operation of swing + boom RAISE
Operation
q At the simultaneous operation of swing + boom
RAISE, the signal pressure of the PPC circuit
is led to the pilot port (BP).
q This pilot pressure (BP) is applied to spool (1).
If it increases and overcomes spring (2), spool
(1) is pushed to the right and the internal pas-
sage is closed. As a result, pump pressure
(PP) is not supplied to pressure reducing valve
(3) of the swing valve any more.
q Swing LS pressure (PLS) is not generated and
only boom RAISE is led to the pump LS valve,
and the pump delivery is controlled with the
boom RAISE LS pressure.
q Pilot pressure (BP) depends on the control
lever (boom RAISE) stroke.
PC78US-8 10-402 33
Boom RAISE merge valve 1
Function
q When the machine starts swinging while the
boom is being raised, the boom RAISE merge
valve merges the gear pump flow into the main
pump circuit to increase the boom RAISE
speed.
Operation
q The pilot pressure is not generally applied to
the pilot port (BP) except for boom RAISE
operation.
q In this state, since spool (1) disconnects gear
pump circuit (P3) from main pump circuit (PP),
the pressurized oil from gear pump circuit (P3)
does not connect into main pump circuit (PP).
10-402 34 PC78US-8
At simultaneous operation of swing + boom RAISE
Operation
q At the simultaneous operation of swing + boom
RAISE, the signal pressure of the boom RAISE
PPC circuit is led to pilot port (BP).
q This pilot pressure (BP) is applied to spool (1).
If it increases and overcomes spring (2), spool
(1) is pushed to the right and check valve (3) in
it is pushed open. As a result, the pressurized
oil from gear pump circuit (P3) merges into
main pump circuit (PP) to increase the boom
RAISE speed.
PC78US-8 10-402 35
Area ratio of pressure compensation valve 1
Function Area ratio (S1) : (S2) and compensation charac-

q The pressure compensation valve delicately teristics
adjusts the ratio of area (S2) of pressure q When the ratio is 1.00:
reducing valve (1) (right side) to area (S1) of [Pump (discharge) pressure (PP) – Spool
flow control valve (2) (left side) (S2/S1) to notch upstream pressure (PPB)] C [LS circuit
decide the compensation characteristics. pressure (PLS) – Actuator circuit pressure (PA)
(= A)], and the flow is distributed as per the
S1: Area of the flow control valve (2) – area of the spool open area ratio.
piston (3) q When the ratio is larger than 1.00:
S2: Area of the pressure reducing valve (1) – area [(PP) – (PPB)] > [(PLS) – (PA)] (= A), and less
of the piston (3) oil flows to the compensated side according to
the spool open area ratio.
q When the ratio is smaller than 1.00:
[(PP) – (PPB)] < [(PLS) – (PA)] (= A), and more
oil flows to the compensated side according to
the spool open area ratio.
10-402 36 PC78US-8
Pressure compensation valve 1
Function q Flow control valve (2) reduces the open area

q When the load pressure becomes lower than between pump circuit (PP) and spool upstream
another actuator and the flow is going to (PPA) to generate a pressure loss between
increase during a compound operation, this (PP) and (PPA).
valve compensates the load pressure. [At this q Flow control valve (2) and pressure reducing
time, the load pressure of another actuator valve (1) are stopped at a position where the
under compound operation (the right side) is pressure difference between (PA) and (PLS)
higher than that of the actuator on this side applied to the both end of pressure reducing
(the left side)]. valve (1) becomes the same as the pressure
loss between (PP) and (PPA) on both sides of
Operation flow control valve (2).
q When the load pressure of another actuator q So, the pressure differences between the
side (the right side) rises during a compound upstream pressures (PPA) and the down-
operation, the flow in actuator circuit (A) on this stream pressures (PA) of the both spools
side (the left side) is apt to increase. under compound operation become the same,
q In this case, the LS pressure (PLS) of another and the pump flow is distributed in proportion
actuator is applied to the spring chamber to the opening area of each spool notch (a).
(PLSS) and pushes the pressure reducing
valve (1) and the flow control valve (2) to the
left.
PC78US-8 10-402 37
Boom hydraulic drift prevention valve 1
Function
q While the boom lever is not operated, the
hydraulic drift prevention valve prevents pres-
surized oil from leaking from the boom bottom
through spool (1) to prevent the boom from
drifting hydraulically.
When boom is raised
Operation
q If the boom is raised, the pressurized oil from
the control valve pushes up poppet (2).
q Pressurized oil from the control valve flows
through the valve into the boom cylinder bot-
tom.
10-402 38 PC78US-8
When boom is in neutral
Operation
q If the control lever is returned to neutral with
the boom raised, the holding pressure on the
boom cylinder bottom side is closed by poppet
(2).
q The pressurized oil flowing in through orifices
(a1) and (a2) is closed by pilot spool (3).
q The boom is held.
PC78US-8 10-402 39
When boom is lowered
Operation
q If the boom is lowered, pilot pressure (P1) from
the PPC valve pushes pilot spool (3) and the
pressurized oil in chamber (b) in the poppet is
drained.
q The oil pressure in port (Ab) is raised by the
pressurized oil from the boom cylinder bottom,
but the oil pressure in chamber (b) is lowered
by orifices (a1) and (a2).
q If the pressure in chamber (b) is lowered below
the pressure in port (Ab), poppet (2) opens and
the pressurized oil from port (Ab) flows through
port (Aa) into the control valve.
10-402 40 PC78US-8
Boom regeneration circuit 1
At boom LOWER and own weight fall
Function Operation
q When the boom is lowered and falls due to its q When the boom is lowered and falls due to its
own weight because the bottom pressure (A) own weight, the bottom side pressure (A) in the
in the cylinder (1) is higher than the head pres- boom cylinder (1) will rise above the head side
sure (B), this circuit brings the return flow on pressure (B).
the bottom side to the head side to increase q A part of the return flow on the bottom side
the cylinder speed. passes through the regeneration passage (a)
of the boom spool (2), pushes the check valve
(3) to open it and flows to the head side.
q The boom LOWER speed is increased.
PC78US-8 10-402 41
At boom LOWER load process
Function Operation
q When the head pressure (B) of the cylinder (1) q When the boom is lowered and is in the load
is higher than the bottom pressure (A) while process, the head side pressure (B) of the
the boom is lowered and the boom is in the boom cylinder (1) rises above the bottom side
load process, the check valve (3) will be pressure (A).
closed, and the circuits on the head side and q Check valve (3) is closed by pressure (B) on
the bottom side will be interrupted. the head side and spring (4).
q The circuits on the head side and bottom side
are disconnected.
10-402 42 PC78US-8
Travel junction valve 1
(Right and left travel junction circuits)
When machine travels straight
PC78US-8 10-402 43
When machine is steered during travel
10-402 44 PC78US-8
Function
q While the machine is traveling straight, if the
right and left travel spools are operated, the
junction circuit is opened to correct the flow dif-
ference between the right and left travel cir-
cuits.
q While the machine is traveling straight, the flow
rates to the right and left travel motors become
almost the same to decrease travel deviation.
q The junction circuit is kept open while the
machine is steered, too, but it does not affect
the steering performance since opening (b) of
travel junction valve spool (3) is narrow.
Operation
When machine travels straight

q Since only the right and left travel valves are
operated and the work equipment valve is not
operated, the pump discharge circuits (PP1)
and (PP2) and LS circuits (PLS1) and (PLS2)
are divided respectively by the merge-divider
spool. (see "Pump merge-divider valve")
q If the right and left travel spools (1) are oper-
ated, the oil from the pump flows through pump
discharge circuits (PP1) and (PP2) and actua-
tor circuit (PB) to (B).
q If the machine is traveled straight, right and left
pressure reducing valves (2) are pushed to the
right and notches (a) are connected to the
junction circuit.
q The right end of travel junction valve spool (3)
is connected to the work equipment PPC pres-
sure circuit, in which no pressure is generated
since the work equipment valve is not oper-
ated.
q If the right and left travel actuator circuits are
connected by the junction circuit and any differ-
ence is made between the right and left travel
motors, that difference is corrected to reduce
the travel deviation.
When machine is steered during travel

q Since only the right and left travel valves are
operated and the work equipment valve is not
operated, the pump discharge circuits (PP1)
and (PP2) and LS circuits (PLS1) and (PLS2)
are divided respectively by the merge-divider
spool. (see "Pump merge-divider valve")
q The machine is steered by supplying demand
flow for the right and left travel spool strokes to
the actuator circuit. (see "Unload valve")
q If right travel spool (Right 1) is returned from
the travel straight position to neutral to steer
the machine, a load pressure difference is
made between right and left travel actuator cir-
cuits (PB). [(Left B) > (Right B)]
PC78US-8 10-402 45
Travel LS bleed circuit and travel junction valve 1
10-402 46 PC78US-8
During travel + operation of another actuator
PC78US-8 10-402 47
Function Operation
q If the travel actuator and another actuator are
operated simultaneously, discarded throttled
flow of LS pressure (PLS) is increased to lower q If boom spool (1) is operated, LS pressure
the pressure compensation accuracy of the (PLS) becomes the same as boom circuit pres-
travel circuit and to decrease lowering of the sure (A).
travel speed. q Since the work equipment valve is operated,
q While only the travel actuator or another actua- pump discharge circuits (PP1) and (PP2), and
tor is operated singly, the LS bleed circuit is LS circuits (PLS1), (PLS2) and (PLS3) are
kept closed. merged respectively by the merge-divider
q In addition, travel junction valve spool (5) valve spool (see "Pump merge-divider valve").
changes from opening (c) (wide) to opening (b) q LS pressure (PLS) is also led to spring cham-
(narrow) by the pressure from the merge- ber (PLSS) of pressure reducing valve (2) of
divider selector solenoid valve for the ease of the travel valve.
correction of the flow difference between the q Since the travel spool is not operated, notch
right and left travel circuits. (a) of pressure reducing valve (2) is closed and
check valves (3) and (4) of the bleed circuit are
also closed.
q While the boom is operated singly, the travel
LS bleed circuit is kept closed.
During travel + operation of another actuator

q If boom spool (1) is operated, LS pressure
(PLS) becomes the same as boom circuit pres-
sure (A).
q Since the work equipment valve is operated,
pump discharge circuits (PP1) and (PP2), and
LS circuits (PLS1), (PLS2) and (PLS3) are
merged respectively by the merge-divider
valve spool. (see "Pump merge-divider valve")
q Since the boom raise actuator circuit pressure
is normally higher than the travel actuator cir-
cuit pressure (A > B), the pressure in spring
chamber (PLSS) of pressure reducing valve
(2) on the travel side is higher than travel cir-
cuit pressure (PB).
q Pressure reducing valve (2) moves to the left
and LS pressure (PLS) flows through check
valves (3) and (4) of the bleed circuit and notch
(a) of pressure reducing valve (2) to travel cir-
cuit (PB).
q LS pressure (PLS), which has been the same
as boom circuit pressure (A), decreases since
it flows out to travel circuit (B).
10-402 48 PC78US-8
PC78US-8 10-402 49
SEN04559-00

©2008 KOMATSU
All Rights Reserved
10-402 50
SEN04560-00
HYDRAULIC EXCAVATOR
PC78US-8



PPC valve ....................................................................................................................................................... 3
Swing motor .................................................................................................................................................. 19
Travel motor .................................................................................................................................................. 30
Center swivel joint......................................................................................................................................... 38
Solenoid valve............................................................................................................................................... 40
PPC accumulator .......................................................................................................................................... 43
Anti-drop valve .............................................................................................................................................. 45
Multi-control valve ......................................................................................................................................... 50
PC78US-8 10-403 1
SEN04560-00
10-403 2 PC78US-8
PPC valve SEN04560-00
PPC valve 1
a PPC: Abbreviation for Proportional Pressure Control
Work equipment and swing PPC valve 1
P: From charge pump P3: L.H. PPC valve: Swing RIGHT port
P1: L.H. PPC valve: Arm IN port R.H. PPC valve: Bucket DUMP port
R.H. PPC valve: Boom RAISE port P4: L.H. PPC valve: Swing LEFT port
P2: L.H. PPC valve: Arm OUT port R.H PPC valve: Bucket CURL port
R.H. PPC valve: Boom LOWER port T: To tank
PC78US-8 10-403 3
SEN04560-00 PPC valve
10-403 4 PC78US-8
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm
Free length x
Installed
10 Centering spring
[For ports (P3) and (P4)]
Outside
diameter
length
Installed load Free length Installed load

42.48 x 15.5 34 — deformed, replace
{1.8 kg} {1.44 kg}
spring.
11 Centering spring
[For ports (P1) and (P2)]
44.45 x 15.5 34
29.4 N
{3 kg}
—
23.5 N
{2.4 kg}
16.7 N 13.3 N
12 Metering spring 26.47 x 8.15 24.9
{1.7 kg}
—
{1.36 kg}
PC78US-8 10-403 5
Operation q The positional relationship between spool (1)

and body (10) [where fine control hole (f) is
When in neutral between drain chamber (D) and pump pres-
q Ports (A) and (B) of the control valve and ports sure chamber (PP)] does not change until
(P1) and (P2) of the PPC valve are connected retainer (9) comes in contact with spool (1).
to drain chamber (D) through fine control hole q Metering spring (2) contracts in proportion to
(f) in spool (1). the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.
During fine control

(neutral fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, and spool (1) is also pushed
through metering spring (2), and moves down-
ward.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).
10-403 6 PC78US-8
During fine control At full stroke

(when control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q The pilot pressure oil from the solenoid valve
ized oil at port (P1) is released. flows through fine control hole (f) and port (P1)
q If the pressure of port (P1) is lowered exces- to chamber (A) to push the control valve spool.
sively, spool (1) is pushed down by metering q The oil returning from chamber (B) passes
spring (2). from port (P2) through fine control hole (f') and
q Fine control hole (f) is shut off from drain flows to drain chamber (D).
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
q The pump pressure is supplied until the pres-
sure in port (P1) recovers to a pressure equiv-
alent to the position of the lever.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
PC78US-8 10-403 7
10-403 8 PC78US-8
Travel PPC valve 1
a For the operation, see "Work equipment and swing PPC valve".
P: From charge pump P4: Right forward

P1: Left reverse P5: Travel signal
P2: Left forward T: To tank
P3: Right reverse
PC78US-8 10-403 9
10-403 10 PC78US-8
1. Plate
2. Body
3. Piston
4. Seal
5. Valve
6. Damper
Unit: mm
Free length x
Installed
7 Centering spring diameter
length If damaged or
deformed, replace
108 N 86.3 N spring.
48.57 x 15.5 32.5 —
{11 kg} {8.8 kg}
16.7 N 13.3 N
8 Metering spring 26.53 x 8.15 24.9
{1.7 kg}
—
{1.36 kg}
PC78US-8 10-403 11
Blade PPC valve 1
a For the operation, see "Work equipment and swing PPC valve".
10-403 12 PC78US-8
P: From solenoid valve

P1: To blade and boom swing valve
P2: To blade and boom swing valve
T: To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
Free length x
Installed
8 Centering spring diameter length If damaged or
deformed, replace
147 N 118 N spring.
42.36 x 15.5 32.5 —
{15 kg} {12.0 kg}
16.7 N 13.3 N
9 Metering spring 22.73 x 8.1 22
{1.7 kg}
—
{1.36 kg}
PC78US-8 10-403 13
Attachment PPC valve 1
(with EPC valve)
a For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
10-403 14 PC78US-8
P: From solenoid valve

P1: To service valve
P2: To service valve
T: To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
Free length x
Installed
9 Centering spring diameter
deformed, replace
125 N 100 N spring.
33.9 X 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
10 Metering spring 22.7 X 8.10 22.0
{1.70 kg}
—
{1.36 kg}
PC78US-8 10-403 15
EPC valve
a EPC: Abbreviation for Electromagnetic Proportional Control
C: To control valve 1. Body

P: From solenoid valve 2. Plug
T: To hydraulic tank 3. Connector
10-403 16 PC78US-8
Function Operation
q EPC valve consists of the proportional sole-
noid and hydraulic valve. When signal current is 0 (coil de-energized)
q Upon receiving signal current (i) from the pump q While the signal current from the controller is
controller, EPC valve generates EPC output not flowing to coil (14), coil (14) is de-ener-
pressure proportional to the intensity of the gized.
current, and outputs it to the control valve. q Spool (11) is pressed to the right by spring
(12).
q Port (P) is closed, and the pressurized oil from
the front pump does not flow to the control
valve.
q The pressurized oil from the control valve is
drained to the tank through ports (C) and (T).
PC78US-8 10-403 17
When signal current is very small (coil ener- When signal current is maximum (coil ener-
gized) gized)
q If small signal current flows to coil (5), coil (5) is q If the signal current flows to coil (5), coil (5) is
energized and a leftward thrust is generated in energized.
plunger (6). q Since the signal current is the maximum at this
q Push pin (4) pushes spool to the left and the time, thrust force of plunger (6) becomes the
pressurized oil from port (P) flows to port (C). maximum.
q Pressure in port (C) increases and the total of q Spool (2) is pushed to the left by push pin (4).
the force applied to surface (a) of spool (2) and q The pressurized oil from port (P) flows to port
spring load of spring (3) becomes greater than (C) at the maximum flow rate and the pressure
the thrust force of plunger (6). in the circuit between the EPC valve and con-
q Spool (2) is pushed to the right, port (P) is dis- trol valve becomes maximum.
connected from port (C), and port (C) is con- q Port (T) is closed and the pressurized oil does
nected to port (T). not flow to the hydraulic tank.
q Spool (2) moves up and down so that the pro-
pulsion force of plunger (6) may be balanced
with pressure of port (C) + spring load of spring
(3).
q The pressure in the circuit between the EPC
valve and control valve is controlled in propor-
tion to the signal current.
10-403 18 PC78US-8
Swing motor SEN04560-00
Swing motor 1
Model: LMF30AEL
B: From swing holding brake solenoid valve Specifications

MA: From control valve Model: LMF30AEL
MB: From control valve Motor capacity: 31 cm3/rev
S: From control valve Relief valve set pressure: 21 MPa {210 kg/cm2}
T: To tank Rated speed: 2,172 rpm
Brake release pressure: 1.32 MPa {13.5 kg/cm2}
1. Reverse prevention valve
2. Relief valve
PC78US-8 10-403 19
SEN04560-00 Swing motor
10-403 20 PC78US-8
1. Output shaft
2. Shoe
3. Piston
4. Cylinder block
5. Housing
6. Valve plate
7. Center spring
8. Swash plate
9. Brake spring
10. Brake piston
11. Disc
12. Plate
13. Relief valve
14. Check valve
15. Shuttle valve
Unit: mm
Free length x Installed
deformed, replace
1.57 N 1.27 N spring.
15.5 x 9.0 8.0 —
{0.16 kg} {0.13 kg}
17 Shuttle valve spring 1.27 N 0.98 N
33 x 13.8 23 —
{0.13 kg} {0.10 kg}
PC78US-8 10-403 21
Brake valve
Outline
q The brake valve consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
Function
q When the machine is in the swing holding
mode, control valve (6) closes the motor outlet
circuit, but the motor rotation is continued by
inertial force.
q The motor output, therefore, is abnormally
increased, resulting in damaging the motor.
q In order to prevent the motor damages, the
relief valve relieves the abnormally high pres-
sure to port (S) from the motor outlet side
(high-pressure side) of the motor.
Operation
When swinging is started

q When the swing control lever is operated to the
right swing, the pressurized oil from the pump
is supplied to port (MA) through control valve
(6).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through the con-
trol valve (6) and returns to the tank.
10-403 22 PC78US-8
When swing is stopped

q When the swing control lever is returned to
neutral, the supply of pressurized oil from the
pump to port (MA) is stopped.
q The pressurized oil from the motor outlet can't
return to the tank since the returning circuit to
the tank is closed from control valve (6). Thus,
pressure on port (MB) increases.
q Rotation resistance is generated on the motor
and hence the brake starts working.
q Shuttle valve (4) is pressed as pressure on
port (MB) goes above port (MA).
q The pressure on chamber (C) is increased to
the s e t p re ss u re of r el ie f va lv e (1 ) a nd
becomes the same as that of port (MB).
q A high braking torque works on the motor,
thereby stopping the motor.
q When relief valve (1) is being actuated, the
relieved pressurized oil and the pressurized oil
from port (S) are fed to port (MA) through
check valve (3).
q Above prevents cavitation on port (MA).
PC78US-8 10-403 23
Modulating relief valve
Function
q The swing motor relief valve restricts sudden
rise of the relief pressure to reduce the shocks
generated when the machine starts and stops
swinging.
Operation
When circuit pressure is (P0)

q The relief valve does not operate.
When circuit pressure rises suddenly

q If the circuit pressure rises to (P1), hydraulic oil
acts on the area difference between (D1) and
(D3) [(D1) > (D3)] and pushes spring (4), thus
valve (3) starts opening.
q At this time, since pressure acts on the area
difference between (D1) and (D2) [(D2) >
(D1)], seat (1) follows valve (3).
q If seat (1) moves, however, the relief passage
to port (S) for the pressurized oil in chamber
(a) is reduced by ball (2), thus seat (1) moves
slower than valve (3).
q Accordingly, the relief pressure rises gradually
from (P1) to (P2) during the time until seat (1)
reaches sleeve (5).
10-403 24 PC78US-8
Swing holding brake
Operation
When solenoid valve is de-energized When solenoid valve is energized

q If the swing holding brake solenoid valve is de- q As the swing holding brake solenoid valve is
energized, the pressurized oil from the charge energized, the valve is switched.
pump is shut off. q The pressurized oil from the charge pump
q Port (B) is connected to tank circuit (T). flows through port (B) to brake chamber (a).
q Brake piston (2) is pushed up by brake spring q After entering chamber (a), the pressurized oil
(1). compresses brake spring (1) and pushes
q Disc (3) and plate (4) are pushed together, and brake piston (2) down.
the brake is applied. q Disc (3) is separated from plate (4), releasing
the brake.
PC78US-8 10-403 25
Reverse prevention valve
10-403 26 PC78US-8
MA: From control valve

MB: From control valve
T1: To tank
T2: To tank
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
PC78US-8 10-403 27
Function When motor is stopped temporarily

q This valve reduces the swing back generation q The motor rotation is reversed by the closing
in the swing body by the inertia of the swing pressure generated at port (MB). (1st time:
body, the backlash and rigidity of the machin- reverse rotation)
er y system, and the c ompression of the q Reversing pressure is generated on port (MA).
hydraulic oil when the swing is stopped. Pressure (MA) is conducted to chamber (a).
q The valve contributes in preventing collapsing q The pressure compresses spring (3) by use of
of load when the swing is stopped and also the difference in areas of circles (φD3 > φD4) of
contributes in reducing cycle time (enhances spool (2) and moves spool (2) to the right side.
the positioning performance, enabling you to q Port (MA) and chamber (b) will be intercon-
proceed to the next work quicker than ever). nected.
q Ports (b) and (f) will be interconnected through
Operation the drilled hole (h) on spool (5). This intercon-
nection bypasses the reversing pressure on
When port (MB) brake pressure is generated port (MA) to port (T), thereby preventing the
q Pressure (MB) is conducted to chamber (d) reverse rotation of the 2nd time.
through notch (g).
q The pressure compresses spring (6) by use of
the difference in areas of circles (øD1 > øD2)
of spool (5) and moves spool (5) to the left
side.
q Port (MB) and chamber (e) will be intercon-
nected.
q Since pressure (MA) is lower than the set pres-
sure of spring (3), spool (2) does not move and
the pressurized oil is kept in. Thus the braking
force is ensured.
10-403 28 PC78US-8
PC78US-8 10-403 29
SEN04560-00 Travel motor
Travel motor 1
A: From center swivel joint, port C2

(L.H. travel motor)
From center swivel joint, port B2
(R.H. travel motor)
B: From center swivel joint, port D2
(L.H. travel motor)
From center swivel joint, port A2
(R.H. travel motor)
D1: To center swivel joint, port DR2
(L.H. travel motor)
Plug (R.H. travel motor)
D2: Plug (L.H. travel motor)
To center swivel joint, port DR2
(R.H. travel motor)
P: From center swivel joint, port G2
1. Oil filler plug

2. Oil level plug
3. Drain plug
10-403 30 PC78US-8
Travel motor SEN04560-00
1. Regulator valve 13. Sun gear A

2. Timing plate 14. Sun gear B
3. Brake piston 15. Ring nut
4. Spindle 16. Pivot
5. Floating seal 17. Piston
6. Swash plate 18. Disc
7. Regulator piston 19. Plate
8. Planetary pinion B 20. Cylinder
9. Hub 21. Flange
10. Carrier 22. Counterbalance valve
11. Cover 23. Check valve
12. Planetary pinion A 24. Check valve
PC78US-8 10-403 31
Specifications
Model GM10VA-B
Displacement Hi 30.5
(cm3/rev) Lo 54.3
Rated speed Hi 2,628
(rpm) Lo 1,507
Brake releasing pressure 0.63
(MPa {kg/cm2}) {6.42}
Hi-Lo switching pressure 2.94
(MPa {kg/cm2}) {30}
Reduction ratio 45.97
Outline
1. Final drive 4. 2nd travel speed selector mechanism

Consists of 2-stage planetary gear mecha- Consists of the regulator valve and regulator
nism. Reduces the hydraulic motor speed from piston. Changes the rotation speed in 2 stages
high speed to low speed high torque. by changing the displacement of the hydraulic
motor.
2. Hydraulic motor
Consists of swash plate type axial piston motor 5. Parking brake
mechanism. Converts oil pressure from the Consists of multiple disc type brake mecha-
hydraulic pump into rotary motion. nism. Forms a unit with the hydraulic motor.
3. Brake valve
Consists of various valves. Provides the follow-
in g functions: sto ps the hydr aul ic motor
smoothly, prevents running away of hydraulic
motor, prevents generation of abnormally high
pressure when the hydraulic motor is stopped
suddenly.
10-403 32 PC78US-8
Operation
Operation of motor
At low speed (the motor swash plate angle is maximized.)
1. 2nd travel speed selector solenoid valve q Since 2nd travel speed selector solenoid valve
2. Regulator valve (1) is de-energized, the pressurized oil from
3. Spring hydraulic pump (8) is not fed to port (P).
4. Check valve q Regulator valve (2) is pushed to the left with
5. Regulator piston spring (3) reaction force.
6. Swash plate q The main pressurized oil, sent from the control
7. Parking brake piston valve through check valve (4), is controlled by
8. Hydraulic pump regulator valve (2) and used to shut off the cir-
9. Travel control valve cuit to regulator piston (5).
10. Pump merge-divider valve q The pressurized oil in control chamber (C) is
11. Brake valve drained from port (D) through oil passage (e) of
regulator valve (2).
q Swash plate (6) reaches its maximum tilt
angle, and the machine travels at low speed
with the maximum motor capacity.
PC78US-8 10-403 33
At high speed (the motor swash plate angle is minimized.)
1. 2nd travel speed selector solenoid valve q When 2nd travel speed selector solenoid valve
2. Regulator valve (1) is energized, the pressurized oil from
3. Spring hydraulic pump (8) is fed to port (P).
4. Check valve q Regulator valve (2) is pushed to the right with
5. Regulator piston the pressurized oil that is sent to port (P).
6. Swash plate q The main pressurized oil from the control valve
7. Parking brake piston passes through check valve (4), and passes
8. Hydraulic pump through oil passage (F) in regulator valve (2) to
9. Travel control valve control chamber (C), and is used to push regu-
10. Pump merge-divider valve lator piston (5) to the left.
11. Brake valve q Swash plate (6) reaches its minimum tilt angle,
and the machine travels at high speed with the
minimum motor capacity.
10-403 34 PC78US-8
Brake valve Operation when pressure oil is supplied

q The brake valve consists of check valves (1a)
and (1b) and counterbalance valve spool (2)
as shown in the following figure.
q If the travel lever is operated, the pressurized

oil is supplied through the control valve to port
(PA).
q The pressurized oil pushes check valve (1a) to
Function open and flows through motor inlet port (MA) to
motor outlet port (MB).
q When the machine travels down a slope, it
q The pressurized oil also flows into chamber (D)
may tr av el fa ste r tha n t he mo tor s pe ed
through orifice (c) of counterbalance valve (2).
because of its own weight.
q When the hydraulic oil pressure in chamber
q If the machine travels down a slope with the
(D) goes above spring (3) reaction force, it
engine speed low, the motor runs idle and the
pushes counterbalance valve (2) to the left.
machine runs away, and this is very danger-
q Ports (MB) and (PB) open and the motor starts
ous.
to rotate.
q The brake valve prevents the machine from
q Ports (PA) and (E) open and the pressurized
running away and has it travel at a speed in
oil flows into brake piston (4) to release the
accordance with the engine speed (pump
parking brake.
delivery).
PC78US-8 10-403 35
Operation when pressure is shut off Brake operation at travelling downhill
q If the travel lever is returned to neutral, the q If the machine starts to run away on a slope,
pr essur iz ed oil from the control valve is the motor runs idle and the motor inlet port
stopped. (MA) pressure decreases and the pressure in
q Counterbalance valve (2) is pushed back to chamber (D) also decreases through orifice
the right with spring (3) reaction force. (c).
q The oil in chamber (D) flows to port (PA) q When the hydraulic oil pressure in chamber
through orifice (c). However, the back pressure (D) goes below spring (3) reaction force, coun-
is generated by closing of orifice (c), controlling terbalance valve (2) starts to return to the right.
the return speed of counterbalance valve (2) to q The oil in chamber (G) flows to port (PB)
the right. through orifice (f). However, the back pressure
q The oil returning from port (MB) is controlled is generated by closing of orifice (f), controlling
gradually with the moving speed of counterbal- the return speed of counterbalance valve (2) to
ance valve (2) and the shape of the cut part to the right.
stop the motor smoothly. q Counterbalance valve (2) moves to a position
q Even after the pressurized oil flowing to port where the force caused by the machine weight
(PA) is stopped, the motor continues rotation and the hydraulic force at motor inlet port (MA)
because of inertia and can cause cavitation. is balanced with the hydraulic force at motor
q Since check valve (1a) operates at very slight outlet port (MB).
negative pressure, ports (PA) and (MA) open q If motor outlet port (MB) is closed, the hydrau-
to prevent cavitation. lic pressure on the outlet side increases and
rotation resistance is generated.
q The travel speed is controlled according to the
pump delivery to prevent the machine from
running away.
10-403 36 PC78US-8
Parking brake
When travel lever is operated When travel lever is set to neutral position
q If the travel lever is operated, the pressurized q If the travel lever is returned to neutral, the
oil from the pump moves spool (1) to the left. pressurized oil from the control valve is
q The pressurized oil flows through port (E) to stopped.
chamber (A) of brake piston (2). q The pressurized oil in chamber (A) of brake
q When the hydraulic pressure in chamber (A) piston (2) is drained into the case.
goes above spring (3) reaction force, it pushes q When the hydraulic pressure in chamber (A)
brake piston (2) to the left. goes below spring (3) reaction force, brake pis-
q Plate (4) and disc (5) are relieved of friction ton (2) is pushed back to the right.
force and the parking brake is released. q Brake piston (2) presses plate (4) and disc (5)
together and the parking brake operates.
PC78US-8 10-403 37
SEN04560-00 Center swivel joint
Center swivel joint 1
Blade specification
A1: From control valve (R.H. travel REVERSE) A2: To R.H. travel motor port B
B1: From control valve (R.H. travel FORWARD) B2: To R.H. travel motor port A
C1: From control valve (L.H. travel REVERSE) C2: To L.H. travel motor port A
D1: From control valve (L.H. travel FORWARD) D2: To L.H. travel motor port B
E1: From control valve (blade RAISE) E2: To L.H. and R.H. blade cylinder head
F1: From control valve (blade LOWER) F2: To L.H. and R.H. blade cylinder bottom
G1: From 2nd travel speed selector solenoid valve G2: To L.H. and R.H. travel motor port P
DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D1 or
D2
1. Cover 3. Slipper seal

2. Rotor 4. Shaft
Unit: mm
Standard size Standard clearance Clearance limit
Clearance between rotor and
5 shaft
Replace
70 0.056 – 0.105 0.111
10-403 38 PC78US-8
Center swivel joint SEN04560-00
Bladeless specification
A1: From control valve (R.H. travel REVERSE) A2: To R.H. travel motor port B
B1: From control valve (R.H. travel FORWARD) B2: To R.H. travel motor port A
C1: From control valve (L.H. travel REVERSE) C2: To L.H. travel motor port A
D1: From control valve (L.H. travel FORWARD) D2: To L.H. travel motor port B
E1: From 2nd travel speed selector solenoid valve E2: To L.H. and R.H. travel motor port P
DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D1 or
D2
1. Cover 3. Slipper seal

2. Rotor 4. Shaft
Unit: mm
Standard size Standard clearance Clearance limit
Clearance between rotor and
5 shaft
Replace
60 0.056 – 0.105 0.111
PC78US-8 10-403 39
SEN04560-00 Solenoid valve
Solenoid valve 1
4-spool solenoid valve
10-403 40 PC78US-8
Solenoid valve SEN04560-00
P1: From hydraulic pump, port P4 Operation

A1: To PPC valve
A3: To swing motor, port B Check valve
A2: To center swivel joint, port G1
A5: To control valve, port PT
T: To hydraulic tank
ACC: To accumulator (for PPC circuit)
1. PPC lock solenoid valve

2. Control relief valve
3. 2nd travel speed selector solenoid valve
4. Swing holding brake solenoid valve
5. Travel junction/ pump merge-divider solenoid
valve
Check valve
6. Plug
7. Plunger q This valve is installed between port (P) and
PPC solenoid valve. When the engine is
Solenoid valve stopped, plunger (1) is pushed back to the left
with spring (2) reaction force, and the path
8. Coil (ON/OFF type)
between ports (ACC) and (P) is closed to
9. Push pin
maintain the pressure in the accumulator.
10. Valve spool
q When the engine is running, plunger (1) is
11. Sleeve
pushed to the right with the pilot pressure that
12. Stopper
is sent to port (P), and ports (P) and (ACC) are
13. Body
interconnected.
Control relief valve
14. Adjustment screw
15. Locknut
16. Cover
17. Return spring
18. Plunger
PC78US-8 10-403 41
SEN04560-00 Solenoid valve
Solenoid valve
When solenoid valve is "de-energized" (circuit Control relief valve

is closed)
q If the oil pressure in port (P) goes above return

q Coil (1) is de-energized when no signal current spring (2) reaction force, plunger (1) moves to
is supplied to coil (1). the right and the path between ports (P) and
q Spool (2) is pushed back to the left with spring (T) opens to relieve the oil.
(3) reaction force. Set pressure: 3.14 MPa {32 kg/cm2}
q As the path between ports (P) and (A) is
closed, the pilot pressure is not fed to the actu-
ator through port (A).
At the same time, the path to port (T) is open,
draining the oil from the actuator to the hydrau-
lic tank.
When solenoid valve is "energized" (circuit is

connected)
q Coil (1) is energized when signal current is

supplied to coil (1).
q Spool (2) is pushed to the right with push pin
(4).
q As the path between ports (P) and (A) is
opened, the pilot pressure is fed to the actuator
through port (A).
At the same time, the path to port (T) is closed,
shutting off the oil from the actuator to the
hydraulic tank.
10-403 42 PC78US-8
PPC accumulator SEN04560-00
PPC accumulator 1
For PPC circuit

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
q This accumulator is mounted on the solenoid
valve. If the engine is stopped with the work
equipment is kept at a raised position, the pilot
pressure is supplied to the control valve by the
pressure of the compressed nitrogen gas in
the accumulator. Therefore, the spool can be
operated to lower the work equipment by its
own weight.
Specifications
Gas to be used: Nitrogen gas
Gas capacity: 300 cc
Sealed gas pressure: 1.18 MPa
{12 kg/cm2} (at 80°C)
Maximum operating pressure: 6.86 MPa
{70 kg/cm2}
PC78US-8 10-403 43
SEN04560-00 PPC accumulator
For breaker
(Machine ready for attachment)
1. Cap
2. Core
3. Ring
4. Lid
5. Bladder
6. Shell
Outline
q This accumulator is connected to the attach-
ment piping. When the breaker operates, the
oil pulsation is absorbed by the pressure of
compressed nitrogen gas of the accumulator,
to protect the hydraulic system devices and
piping.
Specifications
Gas to be used: Nitrogen gas
Gas capacity: 480 cc
Sealed gas pressure: 0.1 MPa {1 kg/cm2} (at 80°C)
Maximum operating pressure: 6.86 MPa
{70 kg/cm2}
10-403 44 PC78US-8
Anti-drop valve SEN04560-00
Anti-drop valve 1
(If equipped)
a This valve can be mounted on the boom cylinder and arm cylinder.
a The valve is the standard equipment for the boom cylinder for EU specification.
V: From control valve

T: To hydraulic tank
CY: To work equipment cylinder
PI: From PPC valve
PCY: For pressure pickup port and equalizer circuit
PC78US-8 10-403 45
SEN04560-00 Anti-drop valve
1. Pilot spool
2. Safety valve
3. Check valve
Unit: mm
Free length x
Installed
4 Spool return spring diameter
length

24.8 x 16.8 22.5 — deformed, replace
{5.65 kg} {4.52 kg}
spring.
22.6 N 18.0 N
5 Spool return spring 19.1 x 8 14
{2.3 kg}
—
{1.84 kg}
15.1 N 12.1 N
{1.54 kg}
—
{1.23 kg}
10-403 46 PC78US-8
Function
q The anti-drop valve prevents the pressurized
oil from flowing back from the work equipment
cylinder and prevents the work equipment from
falling suddenly when the piping from the con-
trol valve to the work equipment bursts.
Operation
When the work equipment lever is in neutral
When the piping is normal

q Check valve (5) is closed under the holding
pressure of the work equipment cylinder led
from port (CY) to chamber (b).
q The anti-drop valve prevents the pressurized
oil from reversing from the work equipment cyl-
inder in order to prevent the work equipment
from falling suddenly when the piping bursts
between the control valve and the work equip-
ment cylinder.
q When the work equipment lever is in neutral,
since the pilot pressure led from the PPC valve
to port (PI) is 0 MPa {0 kg/cm 2}, pilot spool (1)
is moved to the left end by the forces of springs
(2) and (3) and chambers (a) and (b) are dis-
connected.
q No pressurized oil flows from the control valve
to the work equipment cylinder and the work
equipment cylinder is held.
q If the work equipment cylinder has abnormally
high pressure, safety valve (4) is actuated by
holding pressure (Pb) of the work equipment
cylinder.
When the piping bursts

q If piping (A) from the control valve to the work
equipment cylinder bursts, chambers (a) and
(b) are disconnected as in the case when the
piping is normal, thus the work equipment cyl-
inder is held.
q When the work equipment stops above ground
with the engine stopped, the operator can
lower it gradually by opening port (PCY) to dis-
charge the pressurized oil from chamber (b)
through orifice (7) and port (PCY).
PC78US-8 10-403 47
SEN04560-00 Anti-drop valve
When pressurized oil flows from the control

valve to the work equipment cylinder

q If pressurized oil (Pa) led from the control valve
to chamber (a) overcomes the total of pressure
(Pb) in chamber (b) connected to the work
equipment cylinder and the force of spring (6),
check valve (5) opens and chambers (a) and
(b) are connected and then the pressurized oil
flows from the control valve to the work equip-
ment cylinder.

equipment cylinder bursts, the pressurized oil
in chamber (a) flows out of the burst part and
pressure (Pa) in chamber (a) lowers.
q If pressure (Pa) lowers below the total of pres-
sure (Pb) in chamber (b) and the force of
spring (6), check valve (5) closes and cham-
bers (a) and (b) are disconnected, thus cylin-
der pressure (Pb) is held to prevent the work
equipment from falling suddenly.
10-403 48 PC78US-8
When pressurized oil flows from the work

equipment cylinder to the control valve

q Holding pressure of the work equipment cylin-
der is led to chamber (b) and check valve (5)
closes.
q The pilot pressure from the PPC valve is led to
port (PI). If it becomes larger than the force of
spring (2) (area of ød), spool (1) moves to the
standby position on the right side. (1st-stage
stroke)
q At this time, chambers (a) and (b) are not con-
nected.
q If the pilot pressure increases further and
becomes larger than the force of spring (3)
(area of ød), spool (1) moves to the right fur-
ther and chambers (a) and (b) are connected.
(2nd-stage stroke)
q Pressurized oil returns to the control valve
from the work equipment cylinder.

equipment cylinder bursts, the pressurized oil
in chamber (a) flows out of the burst part.
Since the pressurized oil in chamber (b) is sup-
plied to chamber (a) through opening (C) of
spool (1), however, sudden fall of the work
equipment is prevented. In addition, when the
PPC valve is returned to neutral, spool (1)
returns to the left end to disconnect chambers
(b) and (a), thus the work equipment stops.
PC78US-8 10-403 49
SEN04560-00 Multi-control valve
Multi-control valve 1
(If equipped)
a This valve is the standard equipment for North America specification.
(1) ISO pattern

(2) Backhoe pattern
Control pattern switching diagram (Port names correspond to the marks on the above figures.)
10-403 50 PC78US-8
Multi-control valve SEN04560-00
PC78US-8 10-403 51
SEN04560-00

©2008 KOMATSU
All Rights Reserved
10-403 52
SEN04561-00
HYDRAULIC EXCAVATOR
PC78US-8


500 Work equipment

Work equipment .............................................................................................................................................. 2
Dimensions of components............................................................................................................................. 4
Work equipment cylinder .............................................................................................................................. 10
PC78US-8 10-500 1
500 Work equipment
SEN04561-00 Work equipment
Work equipment 1
Unit: mm
Clearance between mounting pin size clearance limit
Shaft Hole
1 and bushing of revolving frame
and boom –0.030 +0.174 0.130 –
65 1.0
–0.100 +0.100 0.274
Clearance between mounting pin –0.030 +0.174 0.130 –
2 and bushing of boom and arm
60
–0.100 +0.100 0.274
1.0
Clearance between mounting pin –0.225 –0.062 0.105 –
3 and bushing of arm and bucket
50
–0.285 –0.120 0.223
1.0
Clearance between mounting pin –0.225 –0.062 0.105 – Replace pin and
4 and bushing of arm and link
50
–0.285 –0.120 0.223
1.0 bushing
Clearance between mounting pin –0.225 –0.040 0.131 –
5 and bushing of bucket and link
50
–0.285 –0.094 0.245
1.0
Clearance between mounting pin –0.030 +0.173 0.130 –
6 and bushing of link and link
60
–0.100 +0.100 0.273
1.0
Clearance between mounting pin
and bushing of track frame and –0.025 +0.142 0.105 –
7 blade 50 –0.087 +0.080 0.229 1.0
(blade specification)
10-500 2 PC78US-8
500 Work equipment
Work equipment SEN04561-00
PC78US-8 10-500 3
500 Work equipment
SEN04561-00 Dimensions of components
Dimensions of components 1
Arm
1,650 mm arm
10-500 4 PC78US-8
500 Work equipment
Dimensions of components SEN04561-00
Unit: mm
PC78US-8
No. Tolerance
Measurement point Standard size
Shaft Hole
–0.030 +0.100
1 — 60
–0.100 0
+1.0
Arm side 71.5
0
2
Cylinder head side 70 ±1.2
3 — 60 –0.030 +0.100
–0.100 0
Boom side 220 +0.5
0
4
Arm side 220 –0.5
–1.0
5 — 142.4 ±2.0
6 — 218.8 ±1.0
7 — 458.6 ±1.0
8 — 1,650 —
9 — 2,093.9 ±3.0
10 — 1,661.2 ±1.3
11 — 258.7 ±0.3
12 — 15.1 ±1.0
13 — 395.1 ±0.1
14 — 342 ±0.1
15 — 312.2 —
16 — 1,066.9 —
–0.225 0
17 — 50
–0.285 –0.150
–1.0
Link side 200
–2.0
18
+2.0
Bucket side 200
0
–0.225 0
19 — 50
–0.285 –0.150
–0.5
Arm side 188
–1.0
20
+3.0
Bucket side 211
0
Min. 1,055 ±1.5
21
Max. 1,765 —
PC78US-8 10-500 5
500 Work equipment
2,250 mm arm
10-500 6 PC78US-8
500 Work equipment
Unit: mm
PC78US-8
No. Tolerance
Measurement point Standard size
Shaft Hole
–0.030 +0.100
1 — 60
–0.100 0
+1.0
Arm side 71.5
0
2
Cylinder head side 70 ±1.2
3 — 60 –0.030 +0.100
–0.100 0
Boom side 220 +0.5
0
4
Arm side 220 –0.5
–1.0
5 — 228.2 ±2.0
6 — 239.5 ±1.0
7 — 465.5 ±1.0
8 — 2,250 —
9 — 2,702.7 ±3.0
10 — 1,652.1 ±1.3
11 — 259 ±0.3
12 — 7.6 ±0.5
13 — 395.1 ±0.1
14 — 342 ±0.1
15 — 312.2 —
16 — 1,066.9 —
–0.225 0
17 — 50
–0.285 –0.150
–1.0
Link side 200
–2.0
18
+2.0
Bucket side 200
0
–0.225 0
19 — 50
–0.285 –0.150
–0.5
Arm side 188
–1.0
20
+3.0
Bucket side 211
0
Min. 1,055 ±1.5
21
Max. 1,765 —
PC78US-8 10-500 7
500 Work equipment
Bucket
10-500 8 PC78US-8
500 Work equipment
Unit: mm
PC78US-8
No.
Measurement point Standard size Tolerance
1 — 309.8 ±0.5
2 — 38.6 ±0.5
3 — 97.1° —
4 — 312.2 —
5 — 1,057.2 —
6 — 143.7 —
7 — 8° —
8 — 5.2° —
0
9 — 50
–0.15
10 — 60 —
+0.2
11 — 70
0
+2.0
12 — 200
0
13 — 40 —
14 — 71 —
+1.0
15 — 296
0
16 — 18 —
17 — 100 —
18 — 115 —
19 — 95 —
+3.0
20 — 211
0
21 — 40 —
22 — 24 —
23 — 89.3 —
24 — 87.9 —
25 — 60 —
26 — 66 —
PC78US-8 10-500 9
500 Work equipment
SEN04561-00 Work equipment cylinder
Work equipment cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
Blade cylinder
10-500 10 PC78US-8
500 Work equipment
Work equipment cylinder SEN04561-00
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
–0.030 +0.262 0.097 –
Boom 65 0.638
–0.076 +0.067 0.338
Clearance between –0.030 +0.151 0.024 –
1 piston rod and bushing Arm 60 0.527 Replace bushing
–0.076 –0.006 0.227
–0.030 +0.151 0.024 –
Bucket 55 0.527
–0.076 –0.006 0.227
–0.030 +0.262 0.097 –
Blade 65 0.638
–0.076 +0.067 0.338
–0.030 +0.174 0.130 –
Boom 60 1.0
–0.100 +0.100 0.274
–0.030 +0.174 0.130 –
Clearance between Arm 60 1.0
–0.100 +0.100 0.274
2 piston rod support
shaft and bushing –0.030 +0.174 0.130 –
Bucket 60 1.0
–0.100 +0.100 0.274
–0.030 +0.174 0.130 –
Blade 70 1.0
–0.104 +0.100 0.278 Replace pin and
–0.030 +0.174 0.130 – bushing
Boom 65 1.0
–0.100 +0.100 0.274
Clearance between –0.030 +0.174 0.130 –
Arm 55 1.0
cylinder bottom –0.100 +0.100 0.274
3 support shaft and –0.030 +0.142 0.110 –
bushing Bucket 50 1.0
–0.100 +0.080 0.242
–0.030 +0.174 0.130 –
Blade 70 1.0
–0.104 +0.100 0.278
Boom 961 ± 96.1 Nm {98 ± 9.8 kgm}
Arm 785 ± 78.5 Nm {80 ± 8.0 kgm}

Procedure:
Tightening torque of 1) Tighten to 1.18 – 1.37 kNm {120 – 140 kgm}.
4 cylinder head 2) Loosen to 0 Nm {0 kgm}.
Bucket
3) Tighten to 0.39 kNm {40 kgm}.
4) Control tightening of cylinder head by turning angle.
(Tighten periphery of cylinder head by 3.5 – 4.5 mm)
Retighten
Blade 1.03 ± 0.10 kNm {105 ± 10.5 kgm}
Boom 2.60 ± 0.26 kNm {265 ± 26.5 kgm} (width across flats: 70 mm)
Arm 2.65 ± 0.26 kNm {270 ± 27.0 kgm} (width across flats: 65 mm)
Tightening torque of
5 cylinder piston locknut
Bucket 2.16 ± 0.22 kNm {220 ± 22.0 kgm} (width across flats: 60 mm)
Blade 3.14 ± 0.31 kNm {320 ± 32.0 kgm} (width across flats: 75 mm)
PC78US-8 10-500 11
SEN04561-00

©2008 KOMATSU
All Rights Reserved
10-500 12
SEN04562-01
HYDRAULIC EXCAVATOR
PC78US-8


600 Cab and its attachments

Air conditioner ................................................................................................................................................. 2
PC78US-8 10-600 1
SEN04562-01 Air conditioner
Air conditioner 1
Air conditioner piping diagram 1
10-600 2 PC78US-8
Air conditioner SEN04562-01
A: Front warm/cool air vent Dual pressure switch

B: Rear warm/cool air vent q If abnormally low or high pressure was gener-
C: Foot warm/cool air vent ated in the refrigerant circulation circuit, this
D: Defroster warm/cool air vent switch releases the magnet clutch of the com-
E: Recirculation air inlet pressor to protect a series of cooler-related
F: Fresh air inlet equipment.
High-pressure OFF:
1. Sunlight sensor 3.14 ± 0.20 MPa {32 ± 2 kg/cm2}
2. Refrigerant piping Low-pressure OFF:
3. Compressor 0.20 ± 0.02 MPa {2 ± 0.2 kg/cm2}
4. Ambient air temperature sensor
5. Air conditioner controller
6. Fresh air filter
7. Recirculation air filter
8. Dual pressure switch
9. Air conditioner unit
10. Machine monitor
11. Sight glass
12. Hot water take-out piping
13. Hot water return piping
14. Receiver
15. Condenser
Specifications
Refrigerant to be used R134a
Refrigerant capacity (g) 780
PC78US-8 10-600 3
Refrigerant circuit diagram
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Sight glass
6. Dual pressure switch
7. Air conditioner unit
Table of tightening torque for refrigerant piping adapter

Unit: Nm {kgm}
8 Lock bolt of compressor

refrigerant piping
7.85 – 11.8 {0.8 – 1.2}
(Screw size: M6 x 1.0)
9 Lock
piping
bolt of condenser refrigerant 3.92 – 6.86 {0.4 – 0.7}
10 Lock bolt of receiver refrigerant
piping and joint
3.92 – 6.86 {0.4 – 0.7}
Retighten
11 Connecting nut of receiver

refrigerant exit side piping
11.8 – 14.7 {1.2 – 1.5}
12 Lock bolt of air conditioner unit
refrigerant piping connector
7.85 – 11.8 {0.8 – 1.2}
10-600 4 PC78US-8
PC78US-8 10-600 5
Air conditioner unit 1
10-600 6 PC78US-8
A: From condenser Outline

B: To compressor q This is the horizontal air conditioner unit on
C: Hot water inlet which evaporator (1) and heater core (2) is
D: Hot water outlet arranged in parallel. Blower motor (4) is driven
to generate cool and hot air.
1. Evaporator q Selecting the temperature on the machine
2. Heater core monitor controls air mix damper (6) to adjust
3. Expansion valve the discharged air temperature.
4. Blower motor
5. Air mix damper actuator Cooler
6. Air mix damper q The cooler circulates refrigerant through evap-
7. Mode selector damper actuator orator (1) to cause heat exchange (dehumidifi-
8. Mode selector damper cation and cooling).
9. Recirculation/fresh air changeover damper actu- q Air taken in by blower motor (4) is cooled with
ator evaporator (1) and then blown out from the
10. Recirculation/fresh air changeover damper duct and grille.
11. Power transistor
12. Evaporator temperature sensor Heater
13. Recirculation air temperature sensor
q The heater circulates engine coolant in heater
14. Recirculation air filter
core (2) to cause heat exchange (heating).
q Air taken in by blower motor (4) is heated with
heater core (2) and then blown out through the
duct and grille.
PC78US-8 10-600 7
Functions of major components

Evaporator Recirculation/fresh air changeover damper
q Evaporator fin is cooled by the low-pressure, actuator
low-temperature refrigerant gas being sent q It starts the built-in motor upon receipt of a sig-
from the expansion valve. Air from the blower nal current from the air conditioner controller in
motor is cooled and dehumidified when pass- order to open or close the recirculation/fresh
ing through the fin. air changeover damper through the link mech-
anism.
Heater core q The motor rotating direction is determined by
q Fin of the heater core is heated by the hot selecting recirculation/fresh air flow on the
water (coolant) being sent from the engine. Air machine monitor.
from the blower motor is heated as it passes q Rotation of the motor is stopped as the contact
through the fin. opens, which is to move interlocked with the
motor, or when signal current from the air con-
Expansion valve ditioner controller is turned "OFF".
q This valve converts high-pressure, high-tem-
perature liquid refrigerant from the condenser Evaporator temperature sensor
to low-pressure, low-temperature misty refrig- q In order to prevent freezing of the evaporator, it
erant through the throttling function. senses the evaporator temperature and sends
Flow rate of refrigerant is controlled by chang- necessary signals to the air conditioner con-
ing level of throttling depending on the thermal troller. The signal sent to the air conditioner
load in the operator's cab. controller is used to control the compressor. As
a result, temperature of the air blown out of the
Blower motor grille is adjusted depending on the volume of
q It suctions air by rotating the fin installed on the refrigerant circulated in the evaporator.
blower motor. And it is also used for sending
air to the evaporator and heater core. Recirculation air temperature sensor
q It senses the recirculation air temperature and
Air mix damper actuator sends necessary signals to the air conditioner
q It starts the built-in motor upon receipt of a sig- controller. The signal sent to the air conditioner
nal current from the air conditioner controller in controller is used to control the compressor. As
order to open or close the air mix damper a result, temperature of the air blown out of the
through the link mechanism. grille is adjusted depending on the volume of
q The motor rotating direction is determined as refrigerant circulated in the evaporator.
the air conditioner controller reads the position
of the potentiometer being built in the actuator.
This reading is done as the target temperature
is set on the machine monitor.
q Rotation of the motor is stopped as the contact
opens, which is to move interlocked with the
ditioner controller is turned "OFF".
Mode selector damper actuator

q It starts the built-in motor upon receipt of a sig-
nal current from the air conditioner controller in
order to open or close the mode selector
damper through the link mechanism.
q The motor rotating direction is determined as
the air conditioner controller reads the position
of the potentiometer being built in the actuator.
This reading is done as the mode is selected
on the machine monitor.
q Rotation of the motor is stopped as the contact
opens, which is to move interlocked with the
ditioner controller is turned "OFF".
10-600 8 PC78US-8
Air conditioner controller 1
Input and output signals

AMP040-36P
Pin Input and Pin Input and
Signal name Signal name
No. output signals No. output signals
1 NC — 17 CAN_H Input/output
2 Air mix damper actuator potentiometer Input 18 CAN_L Input/output
signal Recirculation/fresh air changeover
19 Output
3 Actuator potentiometer power supply Output damper actuator (A)
4 Dual pressure switch Input Recirculation/fresh air changeover
20 Output
5 NC — damper actuator (B)
6 Back-up power supply Input 21 Air mix damper actuator (A) Output
7 Blower feedback signal Input 22 Air mix damper actuator (B) Output
8 Power transistor control signal Output 23 Mode selector actuator (A) Output
Mode selector actuator potentiometer 24 Mode selector actuator (B) Output
9 Input
signal 25 Relay power supply Output
10 NC — 26 NC —
11 Recirculation air temperature sensor Input 27 GND (sensor) Input
12 Evaporator temperature sensor Input 28 NC —
13 Ambient air temperature sensor Input 29 NC —
14 NC — 30 Test terminal —
15 Sunlight sensor Input 31 RAM monitor (for switching display) —
16 GND Output 32 RAM monitor I/F —
33 RAM monitor output —
34 NC —
35 Compressor clutch relay Input
36 Blower main relay Input
PC78US-8 10-600 9
Compressor 1
A: From air conditioner unit Function

B: To condenser q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
tor to high-pressure, high-temperature misty
refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders – bore x
10 – 32 x 20.8
stroke (mm)
Piston capacity
129.2
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Refrigerant oil to be used Denso: ND-OIL 8
Refrigerant oil capacity
180
(cc)
10-600 10 PC78US-8
Condenser 1
A: From compressor Function

B: To receiver q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
compressor.
a If the fin crushes or is clogged with dusts, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection to prevent the fin
from being crushed.
Specifications
Fin pitch (mm) 3.95
Total heat dissipation area (m )
2
3.63
Max. operating pressure (MPa {kg/cm }) 2
3.53 {36}
PC78US-8 10-600 11
Receiver 1
A: From condenser Function

B: To air conditioner unit q It is used to store liquefied high-pressure, high-
temperature liquid refrigerant from the con-
denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
Specifications
Effective cubic capacity (cm3) 550
Weight of desiccating agent (g) 290
10-600 12 PC78US-8
Sensor 1
Sunlight sensor Ambient air temperature sensor
1. Connector 1. Connector
2. Sensor 2. Sensor
Outline Outline
q The sunlight sensor is installed on top of the q The ambient air temperature sensor is installed
machine monitor of the air duct. in the battery room at the rear left of the
q It senses intensity of the sun light and sends machine.
signals to the air conditioner controller. The q It senses the ambient air temperature and
signal sent to the air conditioner controller is sends signals to the air conditioner controller.
used to control the blower motor and compres- The signal sent to the air conditioner controller
sor. is used to control the compressor. As a result,
temperature of the air blown out of the grille is
Output characteristics adjusted depending on the volume of refriger-
ant circulated in the evaporator.
PC78US-8 10-600 13
SEN04562-01

©2008 KOMATSU
All Rights Reserved
10-600 14
SEN04563-01
HYDRAULIC EXCAVATOR
PC78US-8


700 Electrical system

Electronic control system ................................................................................................................................ 2
Monitor system.............................................................................................................................................. 33
KOMTRAX system........................................................................................................................................ 47
Sensor........................................................................................................................................................... 49
PC78US-8 10-700 1
SEN04563-01 Electronic control system
Electronic control system 1
Machine control system diagram
*1: If equipped
10-700 2 PC78US-8
Electronic control system SEN04563-01
PC78US-8 10-700 3
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 q The engine does not start until the lock
5. Starting switch lever is set in the "LOCK" position.
6. Engine controller
7. Lock lever 2. The KOMTRAX engine cut circuit is employed
8. PPC lock switch to disable the engine from starting when the
9. Starting motor cut-out relay (for PPC lock) KOMTRAX terminal receives an engine cut
10. Starting motor cut-out relay (for personal code) command issued through external operation.
11. Fuel control dial
12. Safety relay
13. Starting motor
14. Fuel supply pump
15. Sensors
16. Engine controller power cut-off relay A
17. Engine controller power cut-off relay B
18. Machine monitor
19. KOMTRAX terminal
10-700 4 PC78US-8
Starting engine
q When starting switch (5) is turned to "ON"
position, engine controller (6) sends com-
mand current to fuel supply pump (14).
For this reason, a fail-safe mechanism is
provided with the electrical system to stop
the engine when an electrical failure
occurs.
q When starting switch (5) is turned to
"START" with lock lever (7) set in the
"LOCK" position, a starting current is sup-
plied to starting motor (13) causing the
engine to start.
However, as the neutral safety mecha-
nism is provided, the engine will not start if
lock lever (7) is set in the "FREE" position
at this time; starting motor cut-out relay (9)
cuts off the starting current to starting
motor (13).
q Upon receipt of the engine cut-off com-
man d f ro m th e e x te rn a l s ourc e,
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

q 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
q When starting switch (5) is turned to
"OFF" position, the current from the ACC
terminal of starting switch (5) to engine
controller (6) is cut off, and consequently
the command current to fuel supply pump
(14) is cut off.
Fuel supply pump (14) stops fuel feed,
causing the engine speed to go down and
the engine stops.
PC78US-8 10-700 5
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
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
10-700 6 PC78US-8
Function
q This function is turned ON when 1 of the 5
work modes of P, E, L, ATT and B is selected
with the work mode selector switch of the
machine monitor. The most suitable combina-
tion of engine torque (T) and pump absorption
torque can be selected for the contents of
work. If "Without" is selected for the attach-
ment on the initialization menu of the service
mode, 1 of the 3 modes of P, E and L is select-
able.
q According to the pump absorption torque set at
each mode, based on the engine governor set
speed with the fuel control dial and the actual
engine speed, the controller controls pump
delivery (Q) so that the pump will absorb all
torque at each engine output point.
q When the engine speed (N) is lowered, the
controller prevents the engine from stopping by
throttling the pump absorption torque.
PC78US-8 10-700 7
Control method in each mode
P, E, L, ATT and B mode

q 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}
q Pump delivery (Q) is so controlled that engine

speed (N) will be kept near the matching point
set in each mode.
q 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.
10-700 8 PC78US-8
Control function during travel Control function with emergency pump drive
q In P, ATT or B mode, engine speed (N) at the switch "ON"
matching point is set higher during travel than q If the controller gets out of order and no work is
during working. possible because the hydraulic pump does not
q In E or L mode, engine speed (N) and pump work properly, operating emergency pump
absorption torque are kept constant during drive switch (1) temporarily enables to main-
travel and working. tain functions of the machine with absorption
torques quite similar to those in the E mode.
In this case, a constant current flows from the
battery to the PC-EPC valve, thus the hydrau-
lic pump is not controlled by the controller.
a: Emergency
b: Normal
a Emergency pump drive switch (1) is of the
alternative type. If the machine is operated
after the switch is set to "Emergency (a)" even
though the machine is normal, the user code
"E02" will be shown on the display.
PC78US-8 10-700 9
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
9. Hydraulic pump
10. Control valve
10-700 10 PC78US-8
Function
q When all the control levers are set to NEU-
TRAL for waiting for a dump truck or work, the
engine speed is automatically reduced to a
controlled speed, and fuel consumption and
noise are lowered.
q When any control lever is operated, the engine
speed returns immediately to the speed that is
set with the fuel control dial.
Operation
When control levers are set in neutral
q If all the control levers are kept in neutral for 4
seconds with the engine speed higher than
ap prox . 1,175 rpm, th e en gine speed is
decreased to the controlled speed (approx.
1,175 rpm) and held until any control lever is
operated.
When any control lever is operated

q 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.
PC78US-8 10-700 11
Engine automatic warm-up function 1

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
12. Sensors
13. Hydraulic oil temperature sensor
14. Hydraulic pump
14a. Servo
14b. LS valve
14c. PC valve
15. Control valve
16. PC-EPC valve
10-700 12 PC78US-8
Function
q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after
start-up of the engine.
Operational conditions (all required) Operation
Coolant temperature: Max. 55°C o
Fuel control dial: Max. 1,300 rpm Engine speed: 1,300 rpm
Control levers: NEUTRAL
O
Release conditions (either one required) Release
Coolant temperature: Min. 55°C, and control levers are set to NEUTRAL. o
Engine speed: Any
Fuel control dial: Min. 1,300 rpm, and control levers are set to NEUTRAL.
Overheat prevention function 1
a See "Engine automatic warm-up function" for system circuit diagram.
q Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil tem-
perature becomes too high.
Operational conditions Operation and actions taken Release conditions
Engine speed: Remains same Coolant temperature: Max. 95°C
Coolant temperature: Min. 95°C o • Sends torque control signal to o Hydraulic oil temperature: Max. 95°C
lower the pump absorption • The original conditions are restored if
Hydraulic oil temperature: Min. 95°C
torque and reduce the engine above requirements are met (automatic
load. restoration).

Engine speed: Remains same
Alarm monitor: ON Coolant temperature: Max. 102°C
Coolant temperature: Min. 102°C o • Sends torque control signal to o Hydraulic oil temperature: Max. 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.

Coolant temperature: Max. 105°C
Hydraulic oil temperature: Max. 105°C
Coolant temperature: Min. 105°C o Engine speed: Low idle o Fuel control dial: Returns to low idle (MIN)
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).
PC78US-8 10-700 13
Turbocharger protection function 1
a See "Engine automatic warm-up function" for system circuit diagram.
q When the engine is started at low temperatures and the engine speed is increased sharply, the turbo-
charger may be seized. Controlling the engine speed prevents this problem.
q The turbocharger protection time is controlled according to the coolant temperature.
Operational conditions Operating
o Turbocharger protection
Engine oil pressure: Max. 50 kPa {0.51 kg/cm2} (See the following figure)
A: Start engine
B: Duration of turbocharger protection
(approx. 0 – 20 sec)
C: Modulating time (approx. 1.5 sec)
D: 500 rpm
E: 1,175 rpm
F: 2,050 rpm (*1)
*1. Working mode: P mode

Fuel control dial: High idle (MAX) position
Swing lever full operated
10-700 14 PC78US-8
PC78US-8 10-700 15
Swing control function 1

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
9. Oil pressure sensor
10. Travel/swing alarm buzzer
11. Hydraulic pump
12. Control valve
13. Swing motor
14. Swing holding brake solenoid valve
10-700 16 PC78US-8
Function
Swing holding brake function Swing holding brake release function

q Interlocked with the swing operation, the swing q 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-
q 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.
a 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.
a 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
PC78US-8 10-700 17
Travel control function 1

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
10-700 18 PC78US-8
Function
Travel speed select function

1. Travel speed "Manual" change
q 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
q 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
q 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 travel
speed switch position remains "Hi").
q If the travel pressure decreases on a
f la t o r d o w n hi l l w i t h l o w s pe 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.
PC78US-8 10-700 19
Pump control function during travel

a See "Engine and pump mutual control func-
tion" for details.
Travel junction function

q 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.
q 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.
q 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

q 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.
q 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").
10-700 20 PC78US-8
PPC lock function 1
1. Battery Function
2. Battery relay q Interlocked with the lock lever, the PPC lock
3. Fusible link switch is turned "OFF" when operating the lock
4. Fuse box lever to "LOCK" position.
5. Starting switch q When the PPC lock switch is turned "OFF", the
6. Lock lever current to the PPC lock solenoid valve is cut-
7. PPC lock switch off, causing neither the work equipment nor
8. Hydraulic pump machine moves even if levers or pedal are
9. Control valve operated.
PC78US-8 10-700 21
Oil flow adjuster function for attachment 1
(Machine ready for attachment)

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 q 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
10-700 22 PC78US-8
PC78US-8 10-700 23
System components 1
Engine controller

q 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 —
10-700 24 PC78US-8
DRC-60P(1) [CN-CE01]
Pin Signal Pin Signal
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
No. classification No. classification
1 CAN(+) E 31 NC —
2 NC — 32 Engine controller power cut-off relay GND C
3 NC — 33 NC —
4 NC — 34 NC —
5 NC — 35 Fuel control dial (+) B
6 NC — 36 NC —
7 NC — 37 NC —
8 NC — 38 NC —
9 NC — 39 NC —
10 NC — 40 NC —
11 NC — 41 NC —
12 NC — 42 NC —
13 NC — 43 NC —
14 NC — 44 NC —
15 NC — 45 Starting switch ACC signal B
16 NC — 46 NC —
17 NC — 47 NC —
18 NC — 48 NC —
19 NC — 49 NC —
20 NC — 50 NC —
21 CAN (–) E 51 NC —
22 NC — 52 NC —
23 NC — 53 NC —
24 NC — 54 NC —
25 NC — 55 Engine controller power cut-off relay D
26 NC — 56 NC —
27 Fuel control dial (5 V) A 57 NC —
28 Fuel control dial (–) C 58 NC —
29 NC — 59 NC —
30 NC — 60 NC —
PC78US-8 10-700 25
Pump controller
10-700 26 PC78US-8

AMP-81P [CN-C01]
Pin Input/output Pin 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
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 —
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]
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
PC78US-8 10-700 27
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
q This dial is installed in the right console box.
Potentiometer (5) is installed inside knob (1).
Turning knob (1) causes potentiometer (5)
shaft to rotate.
q This rotation changes the resistance of the
variable resistor within potentiometer (5), and a
throttle signal is sent to the controller.
q The hatched areas in the graph are error
detection areas. If the throttle voltage is within
the area, the engine speed drops down to low
idle.
10-700 28 PC78US-8
Resistor
1. Resistor
2. Connector
Specifications
For PC-EPC valve: 30 z
Function
q This resistor sends an appropriate electric cur-
rent to each EPC valve, when the emergency
pump drive switch is turned to "ON".
a No electric current flows in the normal condi-
tion.
PC78US-8 10-700 29
Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Specifications
Contact type: Normal close
Function
q This oil pressure switch is installed in the cylin-
der block. It detects engine oil pressure, and
turns the switch "ON" when the pressure goes
below the specified value.
10-700 30 PC78US-8
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/cm 2}
Operating pressure to break contact point OFF:
294 ± 49.0 kPa {3.0 ± 0.5 kg/cm 2}
Function
q This oil pressure switch is installed (8 places)
in the control valve. It detects the PPC oil pres-
sure when each actuator is operated, and
turns the switch "ON" when the pressure
exceeds the specified value.
PC78US-8 10-700 31
10-700 32 PC78US-8
Monitor system SEN04563-01
Monitor system 1
1. Machine monitor Outline

2. Battery q 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 q The switches on the machine monitor serve to
set operating conditions of the machine.
PC78US-8 10-700 33
SEN04563-01 Monitor system
Machine monitor 1
Outline Precautions on the machine monitor display

q The machine monitor provides monitor display q 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
q 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. q When the engine is started, the battery voltage
q 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
q 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- q 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

070-18P(1) [CN-CM01]
Signal name signal Signal name signal
No. No.
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]
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]
No. No.
1 For communication terminal, RS232C CD Input 10 For communication terminal, RS232C CTS Input
2 For communication terminal, RS232C RXD Input 11 For communication terminal, RS232C RI Input
3 For communication terminal, RS232C SG — 12 GND (communication terminal power supply) —
4 GND (communication terminal control signal) — 13 Communication terminal status signal CH1 Input
5 Communication terminal selection signal Input 14 Communication terminal power supply control signal Output
6 For communication terminal, RS232C RTS Output 15 Communication terminal control signal CH1 Output
7 For communication terminal, RS232C TXD Output 16 Communication terminal control signal CH2 Output
8 For communication terminal, RS232C DTR Output 17 Communication terminal status signal CH2 Input
9 For communication terminal, RS232C DSR Input 18 Communication terminal power supply (12 V) Output
070-12P(2) [CN-CM04]
No. No.
1 GND (peripheral equipment power supply) — 7 Reserved —
2 Peripheral equipment control signal Output 8 Reserved —
3 GND (for peripheral equipment, RS232C) — 9 Reserved —
4 For peripheral equipment, RS232C TXD Output 10 Reserved —
5 For peripheral equipment, RS232C RXD Input 11 Reserved —
6 Reserved — 12 Peripheral equipment power supply (12 V) Output
B60-8P [CN-CM05]
No. No.
1 Camera power supply (8 V) Output 5 GND (Camera power supply) —
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1) —
PC78US-8 10-700 35
Display 1
A: Normal operation screen

B: All indicators light-up screen
q 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.
q 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.
q 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
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
2b Caution
gauge.
Display Background • Indicates corresponding fuel level.
Quantity (l)
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
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
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
PC78US-8 10-700 39
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 io 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) io 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) o INT o ON o OFF o
INT: Intermittent
5 Wiper switch I (Intermittent) (Continuous) (Stop) O
ON: Continuous
[Numeric keypad: 5] i i i
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
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 io ON
FRESH/RECIRC screen, and pressing it again switches
11 Changes the FRESH/RECIRC. recirculation/fresh air flow.
selector switch
FRESH io RECIRC
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 o 1 o 2 o 3 o 4 o 5 o
5. Defroster I O
i i i i i
Turns the fan and air conditioner OFF.
13 OFF switch • Turns the fan and air conditioner OFF.
Light OFF: OFF
14a Guidance icon

a 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
Guidance icon and function switch

q Functions available with the function switch depend on the guidance icon displayed above the switch.
q No function is available if no guidance icon appears above the function switch.
q 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
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
Operator mode function 1
q The functions in this mode are displayed in normal operation. Display and setting of these functions are
available from the operator's switch operations.
Display and setting of some functions require special operation of the switch.
q Items available in the operator mode are as follows:
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.
a 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".
a For how to set the engine start lock on/off, see "Password setting/cancel manual".
10-700 44 PC78US-8
Oil flow setting for breaker Oil flow setting for attachment
q Oil flow for the breaker can be changed in the q Oil flow for the double-acting attachment can
"Breaker/attachment setting" of the user mode. be changed in the "Breaker/attachment set-
q Oil flow level can be set as follows: ting" of the user mode.
q Oil flow level can be set as follows:
Oil flow level Quantity (l/min) Remarks
1 45 Oil flow level Quantity (l/min) Remarks
2 50 1 20
3 55 2 35
4 60 3 50
5 65 4 65
6 70 5 80
7 75 6 95
8 80 Default 7 110
9 85 8 125 Default
10 90
11 95
Language setting
12 100
13 105
14 110
15 115
q The language used in the machine monitor can

be changed in the "Language setting" of the
user mode.
q The available languages are as follows:
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, Turkish,
Indonesian and Thai
PC78US-8 10-700 45
Service mode function 1
q The functions in this mode are not accessible from the normal operation screen. Display and setting of
these functions are available by the serviceman's special operations of the switch.
This mode is used for special setting, testing, adjusting or troubleshooting.
q Items available in the service mode are as follows:
Monitoring
Mechanical Systems
Abnormality Record Electrical Systems
Air-conditioning System
Maintenance Record
Maintenance Mode Change
Phone Number Entry
Key-on Mode
Unit
Default With/Without attachment
Attachment/Maintenance Password
ECO Display
Pump Absorption Torque
Adjustment
Attachment Flow Adjustment
Cylinder Cut-Out
No Injection
Fuel Consumption
Terminal Status
GPS & Communication Status
KOMTRAX Settings
Modem IP Address (Model TH201)
Modem S/N (Model TH300)
Display of KOMTRAX message
a For how to operate the service mode functions, see "Special functions of machine monitor" in "Testing
and adjusting".
10-700 46 PC78US-8
KOMTRAX system SEN04563-01
KOMTRAX system 1
q The KOMTRAX system consists of the

KOMTRAX terminal, communication antenna,
machine monitor and GPS antenna.
q 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.
q The information available from the KOMTRAX
system are as follows:
1. Operation map
2. Service meter
3. Machine location
4. Error record
a 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 system
KOMTRAX terminal 1
Model: TH300
q Satellite wave is used.
1. Communication antenna connection Outline

2. Machine harness connection (AMP-14P) q 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] data , v i a w ir el es s co m mun ic at 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 q 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 —
q 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
Sensor SEN04563-01
Sensor 1
Atmospheric pressure sensor
1. Connector
2. Pressure inlet port
Function
q This sensor is installed in the bracket on the side face of the cylinder block.
q This sensor senses the atmospheric pressure and converts it into an electric signal and then outputs
that signal.
Boost pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
Function
q This sensor is installed in the intake manifold.
q This sensor senses the boost pressure and boost temperature and converts them into electric signals
and then outputs those signals.
PC78US-8 10-700 49
SEN04563-01 Sensor
Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
Function
q This sensor is installed in the water pump.
q This sensor senses the coolant temperature and converts it into an electric signal and then outputs that
signal.
Crankshaft speed sensor

Camshaft speed sensor
1. Connector
2. Sensor
3. O-ring
Function
q The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is
installed in the gear of the camshaft.
q These sensors sense the gear rotations and convert them into pulse signals and then output those sig-
nals.
10-700 50 PC78US-8
Sensor SEN04563-01
Common rail pressure sensor
1. Common rail
2. Sensor
3. Connector
Function
q This sensor is installed in the common rail.
q This sensor senses the fuel pressure and converts it into an electric signal and then outputs that signal.
Hydraulic oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
q This sensor is installed in the suction pipe of the hydraulic pump.
q This sensor senses the hydraulic temperature and converts it into an electric signal and then outputs
that signal.
PC78US-8 10-700 51
SEN04563-01 Sensor
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function
q This sensor is installed on the side face of the fuel tank.
q This sensor senses the fuel level and converts it into an electric signal and then outputs that signal.
q The float moves up and down according to the fuel level.
q The movement of the float operates the variable resistor through the arm.
10-700 52 PC78US-8
Sensor SEN04563-01
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
q The pump oil pressure sensor is installed in the
control valve, and the boom cylinder bottom oil
pressure sensor is installed in the boom cylin-
der bottom piping.
q The pump pressure sensor senses the pump
discharge pressure and converts it into an
electric signal and then outputs that signal.
q The boom cylinder bottom pressure sensor
senses the cylinder circuit pressure and con-
verts it into an electric signal and then outputs
that signal.
PC78US-8 10-700 53
SEN04563-01 Sensor
PPC oil pressure sensor

(For travel and swing operation)
1. O-ring Output characteristics

2. Sensor
3. Connector
Function
q This sensor is installed in the control valve
connecting part of the pilot circuit for travel and
swing operation.
q This sensor senses the pilot pressure and con-
verts it into an electric signal and then outputs
that signal.
10-700 54 PC78US-8
Sensor SEN04563-01
PC78US-8 10-700 55
SEN04563-01

©2008 KOMATSU
All Rights Reserved
10-700 56

PC78US-8 Structure, Function and Maintenance Standard

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PC78US-8 Structure, Function and Maintenance Standard

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SEN04555-01

Machine model Serial number

10 Structure, function and

100 Engine and cooling system

a PTO: Abbreviation for Power Take Off

1. Breather combined with oil filler plug

1. Reservoir tank 12. Fuel cooler inlet

Radiator Oil cooler Aftercooler Fuel cooler

PC78US-8 Hydraulic excavator

Machine model Serial number

10 Structure, function and

200 Power train

1. Idler 10. Engine

2. Swing circle pinion grease filler port

a. Inner race soft zone position

1. Swing pinion (Number of teeth: 10) Specifications

4 Backlash between No. 1 planetary

PC78US-8 Hydraulic excavator

Machine model Serial number

10 Structure, function and

300 Undercarriage and frame

3. Idler 9. Track shoe

2 Outside diameter of tread 415 407

3 Tread depth 22.5 26.5 Rebuild or replace

5 Overall width 100 —

6 Tread width 28.5 —

Standard Tolerance Standard Clearance

Standard size Repair limit

— Oil capacity 60 cc (engine oil: SAE30CD) —

4 Overall width 136.6 — —

5 Tread width 46.8 — Rebuild or replace

Standard Tolerance Standard Clearance

Standard Tolerance Standard Interference

— Oil capacity 160 – 180 cc (gear oil: GO140) —

2 Tread width 100 — —

Standard Tolerance Standard Interference

— Oil capacity 51 – 56 cc (grease: Alvania EP-2) —

4 Wear on tooth bottom width 38 +0.5 33

City pad shoe, road liner, triple grouser shoe

*1. City pad shoe

a Part P is the link on the bushing press-fitting side.

6 Shoe bolt pitch 73 Replace

9 Link Overall width 30 Repair or replace

10 Tread width 26.3

12 Regular bushing projection 3.15

13 Pin overall length 131

14 Bushing overall length

Standard size Repair limit

17 Bushing 49.0 – 62.8 kN {5 – 6.4 ton}

18 Press-fit force Regular pin 49.0 – 117.7 kN {5 – 12 ton} —

Number of shoes (each side) 39 —

Items marked with * are for the dry track.

City pad shoe, triple grouser shoe

2 Shoe overall height 26 18

3 Plate thickness 6 Rebuild or replace

5 Grouser tip length 10

2 Wear of roller guide 42 58 Replace

PC78US-8 Hydraulic excavator

Machine model Serial number

10 Structure, function and

401 Hydraulic system, Part 1

Hydraulic component layout drawing 1

*1: North America specification

1. Blade control lever 11. Attachment PPC valve