Shop Manual PC78MR-6-SEBM030601 PDF

SEBM030601
MACHINE MODEL SERIAL NUMBER
PC78MR-6 1001 and up
This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require. Materials and
specifications are subject to change without notice.
PC78MR-6 mounts the S4D95LE-3-A engine.
For details of the engine, see the 95-3 Series Engine Shop Manual.
2003
All Rights Reserved
Printed in Japan 12-03(02) 00-1
(1)
CONTENTS
No. of page
01 GENERAL ................................................................................................................01-1
10 STRUCTURE AND FUNCTION,

MAINTENANCE STANDARD......................................................................10-1
20 TESTING AND ADJUSTING .......................................................................20-1
30 DISASSEMBLY AND ASSEMBLY ..........................................................30-1
90 OTHERS ....................................................................................................................90-1
00-2 PC78MR-6
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
q 00-1 (1) 10-6 10-46 10-88 10-125
00-2 10-7 10-47 10-89 10-126
Q 00-2-1 (1) 10-8 10-48 10-90 10-127
Q 00-2-2 (1) 10-9 10-49 10-91 10-128
Q 00-2-3 (1) 10-10 10-50 10-92 q 10-129 (1)
00-3 10-11 10-51 10-93 q 10-130 (1)
00-4 10-12 10-52 10-94 10-131
00-5 10-13 10-53 10-95 Q 10-131-1 (1)
00-6 10-14 10-54 10-96 Q 10-131-2 (1)
00-7 10-15 10-55 10-97 10-132
00-8 10-16 10-56 10-98 10-133
00-9 10-17 10-57 10-99 10-134
00-10 10-18 10-58 10-100 10-135
00-11 q 10-19 (1) 10-59 10-101 10-136
00-12 10-20 10-60 10-102 10-137
00-13 10-21 10-61 10-103 10-138
00-14 10-22 10-62 10-104 10-139
00-15 10-23 10-63 10-105 10-140
00-16 10-24 10-64 10-106 10-141
00-17 10-25 10-65 10-107 10-142
00-18 10-26 10-66 10-108 10-143
00-19 10-27 10-67 10-110 Q 10-143-1 (1)
00-20 10-28 10-68 10-111 q 10-144
00-21 10-29 10-69 10-112 10-145
00-22 10-30 10-70 10-113 10-146
10-31 10-72 10-114 10-147
01-1 10-32 10-73 10-115 q 10-148 (1)
01-2 q 10-34 (1) 10-74 10-116 q 10-149 (1)
01-3 10-35 10-75 10-117 10-150
01-4 Q 10-35-1 (1) 10-76 10-118 10-151
01-5 Q 10-35-2 (1) 10-77 10-119 10-152
01-6 10-36 10-78 10-120 Q 10-152-1 (1)
01-7 10-37 10-79 10-121 10-153
01-8 10-38 10-80 Q 10-121-1 (1) 10-154
01-9 10-39 10-81 Q 10-121-2 (1) 10-155
10-40 10-82 Q 10-121-3 (1) q 10-156 (1)
q 10-1 (1) q 10-41 (1) 10-83 Q 10-121-4 (1) Q 10-156-1 (1)
10-2 10-42 10-84 Q 10-121-5 (1) 10-157
10-3 10-43 10-85 q 10-122 q 10-158 (1)
10-4 10-44 10-86 10-123 q 10-159 (1)
10-5 10-45 10-87 10-124 q 10-160 (1)
PC78MR-6 00-2-1
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Mark Page number Mark Page number Mark Page number Mark Page number Mark Page number
20-1 20-137 20-250 20-516 20-808
20-2 20-138 20-251 20-517 20-809
20-3 20-139 20-252 20-518 20-810
20-4 20-201 20-253 20-519 20-811
20-5 20-202 20-254 20-520 20-812
20-6 20-203 20-255 20-521 20-813
20-7 20-204 20-256 20-522 20-814
20-8 20-205 q 20-257 (1) q 20-601 (1) 20-815
20-9 20-206 20-258 20-602 20-816
20-10 20-207 20-259 20-604 20-817
20-11 20-208 20-260 20-605 20-818
20-12 20-209 20-301 q 20-606 (1) 20-819
20-13 20-210 20-302 q 20-607 (1) 20-820
20-14 20-211 20-303 q 20-608 (1) 20-821
20-15 20-212 20-304 q 20-609 (1) 20-822
20-101 q 20-214 (1) 20-305 q 20-610 (1) 20-823
20-102 q 20-215 (1) 20-306 20-611 20-824
20-103 q 20-216 (1) 20-307 Q 20-611-1 (1) 20-825
20-104 q 20-217 (1) 20-308 Q 20-611-2 (1) 20-826
20-105 q 20-218 (1) 20-309 20-612 20-827
20-106 20-219 20-310 20-613 20-828
20-107 20-220 20-311 20-614 20-829
20-108 20-221 20-312 20-615 20-830
20-109 20-222 20-313 Q 20-615-1 (1) 20-831
20-110 20-223 20-314 q 20-616 (1) 20-832
20-111 20-224 20-315 q 20-617 (1) 20-833
20-112 20-225 20-316 q 20-618 (1) 20-834
20-113 20-226 20-317 q 20-619 (1) 20-835
20-114 20-227 20-318 q 20-620 (1) 20-836
20-115 20-228 20-319 q 20-621 (1) 20-837
20-116 20-229 20-320 q 20-622 (1) 20-838
20-117 20-230 20-321 q 20-623 (1) 20-839
20-118 20-231 20-322 q 20-624 (1) 20-840
20-119 20-232 20-323 q 20-625 (1) 20-841
20-120 20-233 20-324 q 20-626 (1) 20-842
20-121 20-234 20-401 q 20-627 (1) 20-843
20-122 20-235 20-402 q 20-628 (1) 20-844
20-123 20-236 20-501 20-701 20-845
20-124 20-237 20-502 20-702 20-846
20-125 20-238 20-504 20-703 20-847
20-126 20-239 20-505 20-704 20-848
20-127 20-240 20-506 20-705 20-849
20-128 q 20-241 (1) 20-507 20-706 20-850
20-129 q 20-242 (1) 20-508 20-707 20-851
20-130 20-243 20-509 20-708 20-852
20-131 20-244 20-510 20-801 20-853
20-132 q 20-245 (1) 20-511 20-802 20-854
20-133 20-246 20-512 20-804 20-855
20-134 20-247 20-513 20-805 20-856
20-135 20-248 20-514 20-806 20-857
20-136 20-249 20-515 20-807 20-858
00-2-2 PC78MR-6
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Mark Page number Mark Page number Mark Page number Mark Page number Mark Page number
20-859 30-19 q 90-1 (1)
20-860 30-20 q 90-3 (1)
20-861 30-21 q 90-5 (1)
20-901 30-22 q 90-7 (1)
20-902 30-23 Q 90-9 (1)
20-903 30-24 Q 90-11 (1)
20-904 30-25 Q 90-13 (1)
20-905 30-26
20-906 30-27
20-907 30-28
20-908 30-29
20-909 30-30
20-910 30-31
20-911 30-32
20-912 30-33
20-913 30-34
20-914 30-35
20-915 30-36
20-916 30-37
20-917 30-38
20-918 30-39
20-919 30-40
20-920 30-41
20-921 30-42
20-922 30-43
20-923 30-44
20-924 30-45
20-925 30-46
20-926 30-47
20-927 30-48
20-928 30-49
20-929 30-50
30-51
30-1 30-52
30-2 30-53
30-3 30-54
30-4 30-55
30-5 30-56
30-6 30-57
30-7 30-58
30-8 30-59
30-9 30-60
30-10 30-61
30-11 30-62
30-12 30-63
30-13 30-64
30-14 30-65
30-15 30-66
30-16 30-67
30-17 30-68
30-18
PC78MR-6 00-2-3
(1)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive () terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.

but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
Quick hardening type adhesive

Three bond Polyethylene Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly for adhesion of met-
als, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene Resistance to heat, chemicals

79A-129-9110 50 cc Used at joint portions subject to
648-50 container
high temperatures.
Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
Features: Silicon based, resist-

ance to heat, cold
Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
SYG2-400LI General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
Specifiaction dimensions drawing ...................... 01-2

Working range drawing ....................................... 01-3
Specifications ...................................................... 01-4
Weight table ........................................................ 01-7
List of lubricants and coolant .............................. 01-9
PC78MR-6 01-1
GENERAL SPECIFICATION DIMENSIONS DRAWING
SPECIFICATION DIMENSIONS DRAWING
PC78MR-6
Item Unit
Steel shoe spec. Road liner spec.
Machine weight (with blade) kg 8,270 8,300
Bucket capacity m 0.28
Engine model KOMATSU S4D95LE-3-A Diesel engine
Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850
A Overall length mm 6,200 6,230
B Overall height mm 2,730 2,750
C Overall width mm 2,330
D Shoe width mm 450
E Tail swing radius mm 1,310
F Overall length of track mm 2,840 2,900
G Distance between tumbler centers mm 2,235
Minimum ground clearance mm 360 400
Travel speed (Low/High) km/h 2.8/4.2
Continuous swing speed rpm 10.0
01-2 PC78MR-6
GENERAL WORKING RANGE DRAWING
WORKING RANGE DRAWING
Working range (mm) Steel shoe spec.

A Max. digging reach 6,960
B Max. digging depth 4,160
C Max. digging height 6,570
D Max. vertical wall depth 2,900
E Max. dumping height 4,515
Min. swing radius of work equipment 2,775
F
Min. swing radius at boom swinging 2,125
G Max. reach at ground level 6,750
H Max. blade lifting height 380
I Max. blade lowering depth 245
PC78MR-6 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC78MR-6
Serial Number 1001 and up
Bucket capacity m3 0.28
Machine weight kg 8,270 (8,300)
Max. digging depth mm 4,160
Max. vertical wall depth mm 2,900
Max. digging reach mm 6,960
Working range
Max. reach at ground level mm 6,750

Max. digging height mm 6,570
Max. dumping height mm 4,515
Performance
Boom swing (left side/right side) mm 580/930

Max. blade lifting height mm 380
Max. blade lowering depth mm 245
Max. digging force (Bucket) kN {kg} 61.3 {6,250}
Continuous swing speed rpm 10.0
Max. slope angle for swing deg. 16.0
Travel speed (Low/High) km/h 2.8/4.2
Gradeability deg. 35
Ground pressure kPa {kg/cm2} 37.3 {0.38}
Overall length (for transport) mm 6,200
Overall width mm 2,330
Overall height (for transport) mm 2,730 (2,750)
Overall height (for operation) mm 2,710 (2,750)
Ground clearance of counterweight mm 735 (780)
Min. ground clearance mm 360 (400)
Tail swing radius mm 1,310
Dimension
Min. swing radius of work equipment mm 2,125

(at boom swinging)
Height of work equipment at min. swing radius mm 5,210 (5,230)
Overall width of track mm 2,320
Overall length track mm 2,840 (2,900)
Distance between tumbler centers mm 2,235
Track gauge mm 1,870
Machine cab height mm 1,745 (1,795)
Blade width height mm 2,320 470
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
( ) Figures in ( ): Road liner specification
01-4 PC78MR-6

Model S4D95LE-3-A
Type 4-cycle, water-cooled, in-line, direct injection
No. of cylinders - bore stroke mm 4-95 115
Total displacement l {cc} 3.26 {3,260}
kW/rpm 40.5/1,850
Rated output {HP/rpm} {54.0/1,850}
Nm/rpm 337/1,500
Performance
Max. torque
Engine
{kgm/rpm} {24.2/1,500}
Max. speed at no load rpm 2,020
Min. speed at no load rpm 1,130
Min. fuel consumption g/kWh 227 {169}

{g/HPh}
Starting motor 24 V, 3.0 kw
Alternator 24 V, 25 A
Battery 12 V, 48 Ah 2 (55D26R)
Type of radiator core CF29-3
Carrier roller 1 on each side
Undercarriage
Track roller 5 on each side

Track shoe (Steel shoe) Assembly-type triple grouser, 39 on each side
(Road liner) Assembly-type road liner, 39 on each side
(Rubber shoe) Unit-type rubber crawler
Variable-capacity piston pump 1
Type No.
Gear pump 2
Hydraulic pump
Discharge l {cc} 802+60+12.7

Set pressures
(Work equipment, travel) MPa 26.5 {270}
(Swing, blade) {kg/cm2} 21.1 {215}
(Control) 3.1 {32}
Hydraulic system
Type No. 9-spool type 1

Control
valve
Control method Hydraulically assisted

Variable-capacity piston motor
Travel motor
Hydraulic
(with brake valve, parking brake) 2

motor
Fixed-capacity piston motor

Swing motor
(with safety valve, pivot shaft brake) 1
Hydraulic tank Box-shaped, open
Hydraulic oil filter Tank return side
Oil cooler Air-cooled
PC78MR-6 01-5

Type Reciprocating piston
Inside diameter of cylinder mm 115
Boom cylinder
Diameter of piston rod mm 65

Stroke mm 988
Max. distance between pinsmm mm 2,393
Min. distance between pinsmm mm 1,405
Type mm Reciprocating piston
Arm cylinder

Stroke mm 865
Max. distance between pins mm 2,193
Min. distance between pins mm 1,328
Work equipment cylinder

Hydraulic system
Bucket cylinder

Stroke mm 710
Boom swing cylinder

Stroke mm 658
Blade cylinder

Stroke mm 130
Max. distance between pins mm 679
Min. distance between pins mm 549
01-6 PC78MR-6
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This mass list is for reference in handling or transporting these components.
Unit: kg
Engine assembly (without water and oil) 403
Engine (without water and oil) 300
Engine mount 30
PTO 7
Hydraulic pump 66
Cooling assembly (without coolant and oil) 29
Radiator (without coolant) 6.3
Oil cooler (without oil) 5.2
Revolving frame 1,220
Operator's cab 260
Operator's seat 18
Fuel tank (without fuel) 8.3
Hydraulic tank (without hydraulic oil) 70
Control valve 62
Counterweight 950
Additional counterweight 220
Swing motor (Including brake valve) 22
Swing circle 104
Swing machinery 47
Center swivel joint 16
Track frame assembly (without track shoe) 1,067 [1,048]
Track frame 704
Idler assembly 54 x 2
Recoil spring assembly 40 x 2
Carrier roller 3.4 x 2
Track roller 13 x 10
Travel motor (with reduction gears) 81 x 2
Sprocket 19 x 2
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
[ ] Figures in [ ]: Rubber shoe specification
PC78MR-6 01-7
GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly
City pad shoe (450 mm) 410 X 2
Road liner (450 mm) 450 X 2
Rubber shoe (450 mm) 385 X 2
Triple grouser (600 m) 495 X 2
Boom assembly 365
Swing bracket 234
Arm assembly 147
Bucket link assembly 56
Bucket assembly (with side cutter) 210
Blade assembly 374
Boom cylinder assembly 95
Arm cylinder assembly 72
Bucket cylinder assembly 51
Boom swing cylinder assembly 65
Blade cylinder assembly 46
Figures are common to the all specifications unless otherwise specified.
01-8 PC78MR-6
GENERAL LIST OF LUBRICANTS AND COOLANT
LIST OF LUBRICANTS AND COOLANT
AMBIENT TEMPERATURE
KIND OF
RESERVOIR FLUID 22 4 14 32 50 68 86 104 122F
30 20 10 0 10 20 30 40 50C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Swing machinery case
Final drive case Engine oil
PTO gear case SAE 30
SAE 10
Hydraulic system
SAE 10W-30
SAE 15W-40
ASTM D975 No. 2

Fuel tank Diesel fuel
*1
Greasing system Diesel fuel NLGI No. 2
Cooling system Water Add antifreeze
*1: ASTM D975 No. 1 Unit: l
PC78MR-6
Reservoir
Specified capacity Refill capacity
Engine oil pan 7.5 7.0
PTO gear case 0.4 0.4
Swing machinery case 2.0 2.0
Final drive case (each) 1.3 1.3
Hydraulic system 120 64
Fuel tank 125
Cooling system 10.5
PC78MR-6 01-9
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PTO ........................................................................... 10- 2

Cooling system .......................................................... 10- 3
Power train system .................................................... 10- 4
Swing circle ............................................................... 10- 5
Swing machinery ....................................................... 10- 6
Track frame and idler cushion ................................... 10- 8
Idler ........................................................................... 10-10
Track roller..................................................................10-11
Carrier roller .............................................................. 10-12
Sprocket .................................................................... 10-13
Track shoe................................................................. 10-14
Arrangement of hydraulic components...................... 10-19
Hydraulic tank and oil filter ........................................ 10-20
Center swivel joint ..................................................... 10-21
Travel motor .............................................................. 10-22
Work equipment cylinder ........................................... 10-30
Solenoid valve ........................................................... 10-34
Multi-Control Valve .................................................... 10-40
Accumulator for Brake ............................................... 10-41
Hydraulic pump ......................................................... 10-42
Control valve ............................................................. 10-56
CLSS ......................................................................... 10-68
Swing motor ............................................................ 10-100
Work equipment and swing PPC valve ................... 10-108
Travel PPC valve......................................................10-114
Boom swing PPC valve, blade PPC valve ...............10-118
Boom hydraulic anti-burst valve (For EU spec.) ... 10-121-1
Work equipment ...................................................... 10-122
Dimensions of each part of work equipment ........... 10-124
Air conditioner piping (Optional) .............................. 10-128
Electric control system ............................................ 10-129
System components ................................................ 10-146
Monitor system ........................................................ 10-154
Sensors ................................................................... 10-158
PC78MR-6 10-1
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PTO
PTO
1. Drain plug
2. Coupling
3. Flywheel
4. Pump case
5. Cage
6. Level plug
7. Breather/Oil filler plug
10-2 PC78MR-6
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
1. Fan guard SPECIFICATIONS

2. Radiator inlet hose
Radiator Oil cooler
3. Drain valve
4. Radiator outlet hose Type of core CF29-3 CF40-1
5. Radiator cap
6. Oil cooler Fin pitch (mm) 4.0/2 4.5/2
7. Radiator Total heat dissipation area
16.53 6.15
8. Shroud (m2)
9. Oil cooler inlet Pressure valve cracking 88.314.7
pressure (kPa {kg/cm}) (0.90.15)
10. Reservoir tank
11. Oil cooler outlet 4.9
Vacuum valve cracking
pressure (kPa {kg/cm})
(0.05)
PC78MR-6 10-3
MAINTENANCE STANDARD POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
1. Idler 10. Boom RAISE stop EPC valve

2. Control valve 11. Arm IN stop EPC valve
3. Center swivel joint 12. Left offset stop EPC vaolve
4. Swing motor 13. Swing holding brake solenoid valve
5. Travel motor 14. 2-stage travel speed selector solenoid valve
6. Control pump (for pilot control) 15. PPC lock solenoid valve
7. Hydraulic pump (for swing and blade) 16. Swing machinery
8. Hydraulic pump 17. Swing circle
(For travel and work equipment)
9. Engine
10-4 PC78MR-6
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
1 Axial clearance of bearing Replace
0.20 0.80 2.0
2. Greasing for swing circle bearing a. Position of inner race soft zone
3. Greasing for swing circle pinion b. Position of outer race soft zone
4. Outer race
5. Inner race Specifications
6. Ball Reduction ratio 80/10=8.0
7. Seal
Grease G2-LI
Quantity of grease ( ) 5.5
PC78MR-6 10-5
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
1. Swing pinion (Number of teeth: 10) Specification

2. Swing machinery case (14+58)/14X(14+58)/14 =
3. No. 2 planetary carrier Reduction ratio
26.45
4. Ring gear (Number of teeth: 58)
Swing reduction ratio 26.45X8.0 = 211.59
5. No. 2 sun gear (Number of teeth: 14)
6. No. 1 planetary carrier Swing speed (rpm) 10
7. No. 1 sun gear (Number of teeth: 14)
8. Swing motor
9. Oil filler
10. Level gauge
11. No. 1 planetary gear (Number of teeth: 22)
12. No. 2 planetary gear (Number of teeth: 22)
13. Drain plug
10-6 PC78MR-6
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
Backlash between Standard clearance Allowable clearance
1 swing motor shaft and
No. 1 sun gear 0.03 0.11
Backlash between No.

2 1 sun gear and No. 1 0.10 0.27 0.6
planetary gear
3 1 planetary gear and 0.12 0.38 0.6
ring gear
4 1 planetary carrier and 0.10 0.26
No. 2 sun gear
Replace
5 2 sun gear and No. 2 0.10 0.27 0.6
planetary gear
6 2 planetary gear and 0.12 0.38 0.6
ring gear
7 2 planetary carrier and 0.07 0.21
swing pinion
Backlash between
8 swing pinion and swing 0.27 0.83 2.0
circle
Wear of sliding surface Basic dimension Allowance Allowable Limit
Plating with hard
9 of swing pinion collar 0
75 74.8 chromium or replace
against oil seal - 0.074
PC78MR-6 10-7
MAINTENANCE STANDARD TRACK FRAME AND IDLER CUSHION
TRACK FRAME AND IDLER CUSHION
10-8 PC78MR-6
MAINTENANCE STANDARD TRACK FRAME AND IDLER CUSHION
Unit: mm
Basic dimension Allowable limit
Overlay
Vertical width of Track frame 74 78
1
idler guide Idler Overlay or
73 69
support replace
Track frame 158 162 Overlay
Lateral width of
2 Overlay or
idler guide Idler support 156 152
replace
Installed Installed Installed
Free length Free length
length load load
3 Recoil spring Road liner, 47.4 kN 42.2 kN Replace
412 323 402
steel shoe {4,835 kg} {4,305 kg}
69.2 kN 61.6 kN
Rubber shoe 412 283 402
{7,061 kg} {6,284 kg}
4. Idler
5. Track frame
6. Carrier roller
7. Travel motor
8. Sprocket
9. Track roller
10. Track shoe
11. Idler cushion
11a.Support
11b.Yoke
11c.Recoil spring
11d.Cylinder
11e.Collar
11f. Lubricator
12. Idler guard (Road liner specification, steel shoe
specification)
13. Bracket to secure machine body for transporta-
tion (for USA spec. only)
Specification
Grease G2-LI
96 (Steel shoe, road liner)
Quantity of grease (cc)
233 (Rubber shoe)
PC78MR-6 10-9
MAINTENANCE STANDARD IDLER
IDLER
Unit: mm
Outside diameter of Basic dimension Allowable limit
1
projected part 460
2 Outside diameter of tread 415 407
3 Depth of tread 22.5 26.5 Overlay or replace
4 Width of projected part 43 37
5 Overall width 100 92
6 Width of tread 28.5 32
Basic Allowance Standard Allowable
Clearance between idler dimension Shaft Hole clearance clearance
7
shaft and bushing -0.250 + 0.062
44 0.250 0.352 1.5
-0.290 0
Replace
Interference between idler dimension Shaft Hole interference interference
8
and bushing +0.117 +0.025
50 0.062 0.117
+0.087 0
Side clearance of idler Standard clearance Allowable clearance
9
(Each side) 0.190 0.395 1.5
Thickness of tread (at cen- Basic dimension Allowable limit
10 Overlay or replace
ter of width of tread) 13.8 9.8
Quantity of oil 60 cc (Engine oil: SAE30CD)
10-10 PC78MR-6
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
1
projected part 149
Overlay or replace
2 Outside diameter of tread 120 113
3 Width of flange 43 36.6
4 Overall width 129
5 Width of tread 43 47.3 Overlay or replace
Clearance between idler dimension Shaft Hole clearance clearance
6
shaft and bushing -0.250 + 0.075
38 0.225 0.345 1.5
-0.270 - 0.025
Replace
Interference between idler dimension Shaft Hole interference interference
7
48 0.057 0.117
+0.087 0
Side clearance of track Standard clearance Allowable clearance
8
roller (Each side) 0.38 0.73 1.5
Thickness of tread (at cen- Basic dimension Allowable limit
ter of width of tread) 36 32.5
Quantity of oil 210 230 cc (Gear oil: G0140)
PC78MR-6 10-11
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm
tread 82 72
2 Width of tread 100
Interference between shaft dimension Shaft Hole interference interference
3
and bearing +0.009 0 -0.004
30 Replace
-0.004 - 0.010 0.019
Interference between roller 0 + 0.018 -0.031
4 62
and bearing - 0.013 - 0.012 0.012
5 Thickness of tread Overlay or replace
10 5
Quantity of oil 47 52 cc (Grease: ALVANIA EP-2)
10-12 PC78MR-6
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Basic dimension Allowance Allowable limit
1 Wear of root diameter +1.0
433.004 421
-2.0
2 Wear of tip diameter 483.7 2.0 472
Overlay or
3 Wear of dip width 28 - 23 replace
+0.5
4 Wear of root width 38 33
-2.5
+0.475
5 Thickness of root 84.002 78
-1.150
PC78MR-6 10-13
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
CITY PAD SHOE, ROAD LINER, AND TRIPLE SHOE
*1. City pad shoe

Triple shoe (OPT)
*2. Road liner (OPT)
a Part P is the link on the press fitting side of bushing.
10-14 PC78MR-6
Unit: mm
1 Link pitch
154.25 157.25 Reverse or replace
2 Outside diameter of bushing 41.2 37.2
3 Height of link 74 70
Thickness of link (Press fit- Repair or replace
4 20 16
ting part of bushing)
5 89
6 Shoe bolt pitch 73 Replace
7 57
Inside
8 45
width
Overall
9 Link 30 Repair or replace
width
Width of
10 26.3
tread
11 Projection of pin 3
Projection of regular bush-
12 3.15
ing
13 Overall length of pin 131
Overall length of bushing Adjust or replace
14 74.6
(Master bushing)
15 Thickness of bushing
8.4 4.4
16 Thickness of spacer
17 Bushing 19.6 98.1 kN {2 10 ton}
Press fitting Regular
18 49.0 117.7 kN {5 12 ton}
pressure pin
*19 Master pin 39.2 78.5 kN {4 8 ton}
Items marked with * are for the dry track.
PC78MR-6 10-15
Unit: mm
Tightening torque
Retightening angle (deg.)
(Nm {kgm})
City pad 117.7 19.6
a. Regular 90 10
Triple {12 2}
link
60 10
Shoe bolt 117.7 19.6 Retighten
Road liner (Torque after retightening)
20 {12 2}
Min. 343 Nm {35 kgm}
Tightening Retightening
Lower limit torque
b. Master link torque angle (deg.)

Number of shoes
39
(Each side)
Basic dimen- Allowance Standard
Number of shoes sion Shaft Hole interference
21
(Each side) +0.214 +0.062
41 0.112 0.214
+0.174 0
Interference between regular pin +0.150 -0.198
22 24 0.198 0.400
and link 0 -0.250
Clearance between regular pin sion Shaft Hole clearance
23
24 0.180 0.830 Adjust or replace
0 +0.330
Interference between master pin sion Shaft Hole interference
*24
and link +0.020 -0.198
24 0.178 0.270
-0.020 -0.250
Clearance between master pin sion Shaft Hole clearance
*25
and bushing -0.150 +0.630
24 0.380 0.880
-0.250 +0.230
26 Height of grouser Replace
Road liner 42 19
Items marked with * are for the dry track.
10-16 PC78MR-6
TRIPLE SHOE AND CITY PAD SHOE
Unit: mm
1 Height of grouser
20 12
2 Overall height of shoe 26 18
3 Thickness of plate 6
4 20 Overlay or replace
Length of base of grouser
5 16
6 14
7 Length of upper side of grouser 10
8 12
PC78MR-6 10-17
RUBBER SHOE (OPTIONAL)
Unit: mm
1 Wear of lug height
30 5
2 Wear of roller guide 42 58 Replace
Wear of meshing part of Basic dimension Allowance Allowable limit
3
sprocket 22.5 0.5 27
10-18 PC78MR-6
MAINTENANCE STANDARD ARRANGEMENT OF HYDRAULIC COMPONENTS
ARRANGEMENT OF HYDRAULIC COMPONENTS
1. Bucket cylinder 12. Blade PPC valve

2. Arm cylinder 13. Right work equipment PPC valve
3. Boom cylinder 14. Center swivel joint
4. Boom swing cylinder 15. Service PPC valve (Machine to which attach-
5. Hydraulic tank ments can be installed)
6. Control valve 16. Travel PPC valve
7. Swing motor 17. 6-spool solenoid valve
8. Hydraulic pump 18. Boom swing PPC valve
9. Oil cooler 19. Blade cylinder
10. Travel motor 20. Boom hydraulic anti-burst valve (For EU spec.)
11. Left work equipment PPC valve
PC78MR-6 10-19
(1)
MAINTENANCE STANDARD HYDRAULIC TANK AND OIL FILTER
HYDRAULIC TANK AND OIL FILTER
1. Hydraulic tank Specification

2. Sight gauge Tank capacity ( ) 80
3. Strainer
Quantity of oil in tank ( ) 64
4. Drain plug
5. Filter Bypass valve set 0.15 0.03
6. Bypass valve pressure (kPa {kg/cm}) {1.53 0.3}
7. Oil filler cap Pressure valve cracking 38 15
pressure (kPa {kg/cm}) {0.39 0.15}
Vacuum valve cracking 05
pressure (kPa {kg/cm}) {0 0.05}
10-20 PC78MR-6
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
A1: From right travel control valve A2: To right travel motor
B1: From right travel control valve B2: To right travel motor
C1: From left travel control valve C2: To left travel motor
D1: From left travel control valve D2: To left travel motor
E1: From blade control valve E2: To blade cylinder bottom
F1: From blade control valve F2: To blade cylinder head
G1: From 2-stage travel speed selector solenoid valve G2: To 2-stage travel speed selector solenoid valve
DR1: To tank DR2: From travel motor drain port
1. Cover 3. Slipper seal

2. Rotor 4. Shaft
Unit: mm
Clearance Basic dimension Standard clearance Allowable clearance
5 between rotor Replace
and shaft 70 0.056 0.105 0.111
PC78MR-6 10-21
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
A. From travel control valve

B. From travel control valve
D. To tank
P. From 2-stage travel speed selector solenoid
valve
10-22 PC78MR-6
1. Check valve 14. Shaft

2. Counterbalance valve 15. Drive gear
3. Valve plate 16. Cover
4. Cylinder 17. Crankshaft
5. Brake piston 18. Drain plug
6. Plate 19. Driven gear
7. Disc 20. Pivot
8. Piston 21. Spindle
9. Swash plate 22. Floating seal
10. Regulator piston 23. End cover
11. RV gear 24. Regulator valve
12. RV gear 25. Check valve
13. Case
PC78MR-6 10-23
Specification
Model GM09VN-E
Theoretical Hi 24.1
displacement (cm/rev) Lo 36.3
Hi 3,211
Rated speed
Lo 2,154
Brake releasing pressure 0.47
(MPa {kg/cm}) {4.8}
Speed changeover pressure 2.94
(MPa {kg/cm}) {30}
Reduction ratio 66.5
Outline
1. Reduction gears 4. 2-stage travel speed changeover mechanism

The reduction gears consists of spur gear unit The 2-stage travel speed changing mechanism
(1a) and differential gear unit (1b) which uses consists of a changeover valve and a piston,
pericycloid gears and converts the high speed which change the displacement of the hydraulic
revolution of the hydraulic motor into low-speed motor to either of 2 stages.
and high-torque revolution.
5. Parking brake
2. Hydraulic motor The parking brake is a friction plate brake, which
The hydraulic motor is a swash plate-type axial is built as a part of the hydraulic motor.
piston motor, which converts the power of the
hydraulic oil sent from the hydraulic pump into
revolution.
3. Brake valve
The brake valve consists of various valves and
has functions of stopping the hydraulic motor
smoothly, preventing the hydraulic motor from
running away, and preventing generation of
abnormally high pressure when the hydraulic
motor is stopped suddenly.
10-24 PC78MR-6
OPERATION
Operation of motor
At low speed (With swash plate angle at maximum)
1. 2-stage travel speed selector solenoid valve Since 2-stage travel speed selector solenoid
2. Regulator valve valve (1) is de-energized, the hydraulic oil from
3. Spring the control pump does not flow into port Pi.
4. Check valve Accordingly, regulator valve (2) is pressed to the
5. End cover left by spring (3).
6. Regulator piston Under this condition, the main hydraulic oil from
7. Swash plate the control valve pushes check valve (4) and
8. Pump merge-divider valve flows into end cover (5) and then is shut off by
9. Travel control valve regulator valve (2).
10. Brake valve The hydraulic oil in control chamber (a) flows
through passage (b) of regulator valve (2) into
the motor case.
As a result, swash plate (7) is pushed toward the
maximum swash plate angle by the main hydrau-
lic oil in chamber (P) of the cylinder and the
motor capacity is increased to the maximum and
the travel speed lowers.
PC78MR-6 10-25
At high speed (With swash plate angle at minimum)
1. 2-stage travel speed selector solenoid valve If 2-stage travel speed selector solenoid valve
2. Regulator valve (1) is energized, the pilot pressure from the con-
3. Spring trol pump flows into port Pi and pushes regulator
4. Check valve valve (2) to the right.
5. End cover Accordingly, the main hydraulic oil from the con-
6. Regulator piston trol valve flows through passage (c) of regulator
7. Swash plate valve (2) into control chamber (a) and pushes
8. Pump merge-divider valve regulator piston (6) to the left.
9. Travel control valve As a result, swash plate (7) is pushed toward the
10. Brake valve minimum swash plate angle and the motor
capacity is decreased to the minimum and the
travel speed rises.
10-26 PC78MR-6
Operation of brake valve Operation when oil is supplied

The brake valve consists of check valves (1a) If the travel lever is operated, the hydraulic oil
and (1b) and counterbalance valve spool (2) as from the control valve flows in port PA, pushes
shown in the following figure. valve (1a) open, and flows through motor input
port MA to motor outlet port MB.
At the same time, the hydraulic oil also flows
through orifice c of spool (2) to chamber D. If its
pressure becomes higher than the pressure of
spring (3), spool (2) is pushed to the left. As a
result, port MB is connected to port PB and the
motor outlet side opens and the motor starts rev-
olution.
Since port PA is connected to port E, too, the
hydraulic oil operates parking brake piston (4) to
release the parking brake force.
Function
When the machine travels downhill, its speed
may become higher than the motor speed
because of its momentum. If the engine speed is
low at this time, the motor runs idle and the
machine runs away, and this situation is very
dangerous. The brake valve prevents this phe-
nomenon and limits the travel speed according
to the engine speed (pump discharge).
PC78MR-6 10-27
Operation when oil is shut off Operation of brake during downhill travel
If the control lever is returned to neutral, the If the machine starts running away while travel-
hydraulic oil from the control valve is shut off and ing downhill, the motor revolves idle and the
spool (2) is returned to the right by the reaction pressure on the motor inlets side lowers, then
force of spring (3). the pressure in chamber D also lowers through
At this time, the oil flows through orifice (c) of orifice (c).
chamber D into port PA and back pressure is If the pressure in chamber D lowers below the
generated by the throttle effect of orifice (c). This pressure of spring (3), spool (2) is pushed back
back pressure controls the speed of spool (2) to the right.
returning to the right. At this time, the oil in chamber G flows through
Even after the hydraulic oil in port PA is shut off, orifice (f) into port PB. The throttle effect of ori-
the motor continues revolution by inertia. fice (f) generates back pressure, and spool (2)
At this time, the returning oil is reduced gradually returns to the right to control the returning speed
according to the changing speed and shape of of spool (2). Port MB on the outlet side is nar-
spool (2) to stop the motor smoothly. rowed.
The motor continues revolution by inertia and As a result, the pressure on the outlet side rises
can cause cavitation. Since valve (1a) is oper- and revolving resistance is generated in the
ated by very slight negative pressure, however, it motor to prevent the machine from running away.
opens ports PA and MA to prevent cavitation. To put it concretely, spool (2) moves to a position
at which the machine weight and the pressure on
the inlet side are balanced with the pressure at
port MB on the outlet side to narrow the outlet
circuit. Consequently, the speed is controlled
according to the pump discharge.
10-28 PC78MR-6
Operation of parking brake
When travel lever is operated When travel lever is set to neutral position
If the travel lever is operated, the hydraulic oil If the travel lever is set to the neutral position, the
from the pump moves spool (1) to the left and hydraulic oil from the pump is shut off.
flows through port E into chamber A of brake pis- The hydraulic oil in chamber (a) of brake piston
ton (2), then pushes brake piston (2) to the left. (2) is drained into the case and piston (2) is
As a result, the pressing force of spring (5) given pushed to the right by spring (5).
to plate (3) and disc (4) is lost, then plate (3) and As a result, plate (3) and disc (4) are pressed
disc (4) are separated and the brake force is and the braking force is applied.
released.
PC78MR-6 10-29
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

Boom cylinder
Arm cylinder
Bucket cylinder
10-30 PC78MR-6
Boom swing cylinder
Blade cylinder
PC78MR-6 10-31
Unit: mm
Cylinder Basic Allowance Standard Allowable
name dimension Shaft Hole clearance clearance
-0.030 +0.250 0.085
Boom 65 0.654
-0.104 +0.055 0.354
-0.030 +0.163 0.036
Arm 60 0.567
Clearance between -0.104 +0.006 0.267 Replace
1
piston rod and bushing -0.030 +0.163 0.036 bushing
Bucket 55 0.567
-0.104 +0.006 0.267
Boom -0.030 +0.163 0.036
60 0.567
swing -0.104 +0.006 0.267
-0.030 +0.250 0.085
Blade 65 0.654
-0.104 +0.055 0.354
-0.030 +0.174 0.130
Boom 60 1.0
-0.100 +0.100 0.274
-0.030 +0.174 0.130
Arm 60 1.0
-0.100 +0.100 0.274
Clearance between
-0.030 +0.174 0.130
2 piston rod support Bucket 60 1.0
-0.100 +0.100 0.274
shaft and bushing
Boom -0.030 +0.174 0.130
65 1.0
swing -0.100 +0.100 0.274
-0.030 +0.174 0.130
Blade 70 1.0 Replace pin
-0.104 +0.100 0.278
and
-0.030 +0.174 0.130 bushing
Boom 65 1.0
-0.100 +0.100 0.274
-0.030 +0.174 0.130
Arm 55 1.0
-0.100 +0.100 0.274
Clearance between
-0.030 +0.142 0.110
3 cylinder bottom support Bucket 50 1.0
-0.100 +0.080 0.242
shaft and bushing
Boom -0.030 +0.174 0.130
65 1.0
swing -0.076 +0.100 0.250
-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 1) Tighten to 1.18 1.37 kNm {120 140 kgm}.
2) Loosen to 0 Nm {0 kgm}.
Tightening torque Bucket 3) Tighten to 0.39 kNm {40 kgm}.
4
of cylinder head 4) Control tightening of cylinder head by
turning angle (Turning distance: 3.5 4.5 mm).
Boom
981 98.1 Nm {100 10.0 kgm}
swing Retighten
Blade 1.030 103.0 Nm {105 10.5 kgm}
Boom 3.33 0.33 kNm {340 34.0 kgm} (2 Width across flats: 70 mm)
Arm 2.65 0.26 kNm {270 27.0 kgm} (2 Width across flats: 65 mm)
Tightening torque of Bucket 2.16 0.22 kNm {220 22.0 kgm} (2 Width across flats: 60 mm)
5
cylinder piston Boom
2.6 0.26 kNm {265 26.0 kgm} (2 Width across flats: 70 mm)
swing
Blade 3.14 0.31 kNm {320 32.0 kgm} (2 Width across flats: 75 mm)
10-32 PC78MR-6
MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
Serial No.: 1001 1094
10-34 PC78MR-6
(1)
A: From control pump

A4: Plug
A5: From left work equipment PPC valve "ARM IN"
A6: From right work equipment PPC valve "BOOM RAISE"
B1: To PPC valve
B2: To 2-stage travel speed selection valve
B3: To swing holding brake
B4: Plug
B5: To control valve "ARM IN"
B6: To control valve "BOOM RAISE"
T: To hydraulic tank
1. Left boom swing stop EPC valve

2. Right boom swing stop EPC valve
3. Not used
4. Swing holding brake solenoid valve
5. 2-stage travel speed selector solenoid valve
6. PPC lock solenoid valve
Solenoid valve
7. Coil (ON-OFF type)
8. Push pin
9. Valve spool
10. Return spring
11. Valve body
EPC valve
12. Return spring
13. Guide
14. Valve spool
15. Push pin
16. Coil (Proportional)
Check valve
17. Plug
18. Spring
19. Ball
Control relief valve

20. Adjustment screw
21. Locknut
22. Guide
23. Return spring
24. Valve spool
PC78MR-6 10-35
Serial No.: 1095 and up
10-35-1 PC78MR-6
(1)
A: From control pump

A5: From left work equipment PPC valve "ARM IN"
A6: From right work equipment PPC valve "BOOM RAISE"
B1: To PPC valve
B2: To 2-stage travel speed selection valve
B3: To swing holding brake
B4: Plug
B5: To control valve "ARM IN"
B6: To control valve "BOOM RAISE"
T: To hydraulic tank

Solenoid valve
6. Coil (ON-OFF type)
7. Push pin
8. Valve spool
9. Return spring
10. Valve body
EPC valve
11. Return spring
12. Guide
13. Valve spool
14. Push pin
15. Coil (Proportional)
Check valve
16. Plug
17. Spring
18. Ball

19. Adjustment screw
20. Locknut
21. Guide
22. Return spring
23. Valve spool
PC78MR-6 10-35-2
(1)
PPC LOCK SOLENOID VALVE

2-STAGE TRAVEL SPEED SELECTOR SOLENOID VALVE
SWING HOLDING BRAKE SOLENOID VALVE
Operation
When solenoid is de-energized (circuit is broken) When solenoid is energized (circuit is made)
While a signal current does not flow from the If a signal current flows from the PPC hydraulic
PPC hydraulic lock switch or travel speed boost lock switch or travel speed boost pedal to sole-
pedal, solenoid (1) is de-energized. noid (1), solenoid (1) is energized.
Accordingly, spool (2) is pressed up by spring Accordingly, spool (2) is pushed down by push
(3). pin (4).
Under this condition, port A is closed and the Under this condition, the pilot hydraulic oil flows
pilot hydraulic oil does not flow into the actuator. through port A, spool (2), and port B into the
At the same time, the oil from the actuator is actuator.
drained through ports B and T into the tank. At the same time, port T is closed and the oil
does not flow into the tank.
10-36 PC78MR-6
LEFT BOOM SWING STOP EPC VALVE

RIGHT BOOM SWING STOP EPC VALVE
Operation
When signal current is maximum (When coil is When signal current is reduced (When coil is
energized and circuit pressure is maximum) energized and circuit pressure is low)
If the signal current flows from the controller into If the signal current flowing from the controller
coil (1), coil (1) is energized. into coil (1) is reduced, coil (1) is still energized
At this time, the thrust of coil (1) is maximum. but its thrust is lowered in proportion to the signal
As a result, spool (2) is pushed down by push pin current.
(3). As a result, push pin (3) pushes down spool (2)
Accordingly, all the pressurized oil from the PPC and the pressurized oil from port A flows to port
valve flows through port A, spool (2), and port B B.
to the control valve. If the pressure in port B rises and the force
At this time, port T is closed and any oil does not applied to face "a" of spool (2) becomes larger
flow in the tank. than the thrust of coil (1), spool (2) is pushed up
and port A is disconnected from port B and con-
nected to port T.
Accordingly, spool (2) moves up and down so
that the thrust of coil (1) will be balanced with the
pressure in port B.
As a result, the circuit pressure between the
PPC valve and control valve is controlled in pro-
portion to the signal current.
PC78MR-6 10-37
When signal current is 0 (When coil is de-ener-

gized and circuit cut out)
If the signal current flowing from the controller
into coil (1) becomes 0, coil (1) is deenergized.
As a result, spool (2) is pressed up by return
spring (4).
Accordingly, port A is closed and the pressurized
oil from the PPC valve does not flow into the
control valve.
At this time, the oil from the control valve is
drained through ports B and T into the tank.
Signal current is 0 o increased o maximum

The valve operates in the order of 3, 2, and 1
explained above.
10-38 PC78MR-6
If the pressure of the hydraulic oil from the con-

trol pump rises, the oil in port A pushes spool (1).
The reaction force of spool (1) compresses
spring (2) and moves spool (1) to the right to
open ports A and T to relieve the circuit.
Set pressure: 3.1 MPa {32 kg/cm}
PC78MR-6 10-39
MAINTENANCE STANDARD MULTI-CONTROL VALVE
MULTI-CONTROL VALVE
(OPTIONAL)
(1) JIS Pattern (2) Backhoe Pattern

* Operation pattern selection drawing (Port names correspond to symbols in drawing)
10-40 PC78MR-6
MAINTENANCE STANDARD ACCUMULATOR FOR BRAKE
ACCUMULATOR FOR BRAKE

(If equipped)
1. Cap Specification
2. Core Type of gas Nitrogen Gas
3. Guard rubber
Gas volume ( ) 0.48
4. Lid
5. Plug Sealed gas pressure
6. Shell (MPa {kg/cm}) 0.1 {1} (at 80 C)
Max. actuating pressure
(MPa {kg/cm}) 6.86 {70}
PC78MR-6 10-41
(1)
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
Model: LPD45 + 45
P1 : Pump discharge PD2 : Pump drain (plug)

P2 : Pump discharge PDA : Air bleeder
P4 : Pilot pump discharge PEN : Control pressure pickup port
PD : Drain PLS : LS pressure input (From control valve)
PM : PC mode changeover pressure pickup port PPT : PTO oil filler
P1T : Travel deviation adjustment orifice PS1 : Main pump suction
P2T : Travel deviation adjustment orifice PEPC : EPC main pressure pickup port
PPLS : Pump pressure input (From control valve)
10-42 PC78MR-6
T : Drain PAV : Pump average pressure

P1 : Pump discharge PD2 : Drain (Plug)
P2 : Pump discharge PDE : EPC drain
P3 : Gear pump pressure input PEN : Control pressure input
P5 : Gear pump pressure pickup port PPT : PTO oil filler
PD : Drain PS1 : Pump suction
PH : Pump shuttle PEPC : EPC main pressure pickup port
PC78MR-6 10-43
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
10-44 PC78MR-6
With blade
Model: LPD45 + 45
P1 : Pump discharge PD2 : Pump drain (plug)

P2 : Pump discharge PDA : Air bleeder
P3 : Gear pump discharge PEN : Control pressure pickup port
P4 : Pilot pump discharge PGS : Gear pump suction
P5 : Gear pump pressure pickup port PLS : LS pressure input (From control valve)
PD : Drain PPT : PTO oil filler
PM : PC mode changeover pressure pickup port PS1 : Main pump suction
P1T : Travel deviation adjustment orifice PEPC :EPC main pressure pickup port
P2T : Travel deviation adjustment orifice PPLS :Pump pressure input (From control valve)
PC78MR-6 10-45
T : Drain PD3 :Drain

P1 :Pump discharge PDE :EPC drain
P2 : Pump discharge PEN :Control pressure input
PD :Drain PPT :PTO oil filler
PH :Pump shuttle PS1 :Pump suction
PAV :Pump average pressure PEPC :EPC main pressure pickup port
PD2 :Drain (Plug)
10-46 PC78MR-6
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
PC78MR-6 10-47
PDE: EPC drain

1. EPC valve
PC valve LS valve
T: Drain 4. Retainer PE: Control piston pressure 14. Seat
P3: Gear pump pressure input 5. Seat PH: Pump shuttle pressure 15. Spring
PH: Pump shuttle pressure 6. Spool PLS: LS pressure input 16. Seat
PAV: Pump average pressure 7. Sleeve PPL: PC valve output pressure 17. O-ring
PPL: PC valve output pressure 8. Piston PPLS: LS pump pressure input 18. Backup ring
PEPCOUT: EPC output pressure 9. Seal 19. Nut
10. Piston 12. Spool 20. Plug
2. Lever 11. Plug 13. Plug
3. Spring
10-48 PC78MR-6
Function
This pump converts the revolution and torque of The oil in each cylinder of cylinder block (7) can
the engine transmitted to its shaft into hydraulic be drawn and discharged through valve plate (8).
energy and discharges hydraulic oil according to
the load.
The discharge can be changed by changing the
swash plate angle.
Structure
Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported on the
front and rear bearings.
The end of piston (6) is a concave sphere, which
holds shoe (5) as a spherical bearing.
Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) is supported on flange (2) and
ball (12) fixed to the case and slides on the
formed static pressure bearing and high-pres-
sure oil.
Piston (6) moves axially and relatively in each
cylinder of cylinder block (7).
Cylinder block (7) revolves relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic pressure on the revolving surface of
the cylinder block is balanced properly.
PC78MR-6 10-49
Operation
1. Operation of pump
Shaft (1) and cylinder block (7) revolve together If center line X of rocker cam (4) is in the direc-
and shoe (5) slides on plane A. As rocker cam tion of the axis of cylinder block (7) (Swash plate
(4) slants around ball (12) at this time, angle ( ) angle = 0), the difference between volumes E
between the center line X of rocker cam (4) and and F in cylinder block (7) is 0 and oil is not
axis of cylinder block (7) changes. Angle ( ) is sucked or discharged (The swash plate angle is
called the swash plate angle. not reduced to 0 actually, however).
In short, swash plate angle ( ) is in proportion to
the discharge of the pump.
The number of holes on cylinder block (7) is
even 10 and every second one of them is fitted
to 2 grooves of valve plate (8). The quantity of
the oil equivalent to 5 pistons is discharged to
each of P1 and P2.
If the angle between the center line X of rocker

cam (4) and the axis of cylinder block (7) is a,
plane A works as a cam for shoe (5).
Accordingly, piston (6) slides inside cylinder
block (7) and makes difference between volumes
E and F in cylinder block (7) and the oil is drawn
and discharged by the difference.
In short, if cylinder block (7) revolves and volume
of chamber E is reduced, the oil is discharged.
On the other hand, the volume of chamber F is
increased and the oil is sucked. (The figure
shows the end of suction process of chamber F
and the end of discharge process of chamber E.)
10-50 PC78MR-6
2. Control of discharge LS valve

If swash plate angle ( ) is increased, the differ- Function
ence between volumes E and F, or discharge Q, The LS valve controls the discharge of the pump
is increased. Swash plate angle ( ) is changed according to the stroke of the control lever, or the
with servo piston (11). demand flow for the actuator.
Servo piston (11) is reciprocated linearly by the The LS valve calculates the demand flow for the
signal pressure of PC and LS valves. This linear actuator from differential pressure EPLS
motion is transmitted to rocker cam (4) sup- between inlet pressure PPLS and outlet pres-
ported on flange (2) through ball (12). Then, sure PLS of the control valve, and controls dis-
rocker cam (4) slides in the revolutionary direc- charge Q of the main pump.
tion. (PPLS is called the LS pump pressure, EPLS
the LS pressure, and EPLS the LS differential
pressure.)
That is, the discharge of the pump is controlled
according to the demand flow for the actuator by
the following method; The pressure loss made
when the oil flows through the opening of the
control valve spool (LS differential pressure
EPLS) is sensed and discharge Q of the pump
is so controlled that the pressure loss will be con-
stant.
The LS valve receives main pump discharge
pressure PP, LS pump pressure (PPLS), and LS
pressure PLS. The relationship between the LS
differential pressure (EPLS) and pump dis-
charge Q changes as shown below.
PC78MR-6 10-51
PC valve At this time, ports F and G of the LS valve are

connected to each other. As a result, the pres-
Function sure in port J becomes drain pressure PT and
The PC valve limits the oil flow to a certain level servo piston (6) moves to the left.
(according to the discharge pressure) even if the Consequently, the pump discharge is increased.
stroke of the control valve is increased so that As servo piston (6) moves, lever (1) moves to the
the horsepower absorbed by the pump will not left and spring (2) expands and its spring load is
exceed the engine horsepower, as long as pump decreased. Consequently, spool (3) moves to
discharge pressure PP is high. That is, the PC the left to break the connection of ports C and D,
valve performs constant-horsepower control. and then pump discharge ports B and C are con-
In other words, the PC valve decreases the nected.
pump discharge when the load is increased and As a result, the pressure in port C rises and the
the pump discharge pressure rises and piston pressure is increased and servo piston (6)
increases it when the pump discharge pressure stops moving to the left.
lowers.
This pump has 2 discharge openings and the (3) When pump pressure PAVE is high
average of discharge pressures P1 and P2 at The pressure of spool (4) is increased and spool
those openings is sensed. (3) is a little to the left (Fig. 2 and Fig. 5). At this
The average of P1 and P2 is called the PAVE. time, ports C and B are connected to each other
The relationship between this average and pump and the pressure in the LS valve is pump pres-
discharge (discharge from the 2 discharge open- sure PP.
ings) is shown below. At this time, ports F and G of the LS valve are
connected to each other. As a result, the pres-
sure in port J becomes pump pressure PP and
servo piston (6) moves to the right.
Consequently, the pump discharge is decreased.
As servo piston (6) moves, lever (1) moves to the
right and spring (2) is compressed and its spring
load is increased. Consequently, spool (3)
moves to the right to break the connection of
ports C and B, and then drain pressure ports D
and C are connected.
As a result, the pressure in port C lowers and the
piston pressure is decreased and servo piston
(6) stops moving to the right.
Accordingly, the stopping position (= pump dis-
charge) of servo piston (6) is decided by the
position where the pressure caused by pressure
Operation
PP applied to spool (4) is balanced with the force
1. With blade
of spring (2) applied through spool (3) (Fig. 3 and
Fig. 6).
(1) Function of spring
The spring load of spring (2) at the PC valve is
(4) When swing gear pump pressure rises/low-
decided by the position of the swash plate.
ers
If servo piston (6) moves to the right, spring (2) is
The pressure of spool (4) changes and the pump
compressed through lever (1) and its spring load
discharge changes similarly to the case where
changes. The spring constant of this spring
the PAVE rises/lowers.
changes to 2 levels.
The PC-EPC valve changes the output pressure
according to the input current from the controller,
(2) When pump pressure PAVE is low
then the pressure of spool (5) changes and the
The pressure of spool (4) is decreased and spool
pump discharge changes similarly to the case
(3) is a little to the right (Fig. 1 and Fig. 4). At this
where the PAVE rises/lowers.
time, ports C and D are connected to each other
and the pressure in the LS valve is drain pres-
sure PT.
10-52 PC78MR-6
When load is light
When load is heavy
PC78MR-6 10-53
When balanced
2. Without blade
Although the swing gear pump is not mounted, the theory of operation of this model is the same as that of
the machine equipped with the swing gear pump.
When load is light
10-54 PC78MR-6
When load is heavy
When balanced
PC78MR-6 10-55
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline
(1) Outside view
A1: To blade cylinder head

A2: To swing motor
A3: To left travel motor
A4: To right travel motor
A5: To boom swing cylinder head
A6: To boom cylinder bottom
A7: To arm cylinder head
A8: To bucket cylinder head
A9: To attachment
B1: To blade cylinder bottom
B2: To swing motor
B3: To left travel motor
B4: To right travel motor
B5: To boom swing cylinder bottom
B6: To boom cylinder head
B7: To arm cylinder bottom
B8: To bucket cylinder bottom
B9: To attachment
BP: From boom RAISE PPC valve
LS: To pump LS valve (LS pressure input)
P1: From main pump
P2: From main pump
P3: From gear pump
PP: To pump LS valve (Pump pressure input)
PT: To travel pressure switch
TB: To tank
TC: To oil cooler
TS: To tank
PA1: From blade raise PPC valve
PA2: From swing right PPC valve
PA3: From left travel reverse PPC valve
PA4: From right travel reverse PPC valve
PA5: From boom swing right PPC valve
PA6: From boom raise PPC valve
PA7: From arm out PPC valve
PA8: From bucket dump PPC valve
PA9: From attachment PPC valve
PB1: From blade lower PPC valve
PB2: From swing left PPC valve
PB3: From left travel forward PPC valve
PB4: From right travel forward PPC valve
PB5: From boom swing left PPC valve
PB6: From boom lower PPC valve
PB7: From arm in PPC valve
PB8: From bucket curl PPC valve
PB9: From attachment PPC valve
TSW: To swing motor
10-56 PC78MR-6
PC78MR-6 10-57
(2) Sectional view
1. Safety-suction valve (Blade head) 18. Gear pump relief valve

2. Suction valve (Left travel) 19. Safety valve
3. Suction valve (Right travel) 20. Cooler bypass valve
4. Suction valve (Boom swing head) 21. Spool (Boom raise merge)
5. Suction valve (Boom bottom) 22. Spool (Blade)
6. Suction valve (Arm head) 23. Spool (Swing)
7. Suction valve (Bucket head) 24. Spool (Left travel)
8. Suction valve (Attachment) 25. Spool (Right travel)
9. Suction valve (Attachment) 26. Spool (Boom swing)
10. Suction valve (Bucket bottom) 27. Spool (Boom)
11. Suction valve (Arm bottom) 28. Spool (Arm)
12. Suction valve (Boom head) 29. Spool (Bucket)
13. Suction valve (Boom swing bottom) 30. Spool (Attachment)
14. Suction valve (Right travel) 31 Unload valve (P1)
15. Suction valve (Left travel) 32. Unload valve (P2)
16. Suction valve (Blade bottom) 33. LS pressure pickup plug (LS1)
17. Main relief valve 34. LS pressure pickup plug (LS2)
10-58 PC78MR-6
Unit: mm
Basic dimensions Allowable limit
Free length x
Cooler bypass valve Outside diam- Free length
35 length load load
spring eter
73.5 N 58.8 N
34.5 X 17.7 25
{7.5 kg} {6.0 kg}
Spool return spring 34.3 N 27.4 N
36 41.1 X 19.3 40.5
(Work equipment) {3.5 kg} {2.8 kg}
37 42.3 X 19.2 38.9
(Arm out) {10.6 kg} {8.48 kg}
38 29.0 X 17.5 25.0
(Trave) {18.02 kg} {14.74 kg}
129 N 103 N If damaged or
39 Unload valve spring 40.9 X 15.1 33.5
{13.2 kg} {10.6 kg} deformed,
Boom RAISE merge 287.3 N 230 N replace spring.
40 42.4 X 19.0 13
valve spring {29.3 kg} {23.44 kg}
41 29.01 X 18.3 27.5
(Blade) {9.1 kg} {7.28 kg}
Spool return spring 136.4 N 109 N
42 41.13 X 19.3 38.5
(Boom raise) {13.91 kg} {11.13 kg}
Spool return spring
135.53 N 108 N
43 (Bucket curl, 41.47 X 19.3 38.5
{13.82 kg} {11.06 kg}
Boom lower)
44 29.20 X 17.5 25.0
(Boom swing) {16.57 kg} {13.26 kg}
45 29.03 X 18.4 26.0
(Swing) {17.66 kg} {14.13 kg}
PC78MR-6 10-59
1. Spool (Pump merge-divider valve) 16. Pump pressure pickup plug (P2)
2. Pressure compensation valve F (Left travel) 17. LS pressure pickup plug (LS3)
3. Pressure compensation valve F (Right travel) 18. LS bypass plug (LS2)
4. Pressure compensation valve F (Boom swing) 19. LS bleed valve
5. Pressure compensation valve F (Boom) 20. Travel junction valve, LS bleed valve
6. Pressure compensation valve F (Arm) 21. Logic valve
7. Pressure compensation valve F (Bucket) 22. Boom hydraulic drift prevention valve
8. Pressure compensation valve F (Attachment) 23. Check valve (Blade)
9. Pressure compensation valve R (Attachment) 24. Check valve (Swing)
10. Pressure compensation valve R (Bucket) 25. Check valve (Boom bottom)
11. Pressure compensation valve R (Arm) 26. Check valve (Arm)
12. Pressure compensation valve R (Boom) 27. Check valve (Bucket)
13. Pressure compensation valve R (Boom swing) 28. Check valve (Attachment)
14. Pressure compensation valve R (Right travel)
15. Pressure compensation valve R (Left travel) F: Flow control valve
R: Pressure reducing valve
10-60 PC78MR-6
Unit: mm
Free length x
Pressure compensation Outside diam- Free length
29 length load load
valve spring eter
13.7 N 11.0 N
28.0 X 14.4 14.5
{1.4 kg} {1.12 kg}
Pressure compensation 55.9 N 44.7 N
30 33.4 X 14.4 21.5
31 30.9 X 5.2 27
32 20.0 X 8.4 12
valve spring {0.7 kg} {0.56 kg} If damaged or
Pump merge-divider deformed,
49.0 N 39.2 N replace spring.
33 valve spool 33.2 X 14.2 22.5
{5.0 kg} {4.0 kg}
return spring
3.92 N 3.14 N
34 Check valve spring 27.2 X 6.9 22
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
35 Check valve spring 12.3 X 11.4 10.5
{0.4 kg} {0.32 kg}
1.96 N 1.57 N
{0.2 kg} {0.16 kg}
1.96 N 1.57 N
{0.2 kg} {0.16 kg}
38 28.0 X 14.4 14.5
PC78MR-6 10-61
10-62 PC78MR-6
Unit: mm
Free length x
Outside diam- Free length
1 Check valve spring length load load If damaged or
eter
deformed,
21.9 X 5.0 15.8
{0.2 kg} {0.16 kg}
Travel junction valve 15.7 N 12.6 N
2 19.3 X 7.5 14
spring {1.6 kg} {1.28 kg}
PC78MR-6 10-63
10-64 PC78MR-6
1. Pump pressure pickup plug (P1)

2. LS bypass plug (LS1)
3. Check valve (P1)
4. Check valve (P2)
Unit: mm
Free length x
5 Check valve spring length load load
eter
If damaged or
1.96 N 1.57 N
13.0 X 6.5 9.5 deformed,
{0.2 kg} {0.16 kg}
replace spring.
Hydraulic drift preven- 11.2 N 8.96 N
6 16.6 X 13.0 13
tion valve spring {1.14 kg} {0.91 kg}
Hydraulic drift preven- 10.8 N 8.64 N
7 13.0 X 8.8 7.5
tion valve spring {1.1 kg} {0.88 kg}
PC78MR-6 10-65
10-66 PC78MR-6
1. Pump pressure pickup plug (P2)

2. Check valve (Boom head)
3. Pressure release plug
Unit: mm
Free length x
Installed Installed Installed If damaged or
4 Logic valve spring length load load deformed,
eter
replace spring.
5.5 N 4.4 N
11.0 X 6.2 9.5
{0.56 kg} {0.45 kg}
PC78MR-6 10-67
MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- The CLSS consists of a variable capacity single
tem, and has the following featues. piston pump, control valve, and actuators.
Fine control not influenced by load The pump body consists of the main pump, PC
Control enabling digging even with fine control valve and LS valve.
Ease of compound operation ensured by flow
divider function using area of opening of spoll
during compund operations
Energy saving using variable pump control
10-68 PC78MR-6
BASIC PRINCIPLE
1. Control of pump swash plate angle
The pump swash plate angle (pump discharge
amount) is controlled so that LS differential pres-
sure EPLS (the difference between pump (dis-
charge) pressure PP and control valve outlet port
LS pressure PLS) load pressure of actuator) is
constant.
(LS pressure EPLS=Pump discharge pressure
PP-LS pressure PLS)
If LS differential pressure EPLS becomes lower

than the set pressure of the LS valve (when the
actuator load pressure is high), the pump swash
plate moves towards the maximum position; if
the set pressure becomes higher than the set
pressure of the LS valve (when the actuator load
pressure is low), the pump swash plate moves
towards the minimum position.
a For details of the operation, see HYDRAULIC
PUMP.
PC78MR-6 10-69
2. Pressure compensation control

A pressure compensation valve is installed to the stream (outlet port) the same, regardless of the
inlet port side of the control valve spool to bal- size of the load (pressure). In this way, the flow
ance the load. of oil from the pump is divided (compensated) in
When to actuators are operated together, this proportion to the area of openings S1 and S2 of
valve acts to make pressure difference EP each valve when it is operated.
between the upstream (inlet port) and down-
10-70 PC78MR-6
OPERATION FOR EACH FUNCTION AND VALVE

Hydraulic circuit diagram and name of valves
10-72 PC78MR-6
1. Unload valve (P1)

Set pressure: LS pressure + 2.45 MPa
{25 kg/cm2}
2. Unload valve (P2)
Set pressure: LS pressure + 2.45 MPa
{25 kg/cm2}
3. Main relief valve
Set pressure: 26.5 MPa {270 kg/cm2}
4. Gear pump relief valve
5. Cooler bypass valve
6. Suction valve
7. Safety-suction valve
8. Safety valve
9. Pressure compensation valve
10. LS bypass plug (P1)
11. LS bypass plug (P2)
12. Boom raise merge valve
13. LS bleed valve
14. Travel junction valve, LS bleed valve
15. Logic valve
16. Boom hydraulic drift prevention valve
PC78MR-6 10-73
Unload valve
1. When control valve is at HOLD
Function When the control valve is at HOLD, LS pres-

When the control valve is at HOLD, pump dis- sures PLS1 and PLS2 are not generated, so only
charge amount Q discharged by the minimum pump discharge pressures PP1 and PP2 act,
swash plate angle is released to the tank circuit. and PP1 and PP2 are set by only the load of
At this time, pump discharge pressure PP1/PP2 spring (2).
is set at 2.45 MPa {25.0 kg/cm2} by spring (2) in As pump discharge pressure PP1/PP2 rises and
the valve. (LS pressure PLS1/PLS2: 0 MPa {0 reaches the load of spring (2) (2.45 MPa {25.0
kg/cm2}) kg/cm2}), spool (1) is moved to the right. Pump
Since the pump merge-divider valve is at the discharge pressures PP1 and PP2 are con-
merge position, pump discharge pressures PP1 nected to tank circuit T through the cut of spool
and PP2 are merged. LS pressures PLS1, (1)
PLS2, and PLS3 are also merged. As a result, pump discharge pressure PP1/PP2
is set to 2.45 MPa {25.0 kg/cm2}.
Operation
Pump discharge pressures PP1 and PP2 are
acting on the left end of unload spool (1) and LS
pressures PLS1 and PLS2 are acting on the right
end. (PP1 = PP2, PLS1 = PLS2)
10-74 PC78MR-6
2. During fine control of work equipment valve

Work equipment valve: Boom, arm, bucket,
boom swing, or attachment.
Function Operation
During fine control of the work equipment valve, When fine control is carried out on the work
when the demand flow for the actuator is within equipment valve, LS pressures PLS1 and PLS2
the amount discharged by the minimum swash are generated and act on the right end of spool
plate angle of the pump, pump discharge pres- (1) (PP1 = PP2, PLS1 = PLS2). When this hap-
sure PP1/PP2 is set to LS pressure PLS1/PLS2 pens, the area of the opening of the work equip-
+ 2.45 MPa {25.0 kg/cm2}. When the difference ment valve spool is small, so LS pressures PLS1
between pump discharge pressure PP1/PP2 and and PLS2 are very different from pump dis-
LS pressure PLS1/PLS2 reaches the load of charge pressures PP1 and PP2.
spring (2) (2.45 MPa {25.0 kg/cm 2 }), unload When the difference between pump discharge
spool (1) opens, so LS differential pressure pressure PP1/PP2 and LS pressure PLS1/PLS2
EPLS becomes 2.45 MPa {25 kg/cm2}. reaches the load of spring (2) (2.45 MPa {25.0
Since the pump merge-divider valve is at the kg/cm2}), spool (1) moves to the right, and pump
merge position, pump discharge pressures PP1 discharge pressures PP1 and PP2 are con-
and PP2 are merged. LS pressures PLS1, PLS2, nected to tank circuit T.
and PLS3 are also merged. In other words, pump discharge pressure PP1/
PP2 is set to the spring force (2.45 MPa {25.0
kg/cm2}) + LS pressure PLS1/PLS2, and LS dif-
ferential pressure DPLS becomes 2.45 MPa
{25.0 kg/cm2}.
PC78MR-6 10-75
3. When work equipment valve is operated

boom swing, or attachment
Function Operation
When any work equipment valve is operated if When any work equipment valve is operated for
the demand flow for the actuator becomes a long stroke, LS pressures PLS1 and PLS2 are
greater than the pump discharge from the mini- generated and act on the right end of unload
mum swash plate angle, the oil flow to tank cir- spool (1) (PP1 = PP2, PLS1 = PLS2). When this
cuit T is cut off, and all pump discharge amount happens, the area of the opening of the work
Q flows to the actuator circuit. equipment valve spool is large, so LS pressures
Since the pump merge-divider valve is at the PLS1 and PLS2 are not so different from pump
merge position, pump discharge pressures PP1 discharge pressures PP1 and PP2.
and PP2 are merged. LS pressures PLS1,
PLS2, and PLS3 are also merged. For this reason, the difference between pump
discharge pressure PP1/PP2 and LS pressure
PLS1/PLS2 does not reach the load of spring (2)
(2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
to the left by spring (2).
As a result, pump discharge pressures PP1 and
PP2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
10-76 PC78MR-6
4. During fine control of both travel valves
Function Operation
During fine control of both travel valves, when When fine control is carried out on both travel
the demand flow is below the maximum pump valves, LS pressures PLS1 and PLS2 are gener-
discharge amount, pump discharge pressure ated and act on the right end of spool (1) (PP1,
PP1/PP2 is set to LS pressure PLS1/PLS2 + PP2, PLS1, and PLS2 are separated).
2.45 MPa {25.0 kg/cm2}. When this happens, the area of the opening of
When the difference between pump discharge both travel valve spools is small, so LS pres-
pressure PP1/PP2 and LS pressure PLS1/PLS2 sures PLS1 and PLS2 are very different from
reaches the load of spring (2) (2.45 MPa {25.0 pump discharge pressures PP1 and PP2.
kg/cm2}), unload spool (1) opens, so excessive When the difference between pump discharge
oil (maximum pump discharge mount - demand pressure PP1/PP2 and LS pressure PLS1/PLS2
flow) flows into the tank circuit. reaches the load of spring (2) (2.45 MPa {25.0
Since the pump merge-divider valve is at the kg/cm2}), spool (1) moves to the right, and pump
separate position, pump discharge pressures discharge pressures PP1 and PP2 are con-
PP1 and PP2 are separated. LS pressures PLS1 nected to tank circuit T and the excessive oil
and PLS2 are also separated. (maximum pump discharge mount demand
The swash plate angle of the pump becomes flow) flows.
maximum, so the pump discharge amount In other words, the excessive oil (maximum
becomes maximum. (For details, see the sec- pump discharge mount demand flow) above
tions on the pump merge-divider valve and logic the strokes of both travel valves flows into tank
valve.) circuit T.
PC78MR-6 10-77
5. When both travel valves are operated
Function Operation
During operation of both travel valves, when the When both travel valves are operated to the
demand flow becomes maximum, the oil flow to stroke ends, LS pressures PLS1 and PLS2 are
tank circuit T is cut off, and all pump discharge generated and act on the right end of unload
amount Q flows to both travel circuits. spool (1) (PP1, PP2, PLS1, and PLS2 are sepa-
Since the pump merge-divider valve is at the rated).
separate position, pump discharge pressures When this happens, the area of the openings of
PP1 and PP2 are separated. LS pressures PLS1 both travel valve spools is large, so LS pressures
and PLS2 are also separated. PLS1 and PLS2 are not so different from pump
The swash plate angle of the pump becomes discharge pressures PP1 and PP2.
maximum, so the pump discharge amount For this reason, the difference between pump
becomes maximum. (For details, see the sec- discharge pressure PP1/PP2 and LS pressure
tions on the pump merge-divider valve and logic PLS1/PLS2 does not reach the load of spring (2)
valve.) (2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
to the left by spring (2).
PP2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
10-78 PC78MR-6
6. When either travel valve is operated
Function When this happens, the area of the openings of

The demand flow decided by the valve stroke is both travel valve spools is large, so LS pressures
sent to the travel circuit on the operated travel PLS1 is not so different from pump discharge
valve side and the all pump discharge amount is pressures PP1.
sent to the tank circuit on the non-operated travel For this reason, the difference between pump
valve side. discharge pressure PP1 and LS pressure PLS1
Since the pump merge-divider valve is at the does not reach the load of spring (2) (2.45 MPa
separate position, pump discharge pressures {25.0 kg/cm2}), so spool (1) is pushed to the left
PP1 and PP2 are separated. LS pressures by spring (2).
PLS1 and PLS2 are also separated. As a result, pump discharge pressures PP1 and
The swash plate angle of the pump becomes tank circuit T are shut off, and all pump dis-
maximum, so the pump discharge amount charge amount QP1 on the P1 side flows to the
becomes maximum. (For details, see the sec- left travel circuit.
tions on the pump merge-divider valve and logic Since the right travel valve is at HOLD, LS pres-
valve.) sure PLS2 is not generated, so only pump dis-
charge pressure PP2 acts.
Operation When pump discharge pressure PP2 reaches
When left travel valve is operated to stroke end and the load of spring (4) (2.45 MPa {25.0 kg cm2}),
right one is at HOLD. spool (3) moves to the right, and all pump dis-
When the left travel valve is operated to the charge amount QP2 on the P2 side flows into
stroke end, LS pressure PLS1 is generated and tank circuit T.
acts on the right end of unload spool (1).
PC78MR-6 10-79
Pump merge-divider valve and logic valve

1. When control valve is at HOLD
Function
Pump merge-divider valve spool (3) merges
pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 respectively.
Operation
When the control valve is at HOLD, changeover
pressure is not generated on logic spool (1), so
spring (2) pushes spool (1) to the left.
Since both travel valves are at HOLD,
changeover pressure is not generated on the
pump merge-divider spool.
When the control valve is at HOLD, changeover
pressure is not generated on the pump merge-
divider spool, so spring (4) pushes spool (3) to
the right.
Pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 are merged
respectively (PP1 = PP2, PLS1 = PLS2 = PLS3).
10-80 PC78MR-6
2. When work equipment valve is operated

(including compound operation of work
equipment + travel).
boom swing, or attachment.
Function When the work equipment valve is operated,

Pump merge-divider valve spool (3) merges changeover pressure for spool (3) is not gener-
pump discharge pressures PP1 and PP2 and LS ated, so spring (4) pushes spool (3) to the right.
pressures PLS1, PLS2, and PLS3 respectively. Pump discharge pressures PP1 and PP2 are
As the LS pressure, PLS1, PLS2, and PLS3 are merged. LS pressures PLS1, PLS2, and PLS3
output. are also merged (PP1 = PP2, PLS1 = PLS2 =
PLS3).
Operation
When any work equipment valve is operated, the
work equipment PPC pressure or the swing hold-
ing brake release pressure is introduced in the
left chamber of logic spool (1) to change over
spool (1).
When the load of spring (2) reaches 0.6 MPa {6
kg/cm2}, spool (1) moves to the right.
As a result, the right chamber of spool (3) is con-
nected to tank circuit T and changeover pressure
for spool (3) is not generated.
PC78MR-6 10-81
3. When either or both travel valves are oper-

ated
Function Furthermore, PP1 and PLS1 are separated for

Pump merge-divider valve spool (3) separates the left travel circuit and PP2 and PLS2 are sep-
pump discharge pressures PP1 and PP2 and LS arated for the right travel circuit.
pressures PLS1, PLS2, and PLS3 respectively. The higher pressure of pump discharge pres-
As the LS pressure, higher pressure of PP1 and sures PP1 and PP2 is output as the LS pressure
PP2 is output. and the swash plate angle of the pump becomes
maximum, so the pump discharge amount
Operation becomes maximum.
Since the all work equipment valves are at
HOLD, changeover pressure for logic spool (1) is
not generated, spring (2) pushes spool (1) to the
left.
When both travel valves are operated, travel
PPC pressure is introduced as changeover pres-
sure for spool (3) through spool (1) into the right
chamber of spool (3).
When the load of spring (4) reaches 0.49 MPa {5
kg/cm2}, spool (3) is pushed to the left.
PP2 and LS pressures PLS1 and PLS2 are sep-
arated respectively.
10-82 PC78MR-6
Introduction of LS pressure
1. Work equipment valve: Boom, arm, bucket,
boom swing, or attachment
Function When this happens, LS circuit PLS is connected

The LS pressure is the actuator load pressure at to tank circuit T from LS bypass plug (4) (See the
the outlet port end of the control valve. section on the LS bypass plug).
Actually, pump discharge pressure PP is The areas at both ends of reducing valve (3) are
reduced by reducing valve (3) of the pressure the same (SA = SLS), and actuator circuit pres-
compensation valve to the same pressure as sure PA acts on the SA end. The reduced pump
actuator circuit pressure A and sent to LS circuit discharge pressure PP acts on SLS at the other
PLS. end.
In the travel valve, actuator circuit pressure A is As a result, reducing valve (3) is balanced at a
directly introduced to LS circuit PLS. position where actuator circuit pressure PA and
the pressure of spring chamber PLSS are the
Operation same. Pump discharge pressure PP reduced at
When spool (1) is operated, pump discharge notch (c) becomes actuator pressure A and is
pressure PP flows from flow control valve (2) introduced into LS circuit PLS.
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit A.
At the same time, reducing valve (3) also moves
to the right, so pump discharge pressure PP is
reduced by the pressure loss at notch (c). It goes
to LS circuit PLS, and then goes to spring cham-
ber PLSS.
PC78MR-6 10-83
2. Travel valve
Operation
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.
At the same time, reducing valve (3) is moved to
the right by actuator circuit pressure PA, and
notch (c) and notch (d) are interconnected
respectively with travel junction circuit (e) and LS
circuit PLS.
As a result, actuator circuit pressure PA (= A) is
introduced from notch (c) through the internal
check valve and notch (d) into LS circuit PLS.
a The travel circuit is different from the work equip-

ment circuit: actuator circuit pressure PA is
directly introduced into LS circuit PLS.
10-84 PC78MR-6
LS bypass plug
When work equipment valve is operated
When both travel valves are operated
Function (a) of LS bypass plug (2) through orifice (b)

The LS bypass plug releases the residual pres- to tank circuit T.
sure of LS pressure PLS. 2. When either or both travel valves are operated
This lowers the rising speed of LS pressure PLS. Since pump merge-divider spool (1) is at the
In addition, the discarded throttled flow causes a separate position, LS circuits PLS1, PLS2,
pressure loss in the throttled flow in the reducing and PLS3 are separated.
valve, and that lowers the effective LS differential The hydraulic oil PLS1 flows from tip filter (a)
pressure to improve the stability. of LS bypass plug (3) on the P1 side through
orifice (b) to tank circuit T.
Operation The hydraulic oil PLS2 flows from tip filter (a)
1. When work equipment valve is operated (includ- of LS bypass plug (2) on the P2 side through
ing compound operation of work equipment + orifice (b) to tank circuit T.
travel)
Since pump merge-divider spool (1) is at the
merge position, the hydraulic oil in LS circuits
PLS1, PLS2, and PLS3 flows from tip filter
PC78MR-6 10-85
Boom raise merge valve

During normal operation
When machine swings and boom is raised simultaneously
Function 2. When machine swings and boom is raised simul-

When the machine swings and the boom is taneously
raised simultaneously, this valve merges dis- When the machine swings and boom is
charge amount of the gear pump into that of raised simultaneously, the signal pressure of
main pump to heighten the boom raising speed. the boom RAISE PPC circuit is applied to
pilot port BP.
Operation When pilot pressure BP acts on spool (1)
1. During normal operation and increases above the force of spring (2),
When the boom is not raised, the pilot pres- spool is pushed to the right. Then, check
sure is not applied to pilot port BP. valve (3) in spool (1) is pushed open and oil
Under this condition, gear pump circuit P3 in gear pump circuit P3 is merged into that in
and main pump circuit PP are shut off by main pump circuit PP to heighten the boom
spool (1), so oil in gear circuit P3 is not raising speed.
merged into that of main pump circuit PP.
10-86 PC78MR-6
Area ratio of pressure compensation valve
Function Area ratio (S1:S2) and compensation character-

The pressure compensation valve determines istics
the compensation characteristics by carrying out When ratio is 1.00: [Pump discharge pressure
fine adjustment of the area r atio ( S2/S1) PP - spool notch upstream
between (left) area S1 of flow control valve (2) pressure PPB] = [LS circuit
and (right) area S2 of reducing valve (1) to match pressure PLS - actuator cir-
the characteristics of each actuator. cuit pressure PA (= A)] and
oil flow is divided in propor-
S1: Area of flow control valve (2) area of piston (3) tion to area of opening of
S2: Area of reducing valve (1) area of piston (3) spool.
When ratio is more than 1.00:PP PPB > PLS
PA ( = A ) a nd oi l fl o w i s
divided in a proportion less
tha n ar ea of ope ning of
spool.
When ratio is less than 1.00:PP PPB < PLS
PA ( = A ) a nd oi l fl o w i s
divided in a proportion more
tha n ar ea of ope ning of
spool.
PC78MR-6 10-87
Pressure compensation valve
Function Flow control valve (2) throttles the area of open-

During compound operations, if the load pres- ing between pump circuit PP and spool upstream
sure on either actuator becomes lower than the PPA to cause a pressure loss between PP and
other actuator and the oil flow is about to PPA.
increase, compensation is made. [When this Flow control valve (2) and reducing valve (1) are
happens, the other actuator being used for com- balanced in a position where the difference
pound operation (right side) is at a high load than between PLS and PA acting on both ends of
the actuator on this side (left side).] reducing valve (1) and the pressure loss made
between PP and PPA on the sides of flow control
Operation valve (2) will be the same.
When the load pressure on the other actuator In this way, the pressure difference between
(right side) becomes higher during compound upstream pressure PPA and downstream pres-
operations, the oil flow in actuator circuit A on sure PA of both spools used during compound
this side (left side) starts increasing. operations is the same, so the pump flow is
When this happens, the LS pressure PLS on the divided in proportion to the area of opening of
other actuator acts on spring chamber PLSS, notch (a) of each spool.
and reducing valve (1) and flow control valve (2)
are pushed to the left.
10-88 PC78MR-6
Boom hydraulic drift prevention valve
Function
This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) to cause
hydraulic drift of the boom while the boom con-
trol lever is not operated.
1. When boom is raised
Operation
When the boom is "raised", the main pressure
from the control valve pushes up puppet (2). As
a result, the hydraulic oil from the control valve
flows through the valve into the boom cylinder
bottom.
PC78MR-6 10-89
2. When boom is held
When the boom control lever is returned to the

neutral position after the boom is raised, the
holding pressure on the boom cylinder bottom
side is closed by puppet (2) and the hydraulic oil
that flowed through orifices (a1) and (a2) is
closed by pilot spool (3). Accordingly, the boom
is held.
10-90 PC78MR-6
3. When boom is lowered
When the boom is lowered, pilot pressure P1

from the PPC valve pushes pilot spool (3) and
the hydraulic oil in chamber (b) in the puppet is
drained.
The pressure in port (Ab) is heightened by the
hydraulic oil from the boom cylinder bottom, but
the pressure in chamber (b) is lowered by ori-
fices (a1) and (a2).
When the pressure in chamber b lowers below
that in port (Ab), puppet (2) opens and the
hydraulic oil from port (Ab) flows through port
(Aa) into the control valve.
PC78MR-6 10-91
Boom regeneration circuit
1. When boom is lowered by its weight.
Function When this happens, a part of the return oil on the

While the boom is being lowered by its weight, if bottom side flows through regeneration pas-
bottom pressure A of cylinder (1) is higher than sages (a) of bottom spool (2), pushes check
head pressure B, this circuit sends the return oil valve (3) open, and flows into the head side.
on the bottom side to the head side to increase As a result, the boom lowering speed is height-
the cylinder speed by that amount. ened.
Operation
While the boom is being lowered by its weight,
pressure A on the bottom side of boom cylinder
(1) is higher than pressure B on the head side.
10-92 PC78MR-6
2. When boom is lowered under a load.
Function
While the boom is being lowered under a load, if
head pressure B of cylinder (1) is higher than
bottom pressure A, check valve (3) is closed to
shut off the head side and bottom side from each
other.
Operation
While the boom is being lowered under a load,
pressure B on the head side of boom cylinder (1)
is higher than pressure A on the bottom side.
When this happens, check valve (3) is closed by
pressure B on the head side and spring (4) to
shut off the head side and bottom side from each
other.
PC78MR-6 10-93
Travel junction valve

(L.H., R.H. travel junction circuit)
1. When traveling in a straight line
10-94 PC78MR-6
2. When steered during travel
PC78MR-6 10-95
Function
To compensate for any difference in the oil flow
in the left and right travel circuits while machine
travels in a straight line, the junction circuit
opens when the left and right travel spools are
operated.
In this way, the flow rates of oil to the left and
right travel motors are almost the same when the
machine travels in a straight line, so the machine
deviates less.
When the machine is steered, the junction circuit
opens. Since opening (b) of travel junction valve
spool (3) is small, however, the junction circuit
does not affect the steering performance.
Operation
1. When traveling in a straight line
Since only both travel valves are operated
and any work equipment valve is not oper-
ated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are sepa-
rated by the pump merge-divider spool.
(See the section on the LS bypass plug).
When both travel spools (1) are operated,
the oil from the pump flows from pump dis-
charge circuits PP1 and PP2 through actua-
tor circuit PB to B.
When the machine travels in straight line,
both reducing valves (2) are pushed to the
right and notch (a) and travel junction circuit
are opened.
The right end of travel junction spool (3) is
the work equipment PPC pressure circuit.
Since the work equipment valve is not oper-
ated at this time, however, any pressure is
not generated.
In this way, both travel actuator circuits are
interconnected by the travel junction circuit.
If any difference occurs in the flow of oil to
both travel motors, the difference is compen-
sated to reduce travel deviation.
2. When steered during travel
Since only both travel valves are operated
and any work equipment valve is not oper-
ated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are sepa-
rated by the pump merge-divider spool.
(See the section on the LS bypass plug).
The machine is steered by supplying the
demand flow to the actuator circuit according
to the strokes of both travel spools. (See the
section on the unload valve.)
While the machine is traveling in a straight
line, if the right travel spool (right 1) is
returned to the neutral position and the
machine is steered, a difference (left B >
right B) is made between the load pressures
in both travel actuator circuits PB.
10-96 PC78MR-6
Travel LS bleed circuit and travel junction valve
1. During normal operation
PC78MR-6 10-97
2. When travel actuator and another actuator

are operated
10-98 PC78MR-6
Function For this reason, LS circuit pressure PLS,

When the travel actuator and another actuator which is the same pressure as boom circuit
are operated at the same time, the amount of oil pressure A, flows to travel circuit B to reduce
discarded through the throttle in LS circuit PLS the pressure.
increases and the pressure compensation preci-
sion of the travel circuit is lowered to reduce the
drop of the travel speed.
When the travel actuator or any other actuator is
operated singly, the LS bleed circuit is closed.
Travel junction valve spool (5) is set to open (b)
(small) or open (c) (large) by the boom PPC
pressure so that the difference between the flow
rates in both travel circuits can be corrected eas-
ily.
Operation
1. During normal operation
When boom spool (1) is operated, LS circuit
PLS becomes the same pressure as boom
circuit pressure A.
Since the work equipment valve is operated,
pump discharge pressures PP1 and PP2 are
merged by the pump merge-divider valve
spool. LS pressures PLS1, PLS2, and PLS3
are also merged. (See the sections on the
pump merge-divider valve and logic valve.)
At the same time, LS pressure PLS also
goes to spring chamber PLSS of reducing
valve (2) of the travel valve.
Since the travel valve spool is not operated,
notch (a) of reducing valve (2) is closed, and
check valves (3) and (4) of the bleed circuit
are also closed.
As a result, when the boom is operated sin-
gly, the travel LS bypass circuit is closed.
2. When travel actuator and another actuator are
operated
When boom spool (1) is operated, LS circuit
PLS becomes the same pressure as boom
circuit pressure A.
Since the work equipment valve is operated,
pump discharge pressures PP1 and PP2 are
merged by the pump merge-divider valve
spool. LS pressures PLS1, PLS2, and PLS3
are also merged. (See the sections on the
pump merge-divider valve and logic valve.)
As for the actuator circuit pressure, the boom
RAISE pressure is normally higher than the
travel pressure (A > B), so the pressure in
spring chamber PLSS inside reducing valve
(2) of the travel valve is higher than travel cir-
cuit pressure PB.
As a result, reducing valve (2) moves to the
left and LS pressure PLS flows through
check valves (3) and (4) and notch (a) of
reducing valve (2) to travel circuit PB.
PC78MR-6 10-99
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
Model: LMF30AEL
B: From swing brake solenoid valve Specifications

S: From tank Model: LMF30AEL
T: To tank Capacity: 31 cm3/rev
MA: From control valve Set pressure of safety valve: 21 MPa {210 kg/cm2}
MB: From control valve Cracking pressure of check valve: Max. 0.03 MPa
{0.30 kg/cm2}
1. Reverse prevention valve
10-100 PC78MR-6
1. Output shaft 9. Safety valve

2. Housing 10. Check valve
3. Shoe 11. Check valve spring
4. Piston 12. Brake spring
5. Cylinder block 13. Brake piston
6. Valve plate 14. Disc
7. Center spring 15. Plate
8. Swash plate
Unit: mm
A Check valve spring Free length
Outside Installed Installed Free length Installed
diameter length load load If damaged
or deformed,
15.5 9.0 11.5 {0.09 kg} {0.07 kg}
B Valve return spring
1.8 N 1.41 N
33 13.8 19.5 {0.18 kg} {0.14 kg}
PC78MR-6 10-101
BRAKE VALVE
Outline 2. When machine stops swinging
The brake valve consists of a check valve and a If the swing control lever is returned to the
safety valve. neutral position, oil is not supplied from the
pump to port MB any more. Since the return
Function circuit for the oil from the motor outlet to the
When the machine stops swinging, control valve tank is closed by control valve (1), the pres-
(1) closes the outlet circuit of the motor. Since sure in port MA rises and revolution resis-
the motor continues revolving because of the tance is generated in the motor, then the
inertia, the motor output pressure rises abnor- motor is braked.
mally to break the motor. Accordingly, the abnor- The pressure in port MA rises to the set pres-
mally high pressure is released through the sure of the safety valve. As a result, high
outlet (high pressure side) of the motor to protect braking torque is generated in the motor,
the motor. then the motor stops.
While the safety valve is operating, the oil
Operation discharged from the safety valve and the oil
1. When machine starts swinging from port S are supplied through check valve
When the swing control lever is operated to CB to port MB so that cavitation will not
swing to the left, the hydraulic oil from the occur in port MB.
pump flows through control valve (1) into port
MB. As a result, the pressure in port MB
rises and the starting torque is generated in
the motor and the motor starts revolution.
The oil from the motor outlet returns from
port MA through control valve (1) to the tank.
10-102 PC78MR-6
MODULATING RELIEF VALVE

Function
The relief valve for the swing motor prevents the
relief pressure from rising sharply to reduce shocks
when the machine starts and stops swinging.
Operation
1. When circuit pressure is P0
The relief valve does not operate.
2. When circuit pressure rises sharply
When circuit pressure rises to P1, the
hydraulic pressure acts on the area differ-
ence between D1 and D3 (D1 > D3) and
pushes spring (4) to open valve (3).
At this time, pressure acts on the area differ-
ence between D1 and D2 (D2 > D1), so seat
(1) follows valve (3).
As seat (1) moves, the passage for the pres-
surized oil in chamber (a) to flow into port S
is narrowed by ball (2). Accordingly, seat (1)
does not move so fast as valve (3).
As a result, the relief pressure rises gradually
from P1 to P2 while seat (1) is moving to
sleeve (5).
PC78MR-6 10-103
SWING BRAKE
1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
When the solenoid valve of the swing brake is When the solenoid valve of the swing brake is
de-energized, the hydraulic oil from the self- energized, the valve is changed and hydraulic oil
pressure reducing valve is shut off and port B is from the self-pressure reducing valve flows
connected to the tank circuit. through port B into brake chamber A.
As a result, brake piston (13) is pushed up by The hydraulic oil in chamber A pushes brake
brake spring (12) to press disc (14) and disc (15) spring (12) and brake piston (13) moves down.
to apply the brake. As a result, disc (14) and plate (15) are sepa-
rated and the brake is released.
10-104 PC78MR-6
REVERSE ROTATION PREVENTION LEVEL
MA : Port 1. Valve Body

MB : Port 2. Spool (MA end)
T1 : Port 3. Spring (MA end)
T2 : Port 4. Plug (MA end)
5. Spool (MB end)
6. Spring (MB end)
7. Plug (MB end)
PC78MR-6 10-105
EFFECT EXPLANATION DRAWING
10-106 PC78MR-6
Function
This valve reduces the swing back generated in
the swing body by the inertia of the swing body,
the backlash and rigidity of the machinery sys-
tem, and the compression of the hydraulic oil
when the swing is stopped.
This is effective in preventing spillage of the load
when stopping the swing and reducing the cycle
time (the positioning ability is good and it is pos-
sible to move swiftly to the next job).
1. When brake pressure is being generated at

port MB
Operation
Pressure MB passes through the notch and goes
to chamber d, spool (5) compresses spring (6)
according to the difference in area D1 > D2,
moves to the left, and MB o e is connected.
When this happens, pressure MA is below the
set pressure of spring (3), so spool (2) does not
move. For this reason, the pressure oil is closed,
and the braking force is ensured.
2. After motor stops Operation

The motor is reversed by the closing pressure
generated at port MB. (1st reversal)
When this happens, reversal pressure is gener-
ated at port MA. Pressure MA goes to chamber
a, compresses spring (3), spool (2) moves to the
right, and MA o b is connected.
At the same time, b o f is connected through the
drill hole in spool (5), so the reversal pressure at
port MA is bypassed to port T to prevent the 2nd
reversal.
PC78MR-6 10-107
MAINTENANCE STANDARD WORK EQUIPMENT AND SWING PPC VALVE
WORK EQUIPMENT AND SWING PPC VALVE
P : From main pump

T : To tank
P1 : Left - Arm OUT/Right - Boom LOWER
P2 : Left - Arm IN/Right - Boom RAISE
P3 : Left - Swing RIGHT/Right - Bucket CURL
P4 : Left - Swing LEFT/Right - Bucket DUMP
10-108 PC78MR-6
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
6. Nut (For connection of lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
10-110 PC78MR-6
Unit: mm
Free length
Centering spring Outside Installed Installed Free length Installed
12 (For ports P3 and P4) diameter length load load
17.65 N 14.1 N If damaged

42.48 15.5 34.0 {1.80 kg} {1.44 kg} or deformed,
replace spring.
Centering spring 29.42 N 23.5 N
13 (For ports P1 and P2) 44.45 15.5 34.0 {3.0 kg} {2.40 kg}
16.66 N 13.3 N
14 Metering spring 26.47 8.20 24.9 {1.70 kg} {1.36 kg}
PC78MR-6 10-111
OPERATION
1. At neutral
Ports A and B of the control valve and ports P1,
P2, P3 and P4 of the PPC valve are connected
to drain chamber D through fine control hole f in
spool (1). (Fig. 1)
2. During fine control (neutral o fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil passes through fine con-
trol hole f and goes from port P1 to port A.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control 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.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P1. The relation-
ship in the position of spool (1) and body (10)
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool
(1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also
rises in proportion to the travel of the control
lever.
In this way, the control valve spool moves to a
position where the pressure in chamber A (the
same as the pressure at port P1) and the force of
the control valve spool return spring are bal-
anced. (Fig. 2)
10-112 PC78MR-6
3. During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, 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 fill the chamber with oil. (Fig. 3)
4. At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil passes through
fine control hole f and flows to chamber A from
port P1, and pushes the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f and flows to
drain chamber D. (fig. 4)
PC78MR-6 10-113
MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From main pump

T : To tank
P1 : Left travel reverse
P2 : Left travel forward
P3 : Right travel reverse
P4 . Right travel forward
10-114 PC78MR-6
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar 8. Bolt
Unit: mm
Free length Installed Installed Installed
9 Metering spring Outside diam- length load Free length load
eter If damaged
or deformed,
26.53 8.15 24.9 16.7 N 13.3 N replace spring.
{1.70 kg} {1.36 kg}
10 Centering spring 52.06 15.5 31.9 135.2 N 108 N

{13.8 kg} {11.04 kg}
PC78MR-6 10-115
OPERATION
1. At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
2. During fine control (neutral o fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time,
it is connected to pump pressure chamber PP,
and the pilot pressure is sent from port A through
fine control hole f to port P1 .
When the pressure at port P1 rises, spool (1) is
pushed back. Fine control 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.
As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure of port P1.
The relationship in the position of spool (1) and
body (10) (fine control hole f is in the middle
between drain hole D and pump pressure cham-
ber PP) does not change until retainer (9) con-
tacts spool (1).
Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so the
pressure at port P1 also rises in proportion to the
travel of the control lever.
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 bal-
anced. (Fig. 2)
10-116 PC78MR-6
3. Fine control (control lever returned)

When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
Because of this, fine control hole f is connected
to drain chamber D, and the pressurized oil at
port P1 is released.
If the pressure at port P1 drops too much, spool
(1) is pushed up by metering spring (2), so fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, so the pressure at port P1
supplies the pump pressure until the pressure
recovers to a pressure equivalent to the position
of the lever.
When the control valve returns, oil in drain cham-
ber D flows in from fine control hole f of the valve
on the side that is not moving. It passes through
port P2 and enters chamber B to fill the chamber
with oil. (Fig. 3)
4. At full stroke
Disc (5) pushes down piston (4), and retainer (9)
pushes down spool (1). Fine control hole f is shut
off from drain chamber D, and is connected to
pump pressure chamber PP.
Therefore, the pilot pressure oil passes through
fine control hole f and flows to chamber A from
port P1 to push the control valve spool.
The return oil chamber B passes from port P2
through fine control hole f and flows to drain
chamber D. (fig. 4)
PC78MR-6 10-117
MAINTENANCE STANDARD BOOM SWING PPC VALVE, BLADE PPC VALVE
BOOM SWING PPC VALVE

BLADE PPC VALVE
T : To tank
P : From main pump
P1 : To right boom swing/blade raise valve
P2 : To left boom swing/blade lower valve
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
10-118 PC78MR-6
For Boom Swing

Unit: mm
Free length Installed Installed Installed
10 Centering spring Outside length load Free length load
diameter If damaged
or deformed,
124.5 N 100 N replace spring.
33.88 15.3 28.4 {12.7 kg} {10.2 kg}
16.67 N 13.3 N
For Blade
Unit: mm
Free length
Outside Installed Installed Free length Installed
10 Centering spring diameter length load load If damaged
or deformed,
14.7 N 118 N replace spring.
42.36 15.5 32.5 {15 kg} {12 kg}
16.67 N 13.3 N
PC78MR-6 10-119
Operation
1. In the neutral mode
P1 and P2 ports of the operation valves A, B and
PPC valve are connected to drain room D via the
fine control hole f on the spool (1).
2. In the fine control mode

(Neutral o fine control)
As the piston (4) is pushed by disk (5), the
retainer (7) is pushed too. At the same time, the
spool (1) is also pushed down via the metering
spring (2).
By this move, connection of the fine control hole
f is switched from the drain room D to the pump
pressure room PP, and pilot pressure oil for the
control pump is conducted from P1 port to A
port.
As P1 port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure room PP to the drain room D, thereby
relieving P1 port pressure.
As the result, the spool (1) moves up and down
so that force of the metering spring (2) and P1
port pressure may be balanced.
Positional relationship between the spool (1) and
body (8) (fine control hole f is situated at mid
point between the drain room D and pump pres-
sure room PP) remains unchanged until the
retainer (7) is contacted against the spool (1).
The metering spring (2) is, therefore, com-
pressed in proportion to strokes of the operation
lever. Thus, the P1 port pressure too, increases
in proportion to strokes of the operation lever.
As the result, the operation valve spool moves to
the position where the pressure of A room (the
same as P1 port pressure) is balanced against
force of the operation valve spool return spring.
10-120 PC78MR-6
3. In the fine control mode (when the operation

lever is shifted back to its original position)
As the lever (5) starts returning, the spool (1)
is pushed up by force of the centering spring
(3) and P1 port pressure. By this move, the
fine control hole f is connected to the drain
room D and relieves pressurized oil of P1
port to it.
If P1 port pressure goes excessively low, the
spool (1) is pushed down by the metering
spring (2), and passage between fine control
hole f and drain room D is shut down. And,
almost at the same time, the hole is con-
nected to the pump pressure room PP and
starts supplying pump the pressure. This
supply continues until the P1 port pressure is
recovered to the level equivalent to the lever
position.
When the operation valve spool returns, oil
in the drain room D flows in through the fine
control hole f on the not moving side valve.
Oil is then conducted via P2 port to the room
B to fill it up.
4. In the full stroke mode

When the disk (5) pushes down piston (4)
and the retainer (7) pushes down the spool
(1), connection of the fine control hole f is
switched from the drain room D, to the pump
pressure room PP.
Thus, pilot pressurized oil from the control
pump passes through fine control hole f and
conducted to A room via P1 port to push the
operation valve spool.
Return oil from B room is conducted from P2
port to the drain room D via the fine control
hole f.
PC78MR-6 10-121
MAINTENANCE STANDARD BOOM HYDRAULIC ANTI-BURST VALVE
BOOM HYDRAULIC ANTI-BURST VALVE (FOR EU SPEC.)
V : From control valve

T : To hydraulic tank
CY : To hydraulic cylinder
PI : From PPC valve
PCY: For pressure pickup and equalizer circuits
10-121-1 PC78MR-6
(1)
1. Pilot spool
2. Spring (1st stage of spool)
3. Spring (2nd stage of spool)
4. Safety valve
5. Check valve
6. Spring
Unit: mm

Free length x Installed Installed Free Installed
7 Check valve spring Outside diameter length load length load
14.7 1.5 N 10.8 N If damaged or
16.4 x 8.9 11
{1.5 0.15 kg} {1.1 kg} deformed,
24.7 1.5 N 18.6 N replace spring
8 Spool return spring 19.1 8 13.5
{2.52 0.15 kg} {1.9 kg}
55.4 3.0 N 42.2 N
9 Spool return spring 24.8 16.8 22.5
{5.65 0.3 kg} {4.3 kg}
PC78MR-6 10-121-2
(1)
Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the oil
from flowing back from the work equipment cylinder
to prevent sudden fall of the work equipment.
Operation
1. When the work equipment is in neutral
[When piping is normal]
Check valve (5) is closed by the work equip-
ment cylinder holding pressure applied
through port CY to chamber b.
When the work equipment is in neutral, no
pilot pressure is applied from the PPC valve
to port PI. Accordingly, pilot spool (1) is
moved to the left end by the force of springs
(2) and (3), then chambers a and b are shut
off from each other.
Accordingly, oil does not flow from the main
valve to the work equipment cylinder, thus
the work equipment cylinder is held.
If the pressure in the work equipment cylin-
der rises high abnormally, work equipment
cylinder holding pressure Pb operates safety
valve (4).
[When piping bursts]

Even if piping A between the main valve and
work equipment cylinder bursts, chamber a
is shut off from chanber b as in the case
where the piping is normal. Accordingly, the
work equipment cylinder is held.
When the engine is stopped and the work
equipment is held in air, if port PCY is
opened, oil in chamber b flows out through
orifice (7) and port PCY. Accordingly, the
work equipment lowers slowly.
10-121-3 PC78MR-6
(1)
2. When oil is sent from main valve to cylinder

If pressure Pa of the oil sent from the main
valve to chamber a is higher than 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 cham-
bers a and b are connected to each other
and the oil flows from the main valve to the
work equipment cylinder.

If piping A between the main valve and the
work equipment cylinder bursts, the oil in
chamber a flows out through the burst part
and pressure Pa in chamber a lowers.
If Pa lowers below the total of pressure Pb in
chamber b and the force of spring (6), check
valve (5) closes and chambers a and b are
shut off from each other. Accordingly, pres-
sure Pb in the cylinder is held and the work
equipment does not fall suddenly.
PC78MR-6 10-121-4
(1)
3. When oil is returned from work equipment

cylinder to main valve
The work equipment cylinder holding pres-
sure is applied to chamber b and check valve
(5) closes.
The pilot pressure from the PPC valve is
applied to port PI. If it is higher than the force
of spring (2) (area of d), spool (1) moves to
the right standby position (1st-stage stroke).
At this time, chambers a and b are not con-
nected to each other.
If the pilot pressure rises higher than the
force of spring (3) (area of d), spool (1)
moves further to the right and chambers a
and b are connected to each other (2nd-
stage stroke).
Accordingly, the oil is returned from the work
equipment cylinder to the main valve.

If piping A between the main valve and work
equipment cylinder bursts, the oil in chamber
a flows out through the burst part. Since oil
supplied from chamber b to chamber a flows
through opening c of spool (1), however, the
work equipment does not fall suddenly.
If the PPC valve is returned to the neutral

position, spool (1) returns to the left end to
shut off chambers a and b from each other.
Accordingly, the work equipment stops.
10-121-5 PC78MR-6
(1)
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
Unit : mm
Standard Tolerance Standard Clearance

Clearance between swing size Shaft Hole clearance limit
1 bracket and revolving frame
mounting pin and bushing -0.036 +0.204 0.161
110 -0.090 +0.125 0.294 1.0
Clearance between boom and -0.030 +0.174 0.130

2 swing bracket mounting pin 65 -0.100 +0.100 0.274 1.0
and bushing
Clearance between boom and 60 -0.030 +0.174 0.130
3 arm mounting pin and bushing -0.100 +0.100 0.274 1.0
Clearance between arm and -0.225 -0.062 0.105

4 bucket mounting pin and 50 1.0 Replace pin
bushing -0.285 -0.120 0.223 and bushing
Clearance between arm and 50 -0.225 -0.062 0.105

5 link mounting pin and bushing -0.285 -0.120 0.223 1.0
Clearance between link and 60 -0.030 +0.173 0.130

6 link mounting pin and bushing -0.100 +0.100 0.273 1.0
Clearance between bucket -0.225 -0.040 0.131

7 and link mounting pin and 50 -0.285 -0.094 0.245 1.0
bushing
Clearance between blade and -0.025 +0.142 0.105
8 track frame mounting pin and 50 -0.087 +0.080 0.229 1.0
bushing
10-122 PC78MR-6
MAINTENANCE STANDARD WORK EQUIPMENT
PC78MR-6 10-123
MAINTENANCE STANDARD DIMENSIONS OF EACH PART OF WORK EQUIPMENT
DIMENSIONS OF EACH PART OF WORK EQUIPMENT

1. ARM SECTION
10-124 PC78MR-6
PC78MR-6
No. Allowance
Measuring point Basic dimension
Shaft Hole
-0.030 +0.100
1 60
-0.100 0
+1.0
Arm side 71.5
2 0
Cylinder head side 70 1.2
-0.030 +0.100
3 60
-0.100 0
+0.5
Boom side 220
0
4
-0.5
Arm side 220
-1.0
5 142.4 2.0
6 218.8 1.0
7 458.6 1.0
8 1,650
9 2,093.9 3.0
10 1,661.2 1.3
11 258.7 0.3
12 15.1 1.0
13 395.1 0.1
14 342 0.1
15 312.2
16 1,066.9
-0.225 0
17 50
-0.285 -0.150
-1.0
Link side 200
-2.0
18
+2.0
Bucket side 200
0
-0.225 0
19 50
-0.285 -0.150
-0.50
Arm side 188
-1.0
20
+3.0
Bucket side 211
0
Min. 1,055 1.5
21
Max. 1,765
PC78MR-6 10-125
2. BUCKET PORTION
10-126 PC78MR-6
PC78MR-6
No.
Measuring point Basic dimension Allowance
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
PC78MR-6 10-127
MAINTENANCE STANDARD AIR CONDITIONER PIPING
AIR CONDITIONER PIPING (OPTIONAL)
A: Hot/Cool air outlet 1. Hot water take-out piping

B: Inside air circulation opening 2. Air conditioner compressor
C: Fresh air inlet 3. Hot water return piping
4. Refrigerant piping
5. Condenser
6. Receiver drier
7. Air conditioner unit
8. Duct
10-128 PC78MR-6
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
ELECTRIC CONTROL SYSTEM
Engine control function
Engine and pump compound

control function
Overheat prevention function
Swing control function
Travel control function
PPC lock function
(*1)
Electric Overload alarm function
control system
Error code display and alarm function
Self-diagnosis function
Error code memory func
*1. For EU spec. machine only.
PC78MR-6 10-129
(1)
GENERAL SYSTEM DIAGRAM (FOR STD SPEC.)
10-130 PC78MR-6
(1)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency pump drive switch
8. Emergency boom swing operating and swing
holding brake release switch
9. Resistor
(For emergency boom swing operating)
10. Resistor (For emergency pump drive)
11. Safety lock lever
12. PPC lock switch
13. Starting motor cut relay
14. Safety relay
15. One-touch deceleration switch
16. Fuel control motor relay (For accelerator)
17. Fuel control motor relay (For deceleration)
18. Fuel control dial
19. Fuel control motor
20. Monitor panel
21. Travel speed boost pedal
22. Travel alarm (If equipped)
28. TVC-EPC valve
29. Right work equipment PPC valve
30. Travel PPC valve
32. Boom swing PPC valve
33. Blade PPC valve
34. Attachment control PPC valve
35. Boom RAISE PPC oil pressure switch
36. Travel PPC oil pressure switch
37. Arm IN PPC oil pressure switch
38. Swing PPC oil pressure switch
39. Boom swing potentiometer
40. Engine stop solenoid
41. Engine stop solenoid relay
42. Starting motor
43. Engine speed sensor
44. Coolant temperature sensor
45. Hydraulic pump
45a. Servo piston
45b. LS valve
45c. TVC valve
46. Control valve
46a. Pump merge-divider valve
47. Travel motor
48. Swing motor
PC78MR-6 10-131
GENERAL SYSTEM DIAGRAM (FOR EU SPEC.)
10-131-1 PC78MR-6
(1)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency pump drive switch
8. Emergency boom swing operating and swing
holding brake release switch
9. Resistor
(For emergency boom swing operating)
10. Resistor (For emergency pump drive)
12. PPC lock switch
14. Safety relay
20. Monitor panel
21. Travel speed boost pedal
22. Travel alarm (If equipped)
28. TVC-EPC valve
29. Right work equipment PPC valve
30. Travel PPC valve
33. Blade PPC valve
34. Attachment control PPC valve
35. Boom RAISE PPC oil pressure switch
36. Travel PPC oil pressure switch
42. Starting motor
45. Hydraulic pump
45a. Servo piston
45b. LS valve
45c. TVC valve
46. Control valve
47. Travel motor
48. Swing motor
49. Overload alarm actuation switch
50. Overload alarm pressure switch
PC78MR-6 10-131-2
(1)
ENGINE CONTROL FUNCTION
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
8. PPC lock switch
10. Safety relay
16. Monitor panel
19. Starting motor
10-132 PC78MR-6
Starting engine Function of preventing engine stop solenoid

If starting switch (4) is turned to the ON position, from burning
engine stop solenoid (17) moves governor stop Engine stop solenoid relay (18) is installed to
lever to the "RUN" side. prevent engine stop solenoid (17) from burning.
Accordingly, if the electric system has any trou- The time to supply the suction current is limited
ble, the engine stops, that is, a fail-safe mecha- to 3 seconds after starting switch (4) is turned to
nism is formed. the ON position by replacing the 2-wire engine
If starting switch (4) is turned to the START posi- stop solenoid (17) (which uses the same wire for
tion while safety lock lever (7) is at the "LOCK" the suction and holding currents) with the 3-wire
position, the start signal flows to starting motor one (which uses independent wires for the suc-
(19) and the engine starts. If safety lock lever (7) tion and holding currents) and adding a timer
is at the "FREE" position, the start signal to start- function and engine stop solenoid relay (18) to
ing motor (19) is cut out by starting motor cut controller (6).
relay (9) and the engine cannot start.
At this time, since fuel control motor (12) is
linked with fuel control dial (11), the engine
speed is fixed to the speed set with fuel control
dial (11).
Controlling engine speed

Fuel control motor (12) outputs the acceleration
(engine speed raising) signal and deceleration
(engine speed lowering) signal to controller (6)
according to the position of fuel control dial (11).
Upon receiving the signal, controller (6) outputs
the drive signal through fuel control motor relays
(13) and (14) to fuel control motor (12).
Fuel control motor (12) lengthens or shortens A: Operation of starting switch
the cable to control the engine speed according B: Suction coil current
to the drive signal. C: Holding coil current
t: 3 seconds
PC78MR-6 10-133
Stopping engine
If starting switch (4) is turned to the OFF posi-
tion, engine stop solenoid (17) moves the gover-
nor stop lever to the STOP side and the engine
stops.
One-touch deceleration
If one-touch deceleration switch (16) is pressed,
the deceleration signal is output to controller (6).
Controller (6) turns on the one-touch decelera-
tion monitor of monitor panel (16) and drives fuel
control motor (12) to lower the engine speed to
low idling.
If one-touch deceleration switch (15) is pressed
while the engine is being started, the engine
speed is set to low idling. If it is pressed again,
the engine speed returns to the speed set with
fuel control dial (11).
a Even if the engine is stopped while the one-
touch deceleration system is turned on, the latter
is turned off when the engine is started next time
(the engine speed is set the speed set with the
fuel control dial).
a Even if the fuel control dial is operated while the
one-touch deceleration system is turned on, the
engine speed is kept at low idling.
a If the fuel control dial is at low idling, the engine
speed does not lower any more even if the one-
touch deceleration switch is pressed
A: One-touch deceleration switch [ON]

B: One-touch deceleration switch [OFF]
C: Engine speed set with fuel control dial
D: Low idling
E: Max. 1 sec
10-134 PC78MR-6
ENGINE AND PUMP COMPOUND CONTROL FUNCTION
1. Battery Input/Output signals

2. Battery relay a. Controller power source
3. Fusible link b. Solenoid power source
4. Starting switch c. Monitor panel power source
5. Fuse box d. S-NET signal
6. Controller e. Coolant temperature signal
7. Emergency pump drive switch f. Engine speed signal
8. Resistor (For emergency pump drive) g. EPC valve drive signal
9. Monitor panel
10. TVC-EPC valve
13. Control valve
14. Hydraulic pump
14a. Servo piston
14b. LS valve
14c. TVC valve
PC78MR-6 10-135
Functions
The "active" or "E" mode is selected with the
working mode selection switch on the monitor
panel. In each mode, proper engine torque and
pump absorption torque are selected according
to the contents of work.
The controller detects the engine governor
speed set with the fuel control dial and the actual
engine speed and controls the hydraulic system
so that the pump will absorb the all torque at
each output point of the engine, according to the
pump absorption torque set for each mode.
If the engine speed is lowered, the pump absorp-
tion torque is reduced to prevent the engine from
stopping.
10-136 PC78MR-6
Control method in each mode
Active mode
Matching point of active mode:
40.5 kw / 1.850 rpm

Active mode {54.0 HP / 1.850 rpm}
If the pump load increases and the pressure

rises, engine speed lowers.
At this time, the pump discharge is reduced to
heighten the engine speed to near the full output
point. On the other hand, if the pressure lowers,
engine speed is heightened to near the full out-
put point to increase the pump discharge.
The engine is constantly used near the full output
point by repeating this control.
PC78MR-6 10-137
E mode
Matching point of E mode: 85% partial output
point
37.5 kw / 1.660 rpm

E mode {50.0 HP / 1,660 rpm}
In this mode, the engine speed is lowered along

the constant horsepower curve of the engine,
keeping the pump absorption torque at a con-
stant level.
The engine is used in the high fuel efficiency
area by this control method.
10-138 PC78MR-6
Driving pump in an emergency

Even if the controller, etc. has a problem and the
hydraulic pump does not operate normally, the
operator can work temporarily by operating the
emergency pump drive switch (S).
(1) Auto: Normal state

(2) Cancel: Abnormal state
a The emergency pump drive switch (S) is of alter-

native type. If it is set to the "CANCEL (2)" posi-
tion while the machine is normal, user code
"E02" is displayed on the display unit.
OVERHEAT PREVENTION
FUNCTION
a For the system circuit diagram, see "Engine and
pump compound control function".
If the coolant temperature rises too high, the

pump load is lowered to prevent the engine from
overheatin
Operating condition Operation Resetting condition
Pump absorption torque is reduced accord-

ing to torque control system to reduce
Coolant temperature Coolant temperature is
engine load.
is above 99C below 95C
(Matching point: 90% partial output point)
Engine speed is kept as it is.
PC78MR-6 10-139
SWING CONTROL FUNCTION

4. Starting switch c. Solenoid valve drive signal
5. Fuse box d. Swing PPC oil pressure switch signal
6. Controller e. Arm IN PPC oil pressure switch signal
7. Swing holding brake release switch f. Boom swing potentiometer signal
9. Swing motor
13. Engine
14. Hydraulic pump
15. Control valve
10-140 PC78MR-6
Function Relationship between swing holding brake can-

cel switch and swing holding brake
Swing holding brake Swing holding
When the machine stops swinging, the swing brake cancel Operation
holding brake is applied automatically to prevent switch
hydraulic drift on a slope, etc.
If swing control lever or arm IN
When the arm is moved in, the swing holding
lever is set to neutral position,
brake is released to reduce the load on the swing
swing holding brake is applied
unit during digging work.
about 5 seconds later.
The swing holding brake is released automati-
If swing control lever or arm IN
cally when the boom swings to reduce the Auto
lever is operated, swing holding
shocks made at each start and stop of swinging. (Normal state)
brake is released and machine
a If the swing holding brake is released, only the
can swing freely.
hydraulic brake of the safety valve is used to
The swing holding brake is applied
stop swinging. Accordingly, if the machine stops
and released according to boom
swinging on a slope, etc. the boom may drift
swing operation.
hydraulically. Take care.
When swing holding brake system
Releasing swing holding brake has trouble, if swing holding brake
Even if the controller, etc. has a problem and the cancel switch (S) is set to "Cancel
swing holding brake does not operate normally (2)", swing holding brake is
and the machine does not swing, the operator released and machine can swing.
Cancel
can swing the machine by releasing the swing Even if swing control lever or arm
(Abnormal
holding brake with the swing holding brake can- IN lever is set to neutral position,
state)
cel switch (S). swing holding brake does not oper-
ate, however.
(1) Auto: Normal state The swing holding brake does not
(2) Cancel: Abnormal state work even if the boom swing pedal
is in neutral.
a Emergency swing holding brake cancel switch
(S) is of alternative type. If it is set to the "CAN- Time chart of input and output signals
CEL (2)" position while the machine is normal,
user code "E03" or "E41" are displayed on the
display unit.
PC78MR-6 10-141
TRAVEL CONTROL FUNCTION
1. Battery Function
2. Battery relay Changing travel speed
3. Fusible link If the travel speed boost selector switch is oper-
4. Starting switch ated or the travel speed boost pedal is pressed,
5. Fuse box the motor capacity changes to change the travel
6. Controller speed.
7. Monitor panel
8. 2-stage travel speed selector solenoid valve a When the engine is started, the travel speed
9. Left travel motor boost selector switch is set to the low speed
10. Right travel motor position automatically.
11. Travel PPC valve a The travel speed boost pedal is effective only
12. Travel PPC oil pressure switch while the "Lo" lamp of the travel speed boost
13. Travel alarm (If equipped) selector switch is lighting. Even if the pedal is
14. Engine pressed while the "Hi" lamp is lighting up, the
15. Hydraulic pump travel speed does not change.
16. Control valve
16a. Pump merge-divider valve Lo lamp Hi lamp
17. Travel speed boost pedal Travel speed boost
lights up lights up
selector switch
(Low speed) (High speed)
Input/Output signals Motor capacity
a. Controller power source 36.3 24.1
(cc/rev)
b. Solenoid power source
Released
Travel speed
c. Monitor panel power source 3.0 4.5
Travel speed boost pedal
(km/h)
d. S-NET drive signal
e. Solenoid valve drive signal Swash plate
angle of travel Max. Min.
f. Travel PPC oil pressure switch signal
motor
g. Travel alarm drive signal
h. 2nd travel speed selection signal Motor capacity
24.1 24.1
(cc/rev)
Travel speed
Pressed
4.5 4.5
(km/h)
Swash plate
angle of travel Min. Min.
motor
10-142 PC78MR-6
PPC LOCK FUNCTION

4. Starting switch c. Solenoid valve drive signal
5. Fuse box
6. Controller Function
7. Safety lock lever The PPC lock switch is linked with the safety
8. PPC lock switch lock lever. If the safety lock lever is set to the
9. PPC lock solenoid valve LOCK position, the PPC lock switch is turned
10. Left work equipment PPC valve OFF.
11. Right work equipment PPC valve If the PPC lock switch is turned OFF, the current
12. Travel PPC valve to the PPC lock solenoid valve is cut out and the
13. Blade PPC valve work equipment does not move any more even
14. Engine if the work equipment control lever is operated.
15. Hydraulic pump
PC78MR-6 10-143
OVERLOAD ALARM FUNCTION (FOR EU SPEC.)

2. Battery relay a. Power supply of controller
3. Fusible link b. Power supply of solenoids
4. Starting switch c. Power supply of monitor panel
5. Fuse box d. S-NET signal
6. Controller e. Overload alarm actuation signal
7. Monitor panel f. Overload alarm pressure signal
8. Overload alarm actuation switch
9. Overload alarm pressure switch
Function
If the pressure in the boom cylinder bottom cir-
cuit rises above the set value, the caution lamp
lights up and the buzzer sounds to notify the
operator of possibility of tipping over of the
machine by an overload.
10-143-1 PC78MR-6
(1)
BOOM SWING END CUSHION FUNCTION

When the boom is swung, the boom swing speed is reduced before each stroke end to reduce the shock
made at the stroke end. This function reduces the spillage of soil and the load on the chassis.
1. Decelerating function 2. Correction function
If the boom swings and enters area (B) from If the potentiometer is replaced or the work
area (A), its swing speed is lowered gradu- equipment is replaced, an input signal error
ally to reduce the shock made at the stop is made because of the error of the installa-
position. tion of the potentiometer.
At this time, the output pressure from the With the correction function, this error can be
boom swing PPC valve to the boom swing corrected easily without measuring the out-
control valve is reduced by controlling the put voltage or adjusting the potentiometer
EPC valve according to the angle sensor sig- finely.
nal. If the boom is swung to each stroke and the
As a result, the shock made at the stroke end set angle (0) is input, the difference between
is reduced. angle (A) calculated from the actual output
voltage of the potentiometer and standard
angle (B) set in the computer (installation
error) is saved as "correction value (C)".
A. Ordinary area
B. Deceleration area
10-144 PC78MR-6
SELF-DIAGNOSTIC FUNCTION
1. Error code display and alarm function 2. Error code memory function
The system of this function consists of the If a problem occurs in the leading system, it
controller and the electronic components is detected by the self-diagnostic function
such as the potentiometers that output input and its error code is stored in memory.
signals and the solenoid valves and EPC a For details of the display and resetting
valves that receive output signals. The con- method, see TESTING AND ADJUSTING.
troller is constantly checking that those elec-
tronic component and itself are functioning
normally.
If a problem occurs in any of these compo-
nents, the controller carries out trouble-
shooting and displays the result as a "user
code" or "service code" on the display unit
(1) of the monitor panel and turns on the
alarm buzzer to warn the operator of the
trouble.
a For details of the display and action to take,
see TESTING AND ADJUSTING.
PC78MR-6 10-145
MAINTENANCE STANDARD SYSTEM COMPONENTS
SYSTEM COMPONENTS
Fuel control dial

10-146 PC78MR-6
Fuel control motor
1. Motor assembly Input and output signals

2. Cable SWP-6P [CN-K27]
3. Connector
Pin Input/Output
Signal name
No. signal
1 Motor acceleration signal Input
2 Power source
3 One-touch deceleration signal Output
4 Motor deceleration signal Input
5 Acceleration signal Output
6 Deceleration signal Output
PC78MR-6 10-147
CONTROLLER
Input/output signals
DEUTSCH-24P [CN-M95]
Pin Signal name I/O signal Pin Signal name I/O signal
No. No.
1 NC 13 NC
(*1) NC 14 NC
2
(*2) Boom cylinder bottom presser sensor Input 15 NC
3 NC 16 NC
4 GND (Signal) 17 Attachment 1 Input
5 2-stage travel speed selection switch Input 18 Travel PPC oil pressure switch Input
6 Arm IN PPC oil pressure switch Input 19 NC
7 NC 20 NC
8 Boom swing angle Input 21 GND (Analog)
9 NC 22 Sensor power source (+5 V) Output
10 GND signal 23 NC
11 NC 24 Swing PPC oil pressure switch Input
12 Boom RAISE PPC oil pressure switch Input
*1. Serial No.: 1001 1094
*2. Serial No.: 1095 and up
10-148 PC78MR-6
(1)
DEUTSCH-40P (1) [CN-M96]

No. No.
1 NC 21 S-NET Input/Output
2 NC 22 NC
3 NC 23 NC
4 NC 24 NC
5 NC 25 Signal for selecting Tire 2 Input
6 NC 26 NC
7 UU/US selection signal Input 27 Mode selection 2 Input
8 NC 28
9 NC 29 GND (Pulse)
10 NC 30 MR selection signal Input
11 NC 31 GND (S-NET)
12 NC 32 NC
13 NC 33 NC
14 NC 34 GND (232C)
15 Back-up light signal Input 35 NC
16 Main monitor selection signal Input 36 NC
17 Attachment 3 Input 37 Model selection 1 Input
18 NC 38 NC
19 NC 39 GND (Pulse)
20 NC 40 Engine speed sensor (+) Input
DEUTSCH-40P (2) [CN-M97]

No. No.
1 Controller power Input 21 GND (Controller)
2 Solenoid power Input 22 Solenoid power source Input
3 GND (Solenoid) 23 GND (Solenoid)
4 Engine stop solenoid relay Output 24 Key signal Input
5 Left boom swing stop EPC valve Output 25 Governor motor relay (For acceleration) Output
6 NC 26 NC
7 Swing holding brake solenoid valve Output 27 2-stage travel speed selector solenoid valve Output
8 NC 28 NC
9 One-touch deceleration switch Input 29 Deceleration signal Input
10 Air conditioner compressor signal Input 30 NC
11 Controller power Input 31 GND (Controller)
12 Solenoid power Input 32 GND (Controller)
13 GND (Solenoid) 33 GND (Controller)
14 Key signal Input 34 NC
15 Right boom swing stop EPC valve Output 35 Governor motor relay (For deceleration) Output
16 TVC-EPC vlave Output 36 NC
17 Swing and travel alarm Output 37 NC
18 NC 38 NC
19 Acceleration signal Input 39 Auto-deceleration signal Input
(*1) NC 40 NC
20
(*2) Alarm actuation switch Input
*1 Serial No.: 1001 1094
*2 Serial No.: 1095 and up
PC78MR-6 10-149
(1)
Potentiometer
1. Shaft 4. Brush
2. Housing 5. Resistor
3. Bearing 6. Connector
Functions
A potentiometer is installed on each of the boom
feet, arm foot and second boom top to detect the
angle of the boom, arm and offset work equip-
ment.
Using the resistance value of the variable resis-
tor, potentiometers send angle data to the con-
troller by converting the supply voltage (5V) into
signal voltage according to the angle of the work
equipment.
10-150 PC78MR-6
Register
1. Register
2. Connector
Specifications
Model System Resistance ( )

For TVC-EPC valve of 30
hydraulic pump
PC78MR-6 For right boom swing stop
EPC valve 5
For left boom swing stop
EPC valve
Function
When the emergency pump drive switch is
turned ON, this resistor is used to supply a
proper current to EPC valve according to the
condition of the work equipment.
a Current does not flow under the normal condi-
tion.
PC78MR-6 10-151
PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Contact composition: N.O. contact
Operation (ON) pressure: 490 98.1 kPa
{5.0 1.0 kg/cm2}
Reset (OFF) pressure: 294 49.0 kPa
{3.0 0.5 kg/cm2}
Function
The control valve has 5 PPC oil pressure
switches, which sense the operating condi-
tion of each actuator from the PPC pressure
and send it to the controller.
10-152 PC78MR-6
Overload alarm pressure switch (For EU spec.)
1. Plug
2. Sensor
3. Connector
Function
One pressure switch is installed to the boom cyl-
inder bottom circuit to sense the hydraulic pres-
sure on the boom cylinder bottom side.
PC78MR-6 10-152-1
(1)
Engine speed sensor

a See SENSOR.
TVC-EPC valve
a See HYDRAULIC PUMP.
PPC lock solenoid valve
2-stage travel speed selector solenoid valve
Swing holding brake solenoid valve
Left boom swing stop EPC valve
Right boom swing stop EPC valve
a See EPC SOLENOID VALVE.
Monitor panel
a See MONITOR SYSTEM
PC78MR-6 10-153
MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
1. Monitor panel Outline

2. Battery The monitor system monitors the machine condi-
3. Controller tion by the sensors installed to various parts of
4. Sensors and switches the machine and processes and displays it on
5. Wiper motor, windshield washer motor the panel immediately to notify the operator of
the condition of the machine.
Input and output signals
a. Power source
b. Switch signal
c. Caution signal
d. Sensor, switch signal
e. Sensor, switch signal
f. Drive output
10-154 PC78MR-6
MONITOR PANEL
Outline
The monitor panel has the monitor display function, gauge display function, service meter function, electric
system display function, and alarm buzzer.
The monitor panel has a CPU (Center Processing Unit) in it to display and output information.
The monitor switch unit consists of 3 flat sheet switches. Each time those switches are pressed, the dis-
played machine condition changes. The currently displayed condition is indicated by the LED at the top of
the switches.
If there is any trouble in the monitor panel, controller, or wiring between monitor panel and controller, the
monitor does not display information correctly.
AMP040-20P [CN-P02]
Input and output signals Input/
Pin
AMP070-12P [CN-P01] Signal name Output
No.
Input/ signal
Pin
Signal name Output 1 Engine coolant temperature Input
No.
signal 2 Fuel level Input
1 Starting switch (Battery) Input 3 Radiator water level Input
2 Starting switch (Battery) Input 4 NC Input
3 Windshield washer motor output Output 5 Air cleaner clogged Input
4 Starting switch (Terminal C) Input 6 NC Input
5 Wiper W contact Input 7 Engine oil pressure Input
6 GND 8 Engine oil level Input
7 GND Input/
9 S-NET signal
8 VB+ (24 V) Input Output
9 Wiper motor (+) Output Input/
10 S-NET signal
10 Wiper motor (-) Output Output
11 Alarm buzzer ON signal Input 11 Charge level Input
12 Wiper P contact Input 12 NC
13 GND (Analog signal)
14 NC
15 Pull-up window limit switch Input
16 Alarm buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Lamp switch Input
20 GND (S-NET)
PC78MR-6 10-155
METER DISPLAY UNIT (FOR STD SPEC.)
No. Display type Display item Display range Display method Display Remarks
color
Time is measured while engine is running
1 Service meter 0-99999.9 h (alternator is generating) (Lamp always lights
up even if starting switch is at OFF position.)
If electric control system has trouble, 3
alphanumerics (user code, service code) is
[*1] 3 alphanumer- displayed. Blue LCD
2 Display ics Voltage of boom swing potentiometer is
0 99.9 V displayed.
See above Segment of corresponding level and all seg-

3a Gauge drawing. ments below it light up.
Coolant [Monitor lamp blinks when 8th level lights up
temperature Above set
3b Monitor temperature (above 99C). Monitor lamp blinks and alarm Red LED
(99C) buzzer sounds when 9th level lights up.]
4a Gauge drawing. Blue LCD
ments below it light up.
Fuel level [Monitor lamp blinks and alarm buzzer sounds
Below set level
4b Monitor (30 liters) when 1st level lights up (below 30 liters).] Red LED
Lamp lights up for about 30 seconds when

starting switch is turned to HEAT position, then
5 Preheating During preheating blinks (for about 10 seconds) to show that pre-
Pilot heating is finished and then goes off. Green
When one-touch
6 One-touch decelerator Lamp lights up when one-touch decelerator
deceleration operates operates.
Lamp
When charging
is defective Lamp lights up when starting switch is turned
7 Charge level (charge voltage to ON position and goes off after engine
Caution < battery voltate)starts. Lamp is turned off when normal and on Red
when abnormal.
Below set pressure (If trouble occurs while engine is running,
8 Engine oil (49 kPa {0.5 kg/
pressurre buzzer sounds.)
cm2})
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
10-156 PC78MR-6
(1)
METER DISPLAY UNIT (FOR EU SPEC.)
Display
No. Display type Display item Display range Display method color Remarks
Time is measured while engine is running

1 Service meter 0-99999.9 h (alternator is generating) (Lamp always lights
up even if starting switch is at OFF position.)
If electric control system has trouble, 3
[*1] alphanumerics (user code, service code) is Blue LCD
2 Display 3 alphanumerics displayed. In depth 0 set mode, depth from
datum plane is displayed.
3a Gauge drawing. ments below it light up.
Coolant [Monitor lamp blinks when 8th level lights up
temperature Above set
3b Monitor temperature (above 99C). Monitor lamp blinks and alarm Red LED
(99C) buzzer sounds when 9th level lights up.]
4a Gauge drawing. Blue LCD
ments below it light up.
Fuel level [Monitor lamp blinks and alarm buzzer sounds
Below set level
4b Monitor (30 liters) when 1st level lights up (below 30 liters).] Red LED
Lamp lights up for about 30 seconds when

starting switch is turned to HEAT position, then
5 Preheating During preheating blinks (for about 10 seconds) to show that pre-
Pilot heating is finished and then goes off. Green
When one-touch
6 One-touch decelerator Lamp lights up when one-touch decelerator
deceleration operates operates.
Below set pressure

7 Overload (12.7 MPa {130 kg/ Lamp
cm2})
Lamp lights up when starting switch is turned
When charging to ON position and goes off after engine starts.
8 Caution Charge level is defective Lamp is turned off when normal and on when Red
(charge voltage abnormal.
< battery voltate) (If trouble occurs while engine is running,
buzzer sounds.)
Below set pressure
9 Engine oil (49 kPa {0.5 kg/
pressurre
cm2})
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
PC78MR-6 10-156-1
(1)
MONITOR SWITCH UNIT
No. Name Function Operation

Switch used to select 1 of 2 travel speeds
Travel speed selec-
1 When Lo lamp is ON: Low travel speed Lo io Hi
tor switch
When Hi lamp is ON: High travel speed
Switch used to set movement and power of work
equipment
Working mode When E lamp is OFF: Active mode (For heavy load Active (OFF) io E
2
selector switch work) (Lamp OFF)
When E lamp is ON: E mode (For work in which fuel
consumption is more important)
Switch used to operate front glass wiper
When ON lamp is ON: Wiper operates continuously. OFF (Lamp OFF) o INT (Intermittent) o
3 Wiper switch
When INT lamp is ON: Wiper operates intermittently. ON (Continuous)
When all lamps are OFF: Wiper is stopped.
[When wiper is stopped]
ON: Washing liquid spouts and wiper
operates continuously.
OFF:After switch is released, wiper
operates by 2 cycles continuously
and then stops.
Windshield washer
4 Switch used to spout washing liquid over front glass [When wiper is operating intermittently]
switch
ON: Washing liquid spouts and wiper
operates continuously.
OFF:After switch is released, wiper
operates for 2 cycles continuously
and then starts intermittent opera-
tion again.
a The boldfaced letters in the operation column

denote the position to which each switch is reset
when the starting switch is turned to the "ON"
position.
PC78MR-6 10-157
MAINTENANCE STANDARD SENSORS
SENSORS
The signals from the sensors are input directly to the panel or controller.
The sensors are classified into 3 of contact type, resistance type, and electromagnetic type.
Either of each sensor of contact type must be connected to the chassis ground.
Type of display Type of sensor Sensing method When normal When abnormal
Caution Engine oil pressure Contact OFF (Open) ON (Closed)
Coolant temperature Resistance

Gauge
Fuel level Resistance
Engine speed Electromagnetic
Engine oil pressure sensor
1. Plug 3. Contact 5. Spring

2. Contact ring 4. Diaphragm 6. Terminal
Function
This sensor is installed to the engine cylinder block to sense oil pressure with diaphragm (4). If the oil pres-
sure lowers below the set level, the switch is turned on and the signal is sent to the monitor panel.
Coolant temperature sensor
1. Connector 2. Plug 3. Thermistor
Function
This sensor is installed to the engine cylinder block. It senses changes of temperature by changes of the
resistance of thermistor (3) and sends the change signals to the monitor panel.
10-158 PC78MR-6
(1)
Fuel level sensor
1. Float 3. Connector
2. Arm 4. Variable resistor
Function
This sensor is installed to the fuel tank and
its float (1) moves up and down according to
the fuel level. Float (1) operates variable
resistor (4) through arm (2) and sends the
signals to the monitor panel.
PC78MR-6 10-159
(1)
Engine speed sensor
Wire Housing
Magnet Connector
Terminal
Function
This sensor is installed to the engine flywheel cover. It counts the number of teeth which pass in front of it and
sends the signals to the controller.
Reference: Number of teeth of ring gear: 110
10-160 PC78MR-6
(1)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE ........................... 20- 2

Standard value table for engine .................. 20- 2
Standard value table for chassis ................. 20- 3
Standard value table for electrical parts .......20- 11
TESTING AND ADJUSTING.......................... 20-101
TROUBLESHOOTING ................................... 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the
safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized peo-
ple near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be carught in the fan, fan belt or other rotating parts.
PC78MR-6 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Machine Model PC78MR-6
Engine S4D95LE-3
Standard Value for

Item Measurement Conditions Unit Service Limit Value
New Machine
High idling (When mounted on machine) 2,020 50
Revolving speed Low idling (When mounted on machine) rpm
Rated revolving speed 1,850
At sudden acceleration Max. 3.5 6.0

Exhaust gas color At high idling Bosch Index Max. 1.0 2.0
Valve clearance (At nor- Air intake valve 0.35

mm
mal temperature) Exhaust valve 0.50
MPa Min. 2.94 2.06

Compression pressure Oil temperature: 40 60 C
{kg/cm2} {Min. 30} {21}
(SAE15W-40 oil) (Engine speed)
(rpm) 320 360
Blow-by pressure (Water temperature operating range) Pa Max. 490 {50} 980 {100}
(SAE30 oil) At rated output {mmH2O} reference value reference value
(Water temperature operating range)
0.34 0.54 0.25

(SAE30)
{3.5 5.5} {2.5}
At high idling
(SAE10W) 0.29 0.49 0.21
MPa
Oil pressure {3.0 5.0} {2.1}
{kg/cm2}
(SAE30) Min. 0.18 0.15

{Min. 1.8} {1.5}
At low idling
Min. 0.15 0.13
(SAE10W)
{Min. 1.5} {1.3}
Oil temperature All revolution range (In oil pan) C 90 110 120
Fuel injection timing Before compression top dead center (Deg.) 5 0.75 5 0.75
Deflection under
finger pressure of
Tension of fan belt 6 10 6 10
approx. 58.8 N {6
kg}
mm
Deflection under
Tension of air compres- finger pressure of
sor belt approx. 58.8 N {6 6 10 6 10
kg}
20-2 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Cate- Standard Value Service Limit

Item Measurement Conditions Unit
gory for New Machine Value
Engine speed
Hydraulic oil temperature: 45 55 C

Engine water temperature: Within operating
At relief of 1 pump rpm Min. 1,800 Min. 1,800
range
Relief of 1 pump....Arm DUMP relief
Max. 95
Boom control lever N o RAISE, LOWER 85 10
Min. 75
Arm control lever N o IN, OUT Max. 95

85 10
Min. 75
Max. 95
N o CURL, DUMP
Stroke of control lever, pedal stroke
Bucket control lever 85 10

Min. 75
Swing control lever N o LEFT, RIGHT Max. 95

Center of 85 10
Min. 75
lever grip
Boom swing control End of pedal Max. 23
N o LEFT, RIGHT 21 2
pedal Read Max. mm Min. 19
value through
Max. 59
Blade control lever stroke end N o RAISE, LOWER 53 6 Min. 47
Stop engine
N o FORWARD, Max. 127
Travel control lever 115 12
REVERSE Min. 103
Forward Max. 39
Attachment control N o FORWARD, Forward 37 Min. 35
pedal REVERSE Reverse 23 Reverse Max. 25
Min. 21
Play of control lever Max. 10 Max. 15
Boom control lever 15.7 3.9 Max. 24.5

{1.6 0.4} {Max. 2.5}
Arm control lever 15.7 3.9 Max. 24.5

{1.6 0.4} {Max. 2.5}
12.7 2.9 Max. 21.6

Bucket control lever
Measure operating effort of each control lever {1.3 0.3} {Max. 2.2}
Operating effort of control lever
by installing push-pull scale to center of its

Swing control lever grip. 12.7 2.9 Max. 21.6
{1.3 0.3} {Max. 2.2}
Measure operating effort of each control pedal
by installing push-pull scale to its end.
Boom swing control 78.4 19.6 Max. 117.7
pedal Read Max. value through stroke end. N {8.0 2} {Max. 12}
Stop engine. {kg}
25.5 6.9 Max. 39.2
Blade control lever {2.6 0.7} {Max. 4.0}
Forward 22.54.9 Forward Max. 31.0

Attachment control {2.30.5} {Max. 3.2}
pedal Reverse 36.34.9 Reverse Max. 50.9
{3.70.5} {Max. 5.2}
24.5 5.9 Max. 39.2

Lever
{2.5 0.6} {Max. 4.0}
Travel control lever
74.5 18.6 Max. 107.6
Pedal {7.6 1.9} {Max. 11}
PC78MR-6 20-3
Standard
Cate- Value for Service Limit
gory Item Measurement Conditions Unit New Value
Machine
Boom 26.5 0.98 26.5 1.47

{270 10} {270 15}
26.5 0.98 26.5 1.47

Arm {270 10} {270 15}
26.5 0.98 26.5 1.47

Bucket {270 10} {270 15}
Boom swing 26.5 0.98 26.5 1.47

{270 10} {270 15}
Swing With blade 20.5 0.98 20.5 1.47
Relief pressure with engine at full throt- {210 10} {210 15}
tle (Relieve only circuit to be mea-
Oil pressure
sured) MPa 12.74 + 01.95 12.74 1.47

RAISE
{kg/cm2} {130 15} {130 15}
Blade
21.08 0.98 21.08 1.47
LOWER
{215 10} {215 15}
Travel 26.5 0.98 26.5 1.47

{270 10} {270 15}
3.14 + 00.2 3.14 + 0.3

0
Control
{32 + 02 } {32 + 03 }

Lowering of oil Difference between relief pressure at Max. engine speed
pressure Max. 20 Max. 20
and relief pressure at 1/2 of rated engine speed (Pres-
sure at relief of 1 pump)
Position of work equipmentMax. Reach
Overrun of deg 40 10 Max. 60

swing (mm) {297 74} {Max. 446}
Run engine a full throttle

Deviation of swing circle made when it stops after swing-
ing 1 turn
Value in { } is deviation of periphery of swing circle
Swing
2.2 0.3 Max. 2.8

90 sec
{2.6 0.3} {Max. 3.2}
Time required
to start swing-
ing
Run engine at full throttle
Hydraulic oil temperature: 45 55 C 3.7 0.3 Max. 4.3
180
Time required to swing 90 and 180 {4.1 0.3} {Max. 4.7}
from starting point
Value in { } is measured under rated
bucket load
20-4 PC78MR-6
Standard
Service
Cate- Value for
gory Item Measurement Conditions Unit New Limit
Machine Value
Position of work equipment Max. Reach
Time required to
finish swinging sec 30 2 Max. 35

Time required to swing 5 turns after swinging 1 turn
Position of work equipment: Extend to Max. reach with bucket under

rated load or filled with dirt and sand
Swing
(Rated load: 450 kg)
Hydraulic drift of mm 0 0
swing (deg) (0) (0)

Swing upper structure to 45 on slope of 15
Make match marks on swing circle outer race and track frame
Measure deviation of marks made in 15 minutes

Leakage from /
Hydraulic oil temperature: 45 55 C Max. 3.5 Max. 7.0
swing motor min.
Relieve swing circle
Position of work equipment
Low speed 34 3 41
Travel speed (1)

Hydraulic oil temperature: 45 55 C 25 3 30
High speed {23 2} {28}
Raise either track and measure time required to
move 5 turns after finishing 1 turn.
{ }: Rubber shoe specification
Travel
sec
Position of work equipment
26 2 28
Low speed
{25 2} {20}
Travel speed (2)
Run engine at full throttle 17 2 21

Hydraulic oil temperature: 45 55 C High speed
{15.5 2} {19.5}
Measure time required to travel 20 m after run-up
of at least 10 m on flat surface
{ }: Rubber shoe specification
PC78MR-6 20-5
Standard
Service
Cate- Value for
Machine Value
Position for measurement

Travel deviation Measure deviation made during travel of 20 m after run-up mm Max. 300 330
of at least 10 m on flat surface
Measure on firm and level place
Travel
a Measure distance x
Leakage from Hydraulic oil temperature: 45 55 C

swivel joint cc/min. Max. 10 Max. 50
(Each port) Apply relief pressure to port to be measured
Hydraulic drift of mm 0 0
travel
Stop engine
Stop machine on slope of 30 with sprocket up
Measure hydraulic drift of travel made in 5 minutes

Leakage from
travel motor Hydraulic oil temperature: 45 55 C /min. Max. 4.5 Max. 7.0
Lock shoes and relieve travel circuit
20-6 PC78MR-6
Standard
Service
Cate- Value for
Machine Value

Whole work
equipment
(Hydraulic drift of Max. 350 Max. 600
bucket tooth tip)
Boom cylinder
(Retraction of cyl- Max. 8 Max. 12
inder)
Hydraulic drift
Arm cylinder Measure extension and retraction of each cylinder and

(Extension of cyl- Max. 41 Max. 62
inder) hydraulic drift of bucket tooth tip from above position mm
Measure on level and flat surface
Bucket: Apply rated load of 4,413 N {450 kg}
Set lever in neutral
Stop engine
Bucket cylinder Hydraulic oil temperature: 45 55 C
(Retraction of cyl- Max. 25 Max. 38
inder) Start measurement just after setting
Measure hydraulic drift every 5 minutes and judge after
15 minutes
Stop engine
Blade Hydraulic oil temperature: 45 55 C
(Hydraulic drift of Max. 20 Max. 30
blade tip Measure hydraulic drift of blade tip from Max. height in
15 minutes
Work equipment
Leakage from cylinder Hydraulic oil temperature: 45 55 C

cc/min. Max. 1.5 Max. 7.5
(Each cylinder) Apply relief pressure to cylinder to be measured

Boom 3.2 0.3 Max. 4
Bucket tooth on RAISE (To just before (To just before
ground cushion) cushion)
Max. extension of LOWER 3.1 0.3 Max. 3.7

cylinder
Work equipment speed

sec
3.3 0.3 Max. 4.1
Arm IN (To just before (To just before
Max. retraction of cushion) cushion)
cylinder
Max. extension of 2.9 0.3 Max. 3.5

cylinder DUMP (To just before (To just before
Run engine at full throttle cushion) cushion)
PC78MR-6 20-7
Standard
Service
Cate- Value for
Machine Value

Bucket
Max. retraction of CURL 3.2 0.4 Max. 4.0
cylinder
Max. extension of DUMP 2.3 0.3 Max. 3.1

cylinder

Work equipment speed
Boom swing Swing (R.H.) 6.7 0.4 Max. 7.6

Swing (R.H.)
Swing (L.H.) Swing (L.H.) 4.5 0.4 Max. 5.3

Work equipment

sec
Blade RAISE 1.3 0.3 Max. 2.1
Blade on ground
Max. height of blade LOWER 1.3 0.3 Max. 2.1


Time lag
Boom Max. 2 Max. 3.9

Retract arm and bucket cylinder fully and lower boom
from Max. height.
Measure time from when bucket touches ground until
when machine body rises.
20-8 PC78MR-6
Cate- Standard Service Limit

Item Measurement Conditions Unit Value for New
gory Machine Value
Arm 0 Max. 1.0

Set upside of boom level and retract bucket cylinder fully.
Extend bucket cylinder and measure time from when arm
stops on lower side until when arm starts moving again.

Time lag
sec
Bucket 0 Max. 1.0
Work equipment

Set upside of boom level and retract bucket cylinder fully.
Extend bucket cylinder and measure time from when arm
stops on lower side until when arm starts moving again.
Blade Max. 1.0 Max. 2.0

Lower blade from Max. height and measure time from
when blade touches ground until when machine body rises.
Discharge of hydraulic pump
Piston See following See following

See following pages /min.
pump pages pages
PC78MR-6 20-9
Cate- PC78MR-6 (With blade)

gory Main pump discharge
Performance of hydraulic pump
Rated pump speed: 1,850 rpm
Discharge pressure of test

Check- Average pressure Standard discharge Lower limit of criterion
point pump (MPa {kg/cm2}) ( /min.) ( /min.)
(MPa {kg/cm2})
Any P1 (P2) P1 (P2) See graph See graph
a Avoid measuring near a bend of the graph since the error is large there.
a When measuring without removing the pump from the machine, if the engine speed cannot be set to the specified level
with the fuel control dial, calculate the pump discharge pressure at the specified speed from the actual engine speed
and measured pump discharge.
20-10 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRIC PARTS
STANDARD VALUE TABLE FOR ELECTRIC PARTS

Compo- Con- Inspec-
Sys Measurement Condi-
nent nector tion Criteria
tem tions
Name No. Method
If the condition is within the range shown in

the table below, it is normal.
Between (1), (11) chassis ground 20 30 V
Measurement
1) Turn starting
switch OFF.
voltage
Source Since power is constantly supplied, volt-
M97 2) Insert T-adapter.
voltage age is detected even if starting switch is 3) Turn starting
turned OFF.
switch ON.
Between (2), (12) , (22) chassis ground 20 30 V

Between M97 (38) (13) 20 28 V

Measurement
1) Turn starting
PPC main switch OFF.
voltage
pressure M97
When safety 2) Insert T-adapter.
lock sole- M13
noid lock lever is at 20 30 V 3) Turn starting
FREE M13 switch ON.
When safety Between (1) (2)
lock lever is at Max. 0 V
LOCK

Swing the table below, it is normal.
RIGHT stop M97 1) Turn starting
Between (15) (23) 940 50 mmA switch OFF.
solenoid
Measurement
2) Insert T-adapter.
of current
3) Turn starting
switch ON.
Controller

the table below, it is normal. 4) Exclude part near
Swing LEFT swing stroke end.
stop M97
Between (5) (23) 940 50 mmA
solenoid
If the condition is within the range shown in 1) Turn starting

Measurement

of voltage
Potentio switch OFF.

power- M95 2) Insert T-adapter.
Between (22) (21) 5 0.5 V 3) Turn starting
source
switch ON.
If the condition is within the range shown in the table below,

it is normal.
Model PC78MR-6
Measurement
Between M96 (37) M95 (10) Max. 1 V 1) Turn starting

of voltage
switch OFF.
Model M95 2) Insert T-adapter.
selection M96 Between M96 (27) M95 (10) Min. 7 V
3) Turn starting
switch ON.
Between M96 (7) M95 (10) Max. 1 V
Between M96 (30) M95 (10) Max. 1 V
If the condition is within the range shown in the table below,

it is normal
Measurement
Boom 1) Turn starting

of voltage
When boom is raised Between Max. 1V switch OFF..

RAISE
M95 M95 (12) 2) Insert T-adapter.
pressure chassis 3) Turn starting
switch When in neutral ground 5 0.5 V switch ON.
PC78MR-6 20-11
Inspec-
Sys- Component Connector tion Criteria
Measurement
tem Name No. Conditions
Method
If the condition is within the range shown in the table
below, it is normalTurn starting switch OFF.
When machine swings Between

1) Turn starting
Measurement
When arm is moved IN (24) - chas- Max. 1 V
Swing, arm switch OFF.
of voltage
When machine travels sis ground
IN, travel Between 2) Insert T-
pressure M95
(6) - chassis adapter.
switch ground 3) Turn starting
Between switch ON.
When in neutral (18) - chas- Max. 1 V
sis ground

below, it is normal 1) Turn starting
switch OFF.
Measurement
Between (8) (21) 3.8 4.8 V 2) Insert T-

Boom swing
of voltage
adapter.
angle poten-
M95 3) Turn starting
tiometer
signal switch ON.
4) Move right
swing to stroke
end.

below, it is normal 1) Turn starting
switch OFF.
When swing holding brake 2) Disconnect
Measurement
clear switch is OFF 20 30 V

of resistance
Swing connector.
(When normal) Between
holding 3) Insert T-
M97
Controller
brake clear (7) (13) adapter.

solenoid When swing holding brake
4) Turn starting
clear switch is ON Max. 1 V
(When cleared) switch ON.
5) Swing or move
arm in.

below, it is normal
1) Turn starting
Measurement
Between (C) (B) 0.2 7 kz

of resistance
switch OFF.
Swing 2) Disconnect
angle poten- M101 Between (B) (A) 0.2 7 kz
(Male) connector.
tiometer
Between (C) (A) 4 6 kz 3) Insert T-
adapter.

below, it is normal
1) Turn starting
Measurement
of resistance
Between M12 (male) (1) (2) 5 25 z switch OFF.

Right swing M12 2) Disconnect
stop EPC
(Male) Between M12 (male) (1), (2) chas- connector.
solenoid Min. 1 Mz
sis ground 3) Insert T-
adapter.

below, it is normal
1) Turn starting
Measurement
of resistance
Between M11 (male) (1) (2) 5 25 z switch OFF.

Left swing 2) Disconnect
M11
stop EPC (Male)
solenoid Between M11 (male) (1), (2) chassis connector.
ground Min. 1 Mz
3) Insert T-
adapter.
20-12 PC78MR-6
Sys- Connector Inspection Measurement

tem Component Name No. Method Criteria Conditions
If the condition is within the range shown in the

table below, it is normal.
1) Turn starting
Measurement of
Between M13 (Male) switch OFF.
resistance
35 80 z
PPC main pres- M13 (1) (2) 2) Disconnect
sure lock solenoid (Male) adapter.
Between M13 (Male) Min. 1 Mz 3) Connect T-
(1), (2) chassis ground
adapter.

1) Turn starting
Measurement of
Machine control
resistance
Swing holding 35 80 z
M14 (1) (2) 2) Disconnect
brake reset sole-
noid (Male) adapter.
Between M14 (Male) Min. 1 Mz 3) Connect T-
adapter.

1) Turn starting
Measurement of

resistance
35 80 z
2nd travel speed M15 (1) (2) 2) Disconnect
selection solenoid (Male) adapter.
Between M15 (Male) 3) Connect T-
Min. 1 Mz
adapter.
If the monitor panel displays as shown in Tables 1 and 2, it is normal.

Table 1 (Check and caution section).
Sensor
Monitored Item Measurement
(Input connector) Conditions Display Input
Signal
Light is
Machine monitor system
ON. Max. 1 V
Engine oil pressure Start engine.
P02 (7)
Light is
OFF. 20 30 V
Check and caution 1) Connect T-
section adapter
Light is Max. 5 V
ON.
Charge level
P02 (11) Start engine.
Light is 20 30 V
OFF.
Light is
20 30 V
ON.
Preheater
P02 (18) Stop Engine.
Light is Max. 1 V
OFF.
PC78MR-6 20-13
Com-
Sys-
ponent Connector No. Inspection Method Criteria Measurement Conditions
tem
Name
Table 2 (Gauge)
Display level resis- 1) Turn starting switch

tance (kz) OFF and insert dummy
Item indicated by gauge
(Monitor panel input
resistor or measure
resistance)
resistance of sensor.
Turn starting switch 2) Turn starting switch ON
Turn starting switch ON
OFF and check indication.
Min. Max.
Upper side 9 4.00 3.45
8 3.13 3.75
I 7 3.39 3.94
Measurement of resis- 6 3.56 4.39
tance of coolant tem-
perature gauge P02 (1)
(13) Position of indication 5 3.97 5.18
4 4.68 6.89
O 3 6.23 10.88
2 10.34 36.86
Lower side 1 33.35 37.83

Gauge
section a Blink at levels 8 and 9.
Display level resis- 1) Turn starting switch

tance (z) OFF and insert dummy
Item indicated by gauge
(Monitor panel input resistor or measure
resistance)
resistance of sensor.
Turn starting switch 2) Turn starting switch ON
OFF and check indication.
Min. Max.
Upper side 9 10 6.8
8 6.2 13.7
I 7 12.4 22.1
Measurement of resis- 6 20.0 30.5

tance of fuel level
gauge P02 (2) (13) Position of indication 5 27.6 41.0
4 37.1 54.6
O 3 49.4 77.7
2 70.3 101.9
Lower side 1 92.2 10
a Level 1 blinks.
20-14 PC78MR-6
Inspec-
Sys- Component Connector Measurement
tion Criteria
tem Name No. Conditions
Method

below, it is normal.
Check of continuity
Normal
engine oil No continuity 1) Start engine
Engine oil pres- Between termi- pressure
T6 nal chassis 2) Disconnect
sure sensor
ground terminal
Low engine Normal conti-
oil pressure nuity

Measurement of resistance below, it is normal.
Normal 1) Turn start-

temperature Approx. 40 kz ing switch
Coolant temper- Between (25 C)
M18 (Male) OFF
ature sensor (1) (2)
2) Disconnect
Approx. 3.3
105 C kz connector

Measurement of resistance
below, it is normal.
Full 25z 1) Turn start-

Between ing switch
(1) (2)
Fuel level sensor M9 (Male) Empty 105 110 z OFF
2) Disconnect
connector
Measurement of voltage
Between T4 While engine is running (at 1/2 or more of full throttle) o

(Terminal 27.5 29.5 V
Alternator R) chas-
1) Start engine
If battery is deteriorated or temperature is low, voltage
sis ground may not rise for a while after engine is started.
PC78MR-6 20-15
TESTING AND ADJUSTING
List of devices for testing, adjusting, & troubleshooting .............................................................................. 20-102

Measuring engine speed............................................................................................................................. 20-103
Measuring exhaust gas color ...................................................................................................................... 20-104
Adjusting valve clearance ........................................................................................................................... 20-105
Measuring compression pressure ............................................................................................................... 20-106
Measuring blow-by pressure ....................................................................................................................... 20-107
Testing and adjusting fuel injection timing................................................................................................... 20-108
Measuring engine oil pressure .................................................................................................................... 20-112
Adjusting engine stop solenoid ................................................................................................................... 20-113
Adjusting fuel control linkage ...................................................................................................................... 20-115
Adjusting engine speed sensor ................................................................................................................... 20-117
Testing and adjusting hydraulic pressure in work equipment, swing, and travel circuits............................. 20-118
Measuring LS differential pressure and adjusting LS valve ........................................................................ 20-121
Adjusting PC valve ...................................................................................................................................... 20-123
Testing TVC-EPC solenoid output pressure ............................................................................................... 20-123
Measuring control circuit pressure .............................................................................................................. 20-124
Measuring PPC valve output pressure ....................................................................................................... 20-125
Testing solenoid valve output pressure ....................................................................................................... 20-126
Adjusting work equipment valve and swing PPC valve .............................................................................. 20-128
Testing travel deviation ............................................................................................................................... 20-129
Testing parts which can cause hydraulic drift of work equipment ............................................................... 20-131
Measuring oil leakage from swing and travel motors .................................................................................. 20-132
Releasing residual pressure from hydraulic circuit ..................................................................................... 20-133
Testing clearance of swing circle bearing ................................................................................................... 20-134
Testing and adjusting track shoe tension .................................................................................................... 20-135
Bleeding air from hydraulic circuit ............................................................................................................... 20-136
Replacement procedure of potentiometers ................................................................................................. 20-138
Procedure for testing diode ......................................................................................................................... 20-139
PC78MR-6 20-101
TESTING AND ADJUSTING LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING
LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING

Items to Be Sym-
Tested/Adjusted bol Part No. Part Name Remarks
Digital indication L: 60 2,000 rpm

1 799-203-9000 Multi-tachometer
H: 60 19,999 rpm
Engine speed A
2 6210-81-4111 Gear box
Water temperature and oil B 799-101-1500 Digital thermometer -50 1,200 C

temperature
Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa

799-101-5002 Hydraulic tester kit
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester Pressure gauge 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic gauge Pressure gauge 1.0 MPa {10 kg/cm2}
799-101-5160 Nipple PT1/8
3 799-101-5220 Nipple 10 mm P = 1.25

Oil pressure C
07002-11023 O-ring
(Both male and female) 9/16-18 UNF

799-401-2910 Nipple
(Female: PT1/8)
4
02896-11008 O-ring
07043-00108 Nipple PT1/8 (Hexagon hole)
5 799-401-2701 Differential pressure

gauge
1 795-502-1590 Compression gauge 0 6.9 MPa {0 70 kg/cm2}

Compression pressure D Kit No.: 795-502-1205
2 795-502-1370 Adapter
Blow-by pressure E 799-201-1504 Blow-by checker 0 4,900 Pa {0 500 mmH2O}
Valve clearance F Purchased Filler gauge
1 790-201-9000 Handy smoke checker

Discoloration 0 70% (with standard color)
Exhaust gas color G
2 Purchased Smoke meter (Discoloration % x 1/10 Bosch index)
Operating effort H Purchased Push-pull scale
Stroke and hydraulic drift I Purchased Scale
Work equipment speed J Purchased Stopwatch
790-601-9320 Box 24-pin

1
799-601-9310 Plate Applicable to 40-pole connector
2 799-601-8000 Adapter assembly Including 21-pin box
799-601-7310 For SWP12

Troubleshooting for wiring
K 799-601-7050 For SWP6
harnesses and sensors
799-601-7520 Adapter 12 for 070
3
799-601-7360 Relay 5P
799-601-7370 Relay 6P
799-601-9200 Adapter kit
2 795-102-2102 Spring pusher

Fuel injection timing O Commercialy
3 Dial guage
available
20-102 PC78MR-6
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

1. When measuring engine speed during operation 2. When measuring engine speed during measure-
a Measure the engine speed under the follow- ment of compression pressure
ing condition. 1) Remove the cover for setting the injection
Cooling water temperature: Within oper- timing of the injection pump from the timing
ating range gear case and install gear box A2.
1) Remove clamp (1) of the high pressure injec-
tion pipe and install sensor [1] of multi-
tachometer A to injection pipe (2).
2) Install bracket [3] of multi-tachometer A1 to

gear box A2 and connect the wiring harness
to tachometer A1.
3) Revolve the engine with the starting motor
2) Connect the wiring harness of sensor [1] to according to the procedure for measuring
amplifier [2] and connect the output wiring compression pressure and measure the
harness of amplifier [2] to tachometer A1. revolving speed.
3) Start the engine and turn dial a of amplifier
[2] so that the value indicated by tachometer
A1 will be stabilized, then measure the fol-
lowing revolving speeds.
i) Low idling speed and high idling speed
Set the fuel control lever to the low idling
and high idling positions and measure
the revolving speeds at the respective
positions.
ii) Revolving speed when pump is relieved
Relieve the pump and run engine at full
throttle and measure its revolving speed.
PC78MR-6 20-103
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

When an air source and a power source are not 6) Raise the engine speed sharply and press
available in the field, use handy smoke checker accelerator pedal [3] of tool G2 simulta-
G1. When recording formal data, etc., use neously to have the filter paper absorb the
smoke meter G2. exhaust gas.
a Before measuring the exhaust gas color, 7) Place the stained filter paper on the unused
raise the cooling water temperature to the filter paper (at least 10 pieces) in the filter
operating range. paper holder and read the indicated value.
When installing and removing the measuring

instrument, take care not to touch a hot part.
1. Measuring with handy smoke checker G1

1) Install a piece of filter paper to tool G1.
2) Insert the exhaust gas suction pipe in the
exhaust pipe, then raise the engine speed
sharply and operate the handle of tool G1
simultaneously to have the filter paper
absorb the exhaust gas.
3) Remove the filter paper and compare it with
the attached scale.
2. Measuring with smoke meter G2

1) Insert probe [1] of G2 in the outlet of the a The firing order of the engine is as follows
exhaust pipe and tighten the clip to secure Firing order: 1 2 4 3
the probe to the exhaust pipe. a The air intake valves and exhaust valves may be
2) Connect probe hose [2], cable of accelerator adjusted in the firing order by revolving the
pedal [3], and air hose [4] to tool G2. crankshaft forward by 180 (4 cylinders).
a Set the supplied air pressure below 1.47 a For the valve clearance, see TESTING AND
MPa {15 kg/cm}. ADJUSTING, Failure criteria table.
3) Connect the power cable to an outlet of AC
100 V.
a When connecting the power cable, check
that the power switch of tool G2 is turned
OFF.
4) Loosen cap nut [5] of the suction pump and
fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn ON the power switch of tool G2.
20-104 PC78MR-6
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Method of adjusting valve clearance a Adjust the valve clearance according to the
1. Remove the cylinder head cover. following procedure. Loosen locknut (8) of
adjustment screw (7). Insert filler gauge A of
2. Turn the crankshaft forward and bring cylinder the specified thickness between valve stem
No. 1 to the compression top dead center and (6) and rocker arm (5) and adjust the valve
match the TOP mark line of crank pulley (5) to clearance so that the filler gauge will move
pointer (6), watching the movement of the air lightly.
intake valve of cylinder No. 4 (4 cylinders).
a The air intake valve of cylinder No. 4 (4 cylin-
ders) moves (opens) when cylinder No. 1
comes near the compression top dead cen-
ter.
5. Tighten the locknut to secure the adjustment

screw.
Locknut: 44 5.0 Nm {4.5 0.5 kgm}
3. Adjust the clearance of the valves marked with q

in the valve arrangement shown below.
4. Turn the crankshaft forward by 1 turn and adjust

the clearance on the valves marked with Q.
PC78MR-6 20-105
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

When measuring the compression pressure, 6. Disconnect wiring harnesses (2) from the termi-
take care not to touch the exhaust manifold, etc. nals of the engine stop solenoid. Revolve the
to burn yourself or the rotary parts such as the engine with the starting motor and measure the
fan, fan belt, etc. to be caught in them. compression pressure and engine speed at this
time.
1. Adjust the valve clearance accurately. For a Read the pressure gauge when its pointer is sta-
details, see Adjusting valve clearance. bilized.
2. Warm up the engine until the oil temperature is a When measuring the compression pressure,
40 60 C. measure the engine speed, too, and check that it
3. Remove nozzle holder assembly (1) of the cylin- is in the range of the measurement conditions.
der to be measured. a After measuring the compression pressure,
4. Install adapter D2 to the fitting part of the nozzle install nozzle holder assembly (1).
holder and connect pressure gauge D1.
Nozzle holder mounting bolt:
39.2 49 Nm {4 5 kgm}
5. Set the multi-tachometer to the engine.

a See Measuring engine speed.
20-106 PC78MR-6
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measure the blow-by pressure under the follow- a Normally, the blow-by pressure should be
ing condition. measured while the engine is operated at the
Cooling water temperature: rated output. In the field, however, an
Within operating range approximate value can be obtained by reliev-
Hydraulic oil temperature: 40 60C ing the hydraulic circuit.
a If it is impossible to run the engine at the
1. Install the nozzle of blow-by checker E to blow- rated output or relieve the hydraulic circuit,
by hose (2). measure while the engine is running at high
idling.
The value obtained in this case is about 80%
of the blow-by pressure at the rated output.
a The blow-by pressure may vary largely with
the engine condition. If the measured value
is judged abnormal, check for increase of oil
consumption, bad exhaust gas color, deterio-
ration of oil, high deterioration speed of oil,
etc. which are related to the abnormal blow-
by pressure.
2. Connect the nozzle to the gauge by the hose.
3. Set the working mode in the ACTIVE mode, run

the engine at full throttle, and relieve the arm
dump circuit.
4. When the gauge pointer is stabilized, measure

the blow-by pressure.
Do not touch a hot part or a rotary part dur-
ing measurement.
PC78MR-6 20-107
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

Adjustment by use of match marks 2. Remove front cover (3) of the fuel injection
a Apply this method usually. pump.
(Then installing the fuel injection pump to the 3. Install the fuel injection pump holder and drive
original engine without repairing it, when check- gear as one unit to the engine.
ing only the injection timing, etc.) 4. Insert the timing check pin 4.0 4.5 mm in diam-
eter and 80 mm in length on hole a of the front
1. Bring cylinder No. 1 to the compression top dead gear cover and match it to the hole of the drive
center. gear.
1) Turn the crankshaft forward and match a Check that the timing check pin enters
1.4Top line (1) on the crank pulley to pointer straight and the hole of the fuel injection
(2). pump holder is aligned with the mounting
hole of the front gear cover (in which the
mounting bolt will be inserted).
a If the holes are deviated from each other,
remove the fuel injection pump and check its
engagement with the drive gear.
2) Check that cylinder No. 1 is at the compres-

si on top de ad ce nter by the fo ll owi ng
method. If the following condition is not
obtained, turn the crankshaft one more turn.
a If the fuel injection pump is removed:
Check that C is seen at the tooth tip of 5. Remove the timing check pin and tighten each
the idler gear. bolt.
a If the fuel injection pump is installed to
the engine: Remove the head cover and
check that (both air intake valve and
exhaust valve of cylinder No. 1 have the
valve clearance).
20-108 PC78MR-6
Adjustment by delivery valve method 4. Using spring pusher O2, compress the valve
(When installing a repaired or replaced fuel injection spring and remove valve cotter (5).
pump, when checking after disassembling or replac- 5. Loosen spring pusher O2 and remove spring
ing the gear train) seat (6) and valve spring (7).
1. Remove the cylinder head cover.

2. Bring cylinder No. 1 to the compression top dead
center.
1) Turn the crankshaft forward and match injec-
tion timing line (1) on the crank pulley to
pointer (2).
2) Check that both air intake valve and exhaust
valve of cylinder No. 1 have the valve clear-
ance.
a If either or both of the valves do not have
the valve clearance, turn the crankshaft
one more turn.
6. Turn the stem of air intake valve (8) with the fin-
gers while it is in contact with the top of piston (9)
to fit it securely.
3. Remove snap ring (3) from the front end of the

rocker shaft, then remove air intake rocker arm
(4) of cylinder No. 1.
PC78MR-6 20-109
7. Apply dial gauge O3 to the valve stem end and

turn the crankshaft forward or in reverse to set
the dial gauge to 0 when its pointer starts turning
in reverse.
8. Turn the crankshaft about 45 degrees in reverse
from the compression top dead center of cylinder
No. 1.
9. Turn the crankshaft forward so that the dial
gauge indicates standard dimension a.
Standard dimension
BTDC (Deg) 5 0.75
a mm 0.3 0.08
12. Set the fuel injection lever to the FULL position.

13. Loosen the nut at the oblong hole of the injection
pump mounting flange, then loosen the injection
pump mounting bolts (14).
10. Disconnect fuel injection pipe (10) of cylinder No.

1.
11. Remove delivery valve holder (11), and remove
delivery valve (12) and spring (13) from its
inside. Then, install delivery valve holder (11)
again. 14. Turning the injection pump outward and operat-
ing the priming pump, move the injection pump
toward the cylinder block little by little and stop
when the fuel stops flowing out of the delivery
valve holder.
a If the injection pump is slanted out, the injec-
tion timing is delayed. If the former is slanted
toward the cylinder block, the latter is
advanced.
15. Tighten injection pump mounting bolts (14) alter-
nately.
16. Tighten the nut at the oblong hole of the injection
pump mounting flange.
20-110 PC78MR-6
17. Turn the crankshaft forward and check that the

pointer of the dial gauge is in the standard range
shown in the following table when cylinder No. 1
is at the top dead center (when the pointer of the
dial gauge starts moving in reverse). If the
pointer of the dial gauge is out of this range,
repeat the above steps from 7.
Dimension when cylinder is at top dead cen-
ter: 0 0.08 mm
18. Remove the delivery valve holder (11) and install

delivery valve (12) and spring (13) to it, then
install delivery valve holder (14) again.
a Replace the o-ring and copper gasket of the
delivery valve.
Tighten the delivery valve 3 times to secure
it. (If it is not tightened sufficiently, the gas-
ket may be broken.)
Delivery valve holder:

39.2 44.1 Nm {4 4.5 kgm}
19. Connect fuel injection pipe (3).
Sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}
20. Install valve spring (7) and valve seat (6).
21. Compress the valve spring with spring pusher

O2 and install valve cotter (5).
22. Install air intake rocker arm (4) of cylinder No. 1,

then install snap ring (3).
Install the snap ring securely.
23. Install the cylinder head cover.
Sleeve nut:
7.84 9.8 Nm {0.8 1.0 kgm}
PC78MR-6 20-111
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

a Measure the engine oil pressure under he follow- 3. Run the engine at low idling and high idling and
ing condition. measure the engine oil pressure at each speed.
Cooling water temperature: Within operating
range
1. Remove oil pressure pickup plug (1) (PT 1/8)

from the engine block under the alternator.
2. Install oil pressure measuring nipple C3 and con-

nect oil pressure gauge C2 (0.98 MPa {10 kg/
cm}).
20-112 PC78MR-6
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ENGINE STOP SOLENOID

1. Install ball joint (2) to solenoid (1) and tighten 3. Supply power to solenoid (1) to turn it on.
locknut (3). a If stop lever (6) and rod end (5) of the fuel
a a: Approx. 1mm (thread) injection pump are connected before the
solenoid is turned on, the solenoid cannot
pull sufficiently (the operating current flows
continuously) and the coil will burn. Accord-
ingly, do not connect them at this time.
2. Install rod (4) and rod end (5) to ball joint (2) tem-
porarily.
a Screwing depth b of rod in ball joint:
Approx. 12.5 mm
a Screwing depth c of rod end in rod: 4. Check that solenoid (1) is turned on, then con-
Approx. 10.0 mm nect rod end (5) to stop lever (6) and adjust the
length of rod (4) so that the stop lever will touch
the lever end on the service side.
a If solenoid (1) is connected to the power
source without using the machine wiring, do
not keep the PULL terminal cable connected.
(If the PULL terminal cable is kept con-
nected, the operating current flows continu-
ously and the coil will burn.)
PC78MR-6 20-113
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
a Stop lever (6) touches the lever end on the 5. Tighten nut (7) of the joint of stop lever (6) and
service side (inside the fuel injection pump). rod end (5) and insert the cotter pin.
a Play: 0 mm a Install the rod end with grease hole (8) up.
Rod end: Grease (G2-LI)
6. Lengthen rod (4) to give play to the stop lever

end on the service side.
a Play d: 1.0 2.0 mm (loosen rod by 1/2 1
turn.)
a When adjusting the length of rod (4), do not

apply force so strongly that stop lever (6) will
be pulled up more than the lever end.
a Adjust the length of the rod as shown below.
20-114 PC78MR-6
ADJUSTING ENGINE STOP SOLENOID,
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
7. Tighten locknut (8). ADJUSTING FUEL CONTROL

a At this time, take care that rod (4) will not turn
together with locknut (9). Do not twist stop LINKAGE
lever (6) forcibly.
8. Start and stop the engine 2 3 times and check 1. Adjusting control linkage
that solenoid (6) operates smoothly to stop the 1) If any part was replaced, connect the cable
engine. to the fuel injection pump governor lever
securely.
a Connect the cable to the hole at the end
of the injection pump governor lever.
2) Turn the starting switch to the ON position
and set the fuel control dial to the FULL posi-
tion.
3) Bring fuel injection pump governor lever (1)
in contact with stopper (2) on the FULL side.
4) Under this condition, pull cable (3) with force
of about 98 N {about 10 kg} and tighten nuts
(4) and (5) temporarily.
a Tighten the nuts while pulling the cable to
eliminate play.
5) Return nut (4) by 2 turns and tighten nut (5)
by 2 turns retighten them.
6) Start the engine and check that it runs at the
specified speed.
PC78MR-6 20-115
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
2. Adjusting control linkage finely 4) Tighten nuts (6) and (7).

If the control linkage cannot be adjusted by the
method in 1. above, adjust it finely with the turn- Nut: 8.8 10.8 Nm {0.9 1.1 kgm}
buckle above the cable.
When the engine speed (high idling speed) is a At this time, check that clearance A and
below the specified level B between bolt (8) and nuts (6) and (7)
1) Turn the starting switch to the ON position are 5 3.5 mm (1.5 8.5 mm).
and set the fuel control dial to the FULL posi- a At this time, check that the rubber boot
tion. (10) of the cable is not twisted.
2) Loosen nut (6) (right-hand screw) and nut (7) 5) Start the engine and check that it runs at the
(left-hand screw). specified speed.
3) Turn bolt (8) counterclockwise, seeing from
the governor lever side, to eliminate the
clearance between injection pump governor
lever (1) and full stopper (2).
4) Tighten nuts (6) and (7).
Nut: 8.8 10.8 Nm {0.9 1.1 kgm}
a At this time, check that clearance A and

B between bolt (8) and nuts (6) and (7)
are 5 3.5 mm (1.5 8.5 mm) respec-
tively.
a At this time, check that the rubber boot
(10) of the cable is not twisted.
5) Start the engine and check that it runs at the
specified speed.
When the engine speed (low idling speed) is
above the specified speed.
1) Turn the starting switch to the ON position
and set the fuel control dial to the decelera-
tion (SLOW) position.
2) Loosen nut (6) (right-hand screw) and nut (7)
(left-hand screw).
3) Turn bolt (8) counterclockwise, seeing from
the governor lever side, to lengthen the cable
and eliminate the clearance between injec-
tion pump governor lever (1) and low idling
stopper (9).
20-116 PC78MR-6
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

a Adjust the engine speed sensor for the pump
controller according to the following procedure.
a The engine G speed and engine Ne speed sen-
sor for the engine controller cannot be adjusted.
1. Screw in sensor (1) until its tip touches the tooth
tip of flywheel ring gear (2).
a Before installing the sensor check that its tip
is free from steel chips and flaws.
Threads: Hydraulic sealant
2. Return sensor (1) by 1/2 2/3 turns.

a A clearance of 0.75 1.00 mm is made
between the sensor tip and gear tooth tip.
3. Secure sensor (1) with nut (3).
Nut: 69 74 Nm {7.0 7.5 kgm}
PC78MR-6 20-117
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, AND TRAVEL CIRCUITS
a Hydraulic oil temperature for measurement:
45 55 C
Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pres-
sure of the hydraulic tank. Set the safety valve
lock lever to the LOCK position.
Measuring hydraulic pressure in boom arm,

bucket, travel, and swing circuits
1. Measuring
1) Installing pressure gauge
i) Open the top cover of the valve and
remove the side cover.
ii) Remove pressure pickup plug (1) or (2)
(10 mm, P = 1.25) and install nipple C3,
then connect oil pressure gauge C1
(58.8 MPa {600 kg/cm}
a Use plug (1) to measure the hydraulic
pressure in boom, arm, and bucket cir-
cuits and use plug (2) to measure the
hydraulic pressure in the swing and
travel circuits.
2) Measuring unload pressure
Measure the hydraulic pressure while the
engine is running at full throttle and the con-
trol lever is in neutral.
3) Measuring pump relief pressure
Measure the hydraulic pressure when each
actuator is relieved while the engine is run-
ning at full throttle.
Measuring hydraulic pressure in swing and

blade circuits
1. Measuring pump relief pressure

1) Remove the top cover of the valve.
2) Remove pressure pickup plug (3) (10 mm, P
= 1.25) and install nipple C3, then connect oil
pressure gauge (58.8 MPa {600 kg/cm}).
a See the photo.
3) Measure the hydraulic pressure when swing
or blade lower actuator is relieved while the
engine is running at full throttle.
20-118 PC78MR-6
2. Adjusting
Adjusting main relief valve for boom, arm,
bucket, swing, and travel circuits.
Remove cap (2) of main relief valve (1) and
loosen locknut (3), then adjust with adjust-
ment screw (4).
a As the adjustment screw is
rotated to the right, the pressure is
heightened, and it is
rotated to the left, the pressure is low-
ered.
a Quantity of adjustment per turn of adjustment
screw: 12.5 MPa {128 kg/cm}
Locknut: 39 49 Nm {4 5 kgm}
Cap: 39 49 Nm {4 5 kgm}
PC78MR-6 20-119
2. Adjusting Adjusting main relief valve for blade (RAISE)

Adjusting main relief valve for swing and circuits
blade (LOWER) circuits Remove cap (10) of main relief valve (9) and
Remove cap (6) of main relief valve (5) and loosen locknut (11), then adjust with adjust-
loosen locknut (7), then adjust with adjustment screw (12).
ment screw (8). a As the adjustment screw is
a As the adjustment screw is rotated to the right, the pressure is
rotated to the right, the pressure is heightened, and it is
heightened, and it is rotated to the left, the pressure is low-
rotated to the left, the pressure is lowered.
ered. a Quantity of adjustment per turn of adjustment
a Quantity of adjustment per turn of adjustment screw: 19.6 MPa {200 kg/cm}.
screw: 12.5 MPa {128 kg/cm}.
Locknut : 39 49 Nm {4 5 kgm}
Locknut : 39 49 Nm {4 5 kgm} Cap : 39 49 Nm {4 5 kgm}
Cap : 39 49 Nm {4 5 kgm}
20-120 PC78MR-6
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING

LS VALVE
1. Measuring LS differential pressure 2) Measuring with oil pressure gauge
1) Measuring with main relief differential pres- a Measure with the same gauge.
sure gauge i) Remove pump pressure pickup plug (1)
i) Remove pump pressure pickup plug (1) (on the high pressure side) and discon-
(on the high pressure side) and disconnect LS pressure hose (2) (on the low
nect LS pressure hose (2). Install nipple pressure side) and install adapter C3.
C3 to the high pressure side and nipple ii) Connect pressure gauge C1 (39.2 MPa
C4 to the LS pressure side. {400 kg/cm}).
ii) Connect differential pressure gauge C5. a Use a pressure gauge having unit
a Connect the high pressure side of divisions of 1.0 MPa {10 kg/cm}. (If a
the differential pressure gauge to the pressure gauge of 39.2 MPa {400 kg/
main relief pressure side and con- cm} is not available, one of 58.8
nect the low pressure side to the LS MPa {600 kg/cm} will do.)
pressure side. iii) Measure the pump discharge pressure
iii) Measure the LS differential pressure under the condition in Table 1.
under the condition in Table 1. Read the pointer correctly, facing the
gauge.
Table 1 iv) Measure the LS pressure under the con-
Fuel Control Differential dition in Table 1.
Operation a Read the pointer correctly, facing the
Dial Pressure {kg/cm}
gauge.
Set lever in 2.5 4.4 a LS differential pressure = (Pump dis-
FULL
neutral {25 45} charge pressure) (LS pressure)
Curl bucket
2.11 0.1
FULL (With lever at
{21.5 1}
FULL position)
PC78MR-6 20-121
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
Adjusting
1. Adjusting LS valve
a If the differential pressure is abnormal, adjust
the LS valve according to the following pro-
cedure.
a Before loosening the locknut, be sure to
make match marks.
1) Loosen locknut (3) and adjust with adjust-
ment screw (4).
rotated to the right, the pressure is
heightened, and it is
rotated to the left, the pressure is
lowered.
a Quantity of adjustment per turn of adjust-
ment screw: 1.27 MPa {13 kg/cm}.
2) After adjusting, tighten locknut (3).
Locknut: 29.4 39.2 Nm {3 4 kgm}
a After adjusting, measure the LS differen-

tial pressure, referring to Measuring
described above.
a When loosening or tightening the lock-
nut, secure adjustment screw (4) with a
spanner so that it will not be dragged.
20-122 PC78MR-6
TESTING AND ADJUSTING ADJUSTING PC VALVE
ADJUSTING PC VALVE TESTING TVC-EPC SOLENOID

a When the load is increased, the engine speed
OUTPUT PRESSURE
may lower or the engine speed may be normal Measuring
and working speed may be lower. If this trouble a Hydraulic oil temperature for measurement: 45
occurs and the pump discharge pressure and LS 55 C
differential pressure are normal, adjust the pump 1) Remove pump pressure pickup plug (1) (10
PC valve according to the following procedure. mm, P = 1.25) and install nipple C3 of the oil
a Before loosening locknut, be sure to make match pressure gauge kit and connect oil pressure
marks. gauge kit and connect oil pressure gauge C1
1. Loosen locknut (1) and adjust with adjustment (5.9 MPa {60 kg/cm}).
screw (2).
a Since the PC valve is of eccentric type, in which
direction the adjustment screw should be turned
to increase the absorption torque is unknown.
Accordingly, monitor the engine speed when
turning the adjustment screw.
2. After adjusting, tighten locknut (1).
Locknut: 29.4 39.2 Nm {3 4 kgm}
2) Start the engine and measure the oil pres-

sure under the following condition.
Table 1 Measurement Condition

Measure- Measured
Engine Monitor Output
ment Pressure MPa
Speed Current
Condition {kg/cm}
0.54 0.84
FULL Neutral 410 mA
{5.5 8.5}
Float one
0 0.2
FULL side and 100 mA
{0 2}
run idle
2.74 3.53
SLOW Neutral 900 mA
{28 36}
PC78MR-6 20-123
TESTING AND ADJUSTING MEASURING CONTROL CIRCUIT PRESSURE
MEASURING CONTROL CIRCUIT PRESSURE

Measuring 4) Start and run the engine at full throttle and
a Hydraulic oil temperature for measurement: 45 measure the circuit pressure.
55 C
Adjusting
Lower the work equipment to the ground and If the control circuit pressure is abnormal, adjust
stop the engine. Then, loosen the hydraulic oil the control relief valve according to the following
filler cap slowly to release the internal pressure procedure.
of the hydraulic tank. Set the safety valve lock 1) Loosen locknut (2) of relief valve (1) and
lever to the LOCK position. adjust with adjustment screw (3).
1) Remove the front cover front guard plate of rotated to the right, the pressure is
the valve. heightened, and it is
2) Remove pressure pickup plug (1) (10 mm, P rotated to the left, the pressure is low-
= 1.25) from the top of the solenoid valve ered.
block. a Quantity of adjustment per turn of adjustment
screw: 0.32 MPa {3.3 kg/cm}.
a After adjusting, check the set pressure

according to the procedure in 1.
3) Connect nipple C3 and install oil pressure

gauge C1 (5.8 MPa {60 kg/cm}).
20-124 PC78MR-6
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE

a Hydraulic oil temperature for measurement: a Measuring points
45 55 C
a. Blade RAISE J. LEFT swing
1. Measuring PPC valve output pressure
1) Disconnect hose (1) of the circuit to be mea- b. Blade LOWER k. Boom RAISE
sured. c. RIGHT swing l. Boom LOWER
d. LEFT swing m. Arm OUT
e. LEFT REVERSE travel n. Arm IN
f. LEFT FORWARD travel o. Bucket DUMP
g. RIGHT REVERSE travel p. Bucket CURL
h. RIGHT FORWARD travel q. Service
i. RIGHT swing r. Service
2) Install adapter C4 between hose (1) and

elbow.
3) Install oil pressure gauge C1 (5.9 MPa {60
kg/cm}) to adapter C3.
4) Run the engine at full throttle and operate the
control lever of the circuit to be measured
and measure oil pressure.
a If the output on the control valve side is low,

measure the input pressure of the PPC valve. Of
the input pressure of the PPC valve is normal,
the PPC valve is defective.
PC78MR-6 20-125
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE

a Hydraulic oil temperature for measurement: Measuring
45 55 C 1. Measuring output pressure of ON-OFF sole-
1. Measuring output pressure of boom swing noid valve.
stop EPC solenoid valve 1) Disconnect ON-OFF solenoid valve output
1) Disconnect EPC solenoid valve output hose hose and install oil pressure gauge C1 (5.9
(1) and install oil pressure gauge C1 (5.9 MPa {60 kg/cm}), using nipple C3 and C4 in
MPa {60 kg/cm}), using nipples C3 and C4 the oil pressure gauge kit.
in the oil pressure gauge kit. 2) Measure the output pressure of the solenoid
a The EPC solenoid valve is installed in the valve under the condition in Table 2.
6-spool solenoid valve assembly under a The ON-OFF solenoid valve.
the floor plate. Installed in the 6-spool soleoid valve
assembly at the front under the floor
plate.
2) Measure the output pressure under the con-

dition in Table 1.
Table 1
Oil pressure
Solenoid Name Measurement Condition Remarks
MPa {kg/cm}
3.14 0.49
While boom is swinging to right
{32 5}
1 Swing right stop EPC
1.13 0.29
Stroke end
{11.5 3}
3.14 0.49
While boom is swinging to left
Boom swing stop {32 5}
2
EPC 1.13 0.29
Stroke end
{11.5 3}
20-126 PC78MR-6
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
Table 2
Operation of Oil pressure
Solenoid Name Measurement Condition Operating Condition Remarks
solenoid MPa {kg/cm}
Oil pressure is
Set safety lock lever in 3.14 0.29
applied to PPC valve ON
PPC FREE position. {32 3}
circuit.
1 oil pressure-
ssure lock Oil pressure is not
Set safety lock lever in
applied to PPC valve OFF 0
LOCK position.
circuit.
Operate swing or boom 3.14 0.49
Brake is released. ON
swing or arm-in lever. {32 5}
Swing hold-
2 Set swing or arm-in lever
ing brake
in neutral (5 sec after Brake is applied. OFF 0
setting in neutral)
Set travel speed selector Travel speed is 3.14 0.49
ON
Travel speed switch in Hi. increased. {32 5}
3
selector Set travel speed selector Travel speed is
OFF 0
switch in Lo. decreased.
Note: Operation of solenoid valve is as follows;
When ON: Power is applied (Hydraulic oil is generated).
When OFF: Power is not applied (Hydraulic oil is 0).
PC78MR-6 20-127
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE

If the work equipment control lever or swing control
lever has excessive play, adjust it according to the
following procedure.
filler cap slowly to release the internal pressure
of the hydraulic tank. Set the safety valve lock
lever to the LOCK position.
1. Remove the PPC valve.

2. Remove bolt (1).
3. Loosen locknut (2) and screw in disc (3) until it
touches the heads of 4 pistons (4).
a At this time, do not move the pistons.
4. Fix disc (3) and tighten locknut (2) to the speci-
fied torque.
5. Install boot (1).

a The clearance between disc (3) and piston
(4) is eliminated by the above adjustment.
20-128 PC78MR-6
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION

1. Measuring when traveling
1) Set the machine in the travel posture.
a For the travel posture, extend the bucket
and arm cylinder rods fully, and hold the
boom angle at 45.
2) Travel for 10 m, then measure deviation a
when traveling for the next 20 m.
a Measure with the engine at full throttle.
a Install a hydraulic pressure gauge and
measure the pump discharge pressure a
the same time.
PC78MR-6 20-129
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
Adjusting 2. Insert hexagonal wrench (1) (Width across flats:

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

the adjustment limit, high pressure oil spurts
out. Take care extremely.

filler cap slowly to release the internal pressure
of the hydraulic tank.
1. Check the position of each adjustment plug of

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

still deviates, adjust again according to the
above procedure.
a Do not loosen the adjustment plugs more
than the adjustable range (2 turns / 720
degrees).
20-130 PC78MR-6
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT
TESTING AND ADJUSTING OF WORK EQUIPMENT
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF

WORK EQUIPMENT
a Hydraulic oil temperature for measurement: 45
55 C
1. Work equipment cylinder
a If the hydraulic drift of the work equipment
exceeds the standard value, measure the leak-
age in the cylinder according to the following pro-
cedure to see if the cause of the hydraulic drift is
on the cylinder side or control valve side.
If the leakage is less than the standard value,
the cause is on the control valve side.
If the leakage is above the standard value,
the cause is on the cylinder side.
1) Extend the rod of the cylinder to be mea-
sured and stop the engine.
2) Disconnect hoses (1) (4) on the head side 3) Run the engine at full throttle and apply relief
and block the pipes on the machine side with pressure to the cylinder bottom.
plugs.
1. Boom cylinder head hose
2. Arm cylinder head hose
3. Bucket cylinder head hose
4. Swing cylinder head hose
Take care not to disconnect the bottom hoses.
4) After 30 seconds, measure the oil leakage in

1 minute.
PC78MR-6 20-131
TESTING AND ADJUSTING MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL

MOTORS
a Hydraulic oil temperature for measurement: 45 2. Travel motor
55 C 1) Disconnect drain hose (3) of the travel motor
1. Swing motor and plug the hose.
1) Disconnect drain hose (1) of the swing motor 2) Put a block in the grouser of the track shoe
(on the hydraulic tank side). or between the sprocket and the frame to
a Plug the hydraulic tank. lock the track shoe.
2) Stick the bucket into the ground to lock the 3) Run the engine at full throttle and relieve the
swing mechanism. travel circuit.
3) Run the engine at full throttle and relieve the
swing circuit. Since a wrong operation of a lever can cause
4) After 30 seconds, measure the oil leakage in an accident, make signs and confirm the oper-
1 minute. ations security.
a After measuring 1 time, swing 180 degrees
and measure again. 4) After 30 seconds, measure the oil leakage in
1 minute.
a Measure the oil leakage several times, mov-
ing the motor little by little (shifting the valve
plate and piston from the cylinder).
20-132 PC78MR-6
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

a Since an accumulator is not installed, the resid-
ual pressure in the piping between the control
valve and each hydraulic cylinder or swing motor
cannot be released even if the control levers are
operated. Accordingly, when removing the above
piping, observe the following points.
1) Run the engine at low speed and lower the
work equipment to the ground, taking care
not to relieve the cylinder at the stroke end,
then stop the engine.
a If the hydraulic cylinder is relieved at the
stroke end before the engine is stopped,
do not perform the following work for 5 ~
10 minutes.
2) Loosen pressure release plug (4) of the con-
trol valve gradually to release the residual
pressure from the circuit.
PC78MR-6 20-133
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF SWING CIRCLE BEARING

Method of testing clearance of swing circle bear- 4. Set the arm at about right angles to the ground
ing on machine and lower the boom until the front part of the
1. Fix dial gauge with magnet (1) to the swing circle undercarriage floats.
outer ring (2) (or inner ring) (3) and apply the At this time, the front part of the upper structure
probe to the end face of the inner ring (or outer rises and the rear part lowers.
ring). Set the dial gauge to the front or rear part. 5. Read the dial gauge. The indicated value is the
clearance of the swing circle bearing.
Do not put your hand or foot under the under-

carriage during measurement.
2. Extend the work equipment to the maximum

reach and set the bucket tip to the height of the
underside of the revolving frame.
At this time, the front part of the upper structure
lowers and the rear part rises. 6. Set the machine in the position explained in 2
3. Set the dial gauge to the zero point. above again and check that the dial gauge indi-
cates zero. If the dial gauge does not indicate
zero, repeat Steps 2 5.
20-134 PC78MR-6
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

Testing Adjusting
1. Run the engine at low idling and move the a If the track shoe tension is abnormal, adjust it
machine forward by the length of the track on the according to the following procedure.
ground and stop slowly. 1. When tension is too high.
2. Place square wood bar (3) over idler (1) and car- 1) Loosen valve (1) to discharge grease.
rier roller (2).
3. Measure the maximum distance between the top
Since the high pressure grease may spurt out,
of the track and the underside of the wood bar.
do not loosen the valve more than 1 turn.
If the standard slack a is in the following
range, the shoe tension is normal.
a If the grease is not discharged sufficiently,
move the machine slowly forward and in
Specification Standard Slack a reverse.
Road liner, steel shoe 10 30 mm 2) To check that the track shoe tension is nor-
mal, run the engine at low idling and move
Rubber shoe 1 3 mm
the machine forward by the length of track on
ground and stop slowly.
3) Test the track shoe tension again. If it is still
not normal, adjust it again.
2. When tension is low
1) Supply grease through grease fitting (2).
a If the track shoe tension is not tensed
well, move the machine slowly forward
and in reverse.
Grease fitting: Grease (G2-LI)
2) To check that the track shoe tension is nor-

mal, run the engine at low idling and move
the machine forward by the length of track on
ground and stop slowly.
3) Test the track shoe tension again. If it is still
not normal, adjust it again.
PC78MR-6 20-135
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
BLEEDING AIR FROM HYDRAULIC CIRCUIT

Contents of work and procedures for bleeding air
Air bleeding item Procedure for Bleeding Air
1 2 3 4 5 6 7 8
Bleeding
air from cir- Bleeding Bleeding Bleeding
Bleeding Starting
cuit Bleeding Bleeding air from air from air from Starting
air from between air from LS air from
engine swing travel swing PPC operation
pump pump and circuit cylinders
motor motor
hydraulic circuit
Contents of work
tank
Replacing hydraulic oil
Cleaning strainer
Q Q Q Q Q Q Note) Q Note) Q
Replacing return filter element Q Q Q

Replacing or repairing pump
Removing suction pipe
Q Q Q Q Q Q
Replacing or repairing control
valve
Q Q Q Q
Replacing cylinder
Removing cylinder piping
Q Q Q
Replacing swing motor
Removing swing motor piping
Q Q Q
Replacing travel motor and swivel
Removing travel motor and swivel
Q Q Q
Replacing or removing swing
PPC circuit parts (Swing PPC
valve, piping, pressure switch,
Q Q Q
etc.)
Note: Bleed air from the swing motor and travel motor only after the oil in the motor case is drained.
1. Bleeding air from pump 2. Bleeding air between pump and hydraulic tanks.
a If the pump is operated without filling pump a If the pump is operated without bleeding air
case with hydraulic oil, it is heated abnor- from the circuit between the pump and
mally and may be broken soon. Accordingly, hydraulic tank, it is heated abnormally and
bleed all air from the pump before operating may be broken soon. Accordingly, bleed all
the pump. air.
1) Loosen air bleeder (1) installed to the drain 1) Run the engine at medium speed (approx.
port and check that oil oozes out. 1,650 rpm)
2) After bleeding air, tighten the air bleeder. 2) Operate the work equipment slowly for about
5 minutes to bleed air.
Bleeder: 7.8 9.8 Nm {0.8 1.0 kgm}
3. Bleeding air from LS circuit
a Bleed air only after the hoses of the pump,
valve, and LS circuit are replaced.
a If air is not bled from the LS circuit, the work
equipment may malfunction.
1) Loosen air bleeder (2) installed to the LS port
of the pump.
2) Run the engine at low idling for 2 minutes.
3) Operate the bucket (dump and curl bucket to
the stroke ends) for about 2 minutes.
4) After bleeding air, tighten air bleeder (2).
20-136 PC78MR-6
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
4. Bleeding air from hydraulic cylinder

a If the engine speed is heightened or the cyl-
inder is moved to the stroke end at first, the
air in the cylinder will damage the piston
packing, etc.
1) Run the engine at medium speed (approx.
1,650 rpm) and move each cylinder to about
100 mm before each stroke end 4 5 times.
a Never relieve the oil.
2) Move each cylinder to each stroke end 3 4
times.
3) Move each cylinder to each stroke end 4 5
more times to bleed air.
7. Bleeding air from swing PPC circuit
5. Bleeding air from swing motor 1) Stick the bucket into the ground to lock the
a Bleed air from the swing motor only after the swing mechanism.
oil is drained from the swing motor case. 2) Run the engine at low idling.
a If the swing motor is operated without bleed- 3) Loosen air bleeders (4) and (5) of the control
ing air from it, its bearings may be broken. valve.
1) Run the engine at low idling and loosen drain 4) Move the swing control lever through the full
hose (2). If oil oozes out, tighten the drain stroke repeatedly to check that all air is bled
hose. through bleeders (4) and (5).
a Do not swing the machine while bleeding 5) Tighten bleeders (4) and (5).
air.
2) Keep the engine speed at low idling and
Bleeder:
swing evenly at least 2 turns in each direc-
7.8 9.8 Nm {0.8 1.0 kgm}
tion.
6. Bleeding air from travel motor

a Bleed air from the travel motor only after the
oil is drained from the travel motor case.
1) Run the engine at low idling and loosen drain
hose (3). If oil oozes out, tighten the drain
hose.
2) Keep the engine speed at low idling and
swing 90? and float the track a little with the
work equipment, then run idle for 2 minutes.
3) Perform Step 2 above for each side.
PC78MR-6 20-137
TESTING AND ADJUSTING REPLACEMENT PROCEDURE OF POTENTIOMETERS
REPLACEMENT PROCEDURE OF POTENTIOMETERS

1. Remove boom swing potentiometer assemblies
(1), from the work equipment .
a Do not swing a removed potentiometer
assembly around its lever or turn the lever
unnecessarily.
2. Install potentiometer assemblies (1).
3. Be sure to reset input and output signals.
20-138 PC78MR-6
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODE
PROCEDURE FOR TESTING DIODE

Inspect a diode or a wiring harness containing a 2. Set the tester in the diode range, and the voltage
diode according to the following procedure. of the battery in it is indicated. If this voltage
Use a digital tester having a diode range. does not change, the diode doesn't have
1. Apply the red (+) test pin to the anode (P) side of continuity.
the diode, and the black (-) test pin to the cath- changes, the diode has continuity (normal)
ode (N) side. (Note).
a The current flow mark is printed on the diode 0 or near 0, the diode is shorted in it.
body. Note: A normal silicon diode indicates 450 600.
PC78MR-6 20-139
TROUBLESHOOTING
Points to remember when troubleshooting.................................................................................................. 20-202

SEQUENCE of events in troubleshooting ................................................................................................... 20-203
Point to remember when carrying out maintenance ................................................................................... 20-204
Checks before troubleshooting ................................................................................................................... 20-212
Type and location of connectors ................................................................................................................. 20-214
Connector arrangement diagram ................................................................................................................ 20-216
Connection table for connector pin numbers .............................................................................................. 20-219
Explanation of functions of electric system control mechanism .................................................................. 20-242
Display and special functions of monitor panel ........................................................................................... 20-243
TVC valve current adjustment table ............................................................................................................ 20-254
Adjusting service meter............................................................................................................................... 20-255
Method of using judgement table ................................................................................................................ 20-256
How to read flow of troubleshooting............................................................................................................ 20-258
Contents and procedure of troubleshooting ................................................................................................ 20-260
Troubleshooting for engine (S mode).......................................................................................................... 20-301
Troubleshooting for communication system (N mode)................................................................................ 20-401
Troubleshooting for controller (governor control system) (E mode)............................................................ 20-501
Troubleshooting for controller (pump control system) (C mode)................................................................. 20-601
Troubleshooting for controller (input signal system) (F mode).................................................................... 20-701
Troubleshooting for hydraulic and mechanical systems (H mode) ............................................................. 20-801
Troubleshooting for machine monitor system (M mode) ............................................................................. 20-901
PC78MR-6 20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fit-
ted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait
for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some
idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. If components 5) Other maintenance items can be checked
are disassembled immediately after a failure externally, so check any item that is consid-
occurs: ered to be necessary.
Parts that have no connection with the failure
or other unnecessary parts will be disassem- 4. Confirming the failure.
bled. Confirm the extent of the failure yourself, and
It will become impossible to find the cause of judge whether to handle it as a real failure or as a
the failure. problem with the method of operation, etc.
It will also cause a waste of man hours, parts, or a When operating the machine to re-enact the
oil and grease. At the same time, it will also lose troubleshooting symptoms, do not carry out
the confidence of the user or operator. For this any investigation or measurement that may
reason, when carrying out troubleshooting, it is make the problem worse.
necessary to carry out thorough prior investiga-
tion and to carry out troubleshooting in accor- 5. Troubleshooting
dance with the fixed procedure. Use the results of the investigation and inspec-
tion in Steps 2 4 to narrow down the causes of
2. Points to ask the user or operator. the failure, then use the troubleshooting flow-
1) Have any other problems occurred apart chart to locate the position of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1) Start from the simple points.
3) Did the failure occur suddenly, or were there 2) Start from the most likely points.
problems with the machine condition before 3) Investigate other related parts or informa-
this? tion.
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure.
failure? When were these repairs carried Even if the failure is repaired, if the root cause of
out? the failure is not repaired, the same failure will
6) Has the same kind of failure occurred occur again.
before? To prevent this, always investigate why the prob-
lem occurred. Then, remove the root cause.
3. Check before troubleshooting.
1) Check the oil level.
2) Check for any external leakage of oil from the
piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202 PC78MR-6
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
Name of customer
Type, serial number of machine
Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
Condition of failure
Work being carried out at the time of the
failure
Operating environment
Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. Pinpoint locations of failure (carry out
T-adapter troubleshooting)
Hydraulic pressure gauge kit, etc. Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
TEW00189 failure?
PC78MR-6 20-203
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric equip-

ment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one com-
ponent to another component, connectors used for con-
necting and disconnecting one wire from another wire,
and protectors or tubes used for protecting the wiring.
Compared with other electrical components fitted in
boxes or cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water, heat, or vibra-
tion. Furthermore, during inspection and repair opera-
tions, they are frequently removed and installed again,
so they are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when
handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact
between male and female)
Problems with defective contact are likely to occur
because the male connector is not properly inserted into
the female connector, or because one or both of the con-
nectors is deformed or the position is not correctly
aligned, or because there is corrosion or oxidization of
the contact surfaces.
2) Defective crimping or soldering of connectors

The pins of the male and female connectors are in con-
tact at the crimped terminal or soldered portion, but if
there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause improper con-
nection or breakage.
20-204 PC78MR-6
3) Disconnections in wiring
If the wiring is held and the connectors are pulled apart,
or components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be
damaged, or the wiring may be broken.
4) High-pressure water entering connector

The connector is designed to make it difficult for water to
enter (drip-proof structure), but if high-pressure water is
sprayed directly on the connector, water may enter the
connector, depending on the direction of the water jet.
As already said, the connector is designed to prevent
water from entering, but at the same time, if water does
enter, it is difficult for it to be drained. Therefore, if water
should get into the connector, the pins will be short-cir-
cuited by the water, so if any water gets in, immediately
dry the connector or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film
is formed on the mating surface between the male and
female pins, the oil will not let the electricity pass, so
there will be defective contact.
If there is oil or grease stuck to the connector, wipe it off
with a dry cloth or blow it dry with compressed air and
spray it with a contact restorer.
a When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
a If there is oil or water in the compressed air, the con-
tacts will become even dirtier, so remove the oil and
water from the compressed air completely before
cleaning with compressed air.
PC78MR-6 20-205
2) Removing, installing, and drying connectors and

wiring harnesses
Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the con-
nectors and not the wires. For connectors held by a
screw, loosen the screw fully, then hold the male and
female connectors in each hand and pull apart. For
connectors which have a lock stopper, press down
the stopper with your thumb and pull the connectors
apart.
a Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull the con-
nector in a parallel direction to the clip.
a If the connector is twisted up and down or to the
left or right, the housing may break.
3) Action to take after removing connectors

After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from get-
ting in the connector portion.
a If the machine is left disassembled for a long
time, it is particularly easy for improper contact to
occur, so always cover the connector.
20-206 PC78MR-6
Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water stuck to
the connector pins (mating portion).
2) Check that there is no deformation, defective
contact, corrosion, or damage to the connector
pins.
3) Check that there is no damage or breakage to
the outside of the connector.
a If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth. If any
water has got inside the connector, warm the
inside of the wiring with a dryer, but be care-
ful not to make it too hot as this will cause
short circuits.
a If there is any damage or breakage, replace
the connector.
Fix the connector securely.

Align the position of the connector correctly, then
insert it securely.
For connectors with lock stopper, push in the con-
nector until the stopper clicks into position.
Correct any protrusion of the boot and any misalign-

ment of the wiring harness
For connectors fitted with boots, correct any protru-
sion of the boot. In addition, if the wiring harness is
misaligned, or the clamp is out of position, adjust it to
its correct position.
a If the connector cannot be corrected easily,
remove the clamp and adjust the position.
If the connector clamp has been removed, be sure to

return it to its original position. Check also that there
are no loose clamps.
Since the DT 8-pole and 12-pole heavy duty wire con-

nectors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female conector
Normal locking state (Horizontal): a, b, d
Incomplete locking state (Diagonal): c
PC78MR-6 20-207
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off
with a dry cloth. Avoid washing it in water or using
steam. If the connector must be washed in water, do not
use high-pressure water or steam directly on the wiring
harness.
If water gets directly on the connector, do as follows.

Disconnect the connector and wipe off the water with
a dry cloth.
a If the connector is blown dry with compressed
air, there is the risk that oil in the air may cause
defective contact, so remove all oil and water
from the compressed air before blowing with air.
Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry
the connector.
a Hot air from the dryer can be used, but regulate
the time that the hot air is used in order not to
make the connector or related parts too hot, as
this will cause deformation or damage to the
connector.
Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected
and carry out a continuity test to check for any short
circuits between pins caused by water.
a After completely drying the connector, blow it
with contact restorer and reassemble.
20-208 PC78MR-6
3) Handling control box

1) The control box contains a microcomputer and elec-
tronic control circuits. These control all of the elec-
tronic circuits on the machine, so be extremely
careful when handling the control box.
2) Do not open the cover of the control box unless nec-
essary.
3) Do not place objects on top of the control box.

4) Cover the control connectors with tape or a vinyl bag.
Never touch the connector contacts with your hand.
5) During rainy weather, do not leave the control box in
a place where it is exposed to rain.
6) Do not place the control box on oil, water, or soil, or

in any hot place, even for a short time.
(Place it on a suitable dry stand)..
7) Precautions when carrying out arc welding
When carrying out arc welding on the body, discon-
nect all wiring harness connectors connected to the
control box. Fit an arc welding ground close to the
welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step..
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
PC78MR-6 20-209
3. POINTS TO REMEMBER WHEN HANDLING HYDRAU-

LIC EQUIPMENT
With the increase in pressure and precision of hydraulic

equipment, the most common cause of failure is dirt (foreign
material) in the hydraulic circuit. When adding hydraulic oil,
or when disassembling or assembling hydraulic equipment,
it is necessary to be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repairing
the machine in rain or high winds, or places where there
is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried out on
hydraulic equipment in the field, there is danger of dust
entering the equipment. It is also difficult to confirm the
performance after repairs, so it is desirable to use unit
exchange. Disassembly and main-tenance of hydraulic
equipment should be carried out in a specially prepared
dustproof workshop, and the performance should be
confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the openings
should be sealed with caps, tapes, or vinyl bags to pre-
vent any dirt or dust from entering. If the opening is left
open or is blocked with a rag, there is danger of dirt
entering or of the surrounding area being made dirty by
leaking oil so never do this.
Do not simply drain oil out on to the ground, collect it and
ask the customer to dispose of it, or take it back with you
for disposal.
4) Do not let any dirt or dust get in during refilling oper-

ations.
Be careful not to let any dirt or dust get in when refilling
with hydraulic oil. Always keep the oil filler and the area
around it clean, and also use clean pumps and oil con-
tainers. If an oil cleaning device is used, it is possible to
filter out the dirt that has collected during storage, so this
is an even more effective method.
20-210 PC78MR-6
5) Change hydraulic oil when the temperature is high.

When hydraulic oil or other oil is warm, it flows easily. In
addition, the sludge can also be drained out easily from
the circuit together with the oil, so it is best to change the
oil when it is still warm. When changing the oil, as much
as possible of the old hydraulic oil must be drained out.
(Drain the oil from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the circuit.) If
any old oil is left, the contaminants and sludge in it will
mix with the new oil and will shorten the life of the
hydraulic oil.
6) Flushing operations
After disassembling and assembling the equipment, or
changing the oil, use flushing oil to remove the contami-
nants, sludge, and old oil from the hydraulic circuit.
Normally, flushing is carried out twice: primary flushing is
carried out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump, control
valve, etc.) or when running the machine, carry out oil
cleaning to remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3) particles that the filter built into the
hydraulic equipment cannot remove, so it is an
extremely effective device.
PC78MR-6 20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
Value
1. Check fuel level, type of fuel Add fuel
2. Check for impurities in fuel Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level Add oil

4. Check hydraulic oil strainer Clean, drain
5. Check swing machinery oil level Add oil
6. Check engine oil level, type of engine oil Add oil
7. Check coolant level Add coolant
8. Check dust indicator for clogging Clean or replace
9. Check hydraulic oil filter Replace
1. Check for looseness, corrosion of battery terminal, wiring Tighten or replace
equipment
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace
1. Check for abnormal noise, smell Repair
mechanical
equipment
Hydraulic,
2. Check for oil leakage Repair
3. Carry out air bleeding Bleed air
1. Check battery voltage (Engine stopped) 20 - 30 V Replace

2. Check battery electrolyte level Add or replace
3. Check for discolored, burnt, exposed wiring Replace
Electrical equipment
4. Check for missing wiring clamps, hanging wire Repair

5. Check for water leaking on wiring (Pay particular attention to water leaking Disconnect
connector and dry
on connectors or terminals)
6. Check for blown, corroded fuses Replace
After running for sev-
7. Check alternator voltage (Engine running at 1/2 throttle or above) eral minutes: Replace
27.5 ~ 29.5 V
8. Sound of actuation of battery relay (When starting switch is turned ON,

OFF)
20-212 PC78MR-6
TROUBLESHOOTING TYPE AND LOCATION OF CONNECTORS
TYPE AND LOCATION OF CONNECTORS

a The addresses in the follwing table are the addresses used in the connector arrangement drawing
(3-dimensional drawing).
Con- No. Con- No.

Add- Add-
nector Type of Location ress nector Type of Location ress
No. Pins No. Pins
A/C X 1 Air conditioner compressor L7 K20 M 8 Cab inlet R6
D4 SWP 2 Diode (Engine stop solenoid) H1 K21 S 8 Cab inlet R6
D5 SWP 2 Diode (Battery relay BR) G1 K23 5 Starting motor cut-out relay R8
D6 SWP 2 Diode (Battery relay BR) G1 K26 090 2 Horn switch M7
D11 SWP 2 Diode (TVC solenoid) R7 K27 SWP 6 Fuel governor control motor N7
D12 SWP 2 Diode (TVC solenoid) R8 K28 M 3 PPC hydraulic lock switch P2
Diode (PPC basic pressure

D13 SWP 2 Q8 K32 5 Accelerator relay O8
lock solenoid)
D22 SWP 2 Diode (Air conditioner com- H1 K33 5 Decelerator relay N8

pressor)
Diode (Engine stop solenoid Intermediate connector
D25 SWP 2 G1 K42 SUMITOMO 16 P8
relay) (Reset switch)
D26 SWP 2 Diode (Engine stop solenoid H9 K45 M 1 Ground (Radio) Q3

relay)
D30 SWP 2 Diode (PPC basic pressure R7 K51 090 20 Intermediate connector M7
lock solenoid) (Starting, light switch)
D31 SWP 2 Diode (Swing RIGHT stop R7 K52 M 3 Light switch N8

circuit)
D32 SWP 2 Diode (Swing RIGHT stop R6 K53 M 2 Buzzer cancel switch O8
circuit)
Revolving warning lamp
D33 SWP 2 Diode (Swing LEFT stop circuit) Q8 K54 M 3 P8
(Optional)
D34 SWP 2 Diode (Swing LEFT stop circuit) P8 M1 L 2 Intermediate connector M4

(Power supply, ground)
Overload warning cancel Intermediate connector
EU1 M 2 R5 M2 X 2 M4
switch (*1) (Power supply)
Intermediate connector
FB1 Fuse box R3 M3 DT (Gr) 8 M4
(Rotation sensor, etc.)
GND Terminal 1 Key stop solenoid L2 M4 DT (G) 8 Intermediate connector M4

(Swing angle sensor, etc.)
HOLD Terminal Intermediate connector

1 Key stop solenoid L2 M5 DT (Gr) 8 M3
(TVC solenoid)
K1 S 12 Intermediate connector M7 M6 DT (B) 8 Intermediate connector M3

(Monitor panel) (Related to pressure switch)
K2 S 16 Intermediate connector N7 For connection of boom

M7 DT (G) 8 M3
(Monitor panel) pressure sensor (*1)
2nd travel speed selection
K3 DT 2 O2 M9 DT 2 Fuel sensor I2
solenoid valve
Boom swing LEFT stop sole-
K11 SWP 12 Auto A/C unit O2 M11 DT 2 N2
noid
K12 M 2 Resister P8 Boom swing RIGHT stop

M12 DT 2 N2
solenoid
K17 X 2 Optional power supply unit P2 M13 DT 2 PPC hydraulic lock solenoid M2
K18 090 2 Decelerator switch Q2 M13 M 2 Speaker (Right) I9
K19 PA 9 Radio R3 M14 DT 2 Parking brake solenoid N2
20-214 PC78MR-6
(1)
TROUBLESHOOTING TYPE AND LOCATION OF CONNECTORS
Con- No. Con- No.

Add- Add-
nector Type of Location ress nector Type of Location ress
No. Pins No. Pins
M15 DT 2 Travel speed shifting sole- M2 P15 040 2 Sunlight sensor (Optional) M6
noid
M16 DT 2 Engine speed sensor J3 PULL Terminal 1 Key stop solenoid L3
Revolving frame ground

M17 X 1 Glow plug K8 T1 Terminal 1 I2
(Controller system)
Engine water temperature
M18 DT 2 sensor L8 T2 Terminal 1 Revolving frame ground H2
Revolving frame ground

M20 DT 2 TVC/EPC solenoid K8 T3 Terminal 1
(Controller SIG system)
H1
Pressure switch
M21 X 2 (Boom RAISE) G9 T4 Terminal 1 Alternator (Terminal R) L6
M22 X 2 Pressure switch (Swing) I9 T5 Terminal 1 Alternator (Terminal B) L6
M23 X 2 Pressure switch (Swing) G9 T6 Terminal 1 Engine oil pressure switch L5
M24 X 2 Pressure switch (Arm IN) H9 T9 Terminal 1 Battery relay (Terminal E) A4
M25 X 2 Pressure switch (Travel) I9 T10 Terminal 1 Battery relay (Terminal BR) A3
M26 L 2 Fusible link C8 T11 Terminal 1 Battery relay (Terminal M) A6
M27 L 2 Fusible link B8 T12 Terminal 1 Battery relay (Terminal B) A5
Intermediate connector
M28 DT 2 (Working lamp) J9 T16 Terminal 1 Engine stop solenoid relay K3
M30 X 2 Safety relay (S, R) J3 T17 Terminal 1 Engine stop solenoid relay K3
M31 KES 2 Windshield washer C8 T31 Terminal 1 Safety relay (Terminal B) K3
M32 DT 2 Travel/Swing alarm J2 T32 Terminal 1 Safety relay (Terminal C) L5
M35 L 2 Junction wiring harness K1 T33 Terminal 1 Starting motor (Terminal B) L7
M36 DT 2 Engine stop solenoid J2 T34 Terminal 1 Starting motor (Terminal C) L6
M71 M 2 Room light J9 W04 M 6 Wiper motor M5
M73 M 2 Speaker (Left) J9 W19 2 Cigarette lighter M5
M75 DT 2 Working lamp D9 B Terminal 1 Starting switch (Terminal B) M9
M80 040 2 Horn M2 BR Terminal 1 Starting switch (Terminal BR) M8
Boom bottom pressure sen- Starting switch (Terminal

M92 DT 3 D2 ACC Terminal 1 M8
sor (*1) ACC)
M95 DRC23 24 Controller R8 C Terminal 1 Starting switch (Terminal C) M9
M96 DRC23 40 Controller Q8 R1 Terminal 1 Starting switch (Terminal R1) N8
M97 DRC23 40 Controller Q8 R2 Terminal 1 Starting switch (Terminal R2) N8
Boom swing angle potenti-

M101 DT 3 F1
ometer
P01 040 12 Monitor panel M6
P02 P040 20 Monitor panel M6
PC78MR-6 20-215
(1)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM

20-216 PC78MR-6
(1)
PC78MR-6 20-217
(1)
20-218 PC78MR-6
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
Num- X-Type Connector

ber of T-adapter Part
Pins Male (Female Housing) Female (Male Housing)
Number
1 Part Number: 08055-00181 Part Number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
Part Number: 08055-00282 Part Number: 08055-00292
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
Wire size: 0.85 Wire size: 0.85

Grommet: black Grommet: black
Quantity: 20 pieces Quantity: 20 pieces
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410

Grommet: red Grommet: red
PC78MR-6 20-219
Num- SWP-Type Connector

Number
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
20-220 PC78MR-6
Num- SWP-Type Connector

Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:

Grommet: black Grommet: black
Terminal part number: Terminal part number:

Grommet: red Grommet: red
PC78MR-6 20-221
Num- M-Type Connector

Number
1 Part Number: 08056-00171 Part Number: 08056-00181 799-601-7080
BWP04718
2 BWP04717 799-601-7090
3 BWP04719 BWP04720 799-601-7110
4 BWP04721 BWP04722 799-601-7120
6 BWP04723 BWP04724 799-601-7130
8 799-601-7340
BWP04725 BWP04726
20-222 PC78MR-6
Num- S-Type Connector

Number
BWP04728
8 BWP04727 799-601-7140
10 BWP04729 BWP04730
(White) 799-601-7150
12 BWP04731 BWP04732 799-601-7350

(White)
16 BWP04733 BWP04734 799-601-7330

(White)
PC78MR-6 20-223
Num- S-Type Connector

Number
BWP04736
10 BWP04735
(Blue)
12 BWP04737 BWP04738
(Blue) 799-601-7160
16 BWP04739 BWP04740 799-601-7170

(Blue)
20-224 PC78MR-6
Num- MIC-Type Connector

Number
Body Part Number: 79A-222-2640 Body Part Number: 79A-222-2630
7
(Quantity: 5 pieces) (Quantity: 5 pieces)
11 Body Part Number: 79A-222-2680 Body Part Number: 79A-222-2670

BWP04742
BWP04741
5 799-601-2710

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

PC78MR-6 20-225
Num- MIC-Type Connector

Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740


20-226 PC78MR-6
Num- AMP040-Type Connector

Number
BWP04752
8 BWP04751 799-601-7180
Housing Part Number: 79A-222-3430
12 BWP04753 BWP047544 799-601-7190
16 BWP04755 BWP04756 799-601-7210
20 BWP04757 BWP04758 799-601-7220
PC78MR-6 20-227
AMP070-Type Connector
Num-
ber of
Pins Male (Female Housing) Female (Male Housing) T-adapter Part
Number
BWP04760
10 BWP04759 799-601-7510
Part Number: 08195-10210
12 BWP04761 BWP04762 799-601-7520
14 BWP04763 BWP04764 799-601-7530
18 BWP04765 BWP04766 799-601-7540
20 BWP04767 BWP04768 799-601-7550
20-228 PC78MR-6
Num- L-Type Connector

Number
BWP04770
2 BWP04769
Num- PA-Type Connector

Pins Male (Female Housing) Female (Male Housing) Number
BWP04772
9 BWP04771
Num- BENDIX MS-Type Connector

Number
BWP04774
10 BWP04773 799-601-3460
PC78MR-6 20-229
Num- KES1 Automobile-Type Connector

Number
BWP04776
BWP04775
2
Part Number: 08027-10210 (Natural color) Part Number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778
BWP04779 BWP04780
4
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6
08027-10620 (Black) 08027-10670 (Black)
20-230 PC78MR-6
Num- KES1 Automobile-Type Connector

Number
BWP04784
BWP04783
8
08027-10820 (Black) 08027-10870 (Black)
PC78MR-6 20-231
Num- Socket-Type Connector for Relay

Number
BWP04786
5 BWP04785 799-601-7360
BWP04788
6 BWP04787 799-601-7370
20-232 PC78MR-6
Num- F-Type Connector

Number
BWP04786
BWP04785
4
PC78MR-6 20-233
The pin number is also marked on the connector (Electric wire insertion end).
Type HD30 Series Connector

(Shell
Size T-adapter Part
Body (Plug) Body (Receptacle)
Code) Number
Pin (Male Terminal) Pin (Female Terminal)
Part Number: 08191-11201, 08191-11202, Part Number: 08191-14101, 08191-14102,

08191-11205, 08191-11206 08191-14105, 08191-14106
18-8
Pin (Female Terminal) Pin (Male Terminal) 799-601-9210
(1)

08191-12205, 08191-12206 08191-13105, 08191-13106

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
(2) Pin (Female Terminal) Pin (Male Terminal)
Part Number: 08191-22201, 08191-22202 Part Number: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-234 PC78MR-6

(Shell
Size T-adapter Part
Code) Number
18-20 Part Number: 08191-31201, 08191-31202 Part Number: 08191-34101, 08191-34102

(3) 799-601-9230
Pin (Female Terminal) Pin (Male Terminal)
Part Number: 08191-32201, 08191-32202 Part Number: 08191-33101, 08191-33102

18-21 Part Number: 08191-41201, 08191-42202 Part Number: 08191-44101, 08191-44102

(4) 799-601-9240
PC78MR-6 20-235

(Shell
Size T-adapter Part
Code) Number

24-9 (5) 799-601-9250


24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-236 PC78MR-6

(Shell
Size T-adapter Part
Code) Number
Part Number: 08191-74101, 08191-74102, 08191-

Part Number: 08191-71201, 08191-71202,
74105,
24-21 08191-71205, 08191-71206 08191-74106
(7) 799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
Part Number: 08191-81201, 08191-81202, 08191- Part Number: 08191-84101, 08191-84102, 08191-
24-22 81203, 08191-81204, 08191-81205, 08191-81206 84103, 08191-84104, 08191-84105, 08191-84106
799-601-9280
Part Number: 08191-82201, 08191-82202, 08191- Part Number: 08191-83101, 08191-83102, 08191-
82203, 08191-82204, 08191-82205, 08191-82206 83103, 08191-83104, 08191-83105, 08191-83106
PC78MR-6 20-237

(Shell
Size T-adapter Part
Code) Number

24-31 08191-91205, 08191-91206 08191-94105,08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-238 PC78MR-6
No. DT Series Connector

of T-adapter Part
Pins Body (Plug) Body (Receptacle)
Number
2 799-601-9020
Part Number: 08192-12200 (Normal type) Part Number: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC78MR-6 20-239
No. DT Series Connector

of T-adapter Part
Number
8GR:799-601-9060
8B:799-601-9070
8
8G:799-601-9080
8BR:799-601-9080
Part Number: 08192-1820T (Normal type) Part Number: 08192-1810T (Normal type)
08192-2820T (Fine wire type) 08192-2810T (Fine wire type)
12GR:799-601-9110
12B:799-601-9120
12 12G:799-601-9130
12BR:799-601-9140
Part Number: 08192-1920T (Normal type) Part Number: 08192-1910T (Normal type)
08192-2920T (Fine wire type) 08192-2910T (Fine wire type)
20-240 PC78MR-6
No. DTM Series Connector

of T-adapter Part
Number
2 799-601-9000
No. DTHD Series Connector

of T-adapter Part
Number
Part Number: 08192-31200 (Contact size #12) Part Number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC78MR-6 20-241
(1)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM

CONTROL MECHANISM
Machine model: PC78MR-6
The control mechanism of the electric system consists of the monitor panel, governor, and pump controller.
Those components receive signals necessary to them. The governor and pump controller output or input the
necessary signal according to the signals selected by the monitor panel to control the absorption torque, engine
output, etc.
Network information
1) Working mode (Standard, E) information (Monitor panel o Controller)

2) One-touch slow-down (ON/OFF) signal (Monitor panel i Controller)
3) Travel Hi/Lo signal (Monitor panel i Controller)
4) Coolant temperature (Water temperature) information (Monitor panel o Controller)
20-242 PC78MR-6
(1)
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL

1. Diagnostic function of lamps, gauges, and buzzer
If the starting switch is turned ON, all the lamps and gauges light up for about 3 seconds and the buzzer
sounds for about 1 second to check the monitor panel, then the monitor panel displays normally (A lamp
which does not light up at this time is broken).
2. Function of displaying "user code"
All trouble information items of the controller are sent to the monitor panel. An emergent information item
among them is displayed as a "user code" automatically on the display (1) of the monitor panel to urge the
operator to take proper actions.
a The lamps other than display (1), service meter unit (2), and lighting parts (solid parts in the following illus-
tration) are turned OFF.
1) Display of User Code

(1) Display
(2) Service meter unit
(3) Mode selector switch (UP)
(4) Mode selector switch (DOWN)
(5) Set switch
(6) Travel speed selector switch
(7) Working mode selector switch
(8) Buzzer cancel switch
Note) Although switches are not indicated on
3, 4, and 5 of the panel, the functions
are installed to the parts at the tips of
the arrows.
Example) User code "E02" is displayed.
2) User Codes List

User Code Abnormal system
E02 TVC-EPC system
E03 Swing holding brake system
E05 Governor control system
E40 Angle sensor input system
E41 EPC solenoid output system
PC78MR-6 20-243
3. Function of displaying "service code"
All trouble information items of the controller are sent to the monitor panel. All of the information items which
must display "user codes" and those which do not need display "user codes" are saved as "service codes"
in the monitor panel.
If the following operation is executed, the service code is displayed on the display of the monitor panel and
the letter "E" to indicate that the trouble is happening currently and the lapse time (service meter reading)
are displayed on the service meter unit.
1) Method of displaying and deleting service

(1) Display (5) Set switch
code
(2) Service meter unit (6) Travel speed switch
i) The service code is displayed by the fol-
(3) Mode selector switch (7) Working mode
lowing procedure:
(UP) selector switch
(1) Push and hold the "Buzzer cancel
(4) Mode selector switch (8) Buzzer cancel
switch (8)" and "Working mode selec-
(DOWN) switch
tor switch (7)" for 2.5 seconds.
(2) Push the "Buzzer cancel switch (8)"
and "Mode selector switch (UP) (3)"
[or Mode selector switch (DOWN)
(4)] and set "01" tothe 2nd and 3rd
columns from the left on service
meter unit (2).
(3) Push the "Set switch (5)".

the arrows.
Example 1) "01" is displayed on service
meter unit (2).
Example 2) "E213" happened 6 hours

ago.
a If "E213" is still happening, the letter
"E" is displayed in the 2nd column of
service meter unit (2). If "E213" has
been repaired, "E" is not displayed.
a The lapse time is displayed in the 3
columns from the right of service
meter unit (2).
20-244 PC78MR-6
Example 3) If any service code is not iv) To stop display of the service code, push
saved, "-" is displayed in the "Buzzer c ancel switch (8)" and
every column of display (1) "Working mode selector switch (7)".
and service meter unit (2). v) To delete the saved service codes, press
ii) To see the next displayed service code, the "Buzzer cancel switch (8)" and turn
push the "Buzzer cancel switch (8)" and OFF the "starting switch" simultaneously,
"Mode selector switch (UP)" (3). then turn ON the "starting switch" again
iii) To see the previous displayed service and push and hold the "Buzzer cancel
code, push the "Buzzer cancel switch (8)" switch (8)" for 5 seconds.
and "Mode selector switch (DOWN) (4)". a If the number of service codes
exceeds 20, they are deleted one by
one from the oldest one.
2) Service codes list

Error Code Abnormal System User Code
E101 Error history data are abnormal
E108 Engine coolant temperature is 105C
E112 Short circuit in forward system of wiper motor drive
E113 Short circuit in reverse system of wiper motor drive
E114 Short circuit in windshield washer drive system
E115 Wiper does not start wiping in 10 seconds
E116 Wiper is not retracted in 10 seconds
E203 Short circuit or grounding fault in swing holding brake solenoid system E03
E206 Short circuit or grounding fault in 2nd travel speed selection solenoid system E03
E213 Disconnection in swing holding brake solenoid system
E216 Disconnection in 2nd travel speed selection solenoid system
E218 Abnormality in communication between monitor panel and controller
E227 Short circuit or grounding fault in engine speed sensor system
E232 Short circuit or grounding fault in TVC-EPC Solenoid system E02
E233 Disconnection in TVC-EPC Solenoid system E02
Short circuit with chassis ground or disconnection on boom bottom pressure sen-
(*1) E251
sor (overload sensor) signal side or (+) side or disconnection on (-) side.
E258 Grounding fault on power source side of angle sensors
E304 Short circuit or grounding fault in engine stop solenoid relay system
E314 Disconnection in engine stop solenoid relay system
E323 Grounding fault in governor control accelerator relays system E05
E325 Grounding fault in governor control decelerator relays system E05
E328 Abnormality in governor control motor stal E05
E412 Abnormality in boom swing angle sensor (Short circuit in power supply) E40
E413 Abnormality in boom swing angle sensor (Disconnection) E40
E414 Defective correction of boom swing angle sensor
E451 Short circuit in boom swing LEFT stop EPC system E41
E452 Disconnection in boom swing LEFT stop EPC system E41
E453 Short circuit in boom swing RIGHT stop EPC system E41
E454 Disconnection in boom swing RIGHT stop EPC system E41
E501 Machine model not set
E502 Defective machine model selection signal
PC78MR-6 20-245
(1)
4. Function of displaying "monitoring code"
The input signals from the sensors to each component and the output signals to drive the solenoids can be
checked in real time with the monitoring codes.
If the following operation is executed, the monitoring code No. is displayed in the 3rd column through the 5th
column from the left on service meter unit (2) of the monitor panel and the monitoring information is dis-
played on display (1).
1) Method of displaying monitoring code

(1) Display (5) Set switch
i) The monitoring code is displayed by the
(2) Service meter unit (6) Travel speed switch
following procedure:
(3) Mode selector switch (7) Working mode
(1) Push and hold the "Buzzer cancel
(UP) selector switch
switch (8)" and "Working switch (7)"
(4) Mode selector switch (8) Buzzer cancel
for 2.5 seconds.
(DOWN) switch
(2) Push the "Buzzer cancel switch (8)"
and "Mode selector switch (UP) (3)"
[or Mode selector switch (DOWN)
(4)] and set "02" to the 2nd and 3rd
columns from the left on display (2).
(3) Push the "Set switch (5)".
the arrows.
Example 1) A numerical monitoring

code (Engine speed: 2,050
rpm) is displayed.
Example 2) A bit pattern monitoring code

1020 (ON/OFF input state (1)) is
displayed.
20-246 PC78MR-6
ii) To see the next displayed monitoring

code, push the "Buzzer cancel switch (8)"
and "Mode selector switch (UP) (3)".
iii) To see the previous displayed monitoring
code, push the "Buzzer cancel switch (8)"
and "Mode selector switch (DOWN) (4)".
iv) To stop display of the monitoring code,
push and hold the "Buzzer cancel switch
(8)" and "Working mode selector switch
(5)" for 2.5 seconds.
2) Monitoring codes list

a For details of a code marked with "(6 bit)" in the Unit column, see the bit patterns table.
Compo-
Code No. Item Unit
nent Name
0001 Monitor model code - Controller
0008 S-NET connection state (6bit) Controller
0041 Water temperature sensor voltage 10 mA Controller
0042 Fuel level sensor voltage 10 mA Controller
0043 Charge voltage 100 mA Controller
0045 Sensor input 1 (6bit) Controller
0046 Sensor input 2 (6bit) Controller
0047 Output state (6bit) Controller
0048 Wiper state (6bit) Controller
0049 Spare Controller
0200 Software version No. (Monitor) Controller
Software version No. If 1.0 is displayed, version No. of control-
1000 Controller
(Controller) ler is 1.0.
1001 Attachment selection 00: Standard arm Controller
1010 Engine speed 10 rpm Controller
1020 ON/OFF input 1 (6bit) Controller
1024 ON/OFF input/output (6bit) Controller
1033 Boom swing angle sensor voltage V Controller
1050 EPC output current (TVC) 10 mA Controller
EPC output current
1052 If 55 is displayed, current is 55 mA. If cur- 10 mA Controller
(Boom swing LEFT stop)
rent is 1 A, however, FF is displayed.
EPC output current
1053 10 mA Controller
(Boom swing RIGHT stop)
1060 ON/OFF output (6bit) Controller
PC78MR-6 20-247
3) Bit patterns list (Bits of corresponding Nos.

light up)
a [1] - [6] on digital display unit (1) are bit
Nos.
a The monitoring code No. (4 digits) is dis-
played in the 2nd column through 5th col-
umn from the left on service meter
display unit (2).
Code No. Item Bit Details (State When Bit Lights Up)
(1) ID2 is connected.
0008 S-NET connection state
(1) Starting switch is at "ON"
(2) Starting switch is at "START"
0045 Sensor input 1
(3) Starting switch is at "PREHEAT"
(4) Light switch is at "ON"
(2) Constant bit
0046 Sensor input 2 (3) Engine oil pressure (When low)
(6) Charge level is low (Engine is stopped)
0047 State of output (1) Buzzer output
(2) Washer output (Washer switch is turned ON)
(3) Wiper output 1
0048 State of wiper (4) Wiper output 2
(5) Wiper output 3
(6) Wiper output 4
(2) Buzzer cancel switch
(3) Window limit switch (ON)
0049 Spare
(4) W contact (Wiper is operated)
(5) P contact (Wiper is operated)
(1) ATT selection 2 (GND is connected)
ON/OFF input 1 (2) ATT selection 1 (GND is connected)
For detail of model (3) Model selection 1 (GND is connected)
1020 selection, see Table 1.
For detail of ATT selec- (4) ATT selection 3 (GND is connected)
tion, see Table 2. (5) UU/US selection (GND is connected)
(6) Model selection 2 (GND is connected)
(1) MR selection (GND in connected)
(3) Compressor signal
1021 ON/OFF input 2
(4)
(5) (a) Tier 2 selection signal (When power source is connected)
20-248 PC78MR-6
Code No. Item Bit Details (State When Bit Lights Up)
(1) 2nd travel speed selection switch (Panel)
(2) Working mode selector switch
(3) Backup light
1022 ON/OFF input 3
(4) SET/CLEAR switch
(5) Mode selector (E) switch
(6) Mode selector (R) switch
(3) Travel pressure switch
(4) Swing pressure switch
1023 ON/OFF input 4
(5) Arm IN pressure switch
(6) Boom RAISE pressure switch
(1) Deceleration signal
(2) Acceleration signal
(3) Motor drive power supply
1024 ON/OFF input/output
(4) Auto deceleration signal
(5) Motor relay (-)
(6) Motor relay (+)
(1)
(2) Display selector switch (Monitor)
1025 ON/OFF input/output
(3) Arm ground angle alarm cancel switch
(6) Bucket dump prohibition solenoid + Rotary lamp
(1) Deceleration switch
(2) Alarm cancel
1026 ON/OFF input/output (3) Emergency work equipment operation switch
(4) 2nd travel speed selection switch (Pedal)
(5) Slide arm limit switch
(1) Swing holding brake switch (Brake is released)
(2) PPC main pressure lock (Main pressure lock is reset)
1060 ON/OFF input/output 2nd travel speed is selected (Machine travels at 2nd gear
(4)
speed)
(5) Travel/Swing alarm (Alarm is output)
PC78MR-6 20-249
Table 1
Model selection table
Model Selection 1 Model Selection 2
PC78MR-6 GND OPEN
Table 2
1:Connection of the attachment selection wires is shown.
(The bits of GND are displayed during normal operation.)
Connection table of attachment selection wires

Attachment Attachment Selection (1) Attachment Selection (2) Attachment Selection (3)
Standard specification
Standard arm GND OPEN OPEN
20-250 PC78MR-6
Procedure for correcting angle sensor

Back mode (When SP monitor is used)
Table 2 Method of selecting back mode and ordinary display
Back Mode
01 02 06
Mode
Code These modes are set to 2 levels (Note 8)
Emergency Error
(Note 3) Trouble Error Correction Previous Memory
Next Item
(Note 4) Memory Monitoring of potenti- Item Deletion
(Note 6)
Display ometer (Note 6)
PC78MR-6 Q Q Q
B Buzzer cancel Q Q Q Q Q Q
Working mode
a
selection
b Travel
c SET/CLEAR Q Q Q
d Model selection (E) Q
e Model selection (R) Q
Wiper selection
Washer
Continuous opera-
2.5 5 (Note 1)
tion time (SEC)
Note 1) Limited to 5 seconds after the power is turned ON.
Note 3) Displayed on the service meter unit.
Note 4) A flag from the controller is a trigger.
Note 6) Used to save monitoring error.
Note 8) Select with Buzzer cancel + Working mode selection. Select next or previous items with Buzzer can-
cel + E/R. Enter each mode with the SET/CLEAR switch.
Since the suitches "c, d and e" are not indicated on the panel of model MR, operate the same parts as
the panel of model MR.
PC78MR-6 20-251
"06" Correction of boom swing angle sensor

The stroke end is saved for initial setting of each cylinder (portion where the angle sensor is installed).
No. Operation Display
(1) Set the starting switch to the ON position or run the "S-1" is displayed on the display section.
engine, and then hold warning buzzer cancel switch (B)
and working mode selector switch (a) for 2.5 seconds or
longer.
1
(2) Set the code of the service meter section to "06".
(B) + (d): Increase code.
(B) + (e): Decrease code.
(3) Press switch (c).
Set the machine in "position 1" and press switch (c). After switch (c) is pressed, "ooo" is displayed, and
(Position 1) then "S-2" is displayed on the display section.
Boom swing RIGHT end
When normal
If the system is not reset normally, " " flashes. When abnormal
Set the machine in "position 2" and press switch (c). After switch (c) is pressed, "ooo" is displayed, and
(Position 2) then " " is displayed on the display section.
Boom swing LEFT end When normal
(Completion of setting)
3
If the system is not reset normally, " " flashes.

When abnormal
(Flashing)
To finish monitoring, perform the operation of 1-(1), and the

4
monitor panel returns to the ordinary display state.
a If the system is not reset normally, the data UU monitor panel
before writing are deleted and the initial data are
applied. Accordingly, be sure to reset again.
* Although switches are not indicated on 3, 4,
and 5 of the panel, the functions are installed
to the parts at the tips of the arrows.
B: The buzzer cancel switch is installed to the right

console.
20-252 PC78MR-6
"20" How to improve exhaust gas color at high altitude

Adjust the TVC current in this mode to reduce the pump absorption torque and improve the exhaust gas
color at high altitude.
a The work equipment speed, travel speed, and swing speed are lowered by the following operation.
a The following operation is not necessary for the normal work.
No. Operation Display
1) Turn the starting switch ON or run the engine and hold
buzzer cancel switch (B), travel speed shifting switch (b),
and switch (c) for 2.5 seconds.
2) Adjustment code (3) is displayed (flashed) at the left 2
positions and set value (4) is displayed (lighted) at the
1 right 1 position on display unit (1). "5-5E7" (S-SET) is dis-
played on service meter unit (2).
Although switches are not indicated on b, c, and d of the
panel, the functions are installed to the parts at the tips of
the arrows.
Adjustment code "20" flashes. Set the adjustment code with

switch (c).
2
The flashing adjustment code lights up.
The lighting set value flashes.
Increase or decrease the set value with switches (d) or (e)
and set it with switch (c).
(d): Code is increased.
(e): Code is decreased.
3
The lighting adjustment code flashes again.
The flashing set value lights up again.
For details of the adjustment code and set value, see the
TVC valve current adjustment table.
To finish adjustment of the TVC valve current, perform Step Change of setting is completed.
1-1), and the monitor panel returns to the normal display
state.
4 The set value is saved when the monitor panel returns to
the normal display state.
[ 1] Flashing: Code/Set value can be changed.
Caution: If the mode is reset forcibly by turning the starting
[ 2] Lighting: Code is selected/set.
switch OFF, the set value is not changed.
To initialize the set value of the TVC valve current adjustment
mode, set the adjustment code and the set value to "40" and
5 "1" respectively with switches (d) and (e), and then finish the
adjustment mode.
Note) If switch (d) or (e) is pressed at Step 2, the UU monitor panel

adjustment code changes. Accordingly, do
not press those switches.
B: The buzzer cancel switch is installed to the right

console.
PC78MR-6 20-253
TROUBLESHOOTING TVC VALVE CURRENT ADJUSTMENT TABLE
TVC VALVE CURRENT ADJUSTMENT TABLE

Adjustment code Set value
Initial Exhaust gas
(Left 2 positions of (Right 1 position of Contents
value color
display unit) display unit)
Increase pump absorption torque by +2.0 kgm
0
(-100 mA).
1
(-75 mA).
2 Bad
(-50 mA).
3
(-25 mA).
20 4 Q Initial value
Decrease pump absorption torque by -0.5 kgm

5
(+25 mA)
6 Good
(+50 mA)
7
(+75 mA)
8
(+100 mA)
20-254 PC78MR-6
TROUBLESHOOTING ADJUSTING SERVICE METER
ADJUSTING SERVICE METER

Adjust the service meter when the monitor panel
is replaced.
1. Turn the starting switch ON.
2. To set the monitor panel in the service meter

adjustment mode, hold buzzer cancel switch (8)
and press the following switches on the monitor
panel in the order of 1) - 4).
1) Travel speed switch (6)
2) Set switch (5)
3) Working mode selector switch (7)
4) Mode selector (UP) switch (3)
a If the monitor panel is set in the adjustment
mode, both ends of service meter (2) flash
alternately.
3. To select a digit to be corrected, press the buzzer

cancel switch (8), working mode selector switch
(7), and set switch (5) simultaneously. Each time The monitor panel of the MR specification also
those switches are pressed, the selected position has switches (3) (5).
moves to the left. (The selected position moves
to the left only. After it reaches to the left end, it
returns to the right end again.)
4. To set or change the figure, press the buzzer

cancel switch (8), working mode selector switch
(7), and mode selector (UP) switch (3) simulta-
neously.
5. To finish the service meter adjustment mode,

repeat Step 2.
a The currently saved service meter value can-
not be reduced (returned to a smaller value).
When the service meter adjustment is fin-
ished after the service meter is set to a large
value, that value cannot be reduced either.
Take care.
PC78MR-6 20-255
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This decision list is a tool (decision table) for selecting whether a nature of trouble of a chassis is caused by an
electrical system failure or a hydraulic or mechanical failure and advancing to troubleshooting codes (N-OO, E-
OO, S-OO , C-OO, F-OO, H-OO, M-OO) that match each event.
The decision table identifies that processing should advance to which troubleshooting codes according to the
presence of the display of user and service codes.
a The abnormality display (warning) using the monitor panel directly advances to machine monitor trouble-
shooting code (M-OO). (Refer to the machine monitor system troubleshooting.)
1. Controller (Governor Control System) or Engine Related Decision List
When a service code is displayed on the monitor panel, advance to troubleshooting code (E-OO) of the
lowermost step of the decision table.
(A q is marked to the point where a failure mode and a service code match.)
If a service code is not displayed and a nature of trouble appears in the monitor panel, advance to diag-
nostic code (E-OO or S-OO) at the right end which matches the failure mode of the decision list.
<Example> Failure mode "Engine does not start"
[Procedure] Test that a service code is displayed on the monitor panel.
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the controller
(decelerator control) system "E3:OO".
2) When a service code is not displayed on the monitor panel and "Engine does not start":
When the starting motor rotates:
Check the rotation .... Advance to mechanical system troubleshooting "S-2".
of a starting motor. When the starting motor does not rotate:
.... Advance to electrical system troubleshooting "E-8".
20-256 PC78MR-6
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
2. Controller (Pump Control System) or Oil Pressure Related Decision Table

When a service code is displayed on the monitor panel, advance to the troubleshooting code (C-OO) of
the lowermost step of the decision table.
(A q is marked to the point where a failure mode and a service code match.)
If a service code is not displayed and a nature of trouble appears in the monitor panel, check the display
of an input signal that matches the failure mode of the decision table (display the location marked with a
circle (O)) and
When an input signal is displayed normally, advance to the diagnostic code (H-OO) at the right of the
decision list.
When an input signal is not displayed, advance to the diagnostic code (F-OO) at the lowermost step of
the decision list.
<Example> Failure mode "Swing is not performed"

[Procedure] Test that a service code is displayed on the monitor panel.
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the controller
(pump control) system "C:OO".
2) When a service code is not displayed on the monitor panel and "Swing is not performed":
Check controller input When the signal is provided:
signal. .... Advance to mechanical system troubleshooting "H-34" and "C-38".
(Check it in the monitor- When the signal is not provided:
ing mode.) .... Advance to the CR700 controller input signal system troubleshooting
"F-OO". (See section F mode)
PC78MR-6 20-257
(1)
TROUBLESHOOTING HOW TO READ FLOW OF TROUBLESHOOTING
HOW TO READ FLOW OF TROUBLESHOOTING

1. Classification of diagnosis code Nos.
Diagnosis Code No. Objective System of Diagnosis Service code
S-QQ Engine body
N-QQ Communication system
E-QQ Electric system of controller (Governor control system) E323, E325, E328
C-QQ Electric system of controller (Pump control system) E232, E233
F-QQ Controller (Input signal system)
H-QQ Hydraulic and mechanical systems
M-QQ Monitor panel E1-QQ
2. How to read troubleshooting (method) for each failure mode

1) Title column
In the title column of the troubleshooting, the troubleshooting code, service code, and failure mode (trou-
ble) are entered.
2) Classification of cases
If the troubleshooting method for a failure mode (a trouble) varies with the machine model, component,
phenomenon, the failure mode (the trouble) is classified further (This work is called classification of cas-
es), execute an applicable one. (See (2) in the example.) If the cases are not classified, start trouble-
shooting from the first of the failure mode.
3) How to carry out troubleshooting
Perform checking or measurement in the first step . Then, select either branch of YES and
NO and go to the next step . (Note: The "No." at the right shoulder of each is the reference
No. It is not the No. of the step.)
If the branch of YES or NO is connected directly to the Cause column, take the remedy shown in
the Remedy column. (See (3) in the example.)
Under the , the method of inspection, measurement, judgment, etc. are shown. If the result is
matched to the criterion, question, etc., take the branch of YES. If not, take the branch of NO.
Under the , preparation work for inspection and measurement and criterion are also shown. If
your neglect the preparation work or take a wrong method of operation or handling, you may have a
wrong judgment or may damage the devices. Accordingly, read well before starting inspection and
measurement, then carry out the work in the correct order.
4) General precautions
The general precautions for troubleshooting of each failure mode (trouble) are marked with a under the
title (See (4) in the example).
The precautions marked with a are not shown in the . Be sure to take them when performing the
inspections in the .
5) Diagnostic tools
For the diagnostic tools necessary for troubleshooting, see TESTING AND ADJUSTING, Diagnostic
tools list. Prepare them before starting the work.
20-258 PC78MR-6
TROUBLESHOOTING HOW TO READ FLOW OF TROUBLESHOOTING
6) Locations and connector pin Nos.

Before starting the work, check the Nos., inspection points, types, and locations of the wiring connectors
which appear in the flow of the troubleshooting for each failure mode (trouble) with the table of locations and
Nos. of connector pins.
<Example>
(1) M-1[E101](Error history data are abnormal) is displayed
(2) a This error is displayed when the connector P01, connector K1, fuse 18, connector M6, connector M2,
battery relay terminal B, or battery terminal in the monitor panel power supply system is disconnected or
connected for troubleshooting. This phenomenon does not indicate an error.
(When the power supply circuit of the monitor panel is cut out while the starting switch is at the OFF posi-
tion.)
a If the service code is displayed again after the resetting operation is performed, carry out the trouble-
shooting according to the following procedure.
Cause Remedy
1
After resetting operation,
operate machine normally After "resetting operation", is NO
Normal
and observe its condition for service code displayed again?
a while. (See Note 1.)
YES
2
Disconnection, defective contact,
Turn starting switch OFF Is voltage between P01 (8) NO or short circuit with chassis Repair or
ground in wiring harness
20 30 V chassis ground normal? between battery battery relay B replace
M27 (1), (2) P01 (Female) (8)
YES
Defective monitor panel Replace
PC78MR-6 20-259
TROUBLESHOOTING CONTENTS AND PROCEDURE OF TROUBLESHOOTING
CONTENTS AND PROCEDURE OF TROUBLESHOOTING

If a trouble occurs, carry out troubleshooting according to the judgment table, controller (governor control sys-
tem), and controller (pump control system). For the detailed contents and procedure of the troubleshooting,
however, see the following flow.
Before starting the troubleshooting, ask the operator about the trouble as long as possible and check the follow-
ing items in advance. (1) Connecting condition of the controller (Check with monitoring code 0001), (2) Break-
age of the fuses, (3) Battery voltage, (4) Generating (charge input) voltage (Monitoring code 0043 "H-34").
E02 (PC-EPC system)
(Swing holding
brake and 2nd
YES E03 travel speed
selection sole- o Go to No. 2
noid systems)
1 (Governor motor
E05 system)
Is user E200 group: Troubleshooting for pump controller (Pump control system) (C-mode)
code dis- Carry out trouble-
played on shooting in corre-
YES sponding mode.
monitor
panel? E300 group: Troubleshooting for pump controller (Governor control system) (E-mode)
Is service code displayed on

NO monitor panel?
Operate and check ser-

vice code.
Carry out troubleshooting

YES by engine (in S-mode).
5
Engine system Is electric system
of engine with no
failure code nor-
4 mal?
Is trouble in engine sys- Flow of part of
YES tem or hydraulic judgment table
(Mechanical) system?
where no trou-
3 bles are indi-
Adjust hydraulic pres-
Is input/output sure, then judge by cated.
signal of con- engine speed.
NO NO by electric system of
troller normal? Is work equipment engine (in E-mode).
Check by always heavy and (Flow of part where there
monitoring does engine speed is no indication) (E-6 E-
lower under heavy 8)
code.
load?
Hydraulic (Carry out troubleshooting in H-

Mechanical System mode).
NO Troubleshoot by input sig-

nal system (F-mode).
a Judge the details by judgment table for controllers (governor control system) (pump control system).
For the No. and contents of monitoring, see the monitoring codes table.
20-260 PC78MR-6
TROUBLESHOOTING OF ENGINE (S MODE)
Method of using troubleshooting chart........................................................................................................ 20-302

S- 1 Starting performance is poor (Starting always takes time) ............................................................... 20-306
S- 2 Engine does not start ....................................................................................................................... 20-308
(1) Engine does not turn.................................................................................................................. 20-308
(2) Engine turns no but exhaust smoke comes out (Fuel is not being injected) .............................. 20-309
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ........................... 20-310
S- 3 Engine does not pick up smoothly (Follow-up is poor) ......................................................................20-311
S- 4 Engine stops during operations ........................................................................................................ 20-312
S- 5 Engine does not rotate smoothly (Hunting) ...................................................................................... 20-313
S- 6 Engine lacks output (or lacks power) ............................................................................................... 20-314
S- 7 Exhaust smoke is black (Incomplete combustion) ........................................................................... 20-315
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-316
S- 9 Oil becomes contaminated quickly ................................................................................................... 20-317
S-10 Fuel consumption is excessive......................................................................................................... 20-318
S-11 Oil is in cooling water, or water spurts back, or water level goes down............................................ 20-319
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)................................................................ 20-320
S-13 Oil level rises (Water, fuel in oil) ....................................................................................................... 20-321
S-14 Water temperature becomes too high (Overheating) ....................................................................... 20-322
S-15 Abnormal noise is made ................................................................................................................... 20-323
S-16 Vibration is excessive ....................................................................................................................... 20-324
PC78MR-6 20-301
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three
sections: questions, check items, and trouble-
shooting. The questions and check items are
used to pinpoint high probability causes that can
be located from the failure symptoms or simple
inspection without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right cor-
responds to the items where answers can be
obtained from the user. The items in (B) are Causes
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection
to narrow down the causes. The items under
(C) in the chart on the right correspond to this.
The serviceman narrows down the causes
from information (A) that he has obtained from (1) (2) (3)
the user and the results of (C) that he has
obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
(a)
[Check items].
Questions
A (b)
(c)
(d)
(e)
Check items
B
C
i
shooting
Trouble-
ii
iii
20-302 PC78MR-6
The basic method of using the troubleshooting

chart is as follows.
Items listed for [Questions] and [Check items]
that have a relationship with the Cause items
are marked with Q, and of these, causes that
have a high probability are marked with w.
Check each of the [Questions] and [Check
items] in turn, and marked the Q or w in the
chart for items where the problem appeared.
The vertical column (Causes) that has the high-
est number of points is the most probable
cause, so start troubleshooting for that item to
make final confirmation of the cause.
1. For (Confirm recent repair history) in

the [Questions] Section, ask the user,
and mark the Cause column with E to Causes
use as reference for locating the cause
of the failure. However, do not use this
when making calculations to narrow
on)
down the causes.
jecti
2. Use the E in the Cause column as ref-
ve in
erence for [Degree of use (Operated
si
for long period)] in the [Questions] sec-
zle
renc
xces
noz
tion as reference. As a rule, do not use
ent
erfe
p (e
r
tion
it when calculating the points for locat-
lem
inde
ing
, int
pum
n tim
er e
injec
ing the cause, but it can be included if
, cyl
rger
tion
lean
necessary to determine the order for
ectio
ring
cha
ized
injec
troubleshooting. air c
urbo
ston
, se
r inj
ctive
ged
ged
rope
ed t
n pi
Defe
Clog
Clog
Seiz
Wor
Imp
1 Confirm recent repair history
2 Degree of use Operatred for long period
PC78MR-6 20-303
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection Causes
Excessive injection of fuel
d)
d
hea
)
eize
ction
er s
e, va rger and
e inje
lung
eat
ssiv
lve s
leme nce
ck, p
ocha
le
exce
nozz
re
p (ra
nt
turb
terfe
(
er
ance
r
tion
ing
ump
le
valv
pum
n
d
er, in
ff
e
n
m
er e
injec
u
etwe
, cyli
lear
p
dm
t of
ti
ction
harg
tion
ction
lean
lve c
c
ring
gge
ized
air b
onta
injec
Legend
e inje
rboc
air c
r inje
, clo
ton
e
r va
: Possible causes (judging from Questions and check items)
f
c
s
o
ed tu
ctive
ctive
,
n pis
ectiv
kage
hed
ged
ged
rope
rope
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Crus
Defe
Clog
Clog
Seiz
Wor
Deff
Imp
Imp
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
starting engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating
on reduced cylinders
Troubleshooting
When check is made using delivery method, injection timing

is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Adjust
Adjust
Adjust
Remedy
20-304 PC78MR-6
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
PC78MR-6 20-305
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)

Possible causes of the engine not starting though exhaust gas
being discharged.
Electrical system is defective.
Causes
Fuel supply is insufficient.
Air intake is insufficient.
Fuel selection is improper.
(Under the ambient temperature of 10C or lower, use
eat
ASTM D975 No.1
)
ircuit
lve s
a Battery charging rate
ing c
d va
aer
heat
Charging rate
e an
ent
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
r
train
e
elem
der
pre-
in
f valv
20C 1.28 1.26 1.24 1.23 1.22
, stra
cylin
mp s
0C 1.29 1.27 1.25 1.24 1.23
ding
aner
act o
10C 1.30 1.28 1.26 1.25 1.24
filter
ing,
d pu
(inclu
ir cle
cont
ton r
A battery can be used if the specific gravity shows 70% or
l
e
e
e
u
a
plug
f
f
higher charging rate shown in the above table.
ctive
n pis
ging
gibg
ging
In cold weather, 75% or higher charging rate is required.
Glow
Defe
Clog
Clog
Clog
Wor
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Preheat indicator lamp does not light up.

Engine oil consumption became increased.
Filters have not been replaced according to the operation manual.
Non-specified fuel has been used for long.
Dust indicator lamp is ON.
Battery charge lamp is ON.
Starter motor runs slowly.
After engine started, some cylinders are cool when touched the exhaust
manifold.
Engine speed cannot be raised smoothly, and combustion is irregular.
Blow-by gas is excessive.
Check items
Match marks on fuel injection pump are not matched.

Mud is sticking to the fuel tank cap.
When the engine is cranked by the starter motor;
1) Even if the injection pump sleeve nut is loosened, little fuel comes out.
2) Even if the fuel filter air bleeding plug is loosened, little fuel comes out.
Leakage from the fuel piping
Engine hunting (rotation is irregular).
Compression pressure measurement found low pressure.

Direct inspection of the air element found clogging.
Direct inspection of the fuel filter and strainer found clogging.
Direct inspection of the feed pump strainer found clogging.
Troubleshooting
Heater mount section is not heated.

Is voltage 2630V between alternator terminal R and terminal E Yes
with engine at low idling? No
Either specific gravity or voltage of the battery is low.
Speed of some cylinders does not change when operating on reduced
cylinders.
When pushed, the control rack is heavy, or does not return.
(Remove the blind cover at the rear of the pump. Plunger control sleeve does
not move.)
Direct inspection of the fuel cap found clogging.
Legend
Replace
Replace
Correct

Clean
Clean
Clean
: Most probable causes (judging from Questions and check items) Remedy
20-306 PC78MR-6
Replace Defe
ctive
Replace Defe alter
nato
ctive r (ex
Replace Defe a ltern terna
ctive ator l reg
Replace o (buil ulato
PC78MR-6
Defe r deg t-in r r typ
rade egula e)
ctive d b a
Adjust Injec injec
tion t t e ry
tor ty
pe)
tion nozz
Replace Defe
timin
g fail le
tive u re
Correct Leak
injec
tion
age, pum
Clean clog p (ra
TROUBLESHOOTING
Clog ging ck a
ged , or a nd p
Replace Defe
air b
reath ir in
fuel
lung
er st
ctive er ho pipin uck)
Replace Defe f e ed p le in g
Causes
ctive ump fuel

syst
boos em
t com
pens
ator
canc
el
S-1
20-307
TROUBLESHOOTING S-2
S-2 Engine does not start

(1) Engine does not turn
Causes
General causes why engine does not turn

Internal parts of engine seized
a If internal parts of the engine are seized, carry
out troubleshooting for "Engine stops during
ch
operations".
ction
swit
Defective electrical system
it
nne
ttery
circu
fety
a l co
d ba
r sa
id
ting
eno
ch
n
otor
e
lay o
star
i
lay
t
term
swit
iora
t sol
ng m
ry re
ty re
g of
eter
ting
ttery
el cu
ear
atte
tarti
wirin
safe
or d
star
in g g
Legend
a
u
b
b
s
f
ctive
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok

Questions

Condition of horn when Horn does not sound
starting switch is turned ON Horn volume is low
Speed of rotation is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
move out
Check items
When starting switch is turned to ON, there is no clicking

sound
Battery terminal is loose
When starting switch is turned ON, linkage is not actuated
Troubleshooting of defective wiring in starting circuit
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are
Troubleshooting

3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and
terminal E
When ring gear is inspected directly, tooth surface is found to be
chipped
Cannot be moved by hand even when linkage of fuel cut solenoid
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-308 PC78MR-6
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Causes
a Standards for use of fuel
AMBIENT TEMPERATURE
KIND OF
d)
FLUID -4 14 32 50 68 86 F
eize
-20 -10 0 10 20 30
er s
ASTM D975 No. 2
y
ASTM D975 No.2
nk
lung
t, ke
el ta
n
ck, p
shaf
Diesel fuel
pisto
n fu
ASTM D975 No.1
p (ra
er
g
drive
o le i
pipin
l use e n o i d
r
mp
train
n e
pum
u
i
h
stra
tank
ump
fuel
ol
her
eed
cut s
d
pum
tion
ilter,
on p
reat
el in
king
en f
injec
uel f
fuel
air b
jecti
feed
nt fu
r f ue
, lea
Legend
brok
ctive
ctive
en in
fficie
g ed
ged
ged
g ed
rope
ed,
Defe
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Exhaust smoke suddenly stops coming out (when starting again)
Questions
Replacement of filters has not been carried out according to

Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Mud is stuck to fuel tank cap
When starting switch is turned ON, linkage is not actuated
When fuel filter is drained, fuel does not come out
When engine is cranked with starting motor,
Check items
1) Injection pump coupling does no rotate.

2) No fuel comes out even when fuel filter air bleed plug is
loosened
3) No fuel spurts out even when injection pump sleeve nut is
loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
Inspect feed pump directly

When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Even though the linkage of the fuel cut solenoid is
disconnected, it doesnot work
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
PC78MR-6 20-309
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
General causes why exhaust smoke comes out but

engine not start
Lack of rotating force due to defective electrical Causes
system
Insufficient supply of fuel
.)
r, etc
ck)
Improper selection of fuel and oil
r leve
r stu
ap
y
spra
it )
rocke
nk c
nge
circu
em
tive
el ta
, plu
syst
alve,
ating
ery
efec
n fu
k
r
r line
m (v
batt
c
fuel
t
a
e
n
aine
le, d
r
ole i
r e -h
leme
er
(
syste
te d
mp
inde
ir in
rain
p str
nozz
er h
ing p
riora
u
er e
g, a
r, st
, cyl
alve
p
d
h
pum
tion
l use
lean
tion
reat
ggin
e
l filte
ken v
rin g
u
e t
(incl
injec
or d
injec
feed
air b
air c
, clo
r f ue
Legend
e
, bro
ton
u
plug
ctive
ctive
n pis
kage
g ed
ged
ged
ged
ged
rope
ctive
Glow
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Lea
Imp
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around head
Non-specified fuel is being used
Operation Manual
Dust indicator lamp is red
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items
When engine is cranked with starting motor,

1) Little fuel comes out even when injection pump sleeve nut
is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
Troubleshooting
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-310 PC78MR-6
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick up smoothly Causes
Improper condition of fuel injction
Improper fuel used
ap
pray
seat
nk c
ve s
alve
el ta
nce
fecti
nd v
r
n fu
r
fe re
nge
r line
nt
, de
g
iner
ve a
pipin
ole i
leme
iner
inter
lu
ance
inde
e
p
stra
f val
l
nozz
stra
er h
mp
er e
fuel
ger,
lear
, cyl
ump
act o
n pu
h
ilter,
lean
tion
char
reat
king
lve c
ring
ed p
jectio
cont
uel f
injec
air c
air b
, lea
urbo
Legend
r va
n
e
o
f
f
ed in
ctive
n pis
ged
ged
rope
ged
ged
ged
ed t
ged
C lo g
Defe
C lo g
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Troubleshooting
Speed does not change when operation of certain cylinders

is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
PC78MR-6 20-311
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
Causes
Seized parts inside engine
etc.)
Overheating
)
ver,
a If there is overheating and the engine stops,
tuck
ker le
carry out troubleshooting for overheating.
er s
od
, roc
nk
lung
in g r
el ta
g
y
nt
alve
ton
arin
ck, p
t, ke
e
nect
in fu
m
p pis
m (v
t be
p
shaf
p (ra
r
g
i
aine
u
pipin
r
, con
aine
hole
q
shaf
pum
e
train
ry e
t
pum
drive
s
p str
tank
y
iston
, str
lve s
fuel
rank
her
xilia
eed
ear
pum
tion
mp
filter
el in
reat
ic va
king
ed c
ed g
ed p
ed f
a
injec
u
air b
feed
uel p
ump
nt fu
ynam
, lea
Legend
fuel
seiz
seiz
z
seiz
e i
ctive
s
en p
fficie
en f
ged
ged
ged
ged
en,
en d
en,
en,
en,
Defe
Brok
Brok
Clog
Clog
C l og
Clog
Brok
Brok
Brok
Brok
Insu
Brok
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Questions
Engine stopped slowly

There was hunting and engine stopped
Fuel level lamp lights up
Replacement of filters has not been carried out according
to Operation Manual
Engine rotates, but stops when power train is operated
Does not turn at all
Check items
When it is attempted to Turns in opposite direction

turn by hand using
barring tool Moves amount of backlash
Shaft does not turn
Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
When gear train is inspected, it does not turn
Troubleshooting
Rotates when pump auxiliary equipment is removed

found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
20-312 PC78MR-6
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (Hunting)

General causes why engine does not rotate smoothly
Causes
Air in fuel system
Defective governor mechanism
p
zzle
Defective electric governor mechanism
pum
d no
(engine with electric governor)
feed
a If hunting stops when electric governor rod is
p an
an d
disconnected, carry out troubleshooting for
pum
nk
t a nk
el ta
ack
the chassis.
feed
erno
rnor
fuel
ro l r
in fu
r
een
v
gove
een
aine
f go
low
t
ner
n
hole
of co
betw
betw
i
p str
nt o
too
stra
tank
n of
her
it
tion
stme
cuit
e d is
pum
circu
lter,
ratio
el in
reat
ir
pera
c
i
adju
f
ope
air b
air in
nt fu
air in
g sp
fuel
Legend
e
o
e
f
ctive
ctive
ctive
fficie
idlin
g ed
ged
ged
ged,
ged,
Clog
Defe
Clog
Clog
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Occurs at low idling
Condition of hunting
Questions
Occurs even when speed is raised

Occurs on slopes
to Operation Manual
Rust, water are found when fuel tank is drained
Leakage from fuel piping
When feed pump is operated,
1) No response, light, return is quick
Check items
2) No response, light, return is normal

Engine speed sometimes rises too far
Engine is sometimes difficult to stop
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
PC78MR-6 20-313
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
Causes
Improper condition of fuel injection
Improper fuel used
nt
stme
(if non-specified fuel is used, output drops)
eat
ragm
spra
lve s
adju
Lack of output due to overtaking
nk
iaph
tive
el ta
a If there is overheating and lack of output,
ce
d va
tive
efec
or d
eren
in fu
er
carry out troubleshooting for overheating.
c
e an
g
nt
e
ng
r
nsat
le, d
aine
f
f
iner
leme
, de
inter
p pl u
hole
e
i
r
p
inde
valv
c
p i
mpe
n
nozz
p str
stra
kage
a
er e
fuel
ger,
pum
her
lear
, cyl
ct of
st co
pum
lter,
er lin
tion
reat
le a n
char
king
lve c
r in g
onta
o
i
boo
njec
f
b
feed
i
air c
t
Legend
, lea
urbo
l lev
fuel
c
r va
ton
r
c
e
a i
j
i
ctive
ctive
ed in
n pis
t fue
ged
ged
ged
ged
rope
ged
ged
ed t
Defe
Defe
Clog
Clog
Clog
Clog
Clog
C log
Seiz
Seiz
Ben
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-314 PC78MR-6
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (Incomplete combustion)

General causes why exhaust smoke is black
Causes
d)
ead
on)
eize
nd h
jecti
at
er s
e se
er a
ve in
lung
v
harg
l
essi
nce
a
ck, p
timin ozzle
nd v
rboc
fere
(exc
nt
p (ra
ve a
nn
leme
n tu
inter
ance
er
fler
u mp
g
r i n je i n j e c t i o
f val
p um
ylind
twee
u f
er e
ger,
lear
on p
dm
act o
c
tion
ction
lean
ir be
char
lve c
gge
r in g
zed
jecti
injec
cont
air c
of a
Legend
, clo
u rbo
, sei
r va
n
ton
i
ctive
ctive
ctive
n pis
kage
hed
ged
rope
ge d
rope
ed t
Defe
Defe
Defe
Crus
Clog
Clog
Seiz
Wor
Lea
Imp
Imp
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
PC78MR-6 20-315
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

a Do not run the engine at idling for more than 20
Causes
minutes continuously. (Both low and high idling)
rger
General causes why oil consumption is excessive
ocha
Abnormal combustion of oil
Turb
External leakage of oil
seal
d
Wear of lubrication system
hea
ce
stem
se
a
er
ken
r f
der
r ho
cool
al su
r
, bro
r line
e sy
cylin
e
p lug
r oil
h
l, se
t
intak
ide)
brea
nde
d
nd
r
n
er o
ipin g
an o
a
rain
ine e
er e
, gu
e
, cyli
ar s
om
r or
i l f ilt
oil d
oil p
oil p
blow
ring
stem
turb
in fr
oler
e
ring
n re
o
t h
from
rom
from
m
iston
brea
i l co
al at
Legend
lve (
a l at
ked
roke
ton
r o
f
f
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
L ea
L ea
Lea
L ea
Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in damper chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-316 PC78MR-6
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
Causes
Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
Improper oil used
nd
Operation under excessive load
ee
r b in
se
er tu
e
n pip
r ho
r
r line
harg
drai
athe
inde
ide
k
rboc
blac
ger
, bre
e gu
, cyl
at tu
char
r
ke is
ther
oo le
valv
r ing
lter
urbo
seal
brea
smo
oil c
oil fi
Legend
ton
lve,
t
ctive
n pis
ged
g ed
ged
n va
g ed
aust
Defe
Clog
Clog
Clog
Clog
Wor
Wor
Exh
Questions

Non-specified oil is being used
Black
Excessive
Amount of blow-by gas
Check items
None
Carry out troubleshooting for Exhaust smoke is black.

When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly

When breather element is inspected directly, hose is
broken or is found to be clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
PC78MR-6 20-317
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Causes
Leakage of fuel
n)
jectio
ton)
e
er
nkag
el filt
p (pis
ive in
rol li
g, fu
pum
cess
nger
cont
pipin
y
feed
spra
p (ex
lu
timin
fuel
p
fuel
ump
side
nt of
lder
pum
tion
from
p
le ho
al in
stme
injec
tion
tion
age
oil se
Legend
nozz
injec
injec
adju
fuel
leak
ctive
ctive
ctive
ctive
ctive
ctive
rnal
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Exhaust smoke color Black
There is irregular combustion
Check items
When exhaust manifold is touched immediately after starting engine,

temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Speed does not change when operation of certain cylinders is stopped
Troubleshooting
When control rack is pushed, it is found to be heavy, or does not return

When check is made using delivery method, injection timing is found
to be incorrect
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-318 PC78MR-6
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
Causes
Internal leakage in lubrication system
Internal leakage in cooling system
t
aske
lock
g
g
O-rin
ea d
der b
ad, h
ting
ore,
cylin
y pit
er he
ler c
s in
b
Legend
il coo
used
ylind
rack
nal c
en o
en c
s ca
Brok
Hole
Brok
Inter
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Check
Engine oil level has risen, oil is cloudy white

items
Excessive air bubbles inside radiator, spurts back

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage

Replace
Replace
Replace
Replace
Remedy
PC78MR-6 20-319
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)

General causes why oil pressure lamp lights up
Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating
a Standards for engine oil selection
Causes
n
i l pa
i de o
g
pipin
pan
e ins
r
enso
g
aulic
azin
e oil
r
uctio n oil pip
enso
s
valv
hydr
e br
e
insid
l
urna
ve
r
essu
pan
vel s
lator
ump
n pip
f val
shed
roke
g, jo
iner
n oil
lter
n oil
r
oil le
regu
relie
oil p
oil p
oil fi
Legend
or b
stra
, cru
arin
uel i
i
i l
ctive
ctive
ctive
ctive
ctive
of o
en s
n be
ged
ged
ged
king
er, f
Defe
Defe
Defe
Defe
Defe
Lack
Brok
C lo g
Clog
Clog
Wor
Wat
Lea
Questions

Operation Manual
Caution lamp lights up
Lights up at low idling
Condition when oil Lights up at low, high idling
pressure lamp lights up
Lights up on slopes
Sometimes lights up
Check items
There is crushing, leakage from hydraulic piping (external)

Oil level sensor lamp lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
When oil filter is inspected, it is found to be clogged

Troubleshooting
for Oil level rises.
Oil pump rotation is heavy, there is play

There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
20-320 PC78MR-6
S-13 Oil level rises (Water, fuel in oil)

a If there is oil in the cooling water, carry out trouble-
Causes
shooting for Oil is in cooling waterE
ber)
General causes why oil level rises
cham
Water in oil (milky white)
stion
Fuel in oil (diluted, and smells of diesel fuel)
seal
ombu
Entry of oil from other component
t
mp
e n
e
uipm
n pu
(prec
rfac
ve
ring
u
slee
ectio
sket
k
q
s
bloc
e
, O-
seal
y
ad ga
lder
r
e inj
a
der
core
ting
l i
ear
t
auxi
d, he
osta
le ho
nsid
cylin
y pit
r
oler
r hea
ged
herm
p
art i
nozz
pum
de b
side
i l co
Legend
ama
linde
p
t
s ma
ctive
ctive
ctive
ks in
ctive
en o
en cy
n, d
Defe
Defe
Defe
Hole
Defe
Crac
Brok
Wor
Brok
Questions

There is oil in radiator cooling water
Exhaust smoke is white
When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
When water pump breather hole is clean, water comes out
Check items
Oil level goes down or damper chamber

Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel must be added more frequently
Water temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting

Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
PC78MR-6 20-321
S-14 Water temperature becomes too high (Overheating)

General causes why water temperature becomes too high Causes
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature in power train
a Carry out troubleshooting for chassis.
)
pen
ge
t
aske
y
ot o
gau
pulle
ins
ad g
es n
ure
tor f
fan
ler
, he
erat
e
t (do
o
valv
radia
worn
o
core
ting
ead
r
oil c
p
wate
osta
r te m
p
ure
p um
y pit
shed
er h
ing,
ator
ken
erm
ress
o ling
wate
de b
ylind
ater
slipp
, bro
Legend
radi
, cru
p
t
of co
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
Lack
Defe
Brok
Brok
Defe
Clog
Hole
Defe
Clog
Clog
Fan
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator tanks

is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
When water filler port is inspected, core is found to be clogged

When function test is carried out on thermostat, it does not
open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-322 PC78MR-6
S-15 Abnormal noise is made

a Judge if the noise is an internal noise or an external noise.
Causes
General causes why abnormal noise is made
.)
Abnormality due to defective parts
, etc
ead
d)
n)
tion)
Abnormal combustion
eize
ositio
lever
nd h
r
r line
njec
Air sucked in from intake system
er s
t of p
ce
cker
er a
aran
inde
ive i
l ung
e, ro
d ou
harg
e
renc
nce
s
, cyl
e cle
ck, p
le
xces
(valv
boar
rboc
nozz
fere
erfe
ring
ash
valv
p (ra
p (e
ystem
iding
n tu
inter
lt int
ackl
tion
iston
ng
t of
pum
p um
r (div
twee
lve s
injec
ushi
ain b
n be
ger,
n
of p
e
tion
tion
uffle
justm
ir be
ic va
ed b
char
n, fa
ar tr
Defe , seized
ear
injec
injec
ide m
ynam
of a
Legend
seiz
urbo
d
d fa
r ge
ve w
a
ctive
ctive
ctive
ct ins
kage
rme
rope
ged
en d
ed t
ing,
essi
Defe
Defe
Defo
Clog
Miss
Defe
Seiz
Brok
Imp
Lea
Exc
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Remedy
PC78MR-6 20-323
S-16 Vibration is excessive

a If there is abnormal noise together with the vibra- Causes
tion, carry out troubleshooting also for Abnormal
noise is made
uck)
tc. st
tion)
on
General causes why vibration is excessive
ver, e
ushi
injec
Defective parts (abnormal wear, breakage)
r)
ker le
mpe
en c
Improper alignment
sive
ring
brok
e, roc
t (da
Abnormal combustion
xces
bea
(valv
shaf
olts,
ash
in g
p (e
main
bush
ystem
ing b
ackl
tput
pu m
rod,
e ou
ain b
lve s
t
am
oun
tion
a
er, c
cting
nsid
ar tr
mic v
em
injec
art i
Legend
lanc
r ge
ngin
nne
dyna
ctive
en p
n ba
rope
n co
se e
ctive
Defe
Brok
Wor
Wor
Imp
Defe
Loo
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside of output shaft (damper) directly
Remove front cover and inspect directly
Remove head cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
20-324 PC78MR-6
TROUBLESHOOTING OF COMMUNICATION
SYSTEM
(N MODE)
N-1 Defective communication ................................................................................................................... 20-402
a When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-adapter is
removed and the connector is returned, if the service code "E" is not displayed, the condition has returned to
normal.
a If the starting switch was turned OFF after the trouble occurred, turn the starting switch ON and check that
the service code displays "E" at the head. (If "E" is not displayed, the condition has returned to normal.)
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect and disconnected connectors before going on to the next step.
PC78MR-6 20-401
TROUBLESHOOTING N-1
N-1 Defective communication

Cause Remedy
1
Is operation of monitor display switch NO
normal?
YES
Condition is normal
2
Min. 0.75 V Is voltage between M96 (Female) (21) NO
Disconnect M96 and measure chassis ground normal?
voltage on wiring harness side
YES
Defective controller Replace
3
NO Disconnection or defective contact in
Is resistance between P02 (Female) (9), Repair or
wiring harness between P02 (Female)
(10) M96 (Female) (21) normal? replace
(9), (10) M96 (Female) (21)
YES
If the communication becomes defective, the following troubles occur.

The working mode cannot be changed.
The travel speed cannot be changed with the panel switches.
The monitor lamp does not light up when the one-touch slow-down mechanism is turned on.
Normal figures are not displayed on the display and service meter unit.
A mode cannot be selected.
N-1 Electrical circuit diagram of each system
20-402 PC78MR-6
TROUBLESHOOTING FOR CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
Precautions for troubleshooting for controller (governor control system).................................................... 20-502

Action taken by controller when trouble occurs and problems on machine ............................................... 20-504
Judgment table for controller (governor control system) and engine .......................................................... 20-506
E-1 Controller power supply is defective (LED of controller is turned off)................................................. 20-508
E-2 [E323] (Short circuit in accelerator relay system) is displayed ........................................................... 20-509
E-3 [E325] (Short circuit in decelerator relay system) is displayed........................................................... 20-510
E-4 [E328] (Stall of motor) is displayed......................................................................................................20-511
E-5 [E227] (Trouble in engine speed sensor) is displayed........................................................................ 20-513
E-6 One-touch slow-down mechanism does not work.............................................................................. 20-514
E-7 Engine does not start ......................................................................................................................... 20-515
a) [E304] Short circuit in engine stop solenoid relay system is displayed .......................................... 20-515
b) [E314] Disconnection in engine stop solenoid relay system is displayed ...................................... 20-515
c) Engine stop solenoid system.......................................................................................................... 20-516
d) Starting system............................................................................................................................... 20-518
E-8 Engine does not stop.......................................................................................................................... 20-522
PC78MR-6 20-501
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM)

(GOVERNOR CONTROL SYSTEM)
1) Precautions to be taken when trouble is repaired by itself
1) When a trouble is repaired by itself.

2) When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-adapter
is removed and the connector is returned, if the service code is not displayed or the monitor displays
normally, the same trouble will occur again probably. Accordingly, follow up the condition of the machine
sufficiently.
3) After finishing troubleshooting, be sure to delete the saved service code.
2) Handling of function of saving service code
When displaying a saved service code for troubleshooting, "take the notes of the all displayed items and delete
those items", then reproduce the trouble and start the troubleshooting according to the service code displayed
at this time.
(Troubles caused by wrong operation, disconnection of a connector, etc. may be saved in the memory. In this
case, you can avoid unnecessary work by performing the above operation.)
20-502 PC78MR-6
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND
TROUBLESHOOTING PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS

AND PROBLEMS ON MACHINE
User Code Service Code Troubled System Contents of Trouble
1) Short circuit in wiring harness between M97
pin 25 K32 pin 1.
E323 Short circuit in accelerator relay system
2) Short circuit in relay K32.
1) Short circuit in wiring harness between M97

pin 35 K33 pin 1.
E325 Short circuit in decelerator relay system
2) Short circuit in relay K33.
E05
1) Short circuit of M97 pin 19 with power source.
Stall of motor
4) Trouble in motor.
E328 (When burn preventive function of motor oper-
ates)
1) Short circuit or disconnection in wiring har-

Short circuit in engine stop solenoid relay system ness between M97 (4) M36 (1).
E304
2) Disconnection in wiring harness between
E314
Disconnection engine stop solenoid relay system M36 (2) chassis ground.
3) Trouble in M36 relay.
When the motor is normal, its condition can be monitored as shown below.
When fuel control dial is operated (Slow o Full) Displayed code [1024] : (2), (3), (4), (6), light up and motor operates, then (2),
(3), (4), (6) go off and motor stops (Only (4) keeps
lighting up).
When fuel control dial is operated (Full o Slow) Displayed code [1024] : While only (4) is lighting up, (1), (3), (5) light up and
motor operates, then all lamps go off and motor
stops.
In E-mode (When fuel control dial is at FULL Displayed code [1024] : While only (4) is lighting up, (3), (5) light up and
position) motor operates, then (2) lights up and (3), (5) go off
and motor stops (Only (2) and (4) keep lighting up).
When E-mode is changed to standard motor Displayed code [1024] : While only (2), (4) are lighting up, (3), (6) light up and
(When fuel control dial is at FULL position) motor operates, then (2), (3), (6) go off and motor
stops (Only (4) keeps lighting up).
When one-touch slow-down mechanism is Displayed code [1024] : While only (4) is lighting up, (3), (5) light up and
turned on (When fuel control dial is at FULL motor operates, then (2) lights up and (3), (4), (5) go
position) off and motor stops (Only (2) keeps lighting up).
Displayed code [1026] : When one-touch slow-down switch is turned on, (1)
lights up (This is same as in resetting operation).
When one-touch slow-down mechanism is Displayed code [1024] : While only (2) is lighting up, (3), (6) light up and
turned off (When fuel control dial is at FULL motor operates, then (4) lights up and (2), (3), (6) go
position) off and motor stops (Only (4) keeps lighting up).
20-504 PC78MR-6
TROUBLESHOOTING PROBLEMS ON MACHINE
Action taken by controller

Normal condition Problems on machine
when trouble occurs
Between M97 pin 25 chassis ground: Min.: 1 Mz K32 pin 1 If trouble is detected, motor 1. Fuel control dial cannot be oper-
Resistance between K32 relay pin 1 pin 2: 290 z 10% drive relay output, accelerator ated (For acceleration and decel-
Resistance between K32 relay pin 1, 2 pin 3, 5, 6 relay output, and decelerator eration).
: Min. 1 Mz relay output are stopped. 2. One-touch slow-down mecha-
Between M97 pin 35 chassis ground: Min. 1 Mz K33 pin 1 nism cannot be operated.
Resistance between K33 relay pin 1 pin 2: 290 z 10% 3. When working mode is changed,
Resistance between K33 relay pin 1, 2 pin 3, 5, 6 engine speed does not change.
: Min. 1 Mz
Motor starts and stops from slow to full and from full to slow If accelerator, decelerator, or When signal system is troubled
in 2 seconds. one-touch slow-down mecha- Motor operates but stalls soon.
nism works for more than 10 Then, it does not operated even if
seconds, motor drive relay out- dial is moved.
put, accelerator relay output, When motor is troubled
and decelerator relay output Motor stalls from the first, then it
are stopped. does not operate even if dial is
moved.
Relay Stop solenoid output is 1. Stop solenoid cannot be pulled
stopped. (Engine cannot be started).
M97 (female) M36 (male) Resistance
(4) Chassis ground (1) (2) 68 z 10%
Engine governor control system
PC78MR-6 20-505
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)
TROUBLESHOOTING AND ENGINE
JUDGMENT TABLE FOR CONTROLLER

(GOVERNOR CONTROL SYSTEM) AND ENGINE
Controller and Engine Items Checked/Inspected
by
Self-diagnosis Display monitoring
Short circuit in decelerator relay system

Short circuit in accelerator relay system
Trouble in engine speed sensor system

Disconnection in engine stop solenoid
Short circuit in engine stop solenoid
Trouble in controller power supply
Decelerator relay output

Auto deceleration signal
Accelerator relay output

Deceleration signal
Acceleration signal
Stall of motor
relay
relay
User
Code E05 Monitoring Code
Service 323 325 328 (304 314 227 1024

Code 2) ( 2)
1 Engine does not start easily

2 Engine does not start q q q
Engine speed does not rise sharply (Does not follow up accel-
3
erator pedal)
4 Engine stops
5 Engine hunts
6 Engine output (Power) is low
7 Exhaust gas color is bad (Imperfect combustion)
8 Much oil is consumed (or exhaust gas color is bad)
9 Oil becomes dirty soon
10 Much fuel is consumed
11 Cooling water contains oil or blows back or its level lowers
12 Oil pressure caution lamp lights up
13 Oil level rises
14 Water temperature rises too high (Overheating)
15 Abnormal sound is heard
16 Many vibrations are made
17 Engine speed does not follow up throttle valve q q q q
18 One-touch slow-down mechanism does not work q q q q
When working mode is changed, engine speed does not
19
change q q q q q
20 Engine does not stop

Diagnosis code displayed when service code is displayed E-1 E-2 E-3 E-4 E-7 E-7 E-5
Diagnosis code displayed when trouble is detected by monitoring or
with machine monitor
q: Items corresponding to service codes.

Q: Items checked by monitoring or with machine monitor.
: Items checked by monitoring.
20-506 PC78MR-6
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)
TROUBLESHOOTING AND ENGINE
Items
Items checked/ inspected
inspected by with machine
monitoring
monitor Is value in red range?
Diagnosis code displayed

Engine water temperature voltage
when service code is not dis-

played
One-touch slow-down signal
95 Series
Engine speed
Min. 105 C
Acceleration
Signal
1026 1010 0041 108
(S-1)
E-8 (S-2)
(S-3)
(S-4)
(S-5)
(S-6)
(S-7)
(S-8)
(S-9)
(S-10)
(S-11)
(S-12)
(S-13)
Q (S-14)
(S-15)
(S-16)
E-4
E-6
E-4, E-5
E-8

M-2
PC78MR-6 20-507
TROUBLESHOOTING E-1
E-1 Controller power supply is defective (LED of controller is turned off)

a Check that fuse 20 is not broken.
a Carry out the following troubleshooting when the starting motor revolves normally (If the starting motor does
not revolve, see E-8, 19).
Cause Remedy
1
Is voltage between M96 (Female) (1), (11) NO
(21), (31), (32), (33), chassis ground
20 30 V
normal?
YES
2
Turn starting switch ON Is voltage between fuse 20 and chassis NO Disconnection or defective Repair or
contact in wiring harness between
20 30 V ground normal? fuse 20 battery relay terminal B replace
YES Disconnection or defective Repair or
fuse 20 M97 (Female) (1), (11) replace
E-1 Electrical circuit diagram of each system
20-508 PC78MR-6
TROUBLESHOOTING E-2
E-2 [E323] (Short circuit in accelerator relay system) is displayed

Cause Remedy
1
Turn starting switch ON Is voltage between M97 (Female) (25) NO
Operate dial (23) normal?
YES
2
Short circuit with chassis ground
Disconnect M97 and K32 Is resistance between M97 (Female) (25) NO or negative (-) wire in wiring Repair or
Min. 1 Mz and chassis ground normal? harness between M97 (Female) replace
(25) K32 (Female) (1)
YES Repair or
Defective Relay
replace
If the wiring harness between M97 (25) K34 (1) is shorted to the coil actually, the controller output is cut
out. Accordingly, if [E323] is displayed, the controller is defective.
PC78MR-6 20-509
TROUBLESHOOTING E-3
E-3 [E325] (Short circuit in decelerator relay system) is displayed

Cause Remedy
1
Turn starting switch ON Is voltage between M97 (Female) (35) NO
Operate dial (to lower) (23) normal?
YES
2
Disconnect M97 and K33 Is resistance between M97 (Female) (35) NO or negative (-) wire in wiring Repair or
Min. 1 Mz chassis ground normal? harness between M97 (Female) replace
(35) K33 (Female) (1)
YES
Repair or
Defective Relay
replace
If the wiring harness between M97 (35) K33 (1) is shorted to the coil actually, the controller output is cut
out. Accordingly, if [E325] is displayed, the controller is defective.
20-510 PC78MR-6
TROUBLESHOOTING E-4
E-4 [E328] (Stall of motor) is displayed

a Stall of the motor ias displayed when the motor does not follow up the operation of the dial in 10 seconds. In
this period, the input signal and relay output are checked by monitoring.
Cause Remedy
1
For state of bit, see Action
taken by controller when NO
Is monitored value normal?
trouble occurs and problems
on machine.
YES
Turn starting switch ON 2

Max. 4 A when normal
Is current between K27 (Female) (1) NO
When dial is raised
(Motor (+) and (4) (Motor (-)
(1) side: (+), (4) side: (-)
normal?
When dial is lowered
(1) side: (-), (4) side: (+) YES
Defective motor
Replace motor
(Drive system)
Resistance between (1) (2)

of each relay: 290 z 10%
Operation of each relay 3
(when starting switch is ON)
When in neutral, (3) (6) are Do relay of K32, K33 operate NO
Defective relay Replace
connected. normally?
When dial is raised, K32 (3),
(5) are connected. YES
When dial is lowered, K33
(3), (5) are connected.
Disconnection or defective
Repair or
K27 (Female) (1), (4) K32
replace
(Female) (3),
K33 (Female) (3)
4
Is resistance between M97
Disconnect M97 and K27. (Female) (19) K27 (Female) (5),
Resistance between pins: between M97 (29) K27 Disconnection or defective
Max. 1 z (Female) (6), between M97 NO contact in wiring harness between Repair or
Resistance between pin and (Female) (39) K27 (Female) (3) M97 (Female) (19), (29), (39) replace
chassis and ground: normal? Is resistance between K27 (Female) (5), (6), (3)
Min. 1 Mz each wiring harness and chassis
ground normal?
YES
When dial is raised
5
Between K97 (19), (39) (23):
24 V When dial is operated, is each input NO
Defective motor (Signal system) Replace
When dial is lowered signal normal?
(slowed)
Between M97 (29) (23):
24 V YES
PC78MR-6 20-511
TROUBLESHOOTING E-4
20-512 PC78MR-6
TROUBLESHOOTING E-5
E-5 [E227] (Trouble in engine speed sensor) is displayed

Cause Remedy
When starting switch is OFF: 0 1

When engine speed is
+5 Is monitored engine speed normal?
NO
slow: 113 0
When engine speed is at full
throttle: 202 5 YES
2
Disconnect M16 Is resistance between M16 (Male) (1) (2) NO Defective engine speed Repair or
500 1,000 z normal? sensor replace
YES 3
Disconnect M16 Is resistance between M96 (Female) (39) NO contact in wiring harness between Repair or
500 1,000 z (40) normal? M96 (Female) (39) M16 replace
(Female) (1), (2)
YES Defective installation of engine
Test/Adjust
speed sensor
PC78MR-6 20-513
TROUBLESHOOTING E-6
E-6 One-touch slow-down mechanism does not work

Cause Remedy
1
Does deceleration monitor light up NO
normally?
YES
See troubleshooting in E-5
2
Disconnect K18
When switch is ON: Max. 1z Is resistance between K18 (Male) (1) (2) NO Defective one-touch decelerator Replace lever
When switch is OFF: normal? switch assembly
Min. 1 Mz
YES 3
Disconnect K18 Disconnection or defective
Is voltage between K18 (Male) (1) NO contact in wiring harness between Repair or
chassis ground normal? K18 (Female) (1) fuse (11) or replace
20 30 V breakage of fuse (11)
YES Disconnection or defective
contact in wiring harness between Repair or
K18 (Female) (2) M97 (Female) replace
(9)
20-514 PC78MR-6
TROUBLESHOOTING E-7
E-7 Engine does not start

a The signals from battery relay terminal M on the monitor screen, etc. must be normal.
a Carry out the following troubleshooting when the starting motor does not revolve.
a Before carrying out the troubleshooting, check that fuses 12, 14, 15, and 20 are normal.
a Lock the PPC hydraulic lock switch. (Raise the work equipment lever stand.)
a) [E304] Short circuit in engine stop solenoid relay system is displayed
b) [E314] Disconnection in engine stop solenoid relay system is displayed
Cause Remedy
1
Disconnect M97.
Resistance between M97 Is resistance between M97 (female) (4) NO
(female) (4) chassis chassis ground normal?
ground: 68 z 10%
YES
Disconnect M36. 2
Resistance between M36 Is resistance between stop solenoid relay NO
(male) (1) (2): 68 z 10%
M36 (male) (1) (2) and between each Defective stop solenoid relay Replace
Resistance between M36
(male) (1), (2) chassis pin and chassis ground normal?
ground: Min. 1 Mz YES
3
Disconnect D26
(with M36 disconnected). Is resistance between M97 (female) (4) NO Defective wiring harness Repair or
Resistance between M97
(female) (4) chassis chassis ground normal? (Grounding fault) replace
ground: Min. 1 Mz
YES
Defective diode D26 Replace
E-7 a), b) Electrical circuit diagram of each system
PC78MR-6 20-515
TROUBLESHOOTING E-7
c) Engine stop solenoid system

a Check that fuse 15 is normal.
a Check that service codes [E304] and [E314] are not recorded in the history.
Cause Remedy
1
See TESTING AND When engine stop solenoid linkage is NO
ADJUSTING adjusted, does engine start?
YES Defective adjustment of

Adjust
linkage
2
20 29 V Is voltage between engine stop solenoid NO
Turn starting switch ON terminal chassis ground normal?
YES 3
Max. 1 z Is resistance between engine stop Disconnection or defective
NO contact in wiring harness between Repair or
Turn starting switch OFF solenoid terminal GND chassis ground
engine stop solenoid terminal replace
Disconnect T8 normal? GND chassis ground
YES 4
20 29 V Disconnection or defective
Is voltage between engine stop solenoid NO contact in wiring harness between Repair or
Disconnect PULL terminal.
PULL terminal and chassis ground engine stop solenoid PULL
For only 3 seconds after terminal fusible link M26 (male) replace
normal?
starting switch is turned ON. (2)
YES
Defective engine stop solenoid Replace
5
20 29 V Is voltage between outlet of fuse (15) NO
Turn starting switch ON chassis ground normal?

outlet of fuse (15) M3 (3) replace
solenoid terminal HOLD
6
20 29 V Is voltage between starting switch terminal NO Defective starting switch
Replace
Turn starting switch ON ACC chassis ground normal? (Between B ACC)

starting switch terminal ACC replace
inlet of fuse (15)
20-516 PC78MR-6
TROUBLESHOOTING E-7
E-7 c) Electrical circuit diagram of each system
PC78MR-6 20-517
TROUBLESHOOTING E-7
d) Starting System
Cause Remedy
1
Min. 24 V Are battery voltage and specific gravity of NO Insufficient battery Charge or
Specific gravity: Min. 1.26 battery fluid normal? capacity replace
YES 2
When starting switch is turned OFF, does NO
Turn starting switch OFF
battery relay make sound?
YES
3
Is engaging sound of starting motor pinion NO
heard?
YES
4 Defective contact in wiring

harness between battery
Turn starting switch ON Is voltage between starting motor terminal NO (+) terminal battery relay Repair or
terminal B battery relay
20 29 V B chassis ground normal? replace
terminal M starting motor
terminal B
YES (including battery relay)
Defective starting motor Repair or

(Body) Replace
5
Turn starting switch to Defective starting switch
Is voltage between starting switch terminal NO
START position. (Between terminals B and Replace
C and chassis ground normal?
20 29 V C)
YES
6
Is voltage between safety relay terminal S NO
Conditions are same as 5
chassis ground normal?
YES
7
Is voltage between starting motor terminal NO
C chassis ground normal?
YES Defective starting motor Repair or

(Electromagnetic switch) replace
8
Is voltage between safety relay terminal C NO
YES contact in wiring harness Repair or
between starting motor
safety relay terminal C replace
starting motor terminal C
9
Turn starting switch ON Is voltage between safety relay terminal R NO Repair or
Defective alternator
Max. 13 V chassis ground normal? replace
YES
Defective starting motor
Replace
To page 20-520 safety relay
To page 20-519
20-518 PC78MR-6
TROUBLESHOOTING E-7
From page 20-518, 6
Cause Remedy
10
20 29 V NO
Is voltage between V2 (8) chassis
Turn starting switch to
ground normal?
START.
YES contact in wiring harness
Repair or
between safety relay terminal S
M30 (1) M5 (4) V2 replace
(Female) (8)
11
20 29 V NO
Is voltage between V2 (7) chassis
ground normal?
START
contact in wiring harness
between V2 (Male) (7) (8)
12
20 29 V NO
Is voltage between K23 (3) chassis
ground normal?
START
between K23 (Female) (3) V3
replace
(Female) (3)
13
20 29 V NO contact in wiring harness
Is voltage between K23 (5) chassis Repair or
Turn starting switch to between K23 (Female) (5)
ground normal? K51 (6) starting switch replace
START
terminal C
YES 14
20 29 V NO
Is voltage between K23 (1) chassis
ground normal?
Lock PPC lock switch
YES 15
Max. 1 z Disconnection or defective
Is resistance between K23 (Female) (2) NO contact in wiring harness Repair or
chassis ground normal? between K23 (Female) (2) M1 replace
Disconnect K23 (2) chassis ground
YES
Defective K23 relay Replace
16
20 29 V NO
Is voltage between k28 (3) chassis
ground normal?
Lock PPC lock lever
between K28 (Male) (3) K23 replace
(Female) (1) chassis ground
To page 20-520
PC78MR-6 20-519
TROUBLESHOOTING E-7
From page 20-519, 16 Cause Remedy

17
20 29 V Is voltage between K28 (1) chassis NO contact in wiring harness Repair or
Turn starting switch ON ground normal? between K28 (Male) (1) fuse replace
(14)
contact in wiring harness Repair or
between K28 (Female) (3) replace
K23 (Female) (1)
From page 20-518, 2
Cause Remedy
18 Disconnection or defective
Connect (-) pin of tester to (-) contact in wiring harness between
Is voltage at starting switch terminal B NO battery (+) terminal M27 (1), (2)
terminal of battery Replace
normal? M2 (1) fuse (20) K51 (1)
20 29 V starting switch terminal B
YES (including fusible link)
19
Disconnect terminal B
Is there continuity between starting switch NO Defective starting switch
Turn starting switch to Replace
terminals B BR? (between terminal B BR)
START
YES 20
Set tester in diode range and Disconnection or defective
apply (+) to starting switch Is there continuity between starting switch NO contact in wiring harness between
and (-) to battery relay starting switch terminal BR K51 Replace
Disconnect both starting terminal BR battery relay terminal BR? (3) D51 (2), (1) battery relay
switch and battery relay terminal BR (including diode)
YES 21
Defective contact in wiring
Is there continuity between chassis NO harness between battery relay Repair or
ground and battery relay terminal B? terminal E - revolving frame replace
ground terminal
YES
Defective battery relay Replace
20-520 PC78MR-6
TROUBLESHOOTING E-7
E-7 d) Electrical circuit diagram of each system
PC78MR-6 20-521
TROUBLESHOOTING E-8
E-8 Engine does not stop

Cause Remedy
1
When engine stop solenoid linkage is NO
adjusted, does engine stop?
YES Defective adjustment of

Adjust
linkage
2
Is voltage between engine stop solenoid Contact of (+) wiring harness with
Max. 1 V NO wiring harness between starting Replace or
terminal HOLD and chassis ground
Turn starting switch OFF switch terminal ACC fuse (15) repair
normal? M3 (3) solenoid terminal HOLD
YES
Defective engine stop solenoid Replace
20-522 PC78MR-6
PUMP CONTROL SYSTEM
(C MODE)
Precautions for troubleshooting for controller (pump control system) ........................................................ 20-602
Action taken by controller when trouble occurs and problems on machine ................................................ 20-604
Judgement table for controller (pump control system) and hydraulic equipment........................................ 20-608
Electric circuit diagram of C mode system (For STD spec.) ....................................................................... 20-610
Electric circuit diagram of C mode system (For EU spec.)....................................................................... 20-611-1
C- 1 [E232], C-2 [E233] Trouble in TVC-EPC solenoid system.............................................................. 20-612
C- 3 [E203], C-4 [E213] Trouble in swing holding brake solenoid system.............................................. 20-613
C- 5 [E206], C-6 [E216] Trouble in 2nd travel speed selection solenoid system.................................... 20-614
C- 7 [E411] Trouble in boom swing angle sensor correction ................................................................... 20-615
C- 8 [E251] Trouble in boom bottom pressure sensor (overload sensor) system (For EU spec.) ........ 20-615-1
C- 9 [E258] Short circuit in 5V system of sensor power supply (For EU spec.).................................... 20-615-1
C- 9 [E258] Short circuit in 5V system of sensor power supply (For STD spec.) .................................... 20-616
C-10 [E412], C-11 [E413] Trouble in boom swing angle sensor system .................................................. 20-617
C-12 [E451] Short circuit in boom swing LEFT stop EPC solenoid system is displayed .......................... 20-618
C-13 [E452] Disconnection in boom swing LEFT stop EPC solenoid system is displayed ...................... 20-619
C-14 [E453] Short circuit in boom swing RIGHT stop EPC solenoid system is displayed........................ 20-620
C-15 [E454] Disconnection in boom swing RIGHT stop EPC solenoid system is displayed .................... 20-621
C-16 Boom swing LEFT end cushion does not work at all or normally ..................................................... 20-622
C-17 Boom swing RIGHT end cushion does not work at all or normally ................................................... 20-624
C-18 Work equipment still moves after work equipment lock lever is set to LOCK ................................... 20-626
C-19 Machine does not swing ................................................................................................................... 20-627
C-20 Travel speed does not rise................................................................................................................ 20-628
C-21 Trouble in controller power supply (LED of controller is turned OFF)............................................... 20-628
PC78MR-6 20-601
(1)
TROUBLESHOOTING (PUMP CONTROL SYSTEM)

(PUMP CONTROL SYSTEM)
1. Precautions to be taken when trouble is repaired by itself
1) When a trouble is repaired by itself or

2) When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-adapter
is removed and the connector is returned, if the service code is not displayed or the monitor displays
normally, the same trouble will occur again probably. Accordingly, follow up the condition of the machine
sufficiently.
3) After finishing troubleshooting, be sure to delete the saved service code.
2. Handling of function of saving service code
When displaying a saved service code for troubleshooting, "take the notes of the all displayed items and
delete those items", then reproduce the trouble and start the troubleshooting according to the service code
displayed at this time. (Troubles caused by wrong operation, disconnection of a connector, etc. May be
saved in the memory. In this case, you can avoid unnecessary work by performing the above operation.)
20-602 PC78MR-6
TROUBLESHOOTING AND PROBLEMS ON MACHINE

PROBLEMS ON MACHINE
1. Short circuit in wiring harness between M97

Short circuit in TVC-EPC solenoid system
pin 16 M20 pin 1
E232 (When emergency pump drive switch is
2. Short circuit in EPC solenoid
turned ON)
3. (Wrong operation of switch)
E02
1. Disconnection in wiring harness between
M97 pin 16 M20 pin 1
E233 Disconnection in TVC-EPC solenoid system 2. Disconnection in EPC solenoid

Short circuit in swing holding brake solenoid
E203 pin 7 M14 pin 2
system
2. Short circuit in solenoid
E03 1. Disconnection in wiring harness between

M97 pin 7 M14 pin 2
Disconnection in swing holding brake
2. Disconnection in solenoid
E213 solenoid system (When emergency swing
holding brake reset switch is turned ON)
M14 pin 1 M97 pin 3
4. (Wrong operation of switch)

Short circuit in 2nd travel speed selection
E206 pin 27 M15 pin 2
solenoid system
2. Short circuit in solenoid

Disconnection in 2nd travel speed selection
E216 2. Disconnection in solenoid
solenoid system
M15 pin 1 M97 pin 3

E227 Trouble in engine speed sensor 2. Disconnection in sensor
1. Input voltage is abnormal when angle sen-

Trouble in boom swing angle sensor sor is corrected (Out of range)
E414
correction When voltage error is out of 0.5 V Voltage
must be 0.3 4.7 V, however
Short circuit in 5 V system of sensor power 1. Short circuit in wiring harness between M95
E258
supply pin 22 M29 pin C, M71 pin C, M72 pin A
20-604 PC78MR-6
Action Taken by Controller When

Normal Condition Problems on Machine
Trouble Occurs
Between M97 pin 16 chassis ground: Min.

1 Mz
Between M20 pin 1 solenoid body: Min. 1
Mz
Resistance of M20 EPC solenoid (With Current does not flow in TVC-EPC
switch directed down): 3 15 z When trouble is detected, TVC-EPC solenoid.
solenoid output is stopped. Accordingly, if load is large, engine
Resistance between M97 pin 16 M20 pin speed may lower to stall.
1: Max. 1 Mz
Resistance of M20 EPC solenoid: 3 15 z
Resistance between M20 pin 2 M97 pin
23: Max. 1 z
Between M97 pin 7 chassis ground: Min. 1

Mz
Mz
Resistance of M14 solenoid: 35 80 z When trouble is detected, swing
Since motor brake is not released,
holding brake reset solenoid output is
machine does not swing.
Resistance between M97 pin 7 M14 pin 2: stopped.
Max. 1 z
Resistance of M14 solenoid: 35 80 z
Resistance between M14 pin 1 M97 pin 3
(With switch directed down): Max. 1 z
Between M97 pin 27 chassis ground: Min.

1 Mz
Mz
Resistance of M15 solenoid: 35 80 z When trouble is detected, 2nd travel When speed selector switch pedal is
speed selection solenoid output is operated, travel speed does not
Resistance between M97 pin 27 M15 pin stopped. change. (It is kept at 1st gear.)
2: Max. 1 Mz
Resistance of M15 solenoid: 35 80 z
Resistance between M15 pin 1 M97 pin 3:
Max. 1 z
When trouble is detected, constant Since constant current (600 mA) is

current flows in TVC-EPC solenoid output to TVC-EPC solenoid, work
1: Max. 1 z
(600 mA). equipment speed and travel speed
Resistance of M16 sensor: 500 1,000 z
Working mode cannot be changed. are low.
Engine governor control is limited to If engine speed is low, engine may
39: Max. 1 z
operation of fuel control dial. stall.
When potentiometer is corrected,

Boom swing angle sensor voltage for moni- "---" is displayed and initial values are Offset end cushion does not work.
toring selected. Stop position for interference preven-
At RIGHT swing end: 0.9 V If machine is operated without normal tion is wrong.
At LEFT swing end: 4.3 V correction, it is controlled with initial Displayed depth is wrong.
values.
Boom RAISE, arm IN, and offset

Resistance between M95 pin 22, M29 pin C, LEFT operations cannot be exe-
Boom RAISE, arm IN, and offset
M71 pin C, M72 pin A - chassis ground: Min. cuted. (They can be executed if
LEFT EPC outputs are stopped.
1 Mz emergency work equipment opera-
tion switch is turned ON, however.)
PC78MR-6 20-605

M95 pin 22 M92 pin B
(*1) Trouble in boom bottom pressure sensor 2. Short circuit or disconnection in wiring har-

E251 (overload sensor) system ness between M95 pin 2 M92 pin C
M95 pin 21 M92 pin A
Disconnection on GND side of boom swing 1. Disconnection in wiring harness between

E412
angle sensor M95 pin 21 M101 pin A

M95 pin 22 M101 pin A
E40 2. Short circuit in wiring harness between M95
Disconnection on power supply side of boom
pin 8 M101 pin B
E413 swing angle sensor/Short circuit or
disconnection of signal line
M95 pin 8 M101 pin B
4. Defective M101 angle sensor (Internal short
circuit)

Short circuit in boom swing LEFT EPC
E451 pin 5 M11 pin 2
solenoid system

M97 pin 5 M11 pin 2
Disconnection in boom swing LEFT EPC
E452 2. Disconnection in EPC solenoid
solenoid system
E41
Short circuit in boom swing RIGHT EPC
E453 pin 15 M12 pin 2
solenoid system

Disconnection in boom swing RIGHT EPC
E454 2. Disconnection in EPC solenoid
solenoid system
20-606 PC78MR-6
(1)
Action Taken by Controller When

Normal Condition Problems on Machine
Trouble Occurs
Resistance between M95 pin 22 M92 pin B:

Max. 1 z
Resistance between M95 pin 22, M92 pin B
chassis ground: Min. 1 Mz
Overload alarm is turned ON. Overload alarm is turned ON.
Resistance between M95 pin 2 M92 pin C:
Buzzer sounds. Buzzer sounds.
Max. 1 z
Caution lamp flashes. Caution lamp flashes.
Resistance between M95 pin 2, M92 pin C
Resistance between M95 pin 21 M92 pin A:
Max. 1z

C: Max. 1 z
Resistance between M95 pin 21 M29 pin C:

Max. 1 z
Resistance between M95 pin 20, M101 pin B
chassis ground: Min. 1 M z
B: Max. 1 z
Resistance between M72 angle sensor pin A
pin C: 3 7 k z
Resistance between M72 angle sensor pin A,
C pin B (Which changes as shaft is turned):
07kz
Resistance between M97 pin 5, M11 pin 2

Resistance between M97 pin 5 M11 pin 2: Boom swing LEFT EPC solenoid out- Boom cannot be swing to LEFT.
Max. 1 z put is stopped.
Max. 1 z
Resistance between M97 pin 15, M12 pin 2

Resistance between M97 pin 15 M12 pin 2: Boom swing RIGHT EPC solenoid Boom cannot be swing RIGHT.
Max. 1 z output is stopped.
Max. 1 z
PC78MR-6 20-607
(1)
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM)
TROUBLESHOOTING AND HYDRAULIC EQUIPMENT

AND HYDRAULIC EQUIPMENT
Part Which May Cause Trouble Self-diagnosis Display By Controller
Trouble in boom bottom pressure sensor (overload sensor) system

Short circuit in 2nd travel speed selection solenoid system
Disconnection in 2nd travel speed selection solenoid system
Disconnection on GND side of boom swing angle sensor

Disconnection on power supply side boom swing angle
Disconnection in swing holding brake solenoid system
Short circuit in swing holding brake solenoid system
Short circuit in 5 V system of sensor power supply
sensor / short circuit or dsconnection of signal line

Defective correction of boom swing angle sensor
Disconnection in TVC-EPC solenoid system
Short circuit in TVC-EPC solenoid system
Trouble in controller power supply system
Trouble in engine speed sensor system
(*2)
User Code E02 E03 E40
Failure Mode
Service Code 232 233 203 213 206 216 227 414 251 258 412 413
Boom cannot be swing to LEFT and RIGHT. q q q

Speed or power of 2 or more systems of work equip-
Work equipment, travel, swing, and blade is low. q q q
ment, travel,
swing, blade Engine speed lowers extremely or engine stalls. q q q
2 or more systems of work equipment, travel, swing,
and blade do not move.
Boom
Speed or power is low. Arm
Boom swing
Work equip-
ment
Boom
Does not move. Arm
Boom swing
Travel speed or power is low. q q

Travel
Travel speed does not change. q q
Swing speed or power is low.
Swing Machine does not swing. q q

Hydraulic drift is large. q q
Electronic
Boom swing end cushion does not work well or at all. q
cushion Boom swing RIGHT end cushion does not work at all. q
(*2) Alarm does not stop sounding. q
Overload
warning Alarm does not start sounding.
After work equipment lock lever is set to LOCK, work equipment

still moves
Diagnosis code displayed when service code is displayed E-1 C-1 C-2 C-3 C-4 C-5 C-6 E-6 C-7 C-8 C-9 C-10 C-11
Diagnosis code displayed when trouble is detected by monitoring
20-608 PC78MR-6
(1)
TROUBLESHOOTING AND HYDRAULIC EQUIPMENT
Self-diagnosis Dis- Items Checked By Monitoring

play By Controller Disconnection in boom swing RIGHT EPC solenoid system
State of
Disconnection in boom swing LEFT EPC solenoid system
Hydraulic Switch
Short circuit in boom swing RIGHT EPC solenoid system
Solenoid
Short circuit in boom swing LEFT EPC solenoid system
Travel speed selector pedal switch input (4)

Diagnosis
Overload warning cancel signal input (2)

code dis-
Boom swing RIGHT EPC current output

Boom swing LEFT EPC current output
played
when trou-
Deceleration switch signal input (1)
Model selection and selection cod
Offset boom sensor voltage input

ble is not
Air compressor signal input (3)
detected
2nd travel speed selection (4)

by monitor-
ing
TVC-EPC current output

Swing holding brake (1)
PPC main pressure (2)
Boom bottom pressure

Engine speed input
Boom LOWER (5)
Boom RAISE (6)
ATT selection
Swing (4)
Travel (3)
(*2)
(*2)
E41 Monitoring Code
451 452 453 454 1023 1021 1026 1060 1020 1010 1031 1026 1040 1050 1052 1053
(*1) (*1) (*1) (*1) C-7 C-14
(*1) (*1) (*1) H-1
(*1) (*1) (*1) H-2
(*1) (*1) (*1) (*1) (*1) H-3
(*1) H-7
(*1) (*1) H-8
q q q q (*1) H-10
H-11
(*1) H-12
q q q q (*1) H-14
(*1) H-26
(*1) (*1) C-19, H-28
H-33
(*1) (*1) C-18, H-34
(*1) (*1) H-39
q q (*1) C-15
q q (*1) (*1) C-16
(*1) (*1)
(*1) (*1)
C-17
C-12 C-13 C-14 C-15
F-3 F-4 F-2 F-1 F-7 F-5 F-6
q : Items corresponding to service codes

*1. Items that can only be cheked by monitoring
PC78MR-6 20-609
(1)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR STD SPEC.)
20-610 PC78MR-6
(1)
PC78MR-6 20-611
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR EU SPEC.)
20-611-1 PC78MR-6
(1)
PC78MR-6 20-611-2
(1)
TROUBLESHOOTING C-1, C-2
2 C-1 [E232], C-2 [E233] Trouble in TVC-EPC solenoid system

a Since this error is displayed when the emergency pump drive switch is turned ON (RAISE), check that this
switch is turned OFF (LOWER).
Cause Remedy
1
Disconnect M20 Is resistance of EPC solenoid normal Defective TVC-EPC solenoid
3 15 z
NO
and is EPC solenoid insulated from (Internal short circuit, Replace
Resistance between solenoid chassis? disconnection)
and chassis ground: Min. 1 Mz
YES
2
Disconnect M97 Is resistance between M97 (Female) NO contact in wiring harness Repair or
Resistance: 3 15 z (16) (23) normal? between M97 (Female) (16), replace
(23) M20 (Female) (1), (2)
YES
3
Disconnect M97 Is resistance between M97 (Female) NO or negative (-) wire in wiring Repair or
Resistance: Min. 1 Mz (16) chassis ground normal? harness between M97 (Female) replace
(16) M20 (Female) (1)
YES
C-1, C-2 Electrical circuit diagram of each system
20-612 PC78MR-6
C-3 [E203], C-4 [E213] Trouble in swing holding brake solenoid system
a Since this error is displayed when the emergency swing holding brake release switch is turned ON (RAISE),
check that this switch is turned OFF (LOWER).
Cause Remedy
1
Disconnect M14 Defective swing holding brake
Is resistance of solenoid normal and is NO
35 80 z solenoid (Internal short circuit, Replace
Resistance between solenoid solenoid insulated from chassis?
disconnection)
and chassis ground: Min. 1 Mz
YES
2
Resistance: 35 80z (7) (3) normal? between M97 (Female) (7), (3) replace
M14 (Female) (2), (1)
YES
3
(7) M14 (Female) (2)
YES
PC78MR-6 20-613
C-5 [E206], C-6 [E216] Trouble in 2nd travel speed selection solenoid
system
Cause Remedy
1
Disconnect M14 Defective 2nd travel speed
Is resistance of solenoid normal and is
NO
35 80 z selection solenoid (Internal Replace
Resistance between solenoid solenoid insulated from chassis?
short circuit, disconnection)
YES
2
Resistance: 35 80 z (27) (3) normal? between M97 (Female) (27), (3) replace
M15 (Female) (2), (1)
YES
3
(27) M15 (Female) (2)
YES
20-614 PC78MR-6
TROUBLESHOOTING C-7
C-7 [E411] Trouble in boom swing angle sensor correction

a Check by monitoring that model selection code, and ATT selection code are normal.
a Check that the angle sensor are installed normally.
Cause Remedy
1
Reset data again according to Is error turned off after data are reset NO Defective correction (Wrong
potentiometer correction
again resetting)
procedure in back mode
YES
2
Is monitored voltage of angle sensor at NO
See Table 1 Defective controller Replace
each cylinder end normal?
YES
3
M101
Between (A) (C): 3 7 kz NO
Is resistance of each angle sensor Defective angle sensor having
Between (A), (C) (B): 0 7 kz Replace
normal? abnormal resistance
(Resistance changes as shaft is
turned)

contact in wiring harness of
Repair or
circuit having abnormal
replace
resistance (Between M95
M101) (See circuit diagram)
Table 1 Voltage (V)
Position Monitoring Code Standard Arm Long Arm
Boom swing LEFT end 0.9 1.8 0.8 1.8

1033
Boom swing RIGHT end 3.2 4.2 3.2 4.2
C-7 Electrical circuit diagram of each system
PC78MR-6 20-615
C-8 [E251] Trouble in boom bottom pressure sensor (overload sensor)

system (For EU spec.)
C-9 [E258] Short circuit in 5V system of sensor power supply (For EU
spec.)
a Check that fuse 10 is not broken.
Cause Remedy
1
When normal: There is a bit. Is signal input of overload alarm reset NO Disconnection in wiring harness Repair or
When reset: There is not a bit. switch normal? between M97 (20) fuse box replace
(Monitoring code 1026 (2)) (10) or defective switch
YES
2
0 26.5 MPa
(If boom circuit is relieved at Is boom cylinder bottom pressure NO
RAISE end, pressure changes.) sensor signal normal?
(Monitoring code 1040)
YES
3
Is resistance between M95 (2) and
M92 (C), between M95 (21) and M92 Disconnection or short circuit in
(A), and between M95 (22) and M92 wiring harness between M95 (2) Repair or
NO
Disconnect M95 and M92. (B) below 1 z? M92 (C), M95 (21) M92 (A), replace
Is resistance between M95 (2), or M95 (22) M92 (B)
(22), M92 (C), (B) and chassis ground
above 1 Mz?
YES
Defective pressure sensor Replace
20-615-1 PC78MR-6
(1)
TROUBLESHOOTING C-9
C-9 [E258] Short circuit in 5V system of sensor power supply (For STD
spec.)
a If E258 is displayed, E40 is also displayed.
Carry out the following troubleshooting and the troubleshooting for E40 system (C-10 C-11).
Cause Remedy
1
Short circuit with chassis ground in
Is resistance between M95 NO wiring harness between M95 (Female)
Disconnect M95 Repair or
(Female) (22) (21) chassis (22) M101 (Female) (C) (Short circuit
Min. 1Mz Replace
ground normal? of sensor power supply with chassis
ground.)
YES
2
Short circuit with chassis ground or
disconnect M95, M101 and NO
Is resistance between M95 negative (-) wire in wiring harness Repair or
M29.
(Female) (22) (21)normal? between M101 (Female) (A), M72 Replace
Min. 1Mz
(Female) (C)
YES
3
Between (A) (C): 3 7 kz
Between (A), (C) (B): 0 7 kz Is resistance of each angle NO Defective angle sensor having abnormal
Replace
(Resistance changes as shaft is sensor normal? resistance (Internal short circuit)
turned)
YES
20-616 PC78MR-6
(1)
C-10 [E412], C-11 [E413] Trouble in boom swing angle sensor system
Cause Remedy
1
0.3 4.7 V Is monitored voltage of boom NO
(Monitoring code 1033) angle sensor normal?
YES Defective controller Replace
2
Between (A) (C): 3 7 kz
NO Defective boom angle sensor
Between (A), (C) (B): 0 7 kz Is resistance of M101 angle
(Disconnection, short circuit with chassis Replace
(Resistance changes as shaft is sensor normal?
ground)
turned.)
Disconnection or defective contact in

YES wiring harness between M95 (Female)
(B), (3) M101 (Female) (C), (B)
Repair or
Short circuit with chassis ground or
replace
negative (-) wire in wiring harness
between M95 (Female) (8) M101
(Female) (B)
If the wiring harness between M95(3) M101 (B) is shorted actually, the controller output is cut out. Accord-
ingly, if [E402] is displayed, the controller is defective.
PC78MR-6 20-617
(1)
TROUBLESHOOTING C-12
C-12 [E451] Short circuit in boom swing LEFT stop EPC solenoid system
is displayed
Cause Remedy
1
Is resistance between M11 (male) (1) NO Defective boom swing LEFT
Turn starting switch OFF. and (2) and between (2) and chassis stop EPC solenoid Replace
Disconnect M11. ground as shown in Table 1? (Internal disconnection)
YES
2
Is resistance between D33 (female) (1) Disconnection in wiring harness
Turn starting switch OFF. and chassis ground and between D33 NO between D33 (female) (1) M11 Repair or
Disconnect D33 and M97. (female) (1) and M97 (female) (23) as (female) (2), M97 (female) (23) Replace
shown in Table 2? M11 (female) (1)
YES
3
Grounding fault or internal short
Is resistance between M97 (female) NO
Turn starting switch OFF. circuit in wiring harness Repair or
(5) and M97 (female) (23) between
Disconnect D33 and M97. between D33 (female) (2) M97 Replace
M97 (female) (5) as shown table 3?
(female) (5)
YES
Table 1 Table 2 Table 3

Between D33 (1) chassis Between M97 (5) chassis
Between M11 (male) (1) (2) 5 25 z Min. 1 Mz Min. 1 Mz
ground ground
Between M11 (male) (2)
Min. 1 z Between D33 (1) M97 (23) 5 25 z Between M97 (5) M97 (23) Min. 1 Mz
chassis ground
20-618 PC78MR-6
(1)
C-13 [E452] Disconnection in boom swing LEFT stop EPC solenoid sys-
tem is displayed
Cause Remedy
1
Turn starting switch OFF. NO Defective boom swing LEFT stop
Disconnect M11. EPC solenoid Replace
(male) (1) and (2) normal?
Resistance: 5 25z (Internal disconnection)
YES
2
Is resistance between D33 Disconnection in wiring harness
(female) (1) and M97 (female) NO between D33 (female) (1) M11
Turn starting switch OFF. Repair or
(23) and between D33 (female) (female) (2), D15 (female) (2) M97
Disconnect D33 and M97. Replace
(2) and M97 (female) (5) as (female) (5), or M97 (female) (23)
shown in Table 1? M11 (female) (1)
YES
3
Turn starting switch OFF. NO
Disconnect D33. Is diode D15 normal? Defective diode (Disconnection) Replace
* See TESTING AND ADJUSTING.
YES
Table 1
Between D33 (1) M97 (23) 5 25 z
Between D33 (2) M97 (26) Min. 1 z
PC78MR-6 20-619
(1)
C-14 [E453] Short circuit in boom swing RIGHT stop EPC solenoid sys-
tem is displayed
Cause Remedy
1
Is resistance between M12 (male) (1) Defective boom swing RIGHT
Turn starting switch OFF. NO stop EPC solenoid
and (2) and between (2) and chassis Replace
Disconnect M12. ground as shown in Table 1? (Internal short circuit or
grounding fault)
YES
2
Grounding fault or internal short
Is resistance between D31 (female) (1)
NO circuit in wiring harness
Turn starting switch OFF. and chassis ground and between D31 Repair or
between D31 (female) (1) M12
Disconnect D31 and M97. (female) (1) and M97 (female) (23) as Replace
(2) or between M97 (23) M12
shown in Table 2?
(1)
YES
3
Is resistance between M97 (female) Grounding fault or internal short
Turn starting switch OFF. (15) and chassis ground and between NO circuit in wiring harness Repair or
Disconnect D31 and M97. M97 (female) (15) and M97 (female) between D31 (female) (2) M97 Replace
(23) as shown in Table 3? (female) (15)
YES
Table 1 Table 2 Table 3

Between D31 (1) chassis Between M97 (15) chassis
Between M12 (male) (1) (2) 5 25 z Min. 1 Mz Min. 1 Mz
ground ground
Between M12 (male) (2)
Min. 1 z Between D31 (1) M97 (23) 5 25 z Between M97 (15) M97 (23) Min. 1 Mz
chassis ground
20-620 PC78MR-6
(1)
C-15 [E454] Disconnection in boom swing RIGHT stop EPC solenoid sys-
tem is displayed
Cause Remedy
1
Turn starting switch OFF. NO Defective boom swing RIGHT stop
Disconnect M12. EPC solenoid Replace
(male) (1) and (2) normal?
Resistance: 5 25z (Internal disconnection)
YES
2
Is resistance between D31
NO Disconnection in wiring harness
(female) (1) and M97 (female)
Turn starting switch OFF. between D31 (female) (1) M12 (2), Repair or
(23) and between D31 (female)
Disconnect D31 and M97. D31 (female) (2) M97 (15), or M97 Replace
(2) and M97 (female) (15) as
(23) M12 (1))
shown in Table 1?
YES
3
Turn starting switch OFF. NO
Disconnect D31. Is diode D31 normal? Defective diode (Disconnection) Replace
* See TESTING AND ADJUSTING.
YES
Table 1
Between D31 (1) M97 (23) 5 25 z
Between D31 (2) M97 (15) Min. 1 z
PC78MR-6 20-621
(1)
C-16 Boom swing LEFT end cushion does not work at all or normally
a Check that the boom swing angle sensor voltage input is normal by monitoring code 1033.
a (Standard value: 0.9 V when boom swing is at left end)
a Check that the boom swing EPC current output is normal by monitoring code 1052.)
a Check installation of the boom swing angle sensor for abnormality.
Cause Remedy
1
When boom swing angle sensor is
NO
corrected again, does condition
become normal?
YES
Defective correction
2
Between (A) and (C): 3 7 kz
Between (A), (C) and (B): 0 7 Is resistance of boom swing angle NO Defective boom swing angle
Replace
kz (If shaft is rotated, resistance sensor normal? sensor
changes.)
YES
3
Is resistance between M101 (A) and Disconnection or defective
M95 (21), between M101 (B) and M95 NO contact in wiring harness of Repair or
Normal value: Max. 1 z
(8), and between M101 (C) and M95 circuit having abnormal replace
(22) normal? resistance (See circuit diagram)
YES
Defective controller
20-622 PC78MR-6
(1)
PC78MR-6 20-623
(1)
C-17 Boom swing RIGHT end cushion does not work at all or normally
a Check that the boom swing angle sensor voltage input is normal by monitoring code 1033.
(Standard value:At 4.3 V)
a Check that the boom swing RIGHT EPC current output is normal by monitoring code 1053.
a Check installation of the boom swing angle sensor for abnormality.
Cause Remedy
1
When boom swing angle sensor is NO
corrected again, does condition
become normal?
YES
Defective correction
2
Between (A) and (C): 3 7 kz
Between (A), (C) and (B): 0 7 Is resistance of boom swing angle NO Defective boom swing angle
Replace
kz (If shaft is rotated, resistance sensor normal? sensor
changes.)
YES
3
Is resistance between M101 (A) and Disconnection or defective
M95 (21), between M101 (B) and M95 NO contact in wiring harness of Repair or
Normal value: Max. 1 z
(8), and between M101 (C) and M95 circuit having abnormal replace
(22) normal? resistance
YES
20-624 PC78MR-6
(1)
PC78MR-6 20-625
(1)
C-18 Work equipment still moves after work equipment lock lever is set to
LOCK
Cause Remedy
1
When pushed, (1) (3) are
connected to each other. Is PPC hydraulic lock switch
NO
When released, (1) (2) are Defective hydraulic lock switch Replace
normal?
connected to each other
(Test on switch unit)
YES
2
NO Short circuit with positive (+) wire in Repair or
When locked: 0 V Is voltage between M13 (2)
wiring harness between K28 (2) replace wiring
When released: 20 29 V chassis ground normal?
M13 (2) harness
YES
Defective PPC lock solenoid valve Replace
20-626 PC78MR-6
(1)
C-19 Machine does not swing

a Carry out the following troubleshooting when [E-203] and [E-213] are not displayed.
Cause Remedy
Is bit pattern 1023 (4)

NO
Check swing control lever. Go to F-1
displayed?
YES
Go to H-34
PC78MR-6 20-627
(1)
C-20 Travel speed does not rise

a Carry out the following troubleshooting when [E-206] and [E-216] are not displayed.
Cause Remedy
1
20 29 V Is voltage between K3 (Female) (2) NO
Turn starting switch ON chassis ground normal?
Disconnect K3
YES
2
In 1-spool mode: Max. 1Mz
In 2-spool mode: Max. 1Mz Is resistance between K3 (Male) (2) NO Defective 2nd travel speed
Replace
Turn starting switch OFF (1) normal? selection switch
Disconnect K3
YES
between K3 (Female) (1) replace
chassis ground
3
20 29 V NO
Is voltage between M95 (5)
Turn starting switch ON Defective controller Replace
Disconnect K3

between M95 (Female) (5) K3 replace
(Female) (2)
C-21 Trouble in controller power supply (LED of controller is turned OFF)

a See E-1.
20-628 PC78MR-6
(1)
(INPUT SIGNAL SYSTEM)
(F MODE)
F-1 Bit pattern 1023-(4) Swing pressure switch does not light up........................................................... 20-702
F-2 Bit pattern 1023-(3) Travel pressure switch does not light up........................................................... 20-703
F-3 Bit pattern 1023-(6) Boom RAISE pressure switch does not light up ............................................... 20-704
F-4 Bit pattern 1023-(5) Arm IN pressure switch does not light up ......................................................... 20-705
F-5 Bit pattern 1026-(1) Deceleration switch of left knob does not light up............................................. 20-706
F-6 Bit pattern 1026-(4) 2nd travel speed selection switch (pedal) does not light up.............................. 20-707
F-7 Bit pattern 1021-(3) Compressor signal does not light up................................................................. 20-708
removed and the connector is returned, if the monitoring code is displayed normally, the condition has
returned to normal.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
PC78MR-6 20-701
TROUBLESHOOTING F-1
2 F-1 Bit pattern 1023-(4) Swing pressure switch does not light up
Before operating the swing control lever (even a little distance), stick the bucket into the ground to lock the
swing mechanism.
Cause Remedy
Disconnect M22. 1
Start engine.
Set swing control lever in Is resistance between M22 (Male) (1) NO Defective left swing pressure
neutral: Min. 1Mz (2) normal and are they insulated from Replace
switch
Move swing control lever to chassis ground?
swing to left: Max. 1z
See note. YES
Disconnect M23.
2
Start engine.
Set swing control lever in Is resistance between M23 (Male) (1)
NO Defective right swing pressure
neutral: Min. 1 Mz (2) normal and are they insulated from Replace
switch
Move swing control lever to chassis ground?
swing to right: Max. 1 z
See note. YES
3
Turn starting switch OFF. Disconnection, defective
Disconnect M95, M22, and M23. Is resistance between M95 (Female) contact, or short circuit with
Between M95 M22, M23: Max. (24) M22, M23 (Female) (2) normal NO chassis ground in wiring Repair or
1z and are they insulated from chassis harness between M95 (Female) replace
Between wiring harness ground? (24) M22 (Female) (2), M23
chassis ground: Min. 1 z (Female) (2)
YES
4
Start engine.
Set swing control lever in Disconnection or defective
neutral: 20 30 V Is voltage between M95 (24) chassis NO contact in wiring harness Repair or
Move swing control lever: Max. ground normal? between M22 (Female) (1), M23 replace
1V (Female) (1) chassis ground
YES
Note: This item may be judged by fitting a short connector. In this case, judge by the voltage between M95
(24) chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
F-1 Electrical circuit diagram of each system
20-702 PC78MR-6
TROUBLESHOOTING F-2
2 F-2 Bit pattern 1023-(3) Travel pressure switch does not light up
Before operating the travel lever (even a little distance), check the condition and safety around the
machine.
Before operating the travel lever, put a block in the grouser of the track shoe or between the sprocket and
frame to lock the track shoe.
Cause Remedy
Disconnect M25. 1
Start engine. Is resistance between M25 (Male) (1)
Set swing control lever in NO
(2) normal and are they insulated from Defective travel pressure switch Replace
neutral: Min. 1 Mz chassis ground?
Move travel lever: Max. 1 z
See note. YES
2
Is resistance between M95 (Female)
Disconnect M95 and M25. contact, or short circuit with
(18) M25 (Female) (2) normal and NO Repair or
Between M95 M25: Max. 1 z chassis ground in wiring
are they insulated from chassis replace
Between wiring harness harness between M95 (Female)
ground?
chassis ground: Min. 1 Mz (18) M25 (Female) (2)
YES
3
Start engine. Disconnection or defective
Set travel lever in neutral: Is voltage between M95 (18) chassis NO contact in wiring harness Repair or
20 30 V ground normal? between M25 (Female) (1) replace
Move travel lever: Max. 1 V chassis ground
YES
PC78MR-6 20-703
TROUBLESHOOTING F-3
F-3 Bit pattern 1023-(6) Boom RAISE pressure switch does not light up
When measuring while the engine is running, move each lever to the degree that the work equipment will
not move.
Cause Remedy
Start engine. 1
Set boom control lever in Is voltage between M95 (12) chassis NO
neutral: 20 30 V ground normal?
Move boom control lever to
lower boom: Max. 1 V
YES Defective governor or pump
Replace
controller
Disconnect M21.
2
Start engine.
Set boom control lever in Is resistance between M21 (Male) (1) NO Defective boom RAISE
neutral: Min. 1 Mz (2) normal and are they insulated from Replace
pressure switch
Move boom control lever to chassis ground?
lower boom: Max. 1 z
See note. YES
3
Is resistance between M95 (Female)
Disconnect M95 M21. contact, or short circuit with
(12) M21 (Female) (2) normal and NO Repair or
Between M95 M21: Max. 1 z chassis ground in wiring
are they insulated from chassis replace
Between wiring harness harness between M95 (Female)
ground?
chassis ground: Min. 1 Mz (12) M21 (Female) (2)

between M21 (Female) (1) replace
chassis ground
20-704 PC78MR-6
TROUBLESHOOTING F-4
F-4 Bit pattern 1023-(5) Arm IN pressure switch does not light up
When measuring while the engine is running, move each lever to the degree that the work equipment will
not move.
Cause Remedy
Start engine. 1
Set arm control lever in neutral: Is voltage between M95 (6) chassis NO
20 30 V ground normal?
Move arm control lever to move
arm in: Max. 1 V
Replace
controller
Disconnect M24.
2
Start engine.
Set arm control lever in neutral: Is resistance between M24 (Male) (1) NO Defective arm IN pressure
Min. 1 Mz (2) normal and are they insulated from Replace
switch
Move arm control lever to move chassis ground?
arm in: Max. 1 z
See note. YES
3
Turn starting switch OFF.
Disconnection, defective
Disconnect M95 M24.
Is resistance between M95 (Female) NO contact, or short circuit with
Between M95 and M24: Max. Repair or
(6) M24 (Female) (2) normal and are chassis ground in wiring
1z replace
they insulated from chassis ground? harness between M95 (Female)
Between wiring harness
(6) M24 (Female) (2)
between M24 (Female) (1) replace
chassis ground
Note: This item may be judged by fitting a short connector. In this case, judge by the voltage between M95 (6)
chassis ground.
PC78MR-6 20-705
TROUBLESHOOTING F-5
F-5 Bit pattern 1026-(1) Deceleration switch of left knob does not light up
a Check that fuse 1! is normal.
Cause Remedy
1
Turn starting switch ON. Is voltage between M97 (9) chassis NO
Turn knob switch ON: 20 30 V ground normal?
Turn knob switch OFF: Max. 1 V

Replace
controller
2
Turn starting switch ON. Is voltage between K18 (Male) (2) NO contact in wiring harness Repair or
20 30 V chassis ground normal? between fuse (11) K18 (1) replace
knob switch inlet
YES
Turn starting switch OFF. 3

Disconnect knob switch terminal
K18. Is resistance between K18 (Male) (1) NO
Defective left knob switch Replace
Turn knob switch ON: Max. 1z (2) normal?
Turn knob switch OFF: Min. 1
Mz YES Disconnection or defective
between K18 (2) M97 replace
(Female) (9)
20-706 PC78MR-6
TROUBLESHOOTING F-6
2 F-6 Bit pattern 1026-(4) 2nd travel speed selection switch (pedal) does not
light up
Cause Remedy
Turn starting switch OFF. 1
Disconnect 2nd travel speed
selection switch terminal K3. Is resistance between K3 (Male) (1) NO Defective 2nd travel speed
Replace
Turn 2nd travel speed selection (2) normal? selection switch (pedal)
switch ON: Max. 1z
Turn 2nd travel speed selection YES
switch OFF: Min. 1 Mz
2
Disconnect M95 and K3. Is resistance between K3 (Female) (2) NO contact, or short circuit with
Repair or
Between M95 K3: Max. 1z M95 (Female) (5) normal and are chassis ground in wiring
replace
Between wiring harness they insulated from chassis ground? harness between M95 (Female)
chassis ground: Min. 1 Mz (5) K3 (Female) (2)
YES
3
Turn starting switch ON. Disconnection or defective
Turn 2nd travel speed selection Is voltage between M95 (Female) (5) NO contact in wiring harness Repair or
switch ON: Max. 1 V chassis ground normal? between K3 (Female) (1) replace
chassis ground
YES
PC78MR-6 20-707
TROUBLESHOOTING F-7
2 F-7 Bit pattern 1021-(3) Compressor signal does not light up

a Before starting measurement, check that the compressor operates normally when the air conditioner is
turned ON.
Cause Remedy
Turn starting switch ON. 1

Disconnect M97.
When compressor operates
contact, or short circuit with
(= Just after air conditioner is Is voltage between M97 (Female) (10) NO Repair or
chassis ground in wiring
turned ON): 20 30 V chassis ground normal? replace
harness between M97 (Female)
When compressor stops
(10) K11 (Female) (8)
(= After air conditioner is turned
off): Max. 1 V
YES
20-708 PC78MR-6
TROUBLESHOOTING FOR HYDRAULIC AND
MECHANICAL SYSTEMS
(H MODE)
Table of hydraulic failure modes and their causes ...................................................................................... 20-804

H- 1 Speed or power of 2 or more systems of work equipment (boom, arm, bucket), travel, swing,
and blade is low ................................................................................................................................. 20-806
a) Speed or power of all work equipment (including blade), travel, and swing systems is low .......... 20-806
b) Speed or power of all work equipment (excluding blade) and travel is low ................................... 20-807
c) Speed or power of swing and blade is low..................................................................................... 20-807
d) Speed or power of travel and blade is low ..................................................................................... 20-808
e) Speed or power of all work equipment (excluding blade) is low .................................................... 20-808
f) Speed or power of travel and swing is low..................................................................................... 20-808
H- 2 Engine speed lowers extremely or engine stalls................................................................................ 20-809
H- 3 2 or more systems of work equipment (boom, arm, bucket), travel, swing, and blade do not move..........20-811
a) All work equipment (including blade), travel, and swing systems do not move ..............................20-811
b) All work equipment (excluding blade) and travel systems do not move ........................................ 20-812
c) Swing and blade systems do not move ......................................................................................... 20-812
d) Travel and blade systems do not move ......................................................................................... 20-813
e) All work equipment (excluding blade) does not move ................................................................... 20-813
H- 4 Abnormal sound comes out (from around pump) .............................................................................. 20-814
H- 5 Fine controllability or response is low ................................................................................................ 20-815
H- 6 Hydraulic drift is large (all work equipment and blade) ...................................................................... 20-816
H- 7 Boom speed or power is low (other work equipment is normal) ........................................................ 20-817
a) Boom RAISE speed or power is low.............................................................................................. 20-817
b) Boom LOWER speed or power is low ........................................................................................... 20-818
H- 8 Arm speed or power is low (other work equipment is normal) ........................................................... 20-819
a) Arm IN speed or power is low........................................................................................................ 20-819
b) Arm OUT speed or power is low.................................................................................................... 20-820
H- 9 Bucket speed or power is low (other work equipment is normal)....................................................... 20-821
a) Bucket CURL speed or power is low ............................................................................................. 20-821
b) Bucket DUMP speed or power is low ............................................................................................ 20-822
H-10 Boom swing speed or power is low (other work equipment is normal) .............................................. 20-823
a) Swing left speed or power is low ................................................................................................... 20-823
b) Swing right speed or power is low ................................................................................................. 20-824
H-11 Boom does not move ......................................................................................................................... 20-825
a) Boom does not rise........................................................................................................................ 20-825
b) Boom does not lower ..................................................................................................................... 20-826
H-12 Arm does not move............................................................................................................................ 20-827
a) Arm does not move in.................................................................................................................... 20-827
b) Arm does not move out.................................................................................................................. 20-828
H-13 Bucket does not move ....................................................................................................................... 20-829
a) Bucket does not curl ...................................................................................................................... 20-829
b) Bucket does not dump ................................................................................................................... 20-830
H-14 Boom swing does not move .............................................................................................................. 20-831
a) Boom swing LEFT does not move................................................................................................. 20-831
b) Boom swing RIGHT does not move .............................................................................................. 20-832
H-15 Hydraulic drift of boom is large .......................................................................................................... 20-833
H-16 Hydraulic drift of arm is large ............................................................................................................. 20-833
H-17 Hydraulic drift of bucket is large......................................................................................................... 20-834
PC78MR-6 20-801
H-18 Hydraulic drift of swing is large ......................................................................................................... 20-834
a) Hydraulic drift of swing to left is large ............................................................................................ 20-834
b) Hydraulic drift of swing to right is large .......................................................................................... 20-834
H-19 Time lage is large (when engine speed is low) .................................................................................. 20-835
H-20 Part loaded more moves slower in compound operation of work equipment .................................... 20-835
H-21 Boom RAISE speed is low in compound operation of swing and boom RAISE ................................ 20-836
H-22 Travel speed lowers extremely in compound operation of travel and boom RAISE .......................... 20-836
H-23 Speed is low in compound operation of work equipment relief and swing,
work equipment relief and work equipment ....................................................................................... 20-836
H-24 Travel deviation is large ..................................................................................................................... 20-837
a) Travel deviation is large during ordinary travel .............................................................................. 20-837
b) Travel deviation is large when machine starts (but during normal ordinary travel) ........................ 20-838
H-25 Travel deviation is large in compound operation of travel and swing, travel and work
equipment .......................................................................................................................................... 20-839
H-26 Travel speed or power is low (work equipment, swing, and blade operations are normal)................ 20-840
H-27 Machine cannot be steered sharply or steering force is insufficient................................................... 20-842
H-28 Travel speed does not change at all or does not change quickly ...................................................... 20-843
H-29 Machine does not travel..................................................................................................................... 20-844
H-29 Supplement........................................................................................................................................ 20-845
H-30 Overrun of travel is large.................................................................................................................... 20-846
H-31 Travel hydraulic drift is large .............................................................................................................. 20-846
H-32 Fine controllability or response is low ................................................................................................ 20-847
H-33 Swing speed or power is low (work equipment, travel, and blade operations are normal) ................ 20-848
H-34 Machine does not swing (work equipment, travel, and blade operations are normal) ....................... 20-850
a) Swing speed or power is low in both directions ............................................................................. 20-850
b) Swing speed or power is low in either direction ............................................................................. 20-851
H-35 Swing acceleration is low................................................................................................................... 20-852
a) Swing acceleration is low in both directions................................................................................... 20-852
b) Swing acceleration is low in either direction .................................................................................. 20-852
H-36 Overrun of swing is large ................................................................................................................... 20-853
a) Overrun of swing is large in both directions ................................................................................... 20-853
b) Overrun of swing is large in either direction................................................................................... 20-853
H-37 Large shock is made when machine stops swinging ......................................................................... 20-854
H-38 Large abnormal sound is made when machine stops swinging......................................................... 20-854
H-39 Swing hydraulic drift is large .............................................................................................................. 20-855
H-40 Fine controllability more response of swing is low ............................................................................. 20-856
H-41 Blade speed or power is low (work equipment, travel, and swing operations are normal) ................ 20-857
H-42 Blade does not move (work equipment, travel, and swing operations are normal) ........................... 20-858
a) Blade does not rise ........................................................................................................................ 20-858
b) Blade does not lower ..................................................................................................................... 20-859
H-43 Hydraulic drift of blade is large........................................................................................................... 20-860
H-44 Fine controllability or response of blade is low .................................................................................. 20-861
20-802 PC78MR-6
TROUBLESHOOTING TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES

Part Which May Cause Trouble Tank Hydraulic Pump Control Valve
Pressure compensation valve
Main relief circuit check valve

LS bypass choke
Main relief valve

Engine system
Control pump
LS line choke
Unload valve
Piston pump
Hydraulic oil
Merge valve
Servo valve
Logic valve
Gear pump
PTO spline
EPC valve
PC valve
LS valve
Strainer
Orifice
Spool
Failure mode
Cap
Machine model PC78MR-6 Standard specification q
Failure mode
Speed or power of 2 or more systems or work equipment, travel, and
blade is low q q q q q q q q q q
Engine speed lowers extremely or engine stalls q q q q q q q

All work equip- 2 or more systems of work equipment, travel, swing, and blade do not q q q q q q q q
ment, travel, move
swing, blade
Abnormal sound comes out (From around pump) q q q q q q
Fine controllability or response is low q q q q q q q
Hydraulic drift is large (All work equipment and blade)
Boom q q
Speed or
power of work Arm q q
equipment is
low Bucket q q
Boom swing q q
Boom q q
Work equip- Arm q q
Work equipment does not
ment move Bucket q q
Boom swing q q
Boom q
Hydraulic drift Arm q
of work equip-
ment is large Bucket q
Boom swing q
Time lag is large (When engine speed is low) q
Part loaded more moves slower in compound operation of work
equipment
Boom RAISE speed is low in compound operation of swing and boom
RAISE q
Compound
operation Travel speed lowers extremely in compound operation of travel and
boom RAISE
Speed is low in compound operation of work equipment relief and
swing, work equipment relief and other work equipment q q
Travel deviation is large q q q q q q

Travel deviation is large in compound operation of travel and swing,
travel and work equipment q q
Travel speed or power is low q q q q q q

Machine cannot be steered sharply or steering force is insufficient q q q q q q
Travel Travel speed does not change at all or does not change quickly
Machine does not travel q q q

Overrun of travel is large q
Travel hydraulic drift is large
Fine controllability or response is low q q q q q

Swing speed or power is low q q
Machine does not swing q q
Swing acceleration is low q q
Overrun or swing is large
Swing
Large shock is made when machine stops swinging q
Large abnormal sound is made when machine stops swinging
Swing hydraulic drift is large
Fine controllability or response of swing is low q q q

Blade speed or power is low q
Blade does not move q
Blade
Hydraulic drift of blade is large q
Fine controllability or response of blade is low q
20-804 PC78MR-6
q
q
PPC circuit check valve
Travel junction variable throttle
q
q
q
valve
q
Travel LS bleed valve
q
Centralized safety valve
PC78MR-6
q
q
q
q
q
q
q
q
q
q
q
q
q
Suction valve
q q
q
Boom lock valve
Control Valve
q
q
q q q
Boom assist valve
q
q
q q
Gear pump circuit relief valve
q
q
q
q
q q q
Blade safety valve
TROUBLESHOOTING
q
q
Pressure release valve
q
q
Swing PPC slow return valve
q q
q q
q q
q q
q q
Swing PPC line choke
q q
q
2nd travel speed selection choke
q
q
q
q
PPC valve (Right lever) 1 0
q
q
q
q
q
q
q
q
PPC valve (Left lever) 1 0
q
q
q
q
q
q
PPC valve (Travel lever)
PPC valve (Blade bar)
PPC Valve
q q
q
q
PPC valve (Offset pedal)
q

PPC main pressure lock sole-
q
q
noid
2nd travel speed selection
q
solenoid valve
Swing holding brake solenoid
q
q
valve
Solenoid Valve
q
q
Boom RAISE EPC valve
q
q Arm IN EPC valve
q
q
Left offset EPC valve
Piston motor
q
Safety valve
Check valve
q q q
q q q q
Suction valve
Swing Motor
q q q q q
q q q q q
Parking brake
q q
q
q q q q q q
q q q q q q
Reaction prevention valve
q
q
Swing machinery
q
q
q
Center swivel joint
q
q
q
q
q q
Piston motor
q q
q
Counterbalance valve
q q q
q q q
q q q q
q q q q
Check valve
2nd speed select valve and
q
piston
Parking brake
Travel Motor
q q
q q
Parking brake valve
q q q
q q q
q q q
Final drive
q
q
q
q
q
q
q
q
q
q
Hydraulic cylinder
q
q
q
q
q
PPC pressure switch
q q
q
q
q q q
q q q
q
Emergency pump drive switch
H-44
H-43
H-42
H-41
H-40
H-39
H-38
H-37
H-36
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-11
H-10
H- 9
H- 8
H- 7
H- 6
H- 5
H- 4
H- 3
H- 2
H- 1
mode
Failure
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
20-805
TROUBLESHOOTING H-1
H-1 Speed or power of 2 or more systems of work equipment (boom, arm,

bucket), travel, swing, and blade is low
a Before carrying out troubleshooting, check that the oil level in the tank is proper.
a If the engine speed lowers, carry out H-2 first.
a If "individual factor" is indicated, a trouble which occurs less frequently than the detected trouble may have
occurred or several troubles may be combined. Accordingly, carry out troubleshooting for each of those
troubles.
a Select a combination of systems which have low speed or power from Table 1 before going to the next trou-
bleshooting.
a If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators of
each system "which has low speed or power" (H-7 H-10).
Q : Normal
Table 1
x : Speed or power is low
Work Equipment Travel Swing Blade Diagnosis Item
x x x x Go to a
x x Q Q Go to b
Q Q x x Go to c
Q x Q x Go to d
x Q Q Q Go to e
Q x x Q Go to f
a) Speed or power of work equipment (including blade), travel, and swing systems is low
Cause Remedy
1
NO
Is suction strainer clogged?
YES Clogged suction strainer Clean or

(Defective suction by pump) replace
2
3.14 0.3 MPa
Is output pressure of PPC main pressure lock NO
{32 3 kg/cm2}
solenoid valve normal?
YES
Go to H-1, b)
3
When control relief valve is adjusted, is NO
trouble repaired?
YES
Defective adjustment of control valve Adjust
4
When PPC lock solenoid valve is replaced, is NO
Defective pump control Replace
trouble repaired?
YES Defective PPC main pressure lock

Replace
solenoid
20-806 PC78MR-6
TROUBLESHOOTING H-1
b) Speed or power of all work equipment (excluding blade) and travel is low
Cause Remedy
1
Curl bucket
NO
26.5 1.47 MPa {270 15 kg/cm2} Is work equipment relief pressure normal?
YES
2
Curl bucket
NO Go to corresponding section
26.5 1.47 MPa {270 15 kg/cm2} Is travel relief pressure normal?
in H-7 10, 26
YES
3
When blade is relieved in RAISE mode, NO Defective main pump Repair or
(Lowering of volumetric
does the travel speed rise? efficiency) replace
YES Repair or
Defective boom assist valve
replace
4
Curl bucket
NO
26.5 1.47 MPa {270 15 kg/cm2} Is travel relief pressure normal?
YES Go to corresponding section

in H-7 10, 26
5
When travel relief valve is adjusted or NO
replaced, is trouble repaired?
YES Repair or
Defective main relief valve
replace
6
NO Repair or
Does unload valve move smoothly? Defective unload valve
replace
YES Repair or
Go to diagnosis No. 3
replace
c) Speed or power of swing and blade is low
Cause Remedy
1
Lower blade
21.08 1.47 MPa NO
Is gear pump relief pressure normal?
{215 15 kg/cm2}

in H-26, 33
2
When gear pump relief valve is adjusted or NO Repair or
Defective gear pump
replaced, is trouble repaired? replace
YES Defective gear pump relief Adjust or

pressure replace
PC78MR-6 20-807
TROUBLESHOOTING H-1
d) Speed or power of travel and blade is low
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is travel relief pressure normal?

H-26, 41
2
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is blade LOWER relief pressure normal?

H-26, 41
3
When hose is disconnected from valve outlet NO Go to corresponding section

and plugged, is relief pressure normal? H-26, 41
YES Repair or
Defective swivel joint
replace
e) Speed or power of all work equipment (excluding blade) is low
Cause Remedy
1
Is all PPC pressure normal (At PPC pressure NO
inlet of control valve?
YES
2
2.11 0.1 MPa
{21.5 1 kg/cm2} NO Defective adjustment of pump
Is LS differential pressure normal? Adjust
Run engine at full throttle and LS valve
curl bucket
YES
3
When compound operation of travel, work NO Go to corresponding section
equipment, and swing is performed, is trouble
in H-7 10
repaired?
YES Defective travel pressure
compensation valve
4
Is PPC pressure normal at only 1 place NO
(When single operation is performed)?
YES Defective check valve in PPC
circuit having normal PPC Replace
pressure
5
NO Leakage of PPC pressure
Is check valve at swing holding brake
caused by defective ball
pressure inlet of logic valve normal?
check valve

in H-7 10
f) Speed or power of travel and swing is low

Carry out the troubleshooting in b) above.
a If the PPC main pressure is judged low by troubleshooting in b) above, this trouble can occur.
20-808 PC78MR-6
TROUBLESHOOTING H-2
H-2 Engine speed lowers extremely or engine stalls

Cause Remedy
1
When bucket is relieved in CURL
mode and blade is relieved in RAISE NO
mode, does engine speed lower
much?
YES
2
When blade is relieved in RAISE mode
or swing is relieved and work NO
equipment is operated without
relieving simultaneously, does engine
speed lower much?
YES
Execute diagnosis No. 4
3
26.5 1.45 MPa
NO
{270 15 kg/cm2} Is bucket CURL relief pressure normal?
YES
4
12.74 1.47 MPa
NO
{130 15 kg/cm2} Is blade RAISE relief pressure normal?
YES
5
When gear pump circuit relief valve is NO
adjusted, repaired, or replaced, is
trouble repaired?
YES Defective gear pump circuit Adjust or
relief valve replace
6
When main relief valve is replaced, is NO
trouble repaired?
YES Repair or
Defective main relief valve
replace
7
Does monitor display error code "E02" NO
of TVC trouble?
YES
8
NO
Is TVC connector connected? Defective connection Repair
YES Defective TVC-EPC valve

Replace
(Defective solenoid)
9
When engine speed changes, does NO Repair or
Defective controller
TVC current change? replace
YES
To next page
PC78MR-6 20-809
TROUBLESHOOTING H-2
Cause Remedy
From previous page
10
0.54 ~ 0.83 MPa
Is output voltage of TVC-EPC solenoid NO
{5.5 ~ 8.5 kg/cm2}
normal?
YES
11
When PC valve is adjusted, is trouble NO
repaired?
YES Adjust or
Defective PC valve
replace
12
When orifice of servo is cleaned, is NO
trouble repaired?
YES
Clogged orifice
13
When EPC valve of TVC is replaced, is NO
Execute diagnosis No. 11
trouble repaired?
YES Repair or
Defective EPC valve
replace
14
When pump assembly is replaced, is NO
Defective engine system
trouble repaired?
YES Repair or
Defective pump or servo
replace
20-810 PC78MR-6
TROUBLESHOOTING H-3
H-3 2 or more systems of work equipment (boom, arm, bucket), travel,

swing, and blade do not move
a Before carrying out troubleshooting, check that the oil level in the tank is proper.
a Select a combination of systems which do not move from Table 1 before going to the next troubleshooting.
a If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators of
each system "which does not move" (H-10 13).
Q : Normal
Table 1
x : Speed or power is low
Work Equipment Travel Swing Blade Diagnosis Item
x x x x Go to a
x x Q Q Go to b
Q Q x x Go to c
Q x Q x Go to d
x Q Q Q Go to e
Q x x Q Go to f
a) All work equipment (including blade), travel, and swing systems do not move
Cause Remedy
1
When engine is cranked, does oil flow NO
out of pump?
YES
2
When oil does not flow out of any of
following pumps
Main pump
Gear pump
Control pump
YES
3
NO
Is suction strainer clogged?
YES
Clogged suction strainer Clean or adjust
4
NO
Is damper or spline damaged? Defective main pump shaft Replace
YES
Defective damper or spline Replace
5
When oil flows out of main pump but NO
does not flow out of gear pump and
control pump.
YES
6
Is coupling or spline between main NO
Defective gear pump Replace
pump and gear pump damaged?
YES
Defective coupling or spline Replace
To item No. 5 on next page
PC78MR-6 20-811
TROUBLESHOOTING H-3
Cause Remedy
From item 3 on previous page
5
When engine is cranked, does oil flow out of NO Repair or
Defective control pump
control pump? replace
YES
6
Defective PPC main pressure
3.14 0.3 MPa {32 3 kg/cm2} Is output pressure of PPC main pressure lock NO Repair or
lock solenoid valve or
Run engine at full throttle solenoid valve normal? replace
defective electric system

in H-11 ~ 14, 29, 34, 42
b) All work equipment (excluding blade) and travel systems do not move
Cause Remedy
1
Defective control
control? replace
YES
2
3.14 0.3 MPa Defective PPC main pressure Repair or
Is output pressure of PPC main pressure lock NO
{32 3 kg/cm2} lock solenoid valve or
solenoid valve normal? defective electric system replace
YES
3
Is only 1 part of each of work equipment and NO Go to corresponding section Repair or
travel normal? in H-11 14, 29 replace
YES Defective check valve in PPC Repair or
circuit having normal
pressure replace
c) Swing and blade systems do not move
Cause Remedy
1
Defective control pump
pump? replace
YES
2
When gear pump circuit relief valve is NO Go to corresponding section

adjusted or replaced, is trouble repaired? in H-34, 42
YES Defective gear pump circuit Adjust or
relief valve replace
20-812 PC78MR-6
TROUBLESHOOTING H-3
d) Travel and blade systems do not move
Cause Remedy
1
26.5 1.47 MPa
NO

H-29
2
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is blade relief pressure normal?

H-42
3
When hose is disconnected from valve outlet NO Go to corresponding section

and plugged, is relief pressure normal? H-29, 42
YES Repair or
replace
e) All work equipment (excluding blade) does not move
Cause Remedy
1
3.14 0.5 MPa
Are all PPC pressures normal NO
{32 5 kg/cm2}
(At connected PPC pressure inlets)?

in H-11 14
2
NO Go to corresponding section
Is only 1 place normal?
in H-11 14
YES Defective check valve in PPC
circuit having normal Replace
pressure
Note: If machine is equipped with an attach-
ment, check that attachment.
PC78MR-6 20-813
TROUBLESHOOTING H-4
H-4 Abnormal sound comes out (from around pump)

Cause Remedy
1
NO Supply
Is oil level in hydraulic tank normal? Low hydraulic oil level
hydraulic oil
YES
2
NO
Are there bubbles in hydraulic tank?
YES
3
When engine is stopped, do bubbles in tank NO
Low hydraulic oil level
disappear?
YES
4
NO
Foreign matter: Cloth, etc. Is suction strainer clogged with foreign matter?
YES Foreign matter (Cloth, etc.)

Remove
clogging suction strainer
5
Is suction strainer clotted with metallic foreign NO
matter or metal chips?
YES Repair or
Defective inside pump
replace
6
Re-inspect
NO Operate machine and (according to
Is hydraulic tank cap clogged?
observe condition for a while change of
condition)
YES Negative pressure caused by Clean or
clogging of cap replace cap
20-814 PC78MR-6
TROUBLESHOOTING H-5
H-5 Fine controllability or response is low

(Two or more systems have low fine controllability or response simultaneously)
a The following troubleshooting is not applicable to travel, swing, and blade systems.
Cause Remedy
1
See TESTING AND NO
Is LS differential pressure normal?
ADJUSTING
YES
2
NO
Is LS line choke clogged?
YES Clean or
Clogging of LS line choke
replace
3
NO
Is orifice of unload valve clogged?
YES Clogging of orifice of unload

Clean
valve
4
NO Defective PC valve or servo Repair or
Is orifice of piston pump clogged?
piston replace
YES Clogging of orifice or piston
Clean
pump
5
NO Repair or
When LS valve is adjusted, is trouble repaired? Defective LS valve
replace
YES Defective adjustment of LS
Adjust
valve
PC78MR-6 20-815
TROUBLESHOOTING H-6
H-6 Hydraulic drift is large (all work equipment and blade)

a Before carrying out troubleshooting, check that oil level in the tank is proper.
Cause Remedy
1
Is pressure release plug of control valve NO Leakage through pressure
Retighten
tightened? release circuit
YES
2
NO
Is seal of pressure release plug broken?
YES Leakage through pressure

release circuit
3
When centralized safety valve is replaced, is NO Go to corresponding section
trouble repaired? in H-15 H-18
YES Defective concentrated
Clean
safety valve
20-816 PC78MR-6
TROUBLESHOOTING H-7
H-7 Boom speed or power is low (other work equipment is normal)

a) Boom RAISE speed or power is low
a When the boom speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
pressure and carry out troubleshooting No. 2.
a Check that the emergency pump drive switch is turned OFF.
Cause Remedy
1
Run engine at full throttle and
set boom in neutral: 410 mA When boom is raised in monitoring mode NO
Diagnose by F-3
Run engine at full throttle and 1050, does current lower?
raise boom: 100 mA
YES
2
0.54 ~ 0.83 MPa
Is output pressure of pump TVC-EPC NO Defective pump TVC-
{5.5 8.5 kg/cm2} Replace
solenoid normal? EPC solenoid
YES
3
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is boom relief pressure normal?
YES
4
3.14 0.49 MPa
Is PPC valve output pressure normal?
{32 5 kg/cm2}
(PPC pressure inlet of control valve)
YES
5
NO Defective operation of Repair or
Does control valve spool move smoothly?
control valve spool replace
YES
6
NO Defective operation of
Does pressure compensation valve move
pressure compensation
smoothly?
valve
YES
7
26.5 1.47 MPa
NO Defective centralized
{270 15 kg/cm2} Is boom LOWER relief pressure normal? Replace
safety valve
YES Defective suction valve Repair or
(Boom LOWER side) replace
8
When pilot hose of boom assist valve is NO Defective boom cylinder Repair or
disconnected, does speed rise? packing replace
YES Defective seat of check
Repair or
valve of boom assist
replace
valve
9
(Move boom RAISE with arm IN When PPC hose is replaced with arm IN hose NO
oil.) on control valve side, is trouble repaired?
YES Defective boom RAISE Repair or
PPC valve replace
PC78MR-6 20-817
TROUBLESHOOTING H-7
b) Boom LOWER speed or power is low

a When the boom speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is boom LOWER relief pressure normal?
YES
2
3.14 0.49 MPa
Is PPC valve output pressure normal? (At NO
{32 5 kg/cm2}
control valve PPC pressure inlet)
YES
3
NO Defective operation of Repair or
control valve spool replace
YES
4
Does poppet of pilot piston of boom lock NO Repair,
valve move smoothly and its orifice free Malfunction of lock valve clean, or
from clogging? replace
YES Check 3
Malfunction of spool
again
5
26.5 1.47 MPa
NO Defective concentrated
{270 15 kg/cm2} Is boom RAISE relief pressure normal? Replace
safety valve
(Boom LOWER side) replace
6
When PPC hose of control valve is replaced NO
(Move boom LOWER with arm
with arm DUMP, is trouble repaired? (Return Go to diagnosis No. 3
OUT oil.)
it immediately after testing.)
YES Defective boom LOWER Repair or
PPC valve replace
20-818 PC78MR-6
TROUBLESHOOTING H-8
H-8 Arm speed or power is low (Other work equipment is normal)

a) Arm IN speed or power is low
a When the arm speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief pres-
sure and carry out troubleshooting No. 2.
Cause Remedy
Run engine at full throttle and 1

set arm in neutral: 410 mA NO
When arm is moved IN in monitoring
Run engine at full throttle and Diagnose by F-3
mode 1050, does current lower?
raise boom: 100 mA
YES
2
0.54 0.83 MPa NO
Is output pressure of pump TVC-EPC Defective pump TVC-EPC
{5.5 8.5 kg/cm2} Replace
solenoid normal? solenoid
Run engine at full throttle.
YES
3
26.5 1.49 MPa
NO
{270 15 kg/cm2} Is arm IN relief pressure normal?
YES
4
3.14 0.49 MPa
Is EPC valve output pressure normal? NO Repair or
{32 5 kg/cm2} Defective arm IN PPC valve
(PPC pressure inlet of control valve) replace
YES
5
NO Defective operation of control Repair or
valve spool replace
YES
6
Does pressure compensation valve move NO Defective operation of
smoothly? pressure compensation valve
YES
7
26.5 1.47 MPa
NO Defective centralized safety
{270 15 kg/cm2} Is arm OUT relief pressure normal? Replace
valve
YES Defective suction valve (Boom Repair or
LOWER side) replace
8
When PPC hose is replaced with boom
(Move arm IN with boom RAISE hose on control valve side, is NO
RAISE) trouble repaired? (Return it immediately
after testing.)
YES Repair or
Defective arm IN PPC valve
replace
9
When swing operation and arm IN NO
operation are executed simultaneously, is Go to diagnosis No. 3
trouble repaired?
YES Defective seats of swing
Repair or
brake circuit check valve and
replace
swing PPC slow-return valve
PC78MR-6 20-819
TROUBLESHOOTING H-8
b) Arm OUT speed or power is low

a When the arm speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief pres-
sure and carry out troubleshooting No. 2.
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is arm OUT relief pressure normal?
YES
2
3.14 0.49 MPa
Is PPC valve output pressure normal? NO
{32 5 kg/cm2}
(At control valve PPC pressure inlet)
YES
3
NO Malfunction of control valve Repair or
spool replace
YES
4
Does pressure compensation valve move NO Malfunction of pressure Repair or
smoothly? compensation valve replace
YES Defective arm cylinder Repair or
packing replace
5
26.5 1.47 MPa
NO Defective concentrated
{270 15 kg/cm2} Is arm OUT relief pressure normal? Replace
safety valve
(Arm IN side) replace
6
When PPC hose of control valve is
(Move arm OUT with boom replaced with boom LOWER, is trouble NO
LOWER oil) repaired? (Return it immediately after
testing.)
YES Defective arm OUT PPC Repair or
valve replace
20-820 PC78MR-6
TROUBLESHOOTING H-9
H-9 Bucket speed or power is low (Other work equipment is normal)

a) Bucket CURL speed or power is low
a When the bucket speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is bucket CURL relief pressure normal?
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
YES
3
spool replace
YES
4
YES Defective arm cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective concentrated
{270 15 kg/cm2} Is bucket DUMP relief pressure normal? Replace
safety valve
(Bucket CURL side) replace
6
When PPC hose of control valve is NO
(Move bucket CURL with
replaced with arm IN, is trouble repaired? Go to diagnosis No. 3
arm IN oil)
(Return it immediately after testing.)
YES Defective bucket CURL PPC Repair or
valve replace
PC78MR-6 20-821
TROUBLESHOOTING H-9
b) Bucket DUMP speed or power is low

a When the bucket speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is bucket DUMP relief pressure normal?
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
YES
3
spool replace
YES
4
YES Defective bucket cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective concentrated
{270 15 kg/cm2} Is bucket CURL relief pressure normal? Replace
safety valve
(Bucket DUMP side) replace
6
When PPC hose of control valve is replaced NO
(Move bucket DUMP with
with arm OUT, is trouble repaired? (Return it Go to diagnosis No. 3
arm OUT oil)
immediately after testing.)
YES Defective bucket DUMP PPC Repair or
valve replace
20-822 PC78MR-6
TROUBLESHOOTING H-10
H-10 Boom swing speed or power is low (other work equipment is normal)
a) Swing left speed or power is low
a Relieve the swing LEFT actuator in a position at which the swing end cushion system does not detect the
work equipment.
a When the offset speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is swing left relief pressure normal?
YES
2
3.14 0.49 MPa
Is solenoid valve output pressure normal? NO
{32 5 kg/cm2}
YES
3
valve spool replace
YES
4
Does pressure compensation valve move NO Defective operation of Repair or
smoothly? pressure compensation valve replace
YES Defective swing cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective pressure Repair or
{270 15 kg/cm2} Is swing right relief pressure normal?
compensation valve replace
YES Defective packing seal near
Repair or
extraction end of swing
replace
cylinder
6
When PPC hose and bucket CURL hose
(Move swing left by curling are exchanged at control valve, does NO
Go to troubleshooting No. 3
bucket) condition become normal?
(Return hoses immediately after testing.)
YES
7
NO Defective swing left PPC Repair or
valve replace
Defective swing left solenoid Repair or

valve replace
PC78MR-6 20-823
b) Swing right speed or power is low

a Relieve the swing RIGHT actuator in a position at which the swing end cushion system does not detect the
work equipment.
a When the offset speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause Remedy
1
26.5 1.47 MPa
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
YES
3
valve spool replace
YES
4
Does pressure compensation valve move NO Defective operation of Repair or
smoothly? pressure compensation valve replace
YES Defective swing cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective pressure Repair or
(Right swing side) replace
6
When PPC hose and bucket DUMP hose
(Move swing right by dumping are exchanged at control valve, does NO
YES Repair or
Defective swing right PPC
replace
valve
20-824 PC78MR-6
H-11 Boom does not move

a Carry out the following troubleshooting, if the boom does not move when operated singly (when the other
work equipment is normal).
a) Boom does not rise
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is PPC valve output pressure normal? NO
Run engine at full throttle. (At control valve PPC pressure inlet)
YES
2
Does boom lower?
spool replace
YES
3
26.5 1.47 MPa
When boom is raised, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle. Deformation of cylinder or
YES work equipment (Boom does Repair or
not rise above the deformed replace
part
4
NO Malfunction of spool in raising Repair or
Does spool move smoothly?
mode replace
YES Malfunction of pressure Repair or
5
replaced with arm IN, is trouble NO
(Move boom lower with arm IN oil) Go to diagnosis No. 2
repaired? (Return it immediately after
testing.)
YES Defective boom RAISE PPC Repair or
valve replace
PC78MR-6 20-825
b) Boom does not lower
Cause Remedy
1
2.94 0.49 MPa
{30 5 kg/cm2}
YES
2
NO Malfunction of control valve
Repair or
Does boom rise? spool or seizure of lock valve
replace
poppet
YES
3
26.5 1.47 MPa
When boom is lowered, is pump relief NO
{270 15 kg/cm2}
pressure normal?
YES
4
NO Malfunction of spool in Repair or
lowering mode replace
5
(Move boom lower with arm replaced with arm OUT, is trouble NO
OUT oil) repaired? (Return it immediately after
testing.)
YES Defective boom LOWER PPC Repair or
valve replace
6
Is seal drain line of control valve NO Repair or
Defective lock valve
clogged? replace
YES Defective lock valve caused Repair or
by clogging replace
20-826 PC78MR-6
H-12 Arm does not move

a Carry out the following troubleshooting, if the arm does not move when operated singly (when the other
a) Arm does not move in
Cause Remedy
1
Run engine at full throttle (At control valve PPC pressure inlet.)
YES
2
Does arm move out?
spool replace
YES
3
26.5 1.47 MPa
When arm is moved in, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle Deformation of cylinder or
YES work equipment (Arm does Repair or
not move more than replace
deformed part)
4
NO Malfunction of spool in IN Repair or
mode replace
5
(Move arm out with boom RAISE replaced with boom RAISE, is trouble NO Repair or
Defective arm IN PPC valve
oil) repaired? (Return it immediately after replace
testing.)
YES
6
When swing operation and arm IN NO
operation are executed simultaneously, Go to diagnosis No. 2
is trouble repaired?
YES Defective seats of swing
Repair or
brake circuit check valve and
replace
swing PPC slow-return valve
PC78MR-6 20-827
b) Arm does not move out
Cause Remedy
1
Run engine at full throttle (At control valve PPC pressure inlet)
YES
2
Does arm move in?
spool replace
YES
3
26.5 1.47 MPa
When arm is moved out, is pump relief NO
{270 15 kg/cm2}
pressure normal?
YES work equipment (Arm does Repair or
not move more than replace
deformed part)
4
NO Malfunction of spool in OUT Repair or
mode replace
5
(Move arm out with boom LOWER replaced with boom LOWER, is trouble NO Defective arm OUT PPC Repair or
oil.) repaired? (Return it immediately after valve replace
testing.)
YES
20-828 PC78MR-6
H-13 Bucket does not move

a Carry out the following troubleshooting, if the bucket does not move when operated singly (when the other
a) Bucket does not curl
Cause Remedy
1
Run engine at full throttle (At control valve PPC pressure inlet.)
YES
2
Is bucket dumped?
spool replace
YES
3
26.5 1.47 MPa
When bucket is curled, is pump relief NO
{270 15 kg/cm2}
pressure normal?
YES work equipment Repair or
(Bucket does not move more replace
than deformed part)
4
NO Malfunction of spool in CURL Repair or
mode replace
5
replaced with arm IN, is trouble NO
(Move bucket curl with arm IN oil) Go to diagnosis No. 2
testing.)
YES Defective bucket CURL PPC Repair or
valve replace
PC78MR-6 20-829
b) Bucket does not dump
Cause Remedy
1
Run engine at full throttle (At control valve PPC pressure inlet)
YES
2
Is bucket curled?
spool replace
YES
3
26.5 1.47 MPa
When bucket is dumped, is pump relief NO
{270 15 kg/cm2}
pressure normal?
YES work equipment Repair or
(Bucket does not move more replace
than deformed part)
4
NO Malfunction of spool in DUMP Repair or
mode replace
5
replaced with arm OUT, is trouble NO
(Move bucket dump with arm OUT) Go to diagnosis No. 2
testing.)
YES Defective bucket DUMP PPC Repair or
valve replace
20-830 PC78MR-6
H-14 Boom swing does not move

a Carry out the following troubleshooting when the offset boom does not move when it is operated singly (and
the other work equipment is normal).
a) Boom swing LEFT does not move
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is solenoid valve output pressure normal? NO
Run engine at full throttle. (PPC pressure inlet of control valve)
YES
2
Does boom swing right move?
valve spool replace
YES
3
26.5 1.47 MPa
When swing left is operated, is pump NO
{270 15 kg/cm2}
relief pressure normal?
Run engine at full throttle. Deformed cylinder or work
YES equipment Repair or
(Work equipment does not replace
move over deformed part)
4
NO Repair or
Does spool move smoothly? Defective operation of spool
replace
YES Defective operation of Repair or
pressure compensation valve replace
5
When PPC hose and bucket CURL hose
are exchanged at control valve, does NO
(Move swing left by curling bucket) Go to troubleshooting No. 2
condition become normal?
YES
6
NO Defective swing left PPC Repair or
valve replace
YES Defective swing left EPC Repair or
valve replace
PC78MR-6 20-831
b) Boom swing RIGHT does not move
Cause Remedy
1
Run engine at full throttle. (PPC pressure inlet of control valve)
YES
2
Does boom swing left move?
valve spool replace
YES
3
26.5 1.47 MPa
When swing right is operated, is pump NO
{270 15 kg/cm2} relief pressure normal?
Run engine at full throttle. Deformed cylinder or work
YES equipment Repair or
(Work equipment does not replace
move over deformed part)
4
NO Repair or
Does spool move smoothly? Defective operation of spool
replace
YES Defective operation of Repair or
pressure compensation valve replace
5
When PPC hose and bucket DUMP hose
(Move swing right by dumping are exchanged at control valve, does NO
YES
6
NO Defective swing RIGHT PPC Repair or
valve replace
YES Defective swing RIGHT EPC Repair or
valve replace
20-832 PC78MR-6
TROUBLESHOOTING H-15, H-16
H-15 Hydraulic drift of boom is large

Cause Remedy
1
Is leakage from hydraulic cylinder NO Repair or
Defective cylinder piston packing
normal? replace
YES
2
When centralized safety valve is NO Repair or
Defective boom lock valve
YES
Defective boom lock valve Replace
H-16 Hydraulic drift of arm is large

Cause Remedy
1
normal? replace
YES
2
When centralized safety valve is NO
YES
Defective centralized safety valve Replace
3
When suction valve is replaced with NO Defective oil-tightness of control Repair or
blind plug, is trouble repaired? valve spool replace
YES Repair or
Defective centralized safety valve
replace
PC78MR-6 20-833
H-17 Hydraulic drift of bucket is large

Cause Remedy
1
normal? replace
YES
2
When centralized safety valve is NO
YES
3
When suction valve is replaced with NO Defective oil-tightness of control Repair or
blind plug, is trouble repaired? valve spool replace
YES Repair or
Defective suction valve
replace
H-18 Hydraulic drift of swing is large

a) Hydraulic drift of swing to left is large
Cause Remedy
1
normal? replace
YES
2
When suction valve is replaced with NO
Defective oil-tightness of control Repair or
blind plug, does condition become
valve spool replace
normal?
YES Repair or
replace
b) Hydraulic drift of swing to right is large
Cause Remedy
1
normal? replace
YES Defective oil-tightness of control Repair or
valve spool replace
20-834 PC78MR-6
H-19 Time lag is large (When engine speed is low)

Cause Remedy
1
Is suction valve normal (Free from NO
Defective suction valve Replace
seizure)?
YES
2
When poppet and spring of back NO
pressure valve are replaced, is trouble
repaired?
YES
Defective back pressure valve Replace
3
When LS valve is replaced, is trouble NO Replace
Defective pump servo piston pump
repaired? assembly
YES
Defective LS valve Replace
H-20 Part loaded more moves slower in compound operation of work

equipment
Cause Remedy
Defective counterbalance valve on

Replace
lighter load side
Compound Operation Heavier Load Lighter Load

Side Side
1 Boom RAISE + Arm IN Boom RAISE Arm IN
2 Boom RAISE + Arm OUT Arm OUT Boom RAISE
3 Boom RAISE + Bucket CURL Boom RAISE Bucket CURL
4 Arm IN + Bucket DUMP Arm OUT Bucket CURL
5 Boom LOWER + Arm OUT Arm OUT Boom LOWER
PC78MR-6 20-835
TROUBLESHOOTING H-21, H-22, H-23
H-21 Boom RAISE speed is low in compound operation of swing and

boom RAISE
a Carry out the following troubleshooting, if the swing operation and boom RAISE operation are normal when
executed singly (Swing LS pressure is not generated) .
When this operation is executed, the gear pump assists the boom RAISE circuit.
Cause Remedy
Defective boom assist valve or LS Clean or
select valve replace
H-22 Travel speed lowers extremely in compound operation of travel and

boom RAISE
a Carry out the following troubleshooting, if the work equipment (Boom RAISE) operation and travel operation
are normal when executed singly.
a Carry out the following troubleshooting, only when the boom RAISE circuit (LS) pressure is higher than the
travel circuit (LS) pressure.
Cause Remedy
Malfunction of LS bleed valve Repair or
(Clogged choke, etc.) replace
H-23 Speed is low in compound operation of work equipment relief and

swing, work equipment relief and other work equipment
Cause Remedy
Defective choke of LS bypass Replace
20-836 PC78MR-6
H-24 Travel deviation is large

a) Travel deviation is large during ordinary travel
Check shoe tension 1 Cause Remedy

difference between both
sides NO
Check rollers for revolution Is undercarriage troubled?
trouble
Check for deformation and YES
damage Repair or
Defective undercarriage
replace
2
Above 3.14 0.49 MPa
{Above 32 5 kg/cm2} Are PPC output pressures on both NO
Run engine at full throttle sides normal?
Move lever to stroke end
YES
3
When both hoses are exchanged NO
at pump outlet, does deviating
direction change?
YES Wrong adjustment or breakage of Adjust, repair
pump or replace
4
When both hoses between control NO
valve and swivel joint are exchanged,
does deviating direction change?
YES
5
Is pressure at top PP pressure NO
When only travel operation is
pickup port of control valve same
executed
as pump pressure?
YES
6
Does spool of travel junction NO Defective travel junction variable Clean or
variable choke valve move smoothly
and is hole free from clogging? choke valve replace
YES
7
Does spool of pump merge valve NO Repair or
move smoothly and is hole free Defective pump merge valve
from clogging? replace
YES Check, clean,

Malfunction of logic valve repair or
replace
8
When both check valves of main NO
relief circuit are exchanged, does
deviating direction change?
YES Defective check valve of main Repair or
relief circuit replace
9
Does unload valve move smoothly NO Malfunction of unload valve Repair or
and is hole free from clogging? (Clogging of hole, etc.) replace
YES
To 12 on next page To 10 on next page To 13 on next page
PC78MR-6 20-837
From 4 on previous page From 9 on previous page From 2 on previous page Cause Remedy
10
Does pressure compensation NO Defective pressure compensation Repair or
valve move smoothly? valve replace
YES
11
NO Repair or
Does travel spool move smoothly? Malfunction of spool
replace
YES
12
When both hoses between
swivel joint and travel motor are NO Defective travel motor (Motor, Check, repair
exchanged, does deviating counterbalance valve, final drive) or replace
direction change?
YES Repair or
replace
13
When both PPC hose are NO Defective PPC circuit check valve Repair or
exchanged, does deviating
direction change? of control valve replace
YES
14
NO Repair or
Does lever interfere with floor? Defective PPC valve
replace
YES Abnormal PPC pressure output

Adjust
caused by interference
b) Travel deviation is large when machine starts (but normal during ordinary travel)
1 Cause Remedy
When machine starts, is dragging NO
sound of brake heard from travel
motor on deviating side?
YES Delay of release of parking brake Repair or
(Malfunction of brake, brake valve replace
2
Does counterbalance valve of NO
Go to diagnosis No. 5 in (a) above
travel motor move smoothly?
YES Malfunction of counterbalance Repair or

valve replace
20-838 PC78MR-6
H-25 Travel deviation is large in compound operation of travel and swing,

travel and work equipment
a Carry out the following troubleshooting, if the travel operation is normal when executed singly.
Cause Remedy
1
3.14 0.49 MPa
Is output pressure of swing holding NO Defective swing holding brake
{32 5 kg/cm2} brake solenoid normal? solenoid
Replace
YES Seizure of filter and check valve at
output pressure inlet port of swing
Replace
holding brake solenoid of rotary
valve
PC78MR-6 20-839
H-26 Travel speed or power is low (Work equipment, swing, and blade
operations are normal)
a If another part of the work equipment has a trouble, see H-1.
Cause Remedy

1
and set travel lever in When machine is driven in NO
neutral: 410 mA monitoring mode 1050, does
Drive machine with engine current lower?
at full throttle: 100 mA
YES
Run engine at full throttle 2
and set travel lever in
neutral: 0.45 0.83 MPa NO
Is output pressure of TVC-EPC
{5.5 8.5 kg/cm2} Defective TVC-EPC solenoid Replace
Drive machine with engine solenoid normal?
at full throttle: 0 0.2 MPa
{0 2 kg/cm2} YES
3
Is travel pressure switch NO
Omission of connection Connect
connected?

Replace
controller
4
26.5 1.47 MPa
NO
YES
5
as port pressure?
YES
6
Does pump merge-divider spool NO Malfunction pump merge-divider Repair or
move smoothly and is hole free
from clogging? valve replace
YES Repair or
Malfunction logic valve
replace
7
When driven on flat
concrete with engine at full Is pump pressure normal during NO Large resistance to travel motor Repair or
throttle, if pressure is below travel? and undercarriage replace
11.7 MPa {120 kg/cm2}
YES Large leakage through travel Repair or
motor or swivel joint replace
8
Above 3.14 0.49 MPa Is PPC pressure normal? (At PPC NO
{32 5 kg/cm2} pressure inlet of control valve)
YES
9
NO Repair or
Does spool move smoothly? Malfunction of spool
replace
YES
To 12 on next page To 10 on next page
20-840 PC78MR-6
From 8 on previous page From 9 on previous page Cause Remedy

10
Does pressure compensation NO Defective pressure compensation Repair or
valve move smoothly? valve replace
YES
11
Does unload valve move NO Repair or
Defective unload valve
smoothly? replace
YES Large leakage through travel motor

or swivel joint
12
When PPC circuit check valve is NO Repair or
Defective PPC valve
YES
Defective PPC circuit check valve Replace
PC78MR-6 20-841
H-27 Machine cannot be steered sharply or steering force is insufficient
Cause Remedy
1
Does engine speed lower NO
(extremely only when machine is
steered during travel)?
YES Repair or
Defective pump servo
replace
2
as port pressure?
YES
3
Does spool of travel junction NO Defective travel junction variable Repair or
variable choke valve move smoothly
and is hole free from clogging? choke valve replace
YES
4
Does pump merge-divider spool NO Malfunction pump merge-divider Repair or
move smoothly and is hole free
YES Repair or
Malfunction of logic valve
replace
5
Is drive pump pressure of inside
motor normal? (Inside pump
pressure must be below above 10 NO
MPa {100 kg/cm2} while machine is
turning on flat concrete with turning
radius of about 5 m.)
YES
6
NO Repair or
Is inside PPC pressure low? Defective PPC
replace
YES
7
Does spool move smoothly? NO Repair or
Malfunction of spool
replace
YES Repair or
replace
8
When main relief circuit check NO Defective counterbalance valve of Repair or
valve is replaced, is trouble
repaired? travel motor or swivel joint replace
YES Defective main relief circuit check Repair or

valve replace
20-842 PC78MR-6
H-28 Travel speed does not change at all or does not change quickly
Cause Remedy
1
31.4 0.49 MPa Electric trouble in defective 2nd
Is output of 2nd travel speed NO travel speed selection solenoid Repair or
{32 5 kg/cm2} valve, 2nd travel speed selection
selection solenoid valve normal? replace
Run engine at full throttle switch, etc.
YES
2
Is outlet choke of 2nd travel speed NO Repair or
selection solenoid valve free from Malfunction caused by clogging
clogging? replace
YES
3
Is output pressure of 2nd travel NO Repair or
speed selection solenoid valve at Defective swivel joint
travel motor inlet normal? replace
YES Defective travel motor or 2nd travel Repair or

speed selection solenoid valve
piston replace
PC78MR-6 20-843
H-29 Machine does not travel

1 Cause Remedy
26.5 1.47 MPa
Does pump pressure rise to relief NO
{270 15 kg/cm2}
pressure?
YES
2
Is foreign matter drained from final NO
drive?
YES Repair or
Defective final drive
replace
3
Does counterbalance valve of NO Repair or
Defective counterbalance valve
travel motor operate smoothly? replace
YES
4
When driven on flat
concrete with engine at full Is undercarriage deformed or NO Repair or
Defective undercarriage
throttle, if pressure is below damaged? replace
11.7 MPa {120 kg/cm2}
YES Defective travel motor (Motor, Repair or
parking brake system) replace
See 1 5
Above 3.14 0.49 MPa
{Above 32 5 kg/cm2} Is PPC pressure normal?(At PPC NO
Run engine at full throttle pressure inlet of control valve)
Move lever to stroke end
YES
1 6
If machine does not travel on
flat concrete with engine at full
throttle and pump pressure NO
above about 10 MPa Does travel spool move smoothly? Malfunction of spool
{100 kg/cm2}, perform
diagnosis 2.
YES
7
Does pressure compensation valve NO Defective pressure compensation
move smoothly? valve
YES
8
Does unload valve move NO Repair or
smoothly? replace
YES Defective travel motor or swivel Repair or

joint replace
9
Drive machine with boom
PPC pressure When PPC hose is replaced with NO
boom hose on control valve side, Defective PPC circuit check valve
(Return piping immediately does PPC pressure rise?
after testing)
YES
Defective PPC valve
20-844 PC78MR-6
H-29 Supplement
Relationship between PPC circuit check valve and "Machine does not travel"
As shown below, PPC circuit check valves (1) (4) are installed to pick up the changeover signal pressure for
the pump merge-divider valve. If the checking function of these check valves is lost, the machine may not travel.
Example: When checking function of (1) is lost

Normal operations: "Left forward travel", "Left forward travel + Right forward travel", "Left forward travel
+ Right reverse travel"
Operations where machine may not travel: "Left reverse travel", "Right forward travel", "Right reverse
travel", "Left reverse travel + Right forward travel", "Left reverse travel + Right reverse travel"
PC78MR-6 20-845
H-30 Overrun of travel is large

Cause Remedy
1
Does PPC pressure lower immediately NO Repair or
after lever is returned? (At PPC pressure Defective PPC
inlet of control valve) replace
YES
2
NO Repair or
replace
YES
3
When suction valve is replaced, is NO
trouble repaired?
YES Repair or
replace
4
Does travel motor counterbalance NO Repair or
Defective counterbalance valve
valve move smoothly? replace
YES
5
Does travel motor check valve move NO Repair or
Defective check valve
smoothly? replace
YES Repair or
Defective travel motor
replace
H-31 Travel hydraulic drift is large

Cause Remedy
Defective parking brake or parking Repair or

brake valve of travel motor replace
20-846 PC78MR-6
H-32 Fine controllability or response is low

Cause Remedy
1
When air is bled from PPC, is trouble NO
repaired?
YES
Air in PPC Bleed PPC
2
Is pressure at top PP pressure pickup NO
port of control valve same as port
pressure?
YES
3
Does spool of pump merge-divider NO Malfunction of pump merge-divider Repair or
valve move smoothly and is hole free
YES Repair or
Defective logic valve
replace
4
Does unload valve move smoothly NO Repair or
Malfunction of unload valve
and is hole free from clogging? replace
YES
5
Does pressure compensation valve NO Malfunction of pressure Repair or
move smoothly? compensation valve replace
YES
6
NO Repair or
replace
YES
7
When PPC valve is replaced, is NO Repair or
trouble repaired? replace
YES Repair or
Defective PPC
replace
PC78MR-6 20-847
H-33 Swing speed or power is low (Work equipment, travel, and blade
a If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
Cause Remedy
1
When work equipment is relieved, NO
does speed rise?
YES Repair or
Defective boom assist valve
replace
2
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is swing relief pressure normal?
YES
3
Does pressure rise to near relief NO
pressure during stable swing?
YES
4
NO Defective motor unit, brake, or Repair or
Is swing dragging sound heard?
swing machinery circle replace
YES
5
Is swing brake release pressure NO Defective swing brake release
Replace
output? solenoid
YES
6
When controller is replaced, is trouble NO Repair or
Malfunction of swing holding brake
repaired? replace
YES
Malfunction of controller Replace
7
3.14 0.49 MPa {32 5 kg/cm2} Is PPC pressure at PPC control valve NO
Run engine at full throttle. normal?
YES
8
When fixed choke of swing PPC slow- NO
return valve is cleaned, is trouble
repaired?
YES Clean
Clogging of choke
repair or
Malfunction of slow return valve
replace
9
NO Repair or
replace
YES Repair or
Defective swing motor
replace
10
When choke of swing PPC line is NO Repair or
Defective PPC valve
cleaned, is trouble repaired? replace
YES Clean
Clogging of choke repair or
replace
To 11 on next page
20-848 PC78MR-6
From 2 on previous page Cause Remedy

11
When safety valve of swing motor is NO
adjusted or replaced, is trouble
repaired?
YES Adjust or
Defective safety valve
replace
12
When check valve and suction valve NO
of swing motor are replaced, is trouble
repaired?
YES Defective check valve or suction Repair or
valve replace
13
When reverse prevention valve is NO
YES Malfunction of reverse prevention Repair or

valve replace
PC78MR-6 20-849
H-34 Machine does not swing (Work equipment, travel, and blade opera-
tions are normal)
a If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
a Carry out the following troubleshooting, if the electric system is normal. (If the electric system is defective,
carry out E first.)
a) Swing speed or power is low in both directions
Cause Remedy
1
When swing operation and operation NO
other than boom RAISE operation are
executed, does machine move?
YES
Defective LS select valve Replace
2
Does pressure compensation valve NO Defective pressure compensation
move smoothly and is hole free from Replace
clogging? valve
YES
3
21.08 1.47 MPa
NO
YES
4
3.14 0.49 MPa {32 5 kg/cm2} Is swing holding brake relief pressure NO Malfunction of swing holding brake
Run engine at full throttle normal? (At motor inlet) solenoid valve
YES Malfunction of motor unit, brake, or

swing machinery
5
Is swing motor turning? (Judge by NO
sound)
YES Damage of motor shaft or swing Repair or

machinery replace
6
When safety valve of swing motor is NO
adjusted or replaced, is trouble
repaired?
YES Repair or
Defective safety valve
replace
7
When check valve and suction valve NO
of swing motor are adjusted or Go to diagnosis No. 6
YES Clean
Defective check valve or suction
repair or
valve
replace
20-850 PC78MR-6
b) Swing speed or power is low in either direction
Cause Remedy
1
26.5 1.47 MPa NO
YES
2
3.14 0.49 MPa Are swing brake release pressures on NO
{32 5 kg/cm2} both sides normal? (At solenoid
Run engine at full throttle outlet)
Note that swing timer is set to YES Defective swing motor or swing
Replace
5 seconds machinery circle
3
Since motor may be broken, When lever is moved to right and left, NO Repair or
does work equipment move for 5 Malfunction of spool
operate in fine control mode seconds? replace
YES Repair or
Disconnection of wiring harness
replace
4
When check valve and suction valve NO Repair or
of swing motor are replaced, is trouble Malfunction of spool
repaired? replace
YES Defective check valve or suction Repair or

valve replace
PC78MR-6 20-851
H-35 Swing acceleration is low

a) Swing acceleration is low in both directions
Cause Remedy
1
When swing motor safety valve is NO
Execute diagnosis in H-33, H-40
YES
Defective swing motor safety valve Replace
b) Swing acceleration is low in either direction
Cause Remedy
Execute diagnosis in H-33, H-40
20-852 PC78MR-6
H-36 Overrun of swing is large

a) Overrun of swing is large in both directions
Cause Remedy
1
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is swing relief pressure normal? Defective swing motor safety valve Replace
YES Repair or
Go to b)
replace
b) Overrun of swing is large in either direction
Cause Remedy
1
Does control valve spool move NO Repair or
Malfunction of control valve spool
smoothly? replace
YES
2
When swing motor suction valve is NO
YES Defective swing motor suction Repair or

valve replace
3
YES Repair or
Defective reverse prevention valve
replace
4
When swing motor check valve is NO
YES Repair or
Defective swing motor check valve
replace
5
When swing PPC slow-return valve,
swing PPC line, and swing PPC NO Repair or
Defective PPC valve
circuit choke are cleaned, is trouble replace
repaired?
YES Clogging of swing PPC slow-return Repair or
valve, swing PPC line choke, or
swing PPC circuit choke replace
PC78MR-6 20-853
H-37 Large shock is made when machine stops swinging

Cause Remedy
1
Does control valve spool move NO Repair or
Malfunction of control valve spool
smoothly? replace
YES
2
When swing motor safety valve is NO
Go to H-36 Replace
YES Repair or
Defective swing motor safety valve
replace
H-38 Large abnormal sound is made when machine stops swinging

Cause Remedy
1
When safety valve is replaced, is NO
Defective swing motor safety valve Replace
trouble repaired?
YES
2
When suction valve is replaced, is NO
trouble repaired?
YES Defective swing motor suction Repair or

valve replace
3
YES Repair or
Defective reverse prevention valve
replace
4
Is foreign matter drained from final NO Defective swing motor, swing Repair or
drive? machinery, or swing circle replace
YES Repair or
Defective swing machinery
replace
20-854 PC78MR-6
H-39 Swing hydraulic drift is large

a Check that the emergency swing brake release switch is turned OFF.
Cause Remedy
1
When connector of swing pressure NO
switch is disconnected, is trouble
repaired?
YES
Defective swing pressure switch Replace
2
When connector of swing brake NO
release solenoid is disconnected, is
trouble repaired?
YES
Defective controller or wiring Replace
3
When hose of swing brake release NO Repair or
line is disconnected, is trouble Defective swing motor brake
repaired? replace
YES Replace
Malfunction of solenoid valve
assembly
PC78MR-6 20-855
H-40 Fine controllability or response of swing is low

Cause Remedy
1
repaired?
YES
Air in PPC Bleed Air
2
pressure?
YES
3
YES Repair or
replace
4
YES
5
move smoothly and is hole free from
clogging? compensation valve replace
YES
6
NO Repair or
replace
YES
7
YES Repair or
Defective PPC valve
replace
20-856 PC78MR-6
H-41 Blade speed or power is low (Work equipment, travel, and swing
a If there is any other trouble in the work equipment, travel system, or swing system, see H-1.
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} NO Repair or
Is blade PPC pressure normal? Defective PPC valve
Run engine at full throttle replace
YES
2
21.08 1.47 MPa
Is blade LOWER relief pressure NO
{215 15 kg/cm2} Go to diagnosis 5
normal?
YES
3
Does pump pressure reach relief NO
pressure during operation?
YES
4
Is hose between control valve and NO Malfunction of check valve in spool Repair or
cylinder flattened or deformed? or clogging of hole of spool replace
YES
Flattened or deformed hose Replace
5
NO Execute diagnosis in H-43
Is hydraulic drift normal?
(Hydraulic drift of blade is large)
YES Leakage in control valve (Leakage Repair or

from line between swing valve and
blade valve) replace
PC78MR-6 20-857
H-42 Blade does not move (Work equipment, travel, and swing operations
are normal)
a If there is any other trouble in the work equipment, travel system, or swing system, see H-1.
a) Blade does not rise
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} NO Repair or
Is blade PPC pressure normal? Defective PPC valve
Run engine at full throttle replace
YES
2
21.08 1.47 MPa
Is blade LOWER relief pressure NO
{215 15 kg/cm2}
normal?
YES
3
Is cylinder or work equipment NO
deformed?
YES Deformed cylinder or work Repair or

equipment replace
4
NO Repair or
Is hose flattened or deformed? Malfunction of control valve spool
replace
YES
Check hydraulic drift by H-41.
YES
If trouble is not repaired by H-41 Leakage in control valve (Large Repair or
leakage from line between swing replace
valve and blade valve)
20-858 PC78MR-6
b) Blade does not lower
Cause Remedy
1
NO
Is blade held in air?
YES
2
NO Repair or
Is blade PPC normal? Defective blade PPC valve
replace
YES
3
Is cylinder or work equipment NO
deformed?
YES Deformed cylinder or work Repair or

equipment replace
4
NO Repair or
Is hose flattened or deformed? Malfunction of spool
replace
YES
5
Is it impossible to raise machine by
bracing blade on ground?
YES Execute diagnosis in H-41 Repair or

(Hydraulic drift of blade is large) replace
PC78MR-6 20-859
H-43 Hydraulic drift of blade is large

Cause Remedy
1
NO Repair or
Is leakage from cylinder normal? Defective cylinder piston packing
replace
YES
2
When hose is disconnected from NO
valve outlet and plugged, is hydraulic
drift large?
YES Large leakage through swivel Repair or
joint replace
3
If blade is held in air and hydraulic When centralized safety valve is NO
drift is large replaced, is trouble repaired?
YES
4
When suction valve is replaced with NO Repair or
Low oil-tightness of spool
plug, is trouble repaired? replace
YES Repair or
Defective suction safety valve
replace
5
If hydraulic drift is large when When blade safety valve is replaced, NO Repair or
Low oil-tightness of spool
machine body is raised with blade is trouble repaired? replace
YES
Defective blade safety valve Replace
20-860 PC78MR-6
H-44 Fine controllability or response of blade is low

Cause Remedy
1
repaired?
YES
Air in PPC Bleed Air
2
pressure?
YES
3
YES Repair or
replace
4
YES
5
move smoothly and is hole free from
clogging? compensation valve replace
YES
6
NO Repair or
replace
YES
7
YES Repair or
Defective PPC
replace
PC78MR-6 20-861
TROUBLESHOOTING FOR MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by controller when trouble occurs and problems on machine ............................................... 20-902
Electric circuit diagram of M mode system ................................................................................................ 20-904
M- 1 [E101] (Error history data are abnormal) is displayed ..................................................................... 20-906
M- 2 [E108] (Engine coolant temperature is 105 C) is displayed ........................................................... 20-907
M- 3 [E112] (Wiper forward output is shorted) is displayed ..................................................................... 20-907
M- 4 [E113] (Wiper reverse output is shorted) is displayed ..................................................................... 20-907
M- 5 [E114] (Contact with washer output of 24 V) is displayed ............................................................... 20-907
M- 6 [E115] (Wiper does not start wiping in 10 seconds) is displayed ..................................................... 20-907
M- 7 [E116] (Wiper is not retracted in 10 seconds) is displayed .............................................................. 20-907
M- 8 Monitor panel segments do not light up at all for 3 seconds after starting switch is turned ON ...... 20-908
a) Monitor panel segments do not light up at all .............................................................................. 20-908
b) Some monitor panel segments do not light up ............................................................................ 20-908
M- 9 When starting switch is set to ON position, all monitor panel segments light up but do not go off ..... 20-910
M-10 While preheating is not executed, "Preheater monitor" lights up ................................................... 20-910
M-11 When starting switch is set to ON position and engine is started, basic check items flash ............. 20-911
a) Alternator system ........................................................................................................................ 20-911
b) Engine oil system ........................................................................................................................ 20-912
M-12 When starting switch is set to ON position (but engine is stopped), caution items and
emergency stop items (excluding battery and engine oil) flash ....................................................... 20-913
a) Alternator system ........................................................................................................................ 20-913
b) Engine oil pressure sensor system ............................................................................................. 20-914
M-13 When starting switch is set to ON position and engine is started, caution items and
emergency stop items flash (When there is not abnormality in inspection items and
engine before troubleshooting, however) ........................................................................................ 20-915
a) "Engine oil" flashes ..................................................................................................................... 20-915
b) "Charge level" flashes ................................................................................................................. 20-915
c) "Coolant temperature" flashes ..................................................................................................... 20-916
d) "Fuel level" flashes ...................................................................................................................... 20-917
M-14 When starting switch is set to ON position (but engine is stopped), buzzer does not sound
for 1 second
While caution item is flashing, buzzer does not sound .................................................................... 20-918
M-15 Monitor plane lamp for nighttime is not turned on (LC display is normal) ....................................... 20-919
M-16 Coolant temperature gauge does not rise ....................................................................................... 20-920
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to 1st line during operation) ..... 20-920
M-18 Fuel level gauge always displays full .............................................................................................. 20-921
M-19 Fuel level gauge is not displayed .................................................................................................... 20-921
M-20 While engine is running, service meter does not advance .............................................................. 20-922
M-21 Trouble in fuel level sensor .............................................................................................................. 20-923
M-22 Trouble in coolant temperature sensor ............................................................................................ 20-924
M-23 Wiper does not operate or operates while wiper switch is turned off .............................................. 20-925
a) Wiper does not operate ............................................................................................................... 20-925
b) Wiper operates while wiper switch is turned off .......................................................................... 20-925
M-24 Washer motor does not operate or operates while washer switch is turned off .............................. 20-928
a) Washer motor does not operate .................................................................................................. 20-928
b) Washer operates while wiper switch is turned off ....................................................................... 20-928
removed and the connector is returned, if the service code "E" is not displayed, the condition has returned to
normal.
a If the starting switch was turned off after the trouble occurred, turn the starting switch ON and check that the
service code displays "E" at the head. (If "E" is not displayed, the condition has returned to normal.)
a Before carrying out the troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
PC78MR-6 20-901
ACTION TAKEN BY CONTROLLER WHEN TROUBLE
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

AND PROBLEMS ON MACHINE
Service
User Code Code Troubled System Contents of Trouble
1. Trouble in internal memory

Error history data are abnor- 2. Overvoltage (Above 36 V)
E101
mal 3. Undervoltage (Above 12 V)
4. Disconnection of connector
Engine coolant temperature 1. Coolant temperature sensed by coolant tempera-

E108
is 105 C ture sensor is above 105 C
1. Short circuit or short circuit with chassis ground in

wiring between
Short circuit in forward sys- 2. Short circuit or short circuit with chassis ground in
E112
tem of wiper motor drive wiring between monitor panel P01 (Female) (9)
wiper motor W04 (Female) (3)
3. Defective monitor panel
1. Short circuit or short circuit with chassis ground in
wiper motor
Short circuit in reverse sys- 2. Short circuit or short circuit with chassis ground in
E113
tem of wiper motor drive wiring between monitor panel P01 (Female) (10)
wiper motor W04 (Female) (1)
1. Short circuit in washer motor
2. Short circuit with power source in wiring harness
Short circuit in windshield
E114 between monitor panel P01(Female) (3) M31
washer drive system
(Female) (1)
1. Defective wiper motor
2. Disconnection, defective contact, short circuit, or
short circuit with chassis ground in wiring harness
between monitor panel P01 (Female) (5) W04
Wiper does not start wiping in (6)
E115
10 seconds 3. Disconnection, defective contact, short circuit, or
between monitor panel P01 (Female) (12)
W04(4)
1. Defective wiper motor
2. Disconnection, defective contact, short circuit, or
Wiper is not retracted in 10 (6)
E116
seconds 3. Disconnection, defective contact, short circuit, or
(4)
20-902 PC78MR-6
ACTION TAKEN BY CONTROLLER WHEN TROUBLE
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Action Taken By Controller Problem That Appears on

Normal Condition (Voltage, Current, Resistance) When Abnormality is Machine When There is
Detected Abnormality
1. Service code cannot be

cleared
1. If abnormality is detected
continuously, coolant tem-
Resistance between M18 (Male) (1) (2): perature caution lamp
Min. 3.70 kz flashes and buzzer sounds.
(With engine started) 2. If abnormality is detected
continuously, engine
speed is set to low idling.
Voltage between W04 (3) (5): Max. 3 V

Stops outputting to wiper
motor Wiper stops
20 30 V
a Repeated at regular intervals.
Voltage between W04 (1) (5): Max. 3 V

Same as [E112] Same as [E112]
20 30 V
a Repeated at regular intervals.
Voltage between P01 (3) chassis ground

1. Stops outputting to 1. Stops outputting to washer
When washer switch is turned OFF: 20 30 V
washer motor motor
When washer switch is turned ON: Max. 1 V
Timing chart of setting wiper switch to ON and

INT is conformed to Tables 1 and 2 in M-23
Timing chart of setting wiper switch to ON and

INT is conformed to Tables 1 and 2 in M-23
PC78MR-6 20-903
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM

(1/2)
20-904 PC78MR-6
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM
(2/2)
PC78MR-6 20-905
TROUBLESHOOTING M-1
M-1 [E101] (Error history data are abnormal) is displayed

a If connector P01, connector K1, fuse 18, connector M6, connector M2, connector M27, battery relay termi-
nal B, or battery terminal in the monitor panel power supply system is disconnected or connected for trou-
bleshooting, this error is displayed. This phenomenon does not indicate an actual error, however. (When the
monitor panel power circuit is broken by turning off the starting switch.)
a If the service code is displayed again after the resetting operation, check by the following procedure.
Cause Remedy
1
After resetting operation,
operate machine normally After "resetting operation", is NO
Normal
and observe its condition for service code displayed again?
a while. (See Note 1.)
YES
2
Disconnection, defective contact,
Turn starting switch OFF Is voltage between P01 (8) NO or short circuit with chassis Repair or
ground in wiring harness
20 30 V chassis ground normal? between battery battery relay B replace
M27 (1), (2) P01 (Female) (8)
YES
Note: Resetting operation: Turn the starting switch to OFF position, then turn it to the ON position again, with
the buzzer cancel switch pushed, and keep pressing the buzzer cancel switch for 5 seconds. (All the ser-
vice codes saved in the memory are deleted by this operation.)
M-1 Electrical circuit diagram of each system
20-906 PC78MR-6
TROUBLESHOOTING M-2, M-3, M-4, M-5, M-6, M-7
M-2 [E108] (Engine coolant temperature is 105 C) is displayed

Cause Remedy
1
Does coolant temperature gauge of monitor NO
indicate red range and is caution lamp flashing?
YES
See M-13, c)
2
NO
Turn starting switch ON Is "E" attached to head of service code? Trouble in engine unit
(See Note 1)
YES
Note: The display of the monitor panel has been reset normally. Since the coolant temperature sensor
detected coolant temperature above 105C, remove the cause of that temperature rise by troublshooting
the engine unit.
M-3 [E112] (Wiper forward output is shorted) is displayed

a See M-23.
M-4 [E113] (Wiper reverse output is shorted) is displayed

a See M-23.
M-5 [E114] (Contact with washer output of 24 V) is displayed

a See M-24.
M-6 [E115] (Wiper does not start wiping in 10 seconds) is displayed

a See M-23.
M-7 [E116] (Wiper is not retracted in 10 seconds) is displayed

a See M-23.
PC78MR-6 20-907
TROUBLESHOOTING M-8
M-8 Monitor panel segments do not light up at all for 3 seconds after start-
ing switch is turned ON
a Check that fuses 13 and 18 are normal.
a) Monitor panel segments do not light up at all
Cause Remedy
1
Turn starting switch ON. Is voltage between P01 (8) and NO
20 30 V (6), (7) normal?
YES
2
Turn starting switch ON Is voltage between P01 (1), (2) NO
20 30 V and (6), (7) normal?
YES
3
Turn starting switch OFF. Is resistance between P01 NO Disconnection or defective contact
Max. 1 z (female) (6), (7) and chassis in wiring harness between P01 Repair or replace
Disconnect P01. ground normal? (female) (6), (7) chassis ground
YES
4
Turn starting switch ON. Is voltage between fuse 13 and NO Disconnection or defective contact
in wiring harness between fuse 13 Repair or replace
20 30 V chassis ground normal? P01 (female) (1), (2)
YES Disconnection or defective contact
in wiring harness between fuse box Repair or replace
battery relay terminal M
5
Turn starting switch ON. Is voltage between fuse 18 and NO Disconnection or defective contact
in wiring harness between fuse 18 Repair or replace
20 30 V chassis ground normal? P01 (female) (8)
YES Disconnection or defective contact
in wiring harness between fuse box Repair or replace
battery relay terminal B
b) Some monitor panel segments do not light up
Cause Remedy
20-908 PC78MR-6
TROUBLESHOOTING M-8
M-8 a) Electrical circuit diagram of each system
PC78MR-6 20-909
TROUBLESHOOTING M-9,10
M-9 When starting switch is set to ON position, all monitor panel seg-
ments light up but do not go off
Cause Remedy
Defective monitor
Replace
panel
M-10 While preheating is not executed, "Preheater monitor" lights up

Cause Remedy
1
Disconnect terminal R1 NO
Is voltage between starting switch R1 Defective starting
Turn starting switch ON Replace
chassis ground normal? switch
Max. 1 V
YES
2
Short circuit with power
Turn starting switch ON Is voltage between P02 (18) chassis NO source in wiring
harness between Repair or replace
Max. 1 V ground normal? starting switch R1
P02 (Female) (18)
YES
Defective monitor
Replace
panel
20-910 PC78MR-6
TROUBLESHOOTING M-11
M-11 When starting switch is set to ON position and engine is started,

basic check items flash
a Inspect both alternator system and engine hydraulic system.
a) Alternator system
a Check monitoring code "43". If it is 100 or larger while the engine speed is above the medium level, the
monitor panel is defective.
Cause Remedy
1
Run engine above medium Is voltage between alternator
NO
speed level terminal R chassis ground Defective alternator Replace
20 30 V normal?
YES
2
Run engine above medium Disconnection or defective
Is voltage between P02 (11) NO contact in wiring harness Repair or
speed level
chassis ground normal? between alternator terminal R replace
20 30 V P02 (Female) (11)
YES
PC78MR-6 20-911
b) Engine oil system

a Carry out the following troubleshooting when the engine oil pressure is normal.
a Check bit (3) of monitoring code "46". If it is lighting up, the monitor panel is defective.
Cause Remedy
1
When engine speed is low, if oil NO
Run engine at low speed pressure sensor terminal T6 is
disconnected, does error disappear?
Defective oil pressure sensor

Replace
(Low pressure)
2
Turn starting switch OFF NO Short circuit with chassis ground
Is there continuity between P02 (7) Repair or
Disconnect sensor wiring in wiring harness between P02
chassis ground normal? (Female) (7) sensor terminal T6 replace
harness and P02
YES
M-11 b) Electrical circuit diagram of each system
20-912 PC78MR-6
M-12 When starting switch is set to ON position (but engine is stopped),

caution items and emergency stop items (excluding battery and
engine oil) flash
a Inspect both alternator system and engine hydraulic system.
a) Alternator system
a Check monitoring code "43". If it is 100 or larger while the engine speed is above the medium level, the
monitor panel is defective.
Cause Remedy
1
Disconnect terminal R NO
Is voltage between alternator terminal
Turn starting switch ON Defective alternator Replace
R chassis ground normal?
Max. 1 V
YES
2
Disconnect P02 Short circuit with power source in
Is voltage between P02 (Female) (11) NO wiring harness between P02 Repair or
chassis ground normal? (Female) (11) alternator replace
Max. 1 V terminal R
YES
PC78MR-6 20-913
b) Engine oil pressure sensor system

a Carry out the following troubleshooting when the engine oil pressure is normal.
a Check bit (3) of monitoring code "46". If it is lighting up, the monitor panel is defective.
Cause Remedy
1
Turn starting switch OFF NO
Is there continuity between sensor
Disconnect sensor Defective oil pressure sensor Replace
terminal T6 chassis ground?
terminal T6
YES
2
Turn starting switch OFF NO
Is there continuity between P02 contact in wiring harness Repair or
Disconnect P02 sensor
(Female) (11) sensor terminal T6? between P02 (Female) (7) replace
terminal T6
sensor terminal T6
YES
M-12 b) Electrical circuit diagram of each system
20-914 PC78MR-6
M-13 When starting switch is set to ON position and engine is started,

caution items and emergency stop items flash (When there is not
abnormality in inspection items and engine before troubleshooting,
however)
a) "Engine oil" flashes
a Before carrying out the troubleshooting, check that the engine oil pressure is normal.
Cause Remedy
See M-11-b)
b) "Charge level" flashes

Cause Remedy
See M-11-a)
PC78MR-6 20-915
c) "Coolant temperature" flashes

a Before carrying out the troubleshooting, check that the coolant temperature is normal.
Cause Remedy
1
Start engine NO
Is coolant temperature gauge in red
Set engine speed to Defective monitor panel Replace
range?
medium or higher
YES
2
When M18 is disconnected, does gauge NO
Start engine
indicate only level 1 (Lowest line)?
YES Defective coolant temperature

sensor system
(See M-22)
3
Turn starting switch OFF Disconnection or defective contact
Is resistance between P02 (Female) (1) NO Repair or
Disconnect P02 and M18 in wiring harness between P02
M18 (Female) (1) normal? (Female) (1) M18 (Female) (1) replace
Max. 1 z
YES Disconnection or defective contact Repair or

in wiring harness between M18
(Female) (2) chassis ground replace
M-13 c) Electrical circuit diagram of each system
20-916 PC78MR-6
d) "Fuel level" flashes

a Before carrying out the troubleshooting, check that there is fuel in the fuel tank.
Cause Remedy
1
NO
Start engine Is fuel level gauge in red range? Defective monitor panel Replace
YES
2
Start engine When M9 (Female) (1) is
Wait for 2 minutes. (Since connected to chassis ground, do NO
fuel level fluctuates, its gauge segments light up to level 9
display is delayed.) (Right end)?
YES Defective fuel level sensor

system (See M-21)
3
Connect M9 (Female) (1) to Disconnection or defective
chassis ground Is voltage between P02 (2) NO contact in wiring harness Repair or
Turn starting switch ON chassis ground normal? between P02 (Female) (2) M9 replace
Max. 0.3 V (Female) (1)
YES Repair or
Defective monitor panel
replace
M-13 d) Electrical circuit diagram of each system
PC78MR-6 20-917
M-14 When starting switch is set to ON position (but engine is stopped),

buzzer does not sound for 1 second
While caution item is flashing, buzzer does not sound
a Even if the charge level and fuel level among the caution items become abnormal, the buzzer does not
sound.
a The busdzzer is controlled by the monitor panel and turned on when it is required to sound or when the volt-
age at P01 (11) is 20 30 V.
Cause Remedy
Turn starting switch OFF 1
Disconnect K53
When buzzer cancel switch Is resistance between K53 (Female) (1) NO Defective buzzer cancel
is ON: Max. 1 z Replace
(2) normal? switch
When buzzer cancel switch
is OFF: Min. 1 Mz YES
2
Disconnect K53 contact, or short circuit with
Is voltage between P02 (16) chassis NO Repair or
Turn starting switch ON chassis ground in wiring
ground normal? harness between P02 replace
20 30 V
(Female) (16) K53 (Male) (2)
YES
20-918 PC78MR-6
M-15 Monitor plane lamp for nighttime is not turned on (LC display is nor-
mal)
a Carry out the following troubleshooting when the headlamp and working lamp light up normally.
Cause Remedy
1
Turn starting switch ON Is bit (4) of monitoring code "45" NO
Set monitoring code to "45" turned off?
YES
2
Turn starting switch ON NO Disconnection, defective contact
Is voltage between P02 (19) Repair or
Turn light switch ON in wiring harness between P02
chassis ground normal? (Female) (19) K52 (Male) (1) replace
20 30 V
YES
PC78MR-6 20-919
TROUBLESHOOTING M-16, M-17
M-16 Coolant temperature gauge does not rise

a When the engine coolant temperature does not rise actually, inspect the engine system.
Cause Remedy
1
When short connector is connected to NO
Disconnect M18
M18 (Female), does gauge rise 1 level
by 1 and go off at last?
sensor system
(See M-22)
2
Turn starting switch OFF Is there continuity between P02 NO contact in wiring harness Repair or
Disconnect P02 and M18 (Female) (1) M18 (Female) (1)? between P02 (Female) (1) replace
M18 (Female) (1)
YES
3
Turn starting switch OFF Is resistance between M18 (Female) (2) NO contact in wiring harness Repair or
Disconnect M18 chassis ground normal? between M18 (Female) (2) replace
chassis ground
YES
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to
1st line during operation)
Cause Remedy
1
Disconnect M18 When M18 is disconnected, is gauge NO
Turn starting switch ON displayed?

sensor system
(See M-22)
2
Turn starting switch ON Is there continuity between P02 (Female) NO
Disconnect P02 and Defective monitor panel Replace
M18 (1) chassis ground?
YES Short circuit with chassis ground Repair or
in wiring harness between P02
(Female) (1) M18 (Female) (1) replace
M-16, M-17 Electrical circuit diagram of each system
20-920 PC78MR-6
TROUBLESHOOTING M-18, M-19
M-18 Fuel level gauge always displays full

a Before carrying out the troubleshooting, see if the fuel tank is actually full.
Cause Remedy
1
Wait for 2 minutes. (Since When M9 is disconnected, does gauge NO
fuel level fluctuates, its rise 1 level by 1 and go off at last?
display is delayed.)
YES Defective fuel level sensor

system (See M-21)
2
Turn starting switch OFF Is there continuity between P02 NO
Disconnect P02 and M9 (Female) (2) chassis ground?
YES Short circuit with chassis ground Repair or

in wiring harness between P02
(Female) (2) M9 (Female) (1) replace
M-19 Fuel level gauge is not displayed

a Before carrying out the troubleshooting, check that there is fuel in the fuel tank.
Cause Remedy
1
Disconnect M9 When M9 (Female) (1) is connected to NO
Turn starting switch ON chassis ground, does gauge display?
YES Defective fuel level sensor (See

M-21)
2
Turn starting switch OFF Is there continuity between M9 (Female) NO contact in wiring harness Repair or
Disconnect M9 (2) chassis ground? between M9 (Female) (2) replace
chassis ground
YES
M-18, M-19 Electrical circuit diagram of each system
PC78MR-6 20-921
M-20 While engine is running, service meter does not advance

Cause Remedy
1
Start engine NO
Set engine speed to Does charge level caution lamp flash? Defective monitor panel Replace
medium or higher
YES
See M-13 c)
20-922 PC78MR-6
M-21 Trouble in fuel level sensor

a When carrying out the following troubleshooting, remove the fuel level sensor.
Cause Remedy
1
When float is moved up and down, does NO
resistance between connector (1)
flange change as shown in Table 1?
YES
2
NO Defective sensor
Does arm move smoothly? Replace
(See Note 2)
YES
3
Is float cracked, broken off, or scratched NO Clean or replace
Bad contact of connector
badly? connector
YES Replace (See

Interference of sensor in tank
Note 2)
4
Is breakage of wiring harness detected NO
Defective sensor Replace
by visual inspection?
YES
Breakage of wiring harness
(See Note 3)
Replace sensor
(Defective clamp)
(Application of external force)
Table
At upper (FULL)
Approx. 12 or below
stopper
At lower (EMPTY)
Approx. 85 110z
stopper
Note 1. Difference between actual fuel level and level indicated by gauge
When the gauge indicates 14 (F), the fuel level is 78 100%. When the former indicates 1 (E), the lat-
ter is below 14.5%. If the machine body is slanted, the displayed fuel level is different from the actual
fuel level. Accordingly, stop the machine on a level place and check the fuel level gauge after waiting
for at least 2 minutes. (Since fuel level fluctuates, its display is delayed.)
Note 2. Since the sensor may be interfering in the tank or it may be installed wrongly, install it very carefully.
Note 3. Check the installation position of the connector for vibration. If it vibrates remarkably, take proper mea-
sures to suppress the vibration.
PC78MR-6 20-923
M-22 Trouble in coolant temperature sensor

Cause Remedy
1
Is resistance between temperature sensor NO
connector (Male) (1) (2) normal?
YES Bad contact of connector Clean connector

(See Note 1) or replace sensor
2
Is breakage of wiring harness detected by NO
Defective sensor Replace
visual inspection?
YES
Breakage of wiring harness
(See Note 2)
Replace sensor
(Defective clamp)
(Application of external force)
Table
Normal
Approx. 37 50 kz
Temperature (25 C)
100 C Approx. 3.5 4.0 kz
Note 1. If this error is displayed repeatedly, the connector (Female) on the machine side may be defective.
Accordingly, inspect the connector and wiring harness on the machine side.
Note 2. Check the installation position of the connector for vibration. If it vibrates remarkably, take proper mea-
sures to suppress the vibration.
20-924 PC78MR-6
M-23 Wiper does not operate or operates while wiper switch is turned off
a) Wiper does not operate
a If service code "E112", "E113", "E115", or "E116" is displayed, carry out the following troubleshooting.
Cause Remedy
1
Close front window NO
Does bit (3) of monitoring code "49"
light up?
Set monitoring code to "49"
YES
2
Set wiper switch to "ON" or When wiper switch is set to "ON" or NO
"INT" position, do bits (4), (5) of Defective monitor panel Replace
"INT" position monitoring code "49" go off?
YES
3
Is voltage between pins of W04 as NO
shown in Table 1?
YES
Defective wiper motor Replace
4
Is voltage between pins of P01 Disconnection, defective con-
Turn starting switch OFF NO tact, short circuit, or short circuit Repair or
(Female) W04 (Male) as shown in
Disconnect P02 and W04 with chassis ground in wiring replace
Table 2? having improper resistance
YES
5
Max. 1 z
Is resistance between rear limit NO
Turn starting switch OFF Defective rear limit switch or Inspection or
switch terminals W03 (1) (2)
Disconnect terminals (1), (2) opening of front window replace
normal?
of W03.
YES
6
Max. 1 z Is resistance between rear limit Disconnection or defective
Turn starting switch OFF switch terminal W03 (1) P02 NO contact in wiring harness Repair or
Disconnect terminals (1), (2) (Female) (15), between W03 (2) having improper resistance replace
of P02 and W03 chassis ground normal?
YES
b) Wiper operates while wiper switch is turned off
Cause Remedy
1
Close front window NO
Does bit (3) of monitoring code
Turn starting switch ON Defective monitor panel Replace
"49" light up?
YES
2
When wiper switch is set to "ON" NO
Turn starting switch ON or "INT" position, do bits (4), (5) of Defective monitor panel Replace
monitoring code "49" go off?
YES Short circuit with power source in wiring

harness between P01 (Female) (9) Repair or
W04 (Female) (3) or between P01 replace
(Female) (10) W04 (Female) (1)
PC78MR-6 20-925
Table 1
Timing chart of ON-OFF operation of wiper
Item Symbol Set Time

Stop time up to next operation Tia 0.13 sec
Safety circuit during operation of
wiper Tsa 10 sec
[Safety function (1)]
Stop time up to retraction of
Tip 1.5 sec
wiper blade
Safety circuit during retraction of
wiper Tsp 10 sec
Item Symbol Set Time

Stop time up to next operation Tia 4 sec
Safety circuit during operation of
wiper Tsa 10 sec
Stop time up to retraction of
wiper blade Tip 1.5 sec
Safety circuit during retraction of

wiper Tsp 10 sec
Table 2
Diagnosis 4 Resistance
Between P01 (Female) (10) W04 (Female) (1)
Between P01 (Female) (12) W04 (Female) (4) Max. 1 z
Between P01 (Female) (6), (7) W04 (Female) (5)
Between W04 (Female) (1), (3), (4), (5), (6) GND Min. 1 Mz
20-926 PC78MR-6
PC78MR-6 20-927
M-24 Washer motor does not operate or operates while washer switch is
turned off
a) Washer motor does not operate
a)-1 When [E114] is displayed
Cause Remedy
1
Max. 1 V Is voltage between P01 (Female) (3) NO Short circuit with power source in Repair or
Turn starting switch ON M31 (Female) (1) chassis ground wiring harness between P01
normal? replace
Disconnect P02 and M31 (Female) (3) M31 (Female) (1)
YES
a)-2 When [E114] is not displayed
1 Cause Remedy
20 30 V Is voltage between fuse 4 M31 NO Disconnection or defective Repair or
Turn starting switch ON (Female) (2) chassis ground contact in wiring harness between
fuse 4 M31 (Female) (2) replace
Disconnect M31 normal?
YES
2
Max. 1 z Disconnection or defective
Is resistance between P01 (Female) NO contact in wiring harness Repair or
(3) M31 (Female) (1) normal? between P01 (Female) (3) M31 replace
Disconnect P01 and M31 (Female) (1)
YES
3
Max. 1 V NO
Is voltage between P01 (Female) (3)
Turn starting switch ON Defective washer motor Replace
Turn washer switch ON
YES
b) Washer operates while wiper switch is turned off
Cause Remedy
1
Min. 1 Mz NO Short circuit with chassis ground
Is resistance between M31 (Female) Repair or
Turn starting switch OFF in wiring harness between P01
(1) chassis ground normal? (Female) (3) M31 (Female) (1) replace
Disconnect P02 and M31
YES
20-928 PC78MR-6
PC78MR-6 20-929
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ...................30- 2 FUEL TANK

PRECAUTIONS WHEN CARRYING Removal ................................................... 30-43
OUT OPERATION........................................30- 3 Installation ................................................ 30-44
SPECIAL TOOL LIST...................................30- 7 CONTROLLER
COUNTERWEIGHT Removal and Installation.......................... 30-44
Removal and Installation ..........................30-13 MONITOR PANEL
INJECTION PUMP Removal and Installation.......................... 30-45
Removal....................................................30-14 AIR CONDITIONER UNIT
Installation.................................................30-15 Removal ................................................... 30-45
CYLINDER HEAD Installation ................................................ 30-46
Removal....................................................30-16 OPERATORS CAB
Installation.................................................30-19 Removal and Installation.......................... 30-47
MAIN PUMP FLOOR FRAME
Removal....................................................30-20 Removal ................................................... 30-48
Installation.................................................30-21 Installation ................................................ 30-49
CONTROL PUMP REVOLVING FRAME
Removal and Installation ..........................30-21 Removal and Installation.......................... 30-50
ENGINE AND MAIN PUMP SWING CIRCLE
Removal....................................................30-22 Removal and Installation.......................... 30-51
Installation.................................................30-24 WORK EQUIPMENT
HYDRAULIC OIL COOLER Removal ................................................... 30-52
Removal and Installation ..........................30-25 Installation ................................................ 30-53
RADIATOR SWING BRACKET
Removal....................................................30-25 Removal ................................................... 30-54
Installation.................................................30-26 Installation ................................................ 30-55
SWING MOTOR AND SWING MACHINERY STEEL SHOE, RUBBER PAD SHOE,
Removal and Installation ..........................30-27 ROAD LINER
SWING MACHINERY Expansion and Installation ....................... 30-56
Disassembly .............................................30-28 RUBBER SHOE
Assembly ..................................................30-30 Removal and Installation.......................... 30-57
SWING MOTOR FINAL DRIVE
Removal and Installation ..........................30-34 Removal ................................................... 30-57
CENTER SWIVEL JOINT Installation ................................................ 30-58
Removal....................................................30-34 IDLER
Installation.................................................30-35 Assembly.................................................. 30-58
Disassembly and Assembly......................30-36 RECOIL SPRING
CONTROL VALVE Disassembly............................................. 30-60
Removal and Installation ..........................30-37 Assembly.................................................. 30-61
Assembly ..................................................30-38 TRACK ROLLER
WORK EQUIPMENT PPC VALVE Disassembly............................................. 30-62
Assembly ..................................................30-39 Assembly.................................................. 30-63
TRAVEL PPC VALVE HYDRAULIC CYLINDER
Assembly ..................................................30-40 Disassembly............................................. 30-65
HYDRAULIC TANK Assembly.................................................. 30-67
Removal and Installation ..........................30-42
PC78MR-6 30-1
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked [*1], and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation proce-
dure it applies to.
(Example)
REMOVAL OF O O O ASSEMBLY ....................................... Title of operation
k ........................................................................................ Precautions related to safety when carrying
out the operation
1. XXXX (1)......................................................................... Step in operation
a .................................................................................... Technique or important point to remember
when removing XXXX (1).
2. EEE (2): ..................................................................... [*1] Indicates that a technique is listed for
use during installation
3. T T T T assembly (3)
6 ............................................................................. See Lubricant and Coolant Table

INSTALLATION OF O O O ASSEMBLY ............................... Title of operation
Carry out installation in the reverse
order of removal
[*1] ............................................................................. Technique used during installation
a ................................................................................ Technique or important point to remember
when installing E E E (2).
Adding water, oil......................................................... Step in operation
a ................................................................................ Point to remember when adding water or oil
5 ............................................................................ Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOL LIST given in this manual.
30-2 PC78MR-6
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.

After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installed position, or make match marks in the necessary places
before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, disconnect connectors by grasping the con-
nector, not the wire.
Tag wires and hoses to show their installed position to prevent any mistake when reinstalling.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Hoses and tubes using sleeve nuts

Nominal Plug (nut end) Sleeve nut (elbow end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
3) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
PC78MR-6 30-3
4) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 PC78MR-6
2. Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the coolant water level again.
If the hydraulic equipment has been removed and installed again, add hydraulic oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for
repair, always bleed the air from the system after reassembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
4. Other precautions
To maintain the performance of the machine and to prevent failures, it is particularly important to pay atten-
tion to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or
when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are
clean.
To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points
when disassembling or assembling.
Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to
be disassembled.
Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits
of parts that have failed.
When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment
completely.
Do not use the seal tape for the thread of the plug mounts or connectors.
If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment
and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassem-
bled and assembled, also carry out thorough flushing of the hydraulic circuits.
When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping,
always bleed the air before starting the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.
PC78MR-6 30-5
a After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5
times without going to the end of this strike. (Stop approx. 100 mm before the end of the stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the
engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more air
comes out from the plugs.
4. After completing bleeding the air, tighten the plugs
3 Plug: 11.3 1.5 Nm {1.15 0.15 kgm}
a If the engine is run at high speed from the start, or the cylinders are operated to the end of their
stroke, the air inside the cylinder will cause damage to the piston packing.
a After repair or long storage, follow the same procedure.
30-6 PC78MR-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
a Necessity: t : Cannot be substituted, should always be installed (used).
q : Very convenient if available, can be substituted with commercially available part.
a New/remodel: N : Tools with new part numbers, newly developed for this model.
R : Tools with upgraded part numbers, remodeled from items already available for other
models.
Blank : Tools already available for other models, used without any modification.
a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Necessity
Remodel
Sketch
New/
Qty
Component Symbol Part No. Part Name Nature of work, remarks
1 795-799-1130 Gear t 1 Burring of engine

(For Model 102 engine)
Removal, installation of fuel
injection pump assembly 795-799-1390 Remover
Removal of drive gear
2 or t 1
(For Model 102 engine)
795-799-1210 Puller
Removal, installation of noz- A 3 795-799-1170 Puller t 1 Pulling out of nozzle holder
zle holder assembly (For Model 102 engine)
Removal, installation of cyl- 4 790-331-1110 Wrench t 1 Tightening of cylinder head bolt
inder head assembly (For Model 102 engine)
Engine and main pump 5 796-732-1311 Oil stopper q 1 Stopping of hydraulic oil
assembly
1 796T-226-1120 Push tool q 1 N Q Removal, installation of spacer
790-101-3400 Bearing puller q 1

2 Removal of bearing outer race
790-101-3220 Screw q 1
790-101-5201 Push tool kit q 1
790-101-5281 Plate 1
3 Installation of oil seal
790-101-5221 Grip 1
01010-51225 Bolt 1
790-101-5331 Plate 1
Press fitting of sub bearing outer
4
race
790-101-5221 Grip 1
Disassembly, assembly of F
swing machinery assembly
01010-51225 Bolt 1
790-101-5431 Plate 1
Press fitting of main bearing
5 outer race
790-101-5421 Grip 1
01010-51240 Bolt 1
6 796-765-1110 Push tool t 1 N Q Press fitting of main bearing

inner race
7 792T-413-1120 Push tool t 1 N Q Press
race
fitting of sub bearing inner
796-730-2300 Wrench assembly t 1

Measurement of running torque
8 of shaft
795-630-1803 Torque wrench t 1
9 790-201-2770 Spacer q 1 Installation of dust seal
PC78MR-6 30-7
Necessity
Remodel
Sketch
New/
Qty
790-101-5141 Plate 1
1 Press fitting of bushing
Disassembly, assembly of
idler assembly 790-101-5021 Grip 1
01010-50816 Bolt 1
2 796-230-1110 Installer t 1 Installation of floating seal
L 790-101-5001 Push tool kit q 1
790-101-5111 Plate 1
3 Press fitting of bushing
790-101-5021 Grip 1
track roller assembly
01010-50816 Bolt 1
4 796-230-1120 Installer q 1 Installation of floating seal

carrier roller assembly
5 790T-230-1110 Push tool q 1 N Q Press fitting of cap
791-685-8005 Compressor (B) t 1
790-201-2860 Spacer t 1
recoil spring assembly
M 791-635-3160 Extension assembly t 1 Compression of spring
790-101-1600 Cylinder t 1
(686kN{70ton})
790-101-1102 Pump t 1
Remover and
791-616-1030
installer
t 1
Expansion, installation of Cylinder Pulling out and press fitting of
track shoe assembly R 790-105-1100
(294kN{30ton})
t 1
master pin
790-101-1102 Pump t 1
796T-267-1110 Push tool t 1

Press fitting of input shaft oil
S Press fitting of oil seal
seal of main pump
790-201-2730 Spacer t 1
790-101-2501 Push puller kit q 1
790-101-2510 Block 1
790-101-2520 Screw 1
791-112-1180 Nut 1
T 790-101-2540 Washer 1 Separation of rotor and shaft
center swivel joint assembly
790-101-2630 Leg 2
790-101-2570 Washer 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
790-502-1003 Cylinder repair stand t 1
U 1
hydraulic cylinder assembly hydraulic cylinder
790-101-1102 Pump t 1
30-8 PC78MR-6
Necessity
Remodel
Sketch
New/
Qty
Boom, blade Removal,

790-102-3802 Wrench assembly t 1
and boom swing installation of
2
cylinder head
790-330-1100 Wrench assembly t 1 Arm and bucket assembly
790-302-1340 Socket (Width across t 1 Boom and blade

flats: 80mm) Removal,
Socket (Width across t Arm and boom installation of
3 790-102-1470 1
flats: 70mm) swing piston nylon
Socket (Width across t nut
790-302-1290 1 Bucket
flats: 60mm)
4 790-720-1000 Expander q 1 Expansion of piston ring
796-720-1670 Band q 1
Boom
07280-01279 Clamp q 1
796-720-1660 Band q 1
Arm and boom
swing
07281-01159 Clamp q 1
Installation of
5
piston ring
796-720-1650 Band q 1
Bucket
07281-01029 Clamp q 1
796-720-1670 Band q 1
Blade
07281-01279 Clamp q 1
790-101-5021 Grip 1
Disassembly, assembly of Boom and blade
U
hydraulic cylinder assembly
01010-50816 Bolt 1
790-201-1811 Push tool 1
790-101-5021 Grip 1 Press fitting of

Arm and boom
6 swing cylinder head
01010-50816 Bolt 1 bushing
790-201-1791 Push tool 1
790-101-5021 Grip 1
Bucket
01010-50816 Bolt 1
790-201-1771 Push tool 1
790-201-1620 Plate 1
Boom and blade
790-101-5021 Grip 1 Press fitting of
7 cylinder head
01010-50816 Bolt 1 dust seal

Arm and boom
swing
790-201-1610 Plate 1
PC78MR-6 30-9
Necessity
Remodel
Sketch
New/
Qty
790-101-5021 Grip 1
Arm and boom
swing
01010-50816 Bolt 1
790-201-1500 Push tool kit q 1 Press fitting of

U 7 cylinder head
hydraulic cylinder assembly
790-201-1580 Plate 1 dust seal
Bucket
790-101-5021 Grip 1
01010-50816 Bolt 1
790-441-1802 Remover t 1
790-441-1810 Sleeve 1
792-900-1530 Screw 1
790-270-1110 Adapter 1
Removal of work equip-
ment and boom assembly 1 Pulling out of boom foot pin
01803-13034 Nut 1
01643-33080 Washer 1
790-101-4000 Puller (490kN{50ton}) t 1
790-101-1102 Pump t 1
790-101-2102 Puller (294kN{30ton}) t 1

Removal of boom swing Pulling out of boom swing
V 2
beacket bracket pin
790-101-1102 Pump t 1
790-201-2850 Spacer t 1
791-535-1170 Plug t 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
Removal of arm cylinder Pulling out of arm cylinder trun-
assembly 3
nion pin
790-101-2540 Washer t 1
791-112-1180 Nut t 1
790-101-2102 Puller (294kN{30ton}) t 1
790-101-1102 Pump t 1
799-703-1200 Service tool kit t 1

Vacuum pump
Collection and reproduction
799-703-1110 (220V) t 1
X Collection and supply of air con-
of new Freon gas Vacuum pump ditioner gas
799-733-1120 (240V) t 1
799-703-1400 Gas leak tester t 1
30-10 PC78MR-6
Note: Komatsu cannot accept any responsibility for special

tools manufactured according to these drawings.
F-1 Push tool
F-6 Push tool
PC78MR-6 30-11
F-7 Push tool
L-5 Push tool
30-12 PC78MR-6
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT ASSEMBLY 8. Remove fuel filler mounting cover (9) of the fuel
tank.
REMOVAL 9. Remove clamp (11) and float gauge hose (10).
Loosen the clamp of the hose connected to the
a Stop the machine on a level place and set the fuel filler tube on the back side of the fuel filler
upper structure in parallel with the track, then mounting cover, then remove the tube and cover
swing to the right about 20 degrees (since the together.
mounting bolts are above the track) and lower a When removing the float gauge hose, check
the work equipment to the ground and stop the that the fuel level is below the connecting
engine. position of the hose.
1. Remove cover (1) from the top of the hydraulic

tank.
2. Remove engine cover (2).
3. Remove the bracket of damper case breather

(3).
4. Remove 2 mounting bolts of air cleaner bracket

(4) from the right front end of weight (5).
10. Using sling (1), hang weight (5) temporarily and

remove the 3 weight mounting bolts.
11. Lift off weight assembly (5). [*1]

4 Counterweight assembly: 1,170 kg
(With auxiliary weight)
5. Remove the bolt of air conditioner hose clamp.
6. Remove radiator support bracket (7) from the

weight.
7. Remove air inlet cover (8) of the radiator, oil

cooler, etc.
INSTALLATION
Carry out installation in the reverse order to

removal.
[*1]
4 Weight mounting bolt:
1,150 1,1440 Nm {118 147 kgm}
PC78MR-6 30-13
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
INJECTION PUMP ASSEMBLY 4. Remove the engine stop solenoid (8) and
bracket together.
REMOVAL
5. Remove the injection pipe clamp, and loosen the
4 sleeve nuts each on the pump side and nozzle
a Disconnect the wiring harness from the negative
side of the injection pipe (9), then remove the
terminal of the battery.
injection pipe (9). [*1]
a Remove the counterweight. (See REMOVAL OF
COUNTERWEIGHT.)
6. Disconnect the inlet and outlet hoses (10) of the
feed pump and lubrication tube (11).
1. Remove the nut (1) of the engine stop solenoid
rod and the nut of the accelerator cable (2) from
7. Remove the rear bracket (12) of the pump. [*2]
the lever side of the pump, then remove the rod
and cable assembly.
2. Disconnect the 3 terminals (PULL, HOLD, GND)

(3) from the engine stop solenoid.
8. Remove the 6 bolts (14) used to install the pump

holder (13) to the front cover (12).
9. Remove the bolt (15) used to install the holder

from the pump side, then remove the pump
3. Disconnect the connector (M19) (4) of the air
assembly and holder drive gear together. [*3]
conditioner compressor, water temperature sen-
a When drive gear and idler gear are installed,
sor (M18) (5), glow plug (M17) (6) and harness
their marks C must be matched to each
clamp (7).
other. Since those marks are not seen actu-
ally, however, mark match marks on the gear
and pump in white paint when the pump is
removed.
30-14 PC78MR-6
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
INSTALLATION

removal.
3 Sleeve nut:
[*1]
19.6 24.5 Nm {2 2.5 kgm}
3 Outlet and inlet tube bolts of feed pump:

[*2]
19.6 24.5 Nm {2 2.5 kgm}
[*3]
1. When installing holder (13) to pump (16), match
the engraved lines (17) on them to each other.
When installing the pump to the front cover,
match the match marks made on the gear and
pump when the pump was removed. Further-
more, match the engraved lines (18) of holder
(13) and plate to each other and tighten the
mounting bolts temporarily.
2. When the engraved line of 1.4TOP of the clamp

is matched to the pointer, timing check holes (20)
(the bolt hole on this side and the through hole
under it) of tachometer removing opening (19) on
front cover (12) must be matched to each other.
Insert round bar about 100 mm long (21) in the
holes to check that those holes are matched,
then tighten each bolt to the specified torque.
PC78MR-6 30-15
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD ASSEMBLY 8. Remove the air intake connector (6) between the
turbocharger and the air intake manifold.
REMOVAL
k WARNING! Disconnect the battery () terminal

in advance.
1. Remove the engine hood (See REMOVAL OF

COUNTERWEIGHT).
2. Drain the coolant.
6 Coolant: 10.5 l
3. Remove the air intake hose (1) between the air

cleaner and the turbocharger.
9. Disconnect the wiring harness connectors (M17)
(7), (M18) (8) and (M19) (9).
10. Remove the guard (10).
11. Remove the filler pipe (11).
4. Remove the muffler protector (2).
5. Remove the 2 U-clamps (3). [*1]
6. Remove the clamp (4) between the turbocharger

and muffler, and then loosen the 4 mounting nuts
of the turbocharger side of the exhaust pipe. [*2]
7. Remove the muffler (5).
30-16 PC78MR-6
12. Loosen the 2 mounting bolts of the air compres- 17. Disconnect the blow-by hose (19).
sor and adjustment bolt, and remove the air
compressor belt (12). 18. Remove the fuel injection pipe clamp (20) and
then remove the fuel injection pipes (21). [*3]
13. Disconnect the 3 hoses (13) from the fuel filter.
19. Disconnect the spill pipe (22).
14. Remove the air conditioner compressor (14), the
bracket and the fuel filter together.
20. Remove the inspection cover of the turbocharger

back side.
15. Disconnect the 3 terminals (PULL, HOLD, GND)
(16) and linkage mounting nut (17) from the 21. Disconnect the turbocharger lubrication tubes
engine stop solenoid (15). (23) and (24). [*4]
16. Remove the engine stop solenoid (15) and the 22. Remove the turbocharger and exhaust manifold
bracket (18) together. assembly (25). [*5]
PC78MR-6 30-17
23. Remove the cylinder head cover (26). [*6] 29. Remove the 8 mounting bolts and the rocker arm
(35), then remove the push rod. [*7]
30. Remove the lead (36) of the glow plug.
24. Loosen the 2 mounting bolts of the alternator

(27) and remove the fan belt (28).
25. Remove the fan (29). 31. Remove the 17 mounting bolts of the cylinder
head (37), and lift off the cylinder head assembly.
26. Disconnect the heater hoses (30) and (31). [*8]
27. Disconnect the radiator upper hose (32) and 32. Remove the air intake manifold (38) from the cyl-
lower hose (33). inder head assembly.
28. Remove the water pump assembly (34).
30-18 PC78MR-6
INSTALLATION a (1): Exhaust side, (2): Air intake side,

(3): Front, (4): Rear
Carry out the installation in the reverse order to
removal.
3 U-clamp nut:
[*1]
7.8 9.8 Nm {0.8 1.0 kgm}
3 Mounting bolt of clamp between turbo-

[*2]
charger and muffler:

1st time: 39.2 49 Nm {4 5 kgm}
3 Mounting nut of exhaust pipe turbocharger

2nd time:68.6 122.5 Nm {7 12.5 kgm}
side: 27 34 Nm {2.8 3.5 kgm}
3 Fuel injection pipe sleeve nut:

[*3] 5) Mark marks (f) on the bolt heads and seats
on the cylinder head in paint, then tighten the
19.6 24.5 Nm {2 2.5 kgm} bolts in the order of [1] [17] shown in figure
3 Joint bolt of turbocharger lubrication inlet

[*4] until the angle between the mark of each bolt
and the seat is 90 + 30
0 .
tube: 9.8 12.7 Nm {1.0 1.3 kgm}
a After tightening the bolts, make 1 punch
3 Mounting bolt of turbocharger and exhaust
[*5]
mark (g) on each bolt head.
a If there are 5 or more punch marks on a
manifold: 34.3 53.9 Nm {3.5 5.5 kgm}
bolt head, do not use that bolt again but
[*6]
replace it.
a Insert the cylinder head cover O-ring in the
O-ring groove, taking care not to expand or
contact it, and fit it to cylinder head. Apply
3 Head cover mounting bolt:

adhesive, if necessary.
7.84 9.8 Nm {0.8 1.0 kgm}
3 Rocker arm shaft mounting bolt

[*7]
3 Rocker arm adjustment nut

: 19.6 29.4 Nm {2 3 kgm}
: 39.2 49 Nm {4 5 kgm}
[*8]
1. Tighten the cylinder head mounting bolts in the
following order.
1) Apply molybdenum disulphide LM-P all over
the threads and seating face of each bolt and
the seats of the cylinder head holes.
2) Turn the bolts in the order of [1] [17] shown
in figure with the fingers until they are
screwed in the holes of the cylinder head to 2
3 threads.
3) Tighten the bolts in the order of [1] [17]
shown in figure to the torque of 68.6}9.8 Nm
{7}1 kgm}.
4) Tighten the bolts in the order of [1] [17]
shown in figure to the torque of 107.8}4.9 Nm
{11}0.5 kgm}.
PC78MR-6 30-19
DISASSEMBLY AND ASSEMBLY MAIN PUMP
MAIN PUMPASSEMBLY
REMOVAL
a Remove the engine hood and counterweight

(See REMOVAL OF COUNTERWEIGHT).
a Swing the upper structure from the parking posi-
tion to the right by 30 degrees and lower the
work equipment to the ground and stop the
engine (so that the hydraulic oil will be drained
easily).
k Loosen the oil filler cap of the hydraulic tank

gradually to release the residual pressure from
the hydraulic tank.
5. Remove protector (9), joint (10), and 2 U-bolts
1. Remove air cleaner (1) and its bracket and air (11) from muffler (8), then remove muffler (8) and
intake hose (2). bracket (12). [*1]
(Since the engine mount is an obstacle to
2. Remove oil splash protector (3) from the top of removal of the pump, remove the bracket.)
the pump and bottom plate (4) from the bottom of
the pump.
a Cover the manifold from which the air intake
pipe is removed.
6. Remove the wiring harness connector of TVC

solenoid (13). Remove 6 hoses (14) from the
pump. [*2]
a Mask the removed connector and fit male or
3. Remove drain plug (6) from the bottom of the female plugs to the hoses and nipple elbows.
suction tube of pump (5) to drain the oil.
4. Remove drain plug (7) from the PTO case to

drain the oil.
6 Hydraulic oil: Approx. 80 l
6 PTO: 0.5 l
30-20 PC78MR-6
DISASSEMBLY AND ASSEMBLY CONTROL PUMP
7. Lift pump (5) temporarily and remove suction CONTROL PUMP ASSEMBLY
tube (15) and pump mounting bolts, then remove
pump (5). [*3]
REMOVAL
4 Main pump assembly: 75 kg
a Remove the counter weight (See REMOVAL OF
COUNTER WEIGHT).
1. Remove the right side cover.
2. Remove hose (2) of control pump (1).
3. Remove the 4 mounting bolt and the control

pump assembly (1).
a Fit male or female plugs to the removed
hoses and elbows.
INSTALLATION

removal.
a When assembling, take care fully so that dirt,
rust, flaw, etc. will not cause a trouble.
[*1]
1. Tighten the mounting bolts of clamp (10) of the
joint between exhaust muffler (8) and exhaust
pipe to 39.2 49 Nm {4 5 kgm} first, then
tighten to 68.6 122.5 Nm {7 12.5 kgm}.
INSTALLATION
2. Tighten the nuts of mounting U-bolts (11) of
exhaust muffler (8) to 7.8 9.8 Nm {0.8 1.0 Carry out installation in the reverse order to
kgm}. removal.
[*2]
When installing the rubber hoses, be careful not
to twist them.
[*3]
After supplying hydraulic oil and before starting
the engine, bleed air from the main pump.
PC78MR-6 30-21
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
ENGINE AND MAIN PUMP 6. Remove the 2 bolts from the bottom of the
engine to remove centralized wiring harness
ASSEMBLY bracket (8) from the engine block.
REMOVAL

(See REMOVAL OF COUNTERWEIGHT).
a Swing the upper structure from the parking posi-
tion to the right by 30 degrees and lower the
work equipment to the ground and stop the
engine (so that the hydraulic oil will be drained
easily).

the hydraulic tank.
7. Remove the adjustment bolt of alternator (9).
a Disconnect the cable from the negative () termi-
nal of the battery. 8. Loosen the alternator mounting bolts through the
hole of the partition and remove the V-belt.
1. Remove bottom plate (2) from the bottom of
main pump (1) and drain plug (3) from the bot- 9. Remove the mounting bolts to remove the alter-
tom of the suction tube to drain the hydraulic oil. nator.
(This work is required since the engine mount
2. Loosen plug (4) of the remote hose to drain the bolts cannot be removed.)
cooling water from the radiator.
a If the cooling water contains antifreeze, han-
dle it as harmful liquid. Do not handle it ille-
gally.
6 Hydraulic oil: 80 l
6 Cooling water: 8 l
10. Remove the wiring harnesses and connectors of

air conditioner compressor (10), stop solenoid
(11), TVC solenoid (12), water temperature
gauge, glow plug, starting motor, etc.
3. Remove the covers from the boom foot, swing

motor top, and inspection hole on the engine
side.
4. Remove wiring harness (6) of alternator (5).
5. Remove the wiring harness of hydraulic switch

(7) and the rotation sensor connector.
30-22 PC78MR-6
11. Remove guard (13) of air conditioner compres- 20. Remove protector (25) of exhaust muffler (24).
sor (10) from the fan guard. Remove the clamp of the muffler and exhaust
pipe to remove the muffler. Remove the exhaust
12. Remove the mounting bolt of the adjustment bolt pipe from the exhaust manifold. [*2]
and air conditioner compressor (10).
13. Remove return hose (15) for the tank from fuel
filter (14).
14. Remove the 2 mounting bolts and fuel filter (14).
15. Remove 2 heater hoses (16) from the valves on

the thermostat side and engine block side.
21. Remove protector (26) of the pump hose.

Remove the mounting bolts and suction tube
(27) from the pump.
16. Loosen the clamps and disconnect upper hose

(17) and lower hose (18) of the radiator from the
engine.
17. Remove the 6 mounting bolts and fan (19).
18.Remove fuel hose (20) connected to the feed

pump. Remove accelerator wire (21) from the
governor lever. Loosen the locknut of bracket 22. Remove the 6 hoses (28) of pump (1).
(22) and remove the wire. [*1]
23. Remove the 4 bolts of engine support (29).
hoses and elbows.
19. Remove air cleaner (23), bracket, and air intake

hose together from the air intake manifold.
PC78MR-6 30-23
24. Install the hook to engine assembly (30) and a INSTALLATION

sling to main pump (1) and lift off the engine and
pump assembly, hanging it by 3 points. Carry out installation in the reverse order to
removal.
3 Fuel hose bolt:

[*1]
19.6 24.5 Nm {2 2.5 kgm}
[*2]
1. Tighten the mounting bolts of the clamp of the
joint between exhaust pipe and muffler to 39.2
49 Nm {4 5 kgm} first, then tighten to 68.6
122.5 Nm {7 12.5 kgm}.
2. Tighten the nuts of the mounting U-bolts of the

muffler to 7.8 9.8 Nm {0.8 1.0 kgm}.
[*3]
After installing the engine mount to the revolving
frame, apply clear lacquer to the unpainted
engine mount fitting face.
3 Mounting bolt:
249 309 Nm {25 31.5 kgm}
2 Mounting bolt:
Apply liquid adhesive LT-2
30-24 PC78MR-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR
HYDRAULIC OIL COOLER RADIATOR ASSEMBLY

ASSEMBLY REMOVAL
REMOVAL a Remove the hydraulic oil cooler. For details, see
REMOVAL OF HYDRAULIC OIL COOLER. [*1]
(See REMOVAL OF COUNTERWEIGHT). 1. Move oil cooler (2) removed from radiator (1) to
the left, without disconnecting the inlet and outlet
1. Disconnect the hose of reserve tank (1) from the hoses.
radiator and remove it together with the tank
bracket.
2. Remove receiver tank (2) from the frame.
3. Remove condenser (3) and arrange it and

receiver tank so that they will not be obstacles.
4. Remove net (4) of the oil cooler.
2. Loosen remote plug (3) on the bottom of the radi-

ator to drain the cooling water into a container.
Remove protector (4) of the air conditioner com-
pressor from fan guard (1).
6 Cooling water: Approx. 4 l

a If the cooling water contains antifreeze, han-
dle it as harmful liquid. Do not handle it ille-
5. Remove the bottom plate of oil cooler (5) and gally.
prepare an oil receiving container, then remove
cooler inlet hose (6) and outlet hose (7).
6. Remove condenser bracket (8). Remove the 4

bolts used to secure the brackets on the top and
bottom of the oil cooler, then remove the oil
cooler.
INSTALLATION

removal.
PC78MR-6 30-25
DISASSEMBLY AND ASSEMBLY RADIATOR
3. Remove the 6 mounting bolts and fan (5). INSTALLATION

Loosen the clamps on the engine side and
remove upper hose (6) and lower hose (7). [*2] Carry out installation in the reverse order to
removal.
[*1]
When installing the radiator and oil cooler, check
that the sealing material (sponge) between them
is not deformed or broken but normal.
[*2]
1. When inserting each hose, apply LG-6 to the
adapter of the mating part. When tightening
each clamp, check that it is not over the tube
lock part.
3 Hose clamp: 8.8 Nm {0.9 kgm}
4. Remove the 2 bolts and bracket (8) installed to
the partition under the operator's cab. Remove 2
mounting bolts (9) on the underside and radiator
(1).
30-26 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
SWING MOTOR AND SWING 4. Remove the (9) swing machinery mounting bolts.
MACHINERY ASSEMBLY 5. Pull the plugs out of the forcing screw holes of
the swing machinery and hang the body of the
REMOVAL swing machinery with 2 slings wound onto it.
a Extend the work equipment to the maximum 6. Using 2 forcing screws, disconnect the swing
reach and lower it to the ground and stop the motor and swing machinery assembly (6) from
engine. the frame.
k Loosen the oil filler cap of the hydraulic tank 7. Lift off swing motor and swing machinery assem-
gradually to release the residual pressure from bly (6). [*1]
4 Swing motor and

the hydraulic tank.
swing machinery
1. Remove the top cover of the swing motor assembly: 77 kg
2. Remove the level gauge bracket (7) and discon-

nect the hose (8).
hoses and elbows.
INSTALLATION

3. Disconnect hoses (1), (2), (3), (4), and (5) of the removal.
swing motor.
2 Contact faces on underside of swing

a Fit male or female plugs to the removed [*1]
hoses and elbows.
a Record the disconnected hoses to prevent a machinery case and frame:
mistake in re-connecting them. Apply gasket sealant (LG-6)
3 Swing machinery case mounting bolt:

245 308.7 Nm {25 31.5 kgm}
a When installing the assembly, take care not

to break the drain tube of the swing machin-
ery case.
a Refilling with oil (Hydraulic tank)
Run the engine to circulate the oil through
the piping. Then, check the oil level again
and add new oil to the specified level.
PC78MR-6 30-27
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
SWING MACHINERY 3) Disassemble No. 1 carrier assembly accord-

ing to the following procedure.
ASSEMBLY i) Remove snap ring (4), thrust washer (5),
gear (6), bearing (7), and thrust washer
DISASSEMBLY (8).
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
6 Swing machinery case: Approx. 2 l
2. Swing motor assembly

Remove swing motor assembly (1).
4) Drive in pin (9) to push out shaft (10).

a After removing the shaft, remove pin (9).
5) Remove thrust washer (11) from carrier (12).
3. No. 1 sun gear and No. 1 carrier assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 2 carrier (3).
30-28 PC78MR-6
4. No. 2 sun gear 7. Collar

Remove No. 2 sun gear (13). 1) Set the shaft and case assembly to a press
and push sub bearing (25) with tool F1.
5. Ring gear a Operate the press slowly and push the
Remove ring gear (14). bearing until the 2-piece collar can be
removed.
6. No. 2 carrier assembly 2) Remove 2-piece collar (26).
1) Remove No. 2 carrier assembly (15).
2) Disassemble No. 2 carrier assembly accord- 8. Shaft assembly

ing to the following procedure. 1) Set block (1) to shaft and case assembly
i) Remove snap ring (16), thrust washer (27). Using push tool (2) and the press,
(17), gear (18), bearing (19), and thrust remove shaft assembly (28).
washer (20). 2) Remove sub bearing (25).
ii) Drive in pin (21) to push out shaft (22).
a After removing the shaft, remove pin
(21).
iii) Remove thrust washer (23) from carrier
(24).
3) Set the shaft assembly to the press. Using

push tool (3), remove main bearing (29) and
collar (30) from shaft (31).
PC78MR-6 30-29
9. Dust seal, oil seal, and bearing outer race ASSEMBLY

1) Remove dust seal (32) and oil seal (33) from
case (34). a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
1. Oil seal
Using tool F3, press fit oil seal (33) to case (34).
a Replace the oil seal with new one.
3 Lip of oil seal: Grease (G2-LI)
3 Periphery of oil seal:
Gasket sealant (LG-6)
2) Using tool F2, remove bearing outer races

(35) and (36) from case (34).
2. Sub bearing outer race

Using tool F4, press fit outer race (36) to case
(34).
a Press fitting force: Max. 8.82 kN {Max. 0.9
tons}
3. Main bearing outer race

Using tool F5, press fit outer race (35) to case
(34).
a Press fitting force: Max. 19.6 kN {Max. 2.0
tons}
30-30 PC78MR-6
4. Shaft assembly 6) Using tool (8) and the press, press fit shaft
1) Install collar (30) to shaft (31). (31) until 2-piece collar (26) is secured.
2) Using tool F6 and the press, press fit main 7) Using tool F8, measure the running torque of
bearing (29). the shaft.
a Press fitting force: Max. 65.7 ~ 178.4 kN a Running torque: Max. 19.6 Nm {Max. 2.0
{Max. 6.7 ~18.2 tons} kgm}
3) Set case assembly (37) to shaft assembly

(28). 5. Dust seal
a Press fitting force: Max. 27.4 116.6 kN Using tool F9, press fit dust seal (32).
{Max. 2.8 11.9 tons} a Replace the dust seal with new one.
4) Using tool F7 and the press, press fit sub
bearing (25) until the 2-piece collar can be
installed.
a Press fitting force: Max. 27.4 116.6 kN
{Max. 2.8 11.9 tons}
a Turning the case, press fit the bearing
slowly.
5) Install 2-piece collar (26).
PC78MR-6 30-31
6. No. 2 carrier assembly 9. No. 1 carrier assembly

1) Assemble No. 2 carrier assembly according 1) Assemble No. 1 carrier assembly according
to the following procedure. to the following procedure.
i) Install thrust washer (23) to carrier (24). i) Install thrust washer (11) to carrier (12).
ii) Match shaft (22) to the pin hole of the ii) Match shaft (10) to the pin hole of the
carrier and install it by hitting it lightly with carrier and install it by hitting it lightly with
a plastic hammer. a plastic hammer.
iii) Insert pin (21). iii) Insert pin (9).
a After inserting the pin, bend the pin of a After inserting the pin, bend the pin of
the carrier. the carrier.
iv) Install thrust washer (20), bearing (19),
gear (18), thrust washer (17), and snap
ring (16).
iv) Install thrust washer (8), bearing (7),

gear (6), thrust washer (5), and snap ring
(4).
2) Install No. 2 carrier assembly (15) to the
shaft and case assembly.
7. Ring gear
Install ring gear (14).
2 Fitting face of ring gear:
3 Ring gear mounting bolt:
58.5 73.5 Nm {6 7.5 kgm}
8. No. 2 sun gear

Install No. 2 sun gear (13).
a Take care not to install the sun gear and 2) Install No. 1 carrier assembly (3).
planetary gear upside down. 3) Install No. 1 sun gear (2).
30-32 PC78MR-6
10. Swing motor assembly

Install swing motor assembly (1).
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
2 Fitting face of motor:
11. Supplying oil and grease

Tighten the drain plug and supply engine oil
through the oil filler.
6 Swing machinery case: Approx. 2 l
2 Swing machinery case (Main bearing):

Grease (G2-LI), approx. 115 g
a Apply LG-5 to the fitting part of the drain
tube.
3 Drain plug:
44.1 93.1 Nm {4.5 9.5 kgm}
a When mounting the assembly on the
machine, apply gasket sealant LG-6 to the
fitting face of the revolving frame.
PC78MR-6 30-33
DISASSEMBLY AND ASSEMBLY SWING MOTOR, CENTER SWIVEL JOINT
SWING MOTOR ASSEMBLY CENTER SWIVEL JOINT

REMOVAL
ASSEMBLY
a Remove the hoses of the swing motor. For REMOVAL

details, see REMOVAL OF SWING MOTOR
AND SWING MACHINERY ASSEMBLY. a Extend the work equipment to the maximum
reach and lower it to the ground and stop the
1. Remove the 8 swing motor mounting bolts (1). engine.

2. Remove the swing motor assembly.
a After removing the swing motor, cover the
the hydraulic tank.
swing machinery.
1. Remove the top cover of the center swivel joint.
2. Remove travel drain hose (1) and swing motor

hose (2).
3. Remove 5 hoses (3) of the control valve, travel

forward/reverse, lateral hose, and 2nd travel
speed selection from the top one.
hoses, nipples, and elbows.
a Record the disconnected hoses to prevent a
mistake in re-connecting them.
INSTALLATION

removal.

Run the engine to circulate the oil through the
piping. Then, check the oil level again and add
new oil to the specified level.
30-34 PC78MR-6
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
4. Remove the bottom plate of the center swivel. INSTALLATION

5. Remove the 4 travel forward/reverse and lateral Carry out installation in the reverse order to
hoses, 2 2nd travel speed selection hoses, 2 removal.
drain hoses, etc. (4) from the underside of the a When installing the rubber hoses, be careful not
swivel. to twist them.
6. Remove the cotter pin of the lock pin of the cen- Run the engine to circulate the oil through the
ter swivel from above, then pull out the lock pin piping. Then, check the oil level again and add
and disconnect the lock plate. new oil to the specified level.
7. Hang the center swivel joint temporarily and

remove the 4 mounting bolts from plate (5).
hoses, nipples, and elbows and record the
disconnected hoses to prevent a mistake in
re-connecting them.
8. Lift off center swivel joint assembly (6).
4 Center swivel joint assembly: 18.5 kg
PC78MR-6 30-35
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY ASSEMBLY
1. Remove cover (1). 1. Install slipper seal (7) and O-ring (6) to swivel
shaft (5).
2. Remove snap ring (2).
2. Set swivel shaft (5) to the block. Using the push
3. Using tool T, pull swivel rotor (4) and ring (3) out tool, hit swivel rotor (4) with a plastic hammer
of swivel shaft (5). lightly to install it.
a Apply grease (G2-LI) to the contact surfaces
4. Remove O-ring (6) and slipper seal (7). of swivel shaft (5) and swivel rotor (4).
a When installing the rotor, take care fully not
to damage the lips of the slipper seal and oil
seal.
3. Install ring (3) and secure it with snap ring (2).
4. Install the O-ring and cover (1).

3 Mounting bolt:
31.4 2.94 Nm {3.2 0.3 kgm}
a When assembling, take care fully so that dirt,

a After assembling, seal each port with a poly-
ethylene plug.
30-36 PC78MR-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE ASSEMBLY 7. Remove hoses (8) on the operator's cab side of
the control valve in order from the top one. [*1]
REMOVAL
hoses and nipples.
k Lower the work equipment to the ground and
stop the engine, then loosen the oil filler cap
the hydraulic tank.

() terminal of the battery.
1. Remove the top cover of the hydraulic tank.
2. Remove the right side cover.
3. Remove the tool box and the washer tank.
4. Remove 5 connectors (1) of the hydraulic 8. Remove the 4 control valve mounting bolts from
switches and the wiring harness bracket. the underside of control valve stand (9) and lift
off control valve assembly (10), using sling (1).
4 Control valve assembly: 65 kg

5. Remove each pilot hose (2).
6. Remove hoses (3) between the pump and

merge-divider valve.
a Mask the removed connectors.
INSTALLATION

removal.
[*1]
1. When assembling, take care fully so that dirt,
2. When installing the rubber hoses, take care fully

not to twist them.
3. Bleed all air from the swing PPC circuit.
4. After assembling, flush the all piping circuit.

a The number of the control valves and pipes
of a machine equipped with an attachment
and those of Model UU are different from the
above.
PC78MR-6 30-37
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
ASSEMBLY
a When disassembling and assembling the preci-

sion parts of the hydraulic system, keep them
clean extremely and work in a clean place.
Take care fully not to hurt your fingers with the
edges of the machines parts.
a Check the fitting surfaces of the all parts. If a
part has a scratch or a burr, replace it with new
one since it can cause a trouble. Take care fully
not to bruise or damage a part by dropping or hit-
ting it.
a Wash the all metallic parts in clean solvent and
dry them with compressed air. If they are wiped
with cloths or paper, fibers of the cloths and
paper enter the product and contaminate the 3. When loosening or tightening plug (10) of spool
hydraulic system and can cause a trouble. (9) of bucket valve (8), be sure to put spool (9) in
Accordingly, never wipe the parts with cloths or valve chest (8).
paper.
a When assembling, replace the consumable parts 4. When loosening or tightening plugs (13) and (14)
such as the O-rings and seals with new ones, as of spool (12) of arm valve (11), be sure to put
a rule. Apply a little amount of clean grease to spool (12) in valve chest (11).
the O-rings.
a Take care of the installing direction of each 5. When loosening or tightening plugs (17) and (18)
spool. of spool (16) of boom valve (15), be sure to put
spool (16) in valve chest (15).
1. When loosening or tightening mounting bolt (1) a When tightening each of the orifices and
used to install the retainer of the spool return plugs described above, apply 1 drop (approx.
spring to each spool, be sure to put spool (2) in 0.02 g) of LOCTITE (No. 638) to it. Thor-
valve chest (3) (to prevent deformation of the oughly degrease and dry the plug and the
spool). f e m a l e s c r e w o f t h e v a l v e c h e s t wi t h
3: 6.9 9.8 Nm {0.7 1.0 kgm} DRYSOL. Do not apply pressure to them for
2 hours after they are tightened.
3 Orifice and plug:
14.7 19.6 Nm {1.5 2.0 kgm}
2. When loosening or tightening orifice (5) and plug

(6) of merge-divider valve (4), be sure to put
spool (7) in valve chest (4) (to prevent deforma-
tion of the spool).
30-38 PC78MR-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
6. Tighten the combination bolts (1) and (2) in the WORK EQUIPMENT PPC
order of (1) (4) gradually in 3 times.
1) Combination bolt (1) tightening torque. VALVE ASSEMBLY
1st tightening torque:
19.6 29.4 Nm {2 3 kgm} ASSEMBLY
2nd tightening torque:
39.2 49.0 Nm {4 5 kgm} a When assembling, clean and inspect the parts
3rd tightening torque: closely and take care fully so that dirt, rust, flaw,
58.8 73.5 Nm {6 7.5 kgm} etc. will not cause a trouble.
2) Combination bolt (2) tightening torque
29.4 34.3 Nm {3 3.5 kgm} 1. When installing piston (1), apply grease (G2-LI)
to its outside and the inside of the body hole.
2. When installing disc (2), adjust it so that the play

of the lever end will be 0.5 ~ 3 mm (at 200 mm
from the center of rotation of the lever).
3. When installing joint (3) to body (4), apply LOC-

TITE as shown below.
1) When installing the joint, apply 1 drop
(approx. 0.02 g) of LOCTITE (No. 262) each
to 2 places of the female screw of the body.
Bef or e i ns tall in g th e j oi nt, thor ou ghl y
degrease and dry its male screw and the
female screw of the body with DRYSOL.
2) Drop LOCTITE to the following positions.
a For the tightening torque of the auxiliary valves
Female screw of body
(Relief valve, suction safety valve, pressure
compensation valve, etc.), see STRUCTURE
AND OPERATION, MAINTENANCE STAN-
DARD.
a After assembling, seal each port with a nylon
cap, etc.
a When hanging the valve assembly, use eyebolts
(04530-10815).
4. Install spring (5) with its small diameter side on

the shim (6) side.
Diameter of spring (Inside diameter)
Small diameter side: 4.9,
Large diameter side: 5.55
5. When installing plug (7) to body (4), take care

that its tip will not enter the hole of the body 20
mm in diameter.
PC78MR-6 30-39
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
6. Apply grease (G2-LI) to the rocking part of joint TRAVEL PPC VALVE
(3) and the contact surfaces of disc (2) and pis-
ton (1). ASSEMBLY
Quantity of grease
1) Rocking part of joint: 2 4 cc/periphery ASSEMBLY
2) Contact surfaces of disc and piston:
0.3 0.8 cc/place a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
7. Seal the ports (P1 - P4, T, P) with nylon caps, etc. will not cause a trouble.
etc.
1. When installing piston (1), apply grease (G2-LI)
8. Tighten each part to the following torque. to its outside and the inside of the body hole.
Joint (3): 39 49 Nm {4 5 kgm}
Bolt (8): 11.8 14.7 Nm {1.2 1.5 kgm} 2. Install spring (2) with its small diameter side on
Nut (9): 98 127 Nm {10 13 kgm} the shim (3) side.
Plug (10): 6 11 Nm {0.6 1.1 kgm} Diameter of spring (Inside diameter)
Small diameter side: 4.9,
Large diameter side: 5.55
3. Use the insertion jig to insert bushing (4). (Do

not drive in the bushing with impact loads of a
hammer, etc.)
4. Use the insertion jig to insert pin (5). (Do not

drive in the pin with impact loads of a hammer,
etc.)
5. Apply grease (G2-LI) to the rocking part of shaft

(6) and the contact surfaces of lever (7) and pis-
ton (1) and the contact surfaces of plate (8) and
pin of lever (9).
2 Quantity of grease (G2-LI)
Rocking part of shaft:4 8 cc/periphery
Contact surfaces of lever and piston:
0.3 0.8 cc/place
Contact surfaces of plate and pin:
0.3 0.8 cc/place
6. Install washer (10) 1.6 mm thick first. If the dif-

ference between both sides at the stroke end of
the lever exceeds 0.7, change the washer thick-
ness to reduce the difference to below 0.7. (If
the washer thickness is reduced by 0.3 mm, the
stroke end angle is increased by 0.39.)
Thickness of washer t: 1.0, 1.3, 1.6
7. After assembling, seal the ports (P1 P4, T, P)

with nylon caps, etc.
30-40 PC78MR-6
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
8. Tighten each part to the following torque.

Plug (11): 6 11 Nm {0.6 1.1 kgm}
Bolt (12): 3.9 4.9 Nm {0.4 0.5 kgm}
(Apply LOCTITE #262.)
Screw (13): 7.8 9.8 Nm {0.8 1.0 kgm}
Plug (14): 4 9 Nm {0.4 0.9 kgm}
Bolt (15): 25 30 Nm {2.5 3.2 kgm}
Bolt (16): 27 34 Nm {2.8 3.5 kgm}
PC78MR-6 30-41
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK 6. Remove return hose (5), including the swing

hose.
ASSEMBLY
7. Remove hose (6) from the oil cooler and the
REMOVAL other hoses.
a Swing the work equipment to a position at which hoses, elbows, etc.
the hydraulic oil can be drained easily and lower a Record the disconnected hoses to prevent a
the work equipment to the ground. mistake in re-connecting them.
k Stop the engine and loosen the hydraulic oil

filler cap gradually to release the residual pres-
sure from the hydraulic tank.
1. Drain the oil from the hydraulic tank.
2. Remove the top cover and right side cover of the

hydraulic tank.
3. Remove the wiring harness clamp and washer

tank (1).
4. Loosen the clamp and remove pump suction

hose (2). 8. Using sling [1], remove the mounting bolts and
6 Hydraulic tank: 64 l
lift off hydraulic tank assembly (7).
5. Disconnect the return hose (8).
INSTALLATION

removal.
a When installing the rubber hoses, be careful not
to twist them.
30-42 PC78MR-6
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK ASSEMBLY 7. Remove the inspection cover of fuel suction

hose (7) and drain hose (8) from the underside of
the revolving frame under the fuel tank, then
REMOVAL
remove the suction hose and drain hose.
a Drain the fuel through the drain valve.
6 When fuel tank is full: 125 l
1. Remove the front and left deck covers.
2. Remove the mounting bolts of fuel filler mounting

cover (1) and loosen the hose clamp of the fuel
filler tube and pull out the tube.
3. Remove the clamp and hose (2) of the fuel spill

prevention gauge and take out cover (1).
8. Remove the 2 mounting bolts of fuel tank bracket
4. Loosen the clamp of fuel supply hose (3) on the (9) on this side from the underside of the revolv-
fuel tank (4) side and remove the hose from the ing frame.
tank.
9. Remove the mounting bolt of the valve (10) and
5. Remove the clamp of PPC hose (5) from the move them to the left side (to secure winder work
underside of the floor. space).
6. Remove the fuel sensor top cover of the floor 10. Remove the nut and fuel tank band (11) on the
and disconnect sensor connector (6). deeper side from the tank. [*1]
PC78MR-6 30-43
DISASSEMBLY AND ASSEMBLY CONTROLLER
11. Pull out fuel tank (4) and remove the clamp and CONTROLLER ASSEMBLY
tank air bleed hose (12), then remove the fuel
tank.
REMOVAL
1. Remove 4 bolt caps (2) of cover (1) at the rear of

the operator's seat.
2. Remove the 4 bolts and cover (1).
INSTALLATION
Carry out installation in the reverse order to 3. Loosen the mounting bolts and remove connec-
removal. tors (4), (5), and (6) of controller (3).
3 Nut of tank band:

[*1] 4. Remove the 4 mounting bolts and controller
assembly (3).
5.9 0.49 Nm {0.6 0.05 kgm}
INSTALLATION

removal.
a Do not tighten the mounting bolts of connectors
too strongly.
30-44 PC78MR-6
DISASSEMBLY AND ASSEMBLY MONITOR PANEL, AIR CONDITIONER UNIT
MONITOR PANEL ASSEMBLY AIR CONDITIONER UNIT

REMOVAL
ASSEMBLY
1. Pull cover (2) of monitor panel (1) and remove REMOVAL

the claw stopper.
2. Remove side cover (3). terminal of the battery.
a Connect a hose to the compressor charge unit
3. Remove the stopper of cover (4). and collect the refrigerant gas. (If the charge tool
is available, this work becomes easy.) [*1]
1. Remove floor mat (1).
2. Remove dust covers (2) and (3).
3. Remove air conditioner unit cover (4).
4. Remove the 3 mounting bolts of monitor panel

(1) and connectors (5) and (6) on the back side,
then remove monitor panel assembly (1).
4. Remove duct (5) and the rear duct.
5. Remove cover (6) and the rear duct.
6. Remove 2 tubes (7) and push them in under the

floor. [*2]
tubes.
INSTALLATION

removal.
PC78MR-6 30-45
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
7. Loosen the clamp and remove heater hose (8) 11. Remove the 3 front mounting bolts and 3 rear
under the rear part of the operator's seat. ones and air conditioner unit assembly (12).
8. Remove 3 wiring harness connectors (9) for the

air conditioner under the rear part of the opera-
tor's seat.
INSTALLATION

9. Remove 5 mounting bolts of operator's seat removal.
stand (10).
[*1]
10. Raise the operator's seat stand to 60 mm above 1. Connect the power cable for the compressor
the floor by using 4 forcing screws (11) having after charging the air conditioner with refrigerant
screwing length of 70 - 80 mm, and the unit can gas (R134a).
be taken out.
a If the operator's seat stand is raised too high, 2. Do not connect the outlet and inlet hoses of the
it will interfere with the wiring harnesses on receiver drier before the air conditioner is
both sides. charged with refrigerant gas.
3. When assembling, take care that water (mois-

ture), dirt, or air will not enter the air conditioner
cycle.
[*2]
1. When fitting the pipes, apply compressor oil
(SNISO 5GS) to the flared parts and threaded
parts.
2. Tighten the nuts on both ends of the refrigerant

circuit hose to the following torque.
Dimen- Width
Size sions of across Tightening torque Nm
thread flats {kgm}
# 08 16 x 1.5 19 11.8 14.7 {1.2 1.5}

# 11 20 x 1.5 24 19.6 24.5 {2.0 2.5}
# 14 22 x 1.5 27 29.4 34.3 {3.0 3.5}
30-46 PC78MR-6
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
OPERATORS CAB 7. Remove wiring harness connectors (6) and (7) of

the radio system at the left rear and disconnect
ASSEMBLY radio cable (8) from the jack.
REMOVAL 8. Remove connectors (9), (10), and (11) of the

monitor panel at the right rear.
1. Remove the floor mat.
9. Remove the washer tank hose.
2. Remove air conditioner unit cover (1).
3. Remove rear cover (3) of monitor panel (2) and

air conditioner duct.
10. Install a sling to the top of operator's cab assem-

bly (12) and lift off the assembly.
4 Operator's cab assembly: 280 kg

4. Remove the mounting bolts used to install the
operator's cab to the floor.
5. Remove the 4 nuts from the left front, rear, and

right front and 1 bolt from the right rear of the
operator's cab mount.
6. Remove the controller storage cover, wiring har-

ness connectors of controller (4), and clamps (5).
INSTALLATION

removal.
PC78MR-6 30-47
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
FLOOR FRAME ASSEMBLY 7. Remove the 4 hoses connected to travel right

and left control valves (9).
REMOVAL
8. Remove the 2 hoses connected to the attach-
ment control valve (10).
a Remove the operator's cab assembly. (See
REMOVAL OF OPERATOR CAB.)
9. Disconnect the hoses connected to swing control
valve and blade control valve.
a Connect a hose to the compressor charge unit
and collect the refrigerant gas. (If the charge tool
is available, this work becomes easy.) [*1]
1. Remove front deck cover (1) and left deck cover

(2).
2. Remove 8 wiring harness connectors (3) of

engine and pump control systems.
3. Remove 3 solenoid connectors (4) and cable

clamp (5).
4. Remove the wiring harness connector of horn

(6). 10. Loosen the clamps and remove 2 heater hoses
(11). (At the rear of the operator's seat)
5. Remove 2 air conditioner gas tubes (7). (Fit
male or female plugs to the removed tubes.)
11. Remove the 4 mounting bolts used to install the

floor frame to floor mount (12).
6. Remove 8 hoses (8) of the work equipment con-
trol valve from the couplers.
12. Remove the accelerator wire from the injection

pump and pull it out through the hole of the
revolving frame to the floor side.
30-48 PC78MR-6
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
13. Install 4 eyebolts (1) to floor frame (13) and lift off
the floor frame assembly.
4 Floor frame assembly: 200 kg
INSTALLATION

removal.
[*1]
a See INSTALLATION OF AIR CONDITIONER
UNIT.
PC78MR-6 30-49
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REVOLVING FRAME 6. Remove receiver drier (5) and bracket together

from the revolving frame and place them on their
ASSEMBLY side.
REMOVAL

a Remove the work equipment assembly. (See
REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.)
a Remove the operator's cab assembly. (See
REMOVAL OF OPERATOR'S CAB ASSEMBLY.)
a Move the removed work equipment hoses to the
chassis side.
1. Remove the engine hood.

7. Remove the all mounting bolts used to install
2. Remove air cleaner assembly (1) and bracket swing circle outer race (6) to the revolving frame.
hose together.
3. Remove engine ventilator cover (2).
8. Install a sling to the boom foot mounting unit and

both sides of counterweight (7) and lift off the
revolving frame assembly, hanging it by 3 points.
4. Hang boom cylinder assembly (3) temporarily a Use the hole of the revolving frame on the
and remove the hoses on the head side and bot- left rear side from which the receiver drier
tom side. Pull out the mounting pin on the bot- was removed.
tom side and lift off the cylinder assembly.
5. Remove fuel filler mounting cover (4). INSTALLATION

removal.
30-50 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
SWING CIRCLE ASSEMBLY INSTALLATION
REMOVAL Carry out installation in the reverse order to

removal.
1. Remove the revolving frame assembly. For
2 Threads of swing circle mounting bolt:

details, see REMOVAL OF REVOLVING FRAME [*1]
ASSEMBLY.
Liquid adhesive (LT-2)
3 Swing circle mounting bolt:

2. Hang swing circle assembly (1) temporarily and
remove the 24 mounting bolts. [*1]
245 309 Nm {25 31.5 kgm}
Target: 279.5 Nm {28.5 kgm}
3. Remove swing circle assembly (1). [*2]
4 Swing circle assembly: 115 kg

[*2]
a Hang swing circle assembly (1) and install it
to the track frame, directing mark S of the
inner race to the just right s ide of the
machine body as shown below.
2 Quantity of grease to be applied to

circle: Apply sufficient quantity of
grease (G2-LI).
PC78MR-6 30-51
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
ASSEMBLY
REMOVAL
a Extend the work equipment to the maximum

reach and lower it to the ground and stop the
engine.

the hydraulic 6tank.
1. Remove the top cover of the hydraulic tank.
2. Disconnect the working lamp connector (1), then

disconnect the wiring harness (7) from the hose.
3. Remove the handrail (8).
4. Loosen the sleeve nut and disconnect the work

equipment hose (2). [*1]
a Move the removed hoses to the swing motor
side.
hoses and tubes.
a Record the disconnected hoses to prevent a
mistake in re-connecting them.
k Since an accumulator is not installed, 7. Remove the lock plate (9) of the boom foot pin
loosen the sleeve nut of each hose gradu- and handrail (10).
ally and check that oil will not spout out,
then remove the hose. 8. Lift the work equipment assembly (5) tempo-
rarily.
9. Pull out the boom hoot pin (6). [*3]

a Check the quantity and positions of the
inserted shims.
5. Remove the rod pin stopper used to lift boom cyl-

inder (3) temporarily and pull out rod pin (4). [*2]
6. Lift off the boom cylinder (3) onto a stable stand

of proper heght.
inserted shims.
30-52 PC78MR-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
10. Lift off the work equipment assembly (5). INSTALLATION

inserted shims. Carry out installation in the reverse order to
2 Work equipment assembly: 1,100kg removal.
[*1]
1. Check that the O-rings are fitted to the sealing
parts of each hose.
2. When installing the rubber hoses, take care not

to twist them.
[*2]
1. When assembling, apply GT2-T to the sliding
surfaces of the pins.
2. Supply grease until it comes out through the dust

seals on both sides of each bushing.
k When aligning the pin holes, never insert

your fingers in the pin holes.
a Adjust the shims so that the clearance
between the cylinder rod head and bracket
will be less than 1 mm.
[*3]
1. When assembling, apply GT2-T to the sliding
surfaces of the pins.
2. Supply grease until it comes out through the dust

seals on both sides of each bushing.
3. After supplying grease, change the position of

the boom and supply grease further.
k When aligning the pin holes, never insert

your fingers in the pin holes.
a Adjust the shims so that the clearance
between the boom and bracket will be less
than 1 mm.
PC78MR-6 30-53
DISASSEMBLY AND ASSEMBLY SWING BRACKET
SWING BRACKET ASSEMBLY

REMOVAL
1. Remove the work equipment assembly (See

REMOVAL OF WORK EQUIPMENT ASSEM-
BLY).
2. Disconnect the 2 boom cylinder hoses (1). [*1]

hoses and elbows.
3. Lift the boom cylinder assembly (2), then pull out

the bottom pin (3) and remove the boom cylinder
assembly (2). [*2]
a Check the quantity and positions of the 6. Remove the cover (6) and disconnect the con-
inserted shims. nector (7).
4 Boom cylinder assembly: 112kg 7. Remove the bolt of the upper and lower brack-
ets, then remove the potentiometer assembly
(8). [*5]
a After removing the potentiometer assembly,
do not swing it around the lever or turn the
lever unnecessarily.
8. Remove the work equipment hose clamp (9). [*4]

a Make marks on the disconnected hoses so
that you can connect them again in the origi-
nal order.
4. Set the block under the swing cylinder, and

remove the head pin (4). [*3]
inserted shims.
k Start the engine and retract the cylinder.
5. Remove the boom cylinder hose clamp (5). [*4]
30-54 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING BRACKET
9. Lift the swing bracket (10) temporarily, and INSTALLATION

remove the mounting bolts of the swing pin
upper side and lower side. Carry out the installation in the reverse order to
a Plate (11) will be removed from the lower pin. removal.
10. Pull out the pins (12) and (13) toward upper or [*1]
lower. 1. When installing, check that the O-ring is fitted to
a If the pins are difficult to pull out, use puller the sealing part of the hose.
V2.
2. When installing the rubber hoses, be careful not
11. Pull out the work equipment hoses and the boom to twist them.
cylinder hose, and remove the swing bracket
assembly (10). [*6] [*2] [*3]
a Check the quantity of the shims installed to 1) When assembling, apply G2-T to the sliding
the top of pin (13). surface of the pins.
4 Swing bracket assembly: 234kg
2) Use G2-T HYPER WHITE GREASE.
3) Adjust the shims so that the clearance
between the cylinder and bracket will be 1
mm or less.
k When aligning the pin holes, never

insert your fingers in the pin holes.
[*4]
a When installing the hoses, be careful not to
twist them.
[*5]
a Referring to TROUBLESHOOTING, Proce-
dure for correcting angle sensor, correct the
sensor.
[*6]
1) When assembling, apply G2-T to the sliding
surface of the pins.
2) Use G2-T HYPER WHITE GREASE.
3) Adjust the shims so that the clearance
between the swing bracket and the bracket
on the chassis side (the clearance on the
upper side of the lower pin) will be 0.5 mm or
less.
a Shims of 3 thicknesses of 0.5, 1.0, and
2.0 mm are prepared.
k When aligning the pin holes, never

insert your fingers in the pin holes.
a After installing, check that the hydraulic oil level

is normal.
a After installing, check that the electric system
works normally.
PC78MR-6 30-55
DISASSEMBLY AND ASSEMBLY STEEL SHOE, RUBBER PAD SHOE, ROAD LINER
STEEL SHOE, RUBBER PAD 4. Remove tool R and move the machine forward
so that the temporary pin will be in front of the
SHOE, ROAD LINER idler and set block [1].
ASSEMBLY
5. Pull out the temporary pin and move the
machine in reverse to expand track shoe (2).
EXPANSION
1. Stop the machine so that the master pin will be

between the idler and carrier roller and the track
shoe can be expanded forward and backward.
2. Lower the work equipment to the ground and

loosen lubricator (1) to lower the track shoe ten-
sion. [*1]
k Since the internal pressure of the adjustment

cylinder is very high, do not loosen the lubrica-
tor more than 1 turn. If the grease does not
come out easily, move the machine forward and
in reverse.
INSTALLATION

removal.
[*1]
a Adjust the tension of the steel shoe and road
liner. For details, see TESTING AND ADJUST-
ING, Testing and adjusting track shoe tension.
3. Using tool R, pull out the master pin.
30-56 PC78MR-6
DISASSEMBLY AND ASSEMBLY RUBBER SHOE, FINAL DRIVE
RUBBER SHOE ASSEMBLY FINAL DRIVE ASSEMBLY

REMOVAL REMOVAL
1. Lower the work equipment to the ground and 1. Expand the track shoe assembly. (See EXPAN-
loosen lubricator (1) to lower the track shoe ten- SION OF TRACK SHOE.)
sion. [*1]
k Since the internal pressure of the adjustment

2. Swing the work equipment by 90 degrees from
the parking position and raise the machine body
cylinder is very high, do not loosen the lubrica- by pressing the work equipment against the
tor more than 1 turn. If the grease does not ground and set block (1) between the track
come out easily, move the machine forward and frame and track link to float sprocket (1) above
in reverse. the link tread.
2. Swing the work equipment by 90 degrees and k Lower the work equipment to the ground
raise the machine body a little. and stop the engine. Loosen the oil filler
cap of the hydraulic tank to release the
3. Put steel pipes in rubber shoe (2) and turn the residual pressure from the hydraulic tank.
sprocket in the reverse direction. If the rubber
shoe is floated from the idler by the steel pipes, 3. Remove travel motor side cover (2).
slide off the rubber shoe sideways.
INSTALLATION

removal.
[*1]
a Adjust the rubber shoe tension. For details, see
TESTING AND ADJUSTING, Testing and adjust-
ing track shoe tension.
PC78MR-6 30-57
DISASSEMBLY AND ASSEMBLY IDLER
4. Hang final drive assembly (3) temporarily. IDLER ASSEMBLY

ASSEMBLY
1. Using tool L1, press fit bushings (9) and (10) to

idler (4).
a Press fitting force: 26 53 kN {2.6 5.4 tons}
5. Remove 4 travel motor hoses (4).
6. Remove 14 final drive assembly mounting bolts

(5). [*1]
7. Lift off the final drive assembly.

2. Fit the O-ring and install support (7) to shaft (5)
hoses and nipples.
with dowel pin (8).
3. Using tool L2, install floating seal (6) to idler (4)

INSTALLATION and assembly of shaft (5) and support (7).
a Apply oil to the sliding surface of the floating
Carry out installation in the reverse order to seal and take care that dirt will not stick to
removal. that surface.
[*1]
2 Final drive assembly mounting bolt:
Liquid adhesive (LT-2)
a Bleed air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding
air from each part.
Add oil through the oil filler to the specified level.
system. Then, check the oil level again.
30-58 PC78MR-6
DISASSEMBLY AND ASSEMBLY IDLER
a When installing the floating seal, thoroughly 4. Install the assembly of shaft (5) and support (7)
clean, degrease, and dry the parts marked to idler (4).
with the thick lines (the load ring and faces in
contact with the load ring).
5. Supply oil between shaft (5) and idler (4).
6 Quantity of oil: 60 cc (EO-30CD)

a When inserting the floating seal assembly in
the housing, use the push jig. This push jig
must push the load ring.
[1]: Cylindrical push jig
a The metallic faces of the floating seal which

are in contact with each other must be free
from dirt.
a After the floating seal is inserted, check that
it does not slant more than 1 mm and its pro-
jection is as follows.
PC78MR-6 30-59
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
6. Using tool L2, install floating seal (3) to idler (4) RECOIL SPRING ASSEMBLY
and support (2).
a Apply oil to the sliding surfaces of the floating
DISASSEMBLY
seal and take care that dirt will not stick to
the floating seal.
1. Remove lubricator (1).
a Degrease the contact faces of the floating
seal and O-ring.
2. Remove yoke piston assembly (3) from recoil
spring assembly (2).
3. Disassembly of recoil spring assembly

1) Remove set bolt (4).
2) Set recoil spring assembly (2) to tool M.
k Since the installing load of the spring is

heavy and dangerous, set the spring
securely.
a Installing load of spring:
69.2 kN {7,061 kg} (Rubber shoe)
47.4 kN {4,837 kg} (Steel shoe)
7. Fit the O-ring and install support (2) with dowel

pin (1).
30-60 PC78MR-6
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
3) Apply hydraulic pressure slowly. After the 3) Set recoil spring (2) to tool M.
spring is compressed, remove nut (5).
a Compress the spring until the nut is loos-
ened.
a Release the hydraulic pressure slowly to
eliminate the spring force.
4) Remove pilot (7) and cylinder (8) from spring
(6).
a Remove O-ring (13) from the cylinder.
4. Disassembly of yoke piston assembly

1) Remove wear ring (10) from yoke piston (9).
2) Remove snap ring (11) and U-packing (12).
4) Apply hydraulic pressure slowly to compress

the spring. Tighten nut (5) so that the install-
ing length of the spring will be a.
a Installing length a of spring:
283 mm (Rubber shoe)
323 (Steel shoe)
2 Nut:
Lubricant containing molybde-
num disulphide (LM-P)
ASSEMBLY
1. Assembly of yoke piston assembly

1) Fit U-packing (12) to yoke piston (9) and
secure it with snap ring (11).
2) Install wear ring (10).
2. Assembly of recoil spring assembly

1) Fit O-ring (13) to cylinder (8).
2) Install cylinder (8) and pilot (7) to spring (6).
PC78MR-6 30-61
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
5) Remove recoil spring assembly (2) from tool TRACK ROLLER ASSEMBLY
M.
6) Install set bolt (4).
DISASSEMBLY
3 : 58.8 73.5 Nm {6 7.5 kgm}
1. Remove pin (2) from track roller assembly (1),
7) Fill cylinder (8) with grease (G2-LI).
then remove collar (3).
a Quantity of grease (G2-LI):
Approx. 232 cc (Rubber shoe)
Approx. 96 cc (Steel shoe)
8) Loosen lubricator (1) and insert yoke piston
assembly (3) in recoil spring assembly (4)
until grease comes out through part B.
3 Sliding parts of yoke piston and wear
ring: Grease (G2-LI)
9) Tighten lubricator (1).
3: 58.8 88.2 Nm {6.0 9.0 kgm}
a Install the valve so that the fitting will be
on the outside.
2. Remove floating seal (4a) from collar (3).
3. Remove floating seal (4b) from roller (5).
4. Remove shaft and collar assembly (6) from roller

(5).
30-62 PC78MR-6
5. Remove floating seal (7a) from roller (5), then ASSEMBLY

remove floating seal (7b) from shaft and collar
assembly (6). a When installing the floating seal, thoroughly
clean, degrease, and dry the parts marked with
the thick lines (the load ring and faces in contact
with the load ring).
Check that the contact surfaces of the floating
seal are free from dirt.
6. Pull out pin (8) and remove collar (10) from shaft
(9).
7. Remove the O-ring from shaft (9).

a When inserting the floating seal assembly in the
8. Remove bushings (11) and (12) from roller (5). housing, use the push jig. This push jig must
push the load ring.
[1]: Cylindrical push jig
a After the floating seal is inserted, check that it

does not slant more than 1 mm and its projection
is as follows.
PC78MR-6 30-63
a The metallic faces of the floating seal which are 3. Using tool L4, press fit floating seal (7b) to shaft
in contact with each other must be free from dirt. (9).
a Supply GO140 oil.
Quantity of oil: 210 230 cc 4. Using tool L4, press fit floating seal (7a) to roller
a Thoroughly clean the parts to be in contact with (5).
the supplied oil. After cleaning them, the dirt a Press fit floating seal (4b) similarly.
remaining on these parts of 1 roller assembly
must be below 25 mg and the size of the dirt
must be below 0.3.
a Set plug (2) on the outside of the machine body.
5. Install shaft and collar assembly (6) to roller (5).
6. Turn over the assembly of roller (5) and shaft (6).
1. Using tool L3, press fit bushing (12) to roller (5).

a Press fit bushing (11) similarly.
2. Fit the O-ring to shaft (9), then install collar (10)

and pin (8) to shaft (9).
7. Using tool L4, install floating seal (4a) to collar

(3).
30-64 PC78MR-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
8. Install collar (3) to shaft (9), then install pin (2). HYDRAULIC CYLINDER
9. Fill the roller with oil and tighten plug (13). ASSEMBLY
5 Track roller: 210 230 cc (GO-140) DISASSEMBLY
1. Cylinder assembly
1) Set cylinder assembly (1) to tool U1.
2) Using a hydraulic pump or a power wrench
and tool U2, loosen head assembly (2).
3) Pull out piston rod assembly (3).

a Place an oil pan, etc. under the cylinder
to receive the oil.
PC78MR-6 30-65
2. Piston rod assembly

1) Set piston rod assembly (3) to tool U1.
and tool U3, remove nylon nut (4).
a Width across flats of nut:
Cylinder Boom Arm Bucket Swing Blade
Width
across 80 75 60 70 75
flats
3. Disassembly of piston assembly

1) Remove wear ring (9).
2) Remove piston ring (10).
a Apply a screwdriver, etc. to the piston
ring and hit it with a hammer to break off
the piston ring.
3) Remove piston assembly (6) from piston rod

(5).
4) Remove head assembly (2).
4. Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (11).
2) Remove O-ring (12).
3) Remove snap ring (13) and dust seal (14).
5) Remove cap (6) and take out 9 balls (7), then 4) Remove rod packing (15).
remove plunger (8). 5) Remove bushing (16).
Perform this work for only arm cylinder.
30-66 PC78MR-6
ASSEMBLY 2. Assembly of piston assembly

1) Using tool U4, expand piston ring (10).
a Apply engine oil to the sliding surfaces of each a Set the piston ring to tool U4 and revolve
part and take care not to damage the packing, the handle by 8 - 10 turns to expand the
dust seals, O-rings, etc. piston ring.
a Do not insert the backup ring forcibly. Heat it in 2) Using tool U5, contract piston ring (10).
water at 50 - 60C, then insert it carefully.
1. Assembly of cylinder head assembly

1) Using tool U6, press fit bushing (16).
2) Install rod packing (15).
3) Using tool U7, install dust seal (14) and
secure it with snap ring (13).
4) Fit O-ring (12).
5) Fit the backup ring and O-ring (11).
3) Install wear ring (9).

a Take care not to open the closed gap of
the ring too much.
PC78MR-6 30-67
5. Piston rod assembly

1) Set plunger (8) to the piston rod and install 9
balls (7) and secure them with cap (6).
a Check that there is some play at the
plunger tip.
Perform this work for only arm cylinder.
6. Cylinder assembly
1) Set the cylinder to tool U1.
2) Install piston rod assembly (3).
a Push in the piston rod to the end.
2) Install head assembly (2) to piston rod (5).
3) Install piston assembly (6) to piston rod (5).

and tool U2, tighten head assembly (2).
3 Head addembly:
4) Set piston rod assembly (3) to tool U1.
5) Using tool U3, tighten nylon nut (4).
2 Nylon nut: Liquid adhesive (Equiva-
Cylinder Tightening torque
name
lent to LOCTITE 262) Boom 980 98 Nm{100 10 kgm}
3 Nylon nut: Arm 1,107 110 Nm {113 42.0 kgm}
1st time: Tighten to 1,176 1,372 Nm
Cylinder Tightening torque {120 140 kgm}.
name 2nd time: Loosen to 0 Nm {0 kgm}.
Boom 3.97 0.4 kNm {405 40.5 kgm} Bucket 3rd time: Tighten to 392 Nm {40 kgm}
4th time: Apply angle tightening
Arm 4.12 0.41 kNm {420 42.0 kgm} (Tighten periphery of cylinder
Bucket 2.16 0.22 kNm {220 22 kgm} head by 3.5 4.5 mm).
Blade 3.14 0.31 kNm {320 32.0 kgm} Blade 1.03 0.10 Nm {105 10.5 kgm}
Swing 2.6 0.26 kNm {265 26.5kgm} Swing 981 98.1 Nm {100 10 kgm}
a After assembling, clean each part and mask the

piping ports and pin hole
30-68 PC78MR-6
90 OTHERS
Hydraulic circuit diagram (For STD spec.) ............... 90- 3

Hydraulic circuit diagram (For EU spec.) .................. 90- 5
Electrical circuit diagram (For STD spec.) (1/2) ........ 90- 7
Electrical circuit diagram (For STD spec.) (2/2) ........ 90- 9
Electrical circuit diagram (For EU spec.) (1/2)........... 90-11
Electrical circuit diagram (For EU spec.) (2/2)........... 90-13
PC78MR-6 90-1
(1)
HYDRAULIC CIRCUIT DIAGRAM (FOR STD SPEC.)
PC78MR-6 90-3
(1)
HYDRAULIC CIRCUIT DIAGRAM (FOR EU SPEC.)
PC78MR-6 90-5
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC.) (1/2)
PC78MR-6 90-7
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC.) (2/2)
PC78MR-6 90-9
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC.) (1/2)
PC78MR-6 90-11
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC.) (2/2)
PC78MR-6 90-13
(1)

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SEBM030601

MACHINE MODEL SERIAL NUMBER

PC78MR-6 1001 and up

10 STRUCTURE AND FUNCTION,

20 TESTING AND ADJUSTING .......................................................................20-1

30 DISASSEMBLY AND ASSEMBLY ..........................................................30-1

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

Used to prevent rubber gaskets,

Used in places requiring an imme-

Features: Resistance to heat and

Adhesive: Used as adhesive or sealant for

Polyethylene Used as sealant for machined

Holtz Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Loctite Polyethylene Resistance to heat, chemicals

Used as adhesive or sealant for

Used as sealant for various

Features: Silicon based, resist-

Ftures: Silicon based, quick hard-

Three bond Used as heat-resisting sealant for

Used as lubricant for sliding por-

SYG2-400LI General purpose type

SYG2-400CA Used for normal temperature,

Molybdenum 400 g Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.