Documente Academic
Documente Profesional
Documente Cultură
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)
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CONTENTS
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01
GENERAL ................................................................................................................01-1
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OTHERS ....................................................................................................................90-1
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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.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
00-3
SAFETY
00-4
SAFETY NOTICE
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 judgements. 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 further divided into the each main group of components.
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
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
(
....) is recorded on the bottom of the pages.
REVISIONS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
123
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol
Item
Remarks
Safety
Caution
Weight
Tightening
torque
Coat
Oil, water
Drain
4
3
2
5
6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
100%
88%
79%
71%
41%
SAD00479
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
00-7
FOREWORD
Disconnection
1) Release the residual pressure from the hydraulic 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
Type 1
FOREWORD
Type 3
Disassembly
Type 2
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
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of
adhesive and
hardening
agent)
Adhesive:
1 kg
Hardenin
g
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Adhesives
Molybdenum
disulphide
lubricant
LM-P
09940-00040
200 g
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
Various
Molybdenum
disulphide
lubricant
SYG2-400M
400 g
(10 per
case)
Belows type
Grease
Various
Various
00-11
FOREWORD
Width across
flats
mm
mm
6
8
10
12
14
10
13
17
19
22
16
18
20
22
24
24
27
30
32
36
27
30
33
36
39
41
46
50
55
60
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
6
8
10
12
10
13
14
27
7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85
Nm
kgm
0 0.15
0 0.3
0 0.7
01
02
28.5 0 3
39 0 4
56 0 6
76 0 8.5
94.5 0 10.5
135 0 15
175 0 20
225 0 25
280 0 30
335 0 35
0 1.4
03
07
0 10
0 19
279 0 30
382 0 39
549 0 59
745 0 83
927 0 103
1320 0 140
1720 0 190
2210 0 240
2750 0 290
3290 0 340
1.35
3.2
6.7
11.5
18
13.2
31
66
113
177
kgm
0
0
0
0
0.8
1.9
4.1
8.4
0 0.2
0 0.5
0 0.6
0 0.8
Sealing surface
SAD00483
Thread diameter
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
5 2
8 2
14 3
18 3
20 5
25 5
30 5
00-12
Tightening torque
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FOREWORD
Thread diameter
Tightening torque
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7 6.8
112 9.8
279 29
0
0
0
6.7 0.7
11.5 1
28.5 3
0
0
Thread diameter
Tightening torque
mm
mm
Nm
14
20
24
33
42
Varies depending
on type of
connector.
34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3
Norminal No.
02
03, 04
05, 06
10, 12
14
kgm
0
0
0
0
0
0 0.5
01
02
06
0 13.5
3.5
9.5
14.5
43
89.5
Thread diameter
Tightening torque
mm
mm
Nm
kgm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
n
36
n
n
7.35 1.47
11.27 1.47
17.64 1.96
22.54 1.96
29.4 4.9
39.2 4.9
49 4.9
68.6 9.8
107.8 14.7
127.4 19.6
151.9 24.5
210.7 29.4
323.4 44.1
0
0
0
0
0
0
0
0
0
0
0
0
0
0.75 0.15
1.15 0.15
1.8 0.2
2.3 0.2
3 0.5
4 0.5
5 0.5
7 1
11 1.5
13 2
15.5 2.5
21.5 3
33 4.5
Norminal No.
08
10
12
14
16
18
20
24
30
33
36
42
52
0
0
0
0
0
0
0
0
0
0
0
0
0
00-13
FOREWORD
Tightening torque
mm
Nm
6
8
10
12
10 2
24 4
43 6
77 12
kgm
0
0
0
0
1.02
2.45
4.38
7.85
0 0.20
0 0.41
0 0.61
0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6
8
10
12
14
8 2
10 2
12 2
24 4
36 5
kgm
0
0
0
0
0
0.81
1.02
1.22
2.45
3.67
0 0.20
0 0.20
0 0.20
0 0.41
0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter
Tightening torque
inch
Nm
1 / 16
1/8
1/4
3/8
1/2
3/4
1
3 1
8 2
12 2
15 2
24 4
36 5
60 9
kgm
0
0
0
0
0
0
0
0.31
0.81
1.22
1.53
2.45
3.67
6.12
0 0.10
0 0.20
0 0.20
0 0.41
0 0.41
0 0.51
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.
Tightening torque (Nm {kgm})
Nominal size Width across
of hose
flats
Taper seal
type
Nominal thread
Thread size size - Threads per
Root diameter
(mm)
(mm) (Reference)
inch, Thread series
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
14
9
- 18UNF
16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
11
- 16UN
16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
04
27
103 {10.5}
22
13
- 16UN
16
20.7
05
32
157 {16.0}
24
1 - 14UNS
25.4
06
36
216 {22.0}
30
3
1 - 12UNF
16
30.3
(10)
41
216 {22.0}
33
(12)
46
245 {25.0}
36
(14)
55
294 {30.0}
42
02
03
00-14
FOREWORD
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
0.32
2.09
3.1
20
65
0.32
5.23
4.6
37
15
84
0.45
13.36
7.0
59
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
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm 2)
0.85
11
0.32
26
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2
Color White & Red
Code
WB
3
Color White & Black
Code
4
Auxiliary
WL
WG
5
Color White & Green
Code
6
Color
n
n
n
n
n
n
n
n
n
n
n
n
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
RY
n
n
n
n
RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
n
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.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters 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.
A
B
B
Millimeters to inches
1 mm = 0.03937 in
00-16
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
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
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
FOREWORD
CONVERSION TABLE
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
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
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
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
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
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
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column 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
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
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
Item
Unit
PC78MR-6
Steel shoe spec.
8,270
8,300
kg
Bucket capacity
0.28
Engine model
kW {HP}/rpm
40.5 {54.0}/1,850
Overall length
mm
6,200
6,230
Overall height
mm
2,730
2,750
Overall width
mm
2,330
Shoe width
mm
450
mm
1,310
mm
mm
01-2
2,840
2,900
2,235
mm
km/h
360
2.8/4.2
400
rpm
10.0
PC78MR-6
GENERAL
6,960
4,160
6,570
2,900
4,515
2,775
2,125
6,750
380
245
PC78MR-6
01-3
GENERAL
SPECIFICATIONS
Dimension
Machine model
PC78MR-6
Serial Number
1001 and up
Bucket capacity
m3
0.28
Machine weight
kg
8,270 (8,300)
mm
4,160
mm
2,900
mm
6,960
mm
6,750
mm
6,570
mm
4,515
mm
580/930
mm
380
mm
245
kN {kg}
61.3 {6,250}
rpm
10.0
deg.
16.0
km/h
2.8/4.2
Gradeability
deg.
35
Ground pressure
{kg/cm2}
Working range
Performance
SPECIFICATIONS
kPa
37.3 {0.38}
mm
6,200
Overall width
mm
2,330
mm
2,730 (2,750)
mm
2,710 (2,750)
mm
735 (780)
mm
360 (400)
mm
1,310
mm
2,125
mm
5,210 (5,230)
mm
2,320
mm
2,840 (2,900)
mm
2,235
Track gauge
mm
1,870
mm
1,745 (1,795)
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
GENERAL
SPECIFICATIONS
Machine model
PC78MR-6
Serial Number
1001 and up
Model
S4D95LE-3-A
Type
mm
4-95 115
l {cc}
3.26 {3,260}
kW/rpm
{HP/rpm}
Nm/rpm
{kgm/rpm}
40.5/1,850
{54.0/1,850}
337/1,500
{24.2/1,500}
rpm
2,020
rpm
1,130
g/kWh
{g/HPh}
227 {169}
Total displacement
Performance
Engine
Rated output
Max. torque
Starting motor
24 V, 3.0 kw
Alternator
24 V, 25 A
Battery
12 V, 48 Ah 2 (55D26R)
1 on each side
Track roller
5 on each side
Track shoe
Control
valve
Hydraulic
motor
Hydraulic system
CF29-3
Carrier roller
Hydraulic pump
Undercarriage
(Steel shoe)
(Road liner)
(Rubber shoe)
Type No.
Discharge
Set pressures
(Work equipment, travel)
(Swing, blade)
(Control)
Type No.
Control method
Travel motor
Swing motor
Hydraulic tank
Hydraulic oil filter
Oil cooler
PC78MR-6
l {cc}
802+60+12.7
MPa
{kg/cm2}
26.5 {270}
21.1 {215}
3.1 {32}
9-spool type 1
Hydraulically assisted
Variable-capacity piston motor
(with brake valve, parking brake) 2
Fixed-capacity piston motor
(with safety valve, pivot shaft brake) 1
Box-shaped, open
Tank return side
Air-cooled
01-5
GENERAL
SPECIFICATIONS
Machine model
PC78MR-6
Serial Number
1001 and up
Bucket cylinder
Blade cylinder
Hydraulic system
Arm cylinder
Boom cylinder
Type
01-6
Reciprocating piston
mm
115
mm
65
Stroke
mm
988
mm
2,393
mm
1,405
Type
mm
Reciprocating piston
mm
100
mm
60
Stroke
mm
865
mm
2,193
mm
1,328
Type
mm
Reciprocating piston
mm
90
mm
55
Stroke
mm
710
mm
1,765
mm
1,055
Type
mm
Reciprocating piston
mm
120
mm
60
Stroke
mm
658
mm
1,687
mm
1,029
Type
mm
Reciprocating piston
mm
mm
65
Stroke
mm
130
mm
679
mm
549
130
PC78MR-6
GENERAL
WEIGHT TABLE
WEIGHT TABLE
PC78MR-6
Serial Number
1001 and up
403
300
Engine mount
30
PTO
Hydraulic pump
66
29
6.3
5.2
Revolving frame
1,220
Operator's cab
260
Operator's seat
18
8.3
70
Control valve
62
Counterweight
950
Additional counterweight
220
22
Swing circle
104
Swing machinery
47
16
1,067 [1,048]
704
Idler assembly
54 x 2
40 x 2
Carrier roller
3.4 x 2
Track roller
13 x 10
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
Machine model
PC78MR-6
Serial Number
1001 and up
410 X 2
450 X 2
385 X 2
495 X 2
Boom assembly
365
Swing bracket
234
Arm assembly
147
56
210
Blade assembly
374
95
72
51
65
46
01-8
PC78MR-6
GENERAL
RESERVOIR
KIND OF
FLUID
AMBIENT TEMPERATURE
22
30
4
20
14
10
32
0
50
10
68
20
86
30
104
40
122F
50C
SAE 30
SAE 10W
SAE 10W-30
SAE 15W-40
Swing machinery case
Final drive case
PTO gear case
Engine oil
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
Cooling system
Water
NLGI No. 2
Add antifreeze
Unit: l
PC78MR-6
Specified capacity
Refill capacity
7.5
7.0
0.4
0.4
2.0
2.0
1.3
1.3
Hydraulic system
120
64
Fuel tank
125
Cooling system
10.5
PC78MR-6
01-9
PC78MR-6
10-1
(1)
PTO
PTO
1.
2.
3.
4.
5.
6.
7.
Drain plug
Coupling
Flywheel
Pump case
Cage
Level plug
Breather/Oil filler plug
10-2
PC78MR-6
COOLING SYSTEM
COOLING SYSTEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Fan guard
Radiator inlet hose
Drain valve
Radiator outlet hose
Radiator cap
Oil cooler
Radiator
Shroud
Oil cooler inlet
Reservoir tank
Oil cooler outlet
PC78MR-6
SPECIFICATIONS
Radiator
Oil cooler
Type of core
CF29-3
CF40-1
4.0/2
4.5/2
16.53
6.15
88.314.7
(0.90.15)
4.9
(0.05)
10-3
1.
2.
3.
4.
5.
6.
7.
8.
Idler
Control valve
Center swivel joint
Swing motor
Travel motor
Control pump (for pilot control)
Hydraulic pump (for swing and blade)
Hydraulic pump
(For travel and work equipment)
9. Engine
10-4
10.
11.
12.
13.
14.
15.
16.
17.
PC78MR-6
SWING CIRCLE
SWING CIRCLE
Unit: mm
2.
3.
4.
5.
6.
7.
No.
Item
PC78MR-6
Criteria
Remedy
Standard clearance
Allowable clearance
0.20 0.80
2.0
Replace
80/10=8.0
Grease
G2-LI
Quantity of grease ( )
5.5
10-5
SWING MACHINERY
SWING MACHINERY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
10-6
Specification
Reduction ratio
(14+58)/14X(14+58)/14 =
26.45
26.45X8.0 = 211.59
10
PC78MR-6
SWING MACHINERY
Unit: mm
No.
Item
Backlash between
swing motor shaft and
No. 1 sun gear
Criteria
Remedy
Standard clearance
Allowable clearance
0.03 0.11
0.10 0.27
0.6
0.12 0.38
0.6
0.10 0.26
0.10 0.27
0.6
0.12 0.38
0.6
0.07 0.21
Backlash between
swing pinion and swing
circle
0.27 0.83
2.0
PC78MR-6
Replace
Basic dimension
75
Allowance
0
- 0.074
Allowable Limit
74.8
10-7
10-8
PC78MR-6
Unit: mm
No.
Item
Criteria
Basic dimension
Allowable limit
74
78
73
69
Track frame
Lateral width of
idler guide
Idler support
158
162
Overlay
152
Overlay or
replace
156
Basic dimension
Remedy
Recoil spring
Overlay
Overlay or
replace
Allowable limit
Free length
Installed
length
Installed
load
Free length
Installed
load
Road liner,
steel shoe
412
323
47.4 kN
{4,835 kg}
402
42.2 kN
{4,305 kg}
Rubber shoe
412
283
69.2 kN
{7,061 kg}
402
61.6 kN
{6,284 kg}
Replace
4.
5.
6.
7.
8.
9.
10.
11.
Idler
Track frame
Carrier roller
Travel motor
Sprocket
Track roller
Track shoe
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 transportation (for USA spec. only)
Specification
Grease
G2-LI
PC78MR-6
10-9
IDLER
IDLER
Unit: mm
No.
1
Item
Outside diameter of
projected part
Depth of tread
5
6
Criteria
Basic dimension
Remedy
Allowable limit
460
415
407
22.5
26.5
43
37
Overall width
100
92
Width of tread
28.5
32
10
Quantity of oil
10-10
Basic
dimension
44
Basic
dimension
50
Allowance
Shaft
Hole
-0.250
-0.290
+ 0.062
0
Allowance
Shaft
Hole
+0.117
+0.087
+0.025
0
Standard clearance
Overlay or replace
Standard
clearance
Allowable
clearance
0.250 0.352
1.5
Standard
interference
Allowable
interference
0.062 0.117
Replace
Allowable clearance
0.190 0.395
1.5
Basic dimension
Allowable limit
13.8
9.8
60 cc (Engine oil: SAE30CD)
Overlay or replace
PC78MR-6
TRACK ROLLER
TRACK ROLLER
Unit: mm
No.
Item
Criteria
Basic dimension
Remedy
Allowable limit
Outside diameter of
projected part
149
120
113
Width of flange
43
Overall width
129
Width of tread
43
47.3
Overlay or replace
Quantity of oil
PC78MR-6
38
Shaft
Hole
-0.250
-0.270
+ 0.075
- 0.025
Allowance
Basic
dimension
48
36.6
Allowance
Basic
dimension
Overlay or replace
Shaft
Hole
+0.117
+0.087
+0.030
0
Standard clearance
Standard
clearance
Allowable
clearance
0.225 0.345
1.5
Standard
interference
Allowable
interference
0.057 0.117
Replace
Allowable clearance
0.38 0.73
1.5
Basic dimension
Allowable limit
36
32.5
210 230 cc (Gear oil: G0140)
Overlay or replace
10-11
CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No.
Item
Outside diameter of
tread
Width of tread
Thickness of tread
Quantity of oil
10-12
Criteria
Basic dimension
Remedy
Allowable limit
82
100
Allowance
Basic
dimension
Overlay or replace
72
Shaft
Hole
Standard
interference
Allowable
interference
30
+0.009
-0.004
0
- 0.010
-0.004
0.019
62
0
- 0.013
+ 0.018
- 0.012
-0.031
0.012
Basic dimension
Allowable limit
10
Replace
Overlay or replace
PC78MR-6
SPROCKET
SPROCKET
Unit: mm
No.
Item
Criteria
Basic dimension
Allowance
433.004
+1.0
-2.0
2.0
Remedy
Allowable limit
421
483.7
28
23
38
+0.5
-2.5
33
Thickness of root
84.002
+0.475
-1.150
78
PC78MR-6
472
Overlay or
replace
10-13
TRACK SHOE
TRACK SHOE
CITY PAD SHOE, ROAD LINER, AND TRIPLE SHOE
10-14
PC78MR-6
TRACK SHOE
Unit: mm
No.
Item
Criteria
Basic dimension
Allowable limit
154.25
157.25
41.2
37.2
Height of link
74
70
20
16
Link pitch
3
4
5
6
Repair or replace
73
Replace
57
8
Link
10
Inside
width
45
Overall
width
30
Width of
tread
26.3
11
Projection of pin
12
3.15
13
131
14
74.6
15
Thickness of bushing
16
Thickness of spacer
17
18
Reverse or replace
89
Remedy
Press fitting
pressure
*19
Repair or replace
Basic dimension
Adjust or replace
Allowable limit
8.4
4.4
Bushing
Regular
pin
Master pin
PC78MR-6
10-15
TRACK SHOE
Unit: mm
No.
Item
Criteria
Tightening torque
(Nm {kgm})
a. Regular
link
Shoe bolt
20
b. Master link
City pad
Triple
117.7 19.6
{12 2}
90 10
Road liner
117.7 19.6
{12 2}
60 10
(Torque after retightening)
Min. 343 Nm {35 kgm}
Tightening
torque
Retightening
angle (deg.)
Number of shoes
(Each side)
21
22
23
*24
*25
26
39
Hole
41
+0.214
+0.174
+0.062
0
0.112 0.214
24
+0.150
0
-0.198
-0.250
0.198 0.400
Allowance
24
Shaft
Hole
+0.150
0
+0.830
+0.330
Standard
clearance
0.180 0.830 Adjust or replace
Allowance
Basic dimension
24
Shaft
Hole
+0.020
-0.020
-0.198
-0.250
Standard
interference
0.178 0.270
Allowance
Basic dimension
Road liner
Standard
interference
Shaft
Basic dimension
24
Retighten
Allowance
Basic dimension
Number of shoes
(Each side)
Height of grouser
Remedy
Shaft
Hole
-0.150
-0.250
+0.630
+0.230
Standard
clearance
0.380 0.880
Basic dimension
Allowable limit
42
19
Replace
10-16
PC78MR-6
TRACK SHOE
Unit: mm
No.
Item
Height of grouser
Thickness of plate
4
5
6
7
Criteria
Remedy
Basic dimension
Allowable limit
20
12
26
18
6
20
Overlay or replace
16
14
PC78MR-6
10
12
10-17
TRACK SHOE
Unit: mm
No.
Item
10-18
Criteria
Remedy
Basic dimension
Allowable limit
30
42
58
Replace
Basic dimension
Allowance
Allowable limit
22.5
0.5
27
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Bucket cylinder
Arm cylinder
Boom cylinder
Boom swing cylinder
Hydraulic tank
Control valve
Swing motor
Hydraulic pump
Oil cooler
Travel motor
Left work equipment PPC valve
PC78MR-6
12.
13.
14.
15.
16.
17.
18.
19.
20.
10-19
(1)
1.
2.
3.
4.
5.
6.
7.
Hydraulic tank
Sight gauge
Strainer
Drain plug
Filter
Bypass valve
Oil filler cap
10-20
Specification
Tank capacity ( )
80
64
0.15 0.03
{1.53 0.3}
38 15
{0.39 0.15}
05
{0 0.05}
PC78MR-6
DR1: To tank
1. Cover
2. Rotor
3. Slipper seal
4. Shaft
Unit: mm
No.
5
Item
Clearance
between rotor
and shaft
PC78MR-6
Criteria
Basic dimension
70
Remedy
Standard clearance
Allowable clearance
0.056 0.105
0.111
Replace
10-21
TRAVEL MOTOR
TRAVEL MOTOR
A.
B.
D.
P.
10-22
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Check valve
Counterbalance valve
Valve plate
Cylinder
Brake piston
Plate
Disc
Piston
Swash plate
Regulator piston
RV gear
RV gear
Case
PC78MR-6
TRAVEL MOTOR
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Shaft
Drive gear
Cover
Crankshaft
Drain plug
Driven gear
Pivot
Spindle
Floating seal
End cover
Regulator valve
Check valve
10-23
TRAVEL MOTOR
Specification
Model
Theoretical
displacement (cm/rev)
Rated speed
GM09VN-E
Hi
24.1
Lo
36.3
Hi
3,211
Lo
2,154
0.47
{4.8}
2.94
{30}
Reduction ratio
66.5
Outline
1. Reduction gears
The reduction gears consists of spur gear unit
(1a) and differential gear unit (1b) which uses
pericycloid gears and converts the high speed
revolution of the hydraulic motor into low-speed
and high-torque revolution.
2. Hydraulic motor
The hydraulic motor is a swash plate-type axial
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
TRAVEL MOTOR
OPERATION
Operation of motor
At low speed (With swash plate angle at maximum)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
PC78MR-6
10-25
TRAVEL MOTOR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
10-26
PC78MR-6
TRAVEL MOTOR
Function
PC78MR-6
10-27
TRAVEL MOTOR
10-28
If the machine starts running away while traveling downhill, the motor revolves idle and the
pressure on the motor inlets side lowers, then
the pressure in chamber D also lowers through
orifice (c).
If the pressure in chamber D lowers below the
pressure of spring (3), spool (2) is pushed back
to the right.
At this time, the oil in chamber G flows through
orifice (f) into port PB. The throttle effect of orifice (f) generates back pressure, and spool (2)
returns to the right to control the returning speed
of spool (2). Port MB on the outlet side is narrowed.
As a result, the pressure on the outlet side rises
and revolving resistance is generated in the
motor to prevent the machine from running away.
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.
PC78MR-6
TRAVEL MOTOR
PC78MR-6
10-29
Arm cylinder
Bucket cylinder
10-30
PC78MR-6
Blade cylinder
PC78MR-6
10-31
Unit: mm
No.
Item
Criteria
Cylinder
name
Clearance between
piston rod and bushing
Clearance between
piston rod support
shaft and bushing
Clearance between
cylinder bottom support
shaft and bushing
Tightening torque of
cylinder piston
10-32
Shaft
Hole
Standard
clearance
Allowable
clearance
+0.250
+0.055
0.085
0.354
0.654
Boom
65
Arm
60
-0.030
-0.104
+0.163
+0.006
0.036
0.267
0.567
Bucket
55
-0.030
-0.104
+0.163
+0.006
0.036
0.267
0.567
Boom
swing
60
-0.030
-0.104
+0.163
+0.006
0.036
0.267
0.567
Blade
65
-0.030
-0.104
+0.250
+0.055
0.085
0.354
0.654
Boom
60
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Arm
60
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Bucket
60
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Boom
swing
65
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Blade
70
-0.030
-0.104
+0.174
+0.100
0.130
0.278
1.0
Boom
65
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Arm
55
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Bucket
50
-0.030
-0.100
+0.142
+0.080
0.110
0.242
1.0
Boom
swing
65
-0.030
-0.076
+0.174
+0.100
0.130
0.250
1.0
Blade
70
-0.030
-0.104
+0.174
+0.100
0.130
0.278
1.0
Arm
Tightening torque
of cylinder head
Allowance
-0.030
-0.104
Boom
Basic
dimension
Remedy
Bucket
Replace
bushing
Replace pin
and
bushing
Boom
swing
Blade
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)
Bucket
2.16 0.22 kNm {220 22.0 kgm} (2 Width across flats: 60 mm)
Boom
swing
2.6 0.26 kNm {265 26.0 kgm} (2 Width across flats: 70 mm)
Blade
3.14 0.31 kNm {320 32.0 kgm} (2 Width across flats: 75 mm)
Retighten
PC78MR-6
SOLENOID VALVE
SOLENOID VALVE
Serial No.: 1001 1094
10-34
(1)
PC78MR-6
A:
A4:
A5:
A6:
B1:
B2:
B3:
B4:
B5:
B6:
T:
1.
2.
3.
4.
5.
6.
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
SOLENOID VALVE
10-35-1
(1)
PC78MR-6
A:
A5:
A6:
B1:
B2:
B3:
B4:
B5:
B6:
T:
1.
2.
3.
4.
5.
SOLENOID VALVE
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
Control relief valve
19. Adjustment screw
20. Locknut
21. Guide
22. Return spring
23. Valve spool
PC78MR-6
10-35-2
(1)
SOLENOID VALVE
10-36
PC78MR-6
SOLENOID VALVE
PC78MR-6
10-37
SOLENOID VALVE
When signal current is 0 (When coil is de-energized 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.
10-38
PC78MR-6
SOLENOID VALVE
If the pressure of the hydraulic oil from the control 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
MULTI-CONTROL VALVE
MULTI-CONTROL VALVE
(OPTIONAL)
10-40
PC78MR-6
1.
2.
3.
4.
5.
6.
Cap
Core
Guard rubber
Lid
Plug
Shell
PC78MR-6
Specification
Type of gas
Nitrogen Gas
Gas volume ( )
0.48
(MPa {kg/cm})
(MPa {kg/cm})
6.86 {70}
10-41
(1)
HYDRAULIC PUMP
HYDRAULIC PUMP
Model: LPD45 + 45
P1
P2
P4
PD
PM
P1T
P2T
: Pump discharge
: Pump discharge
: Pilot pump discharge
: Drain
: PC mode changeover pressure pickup port
: Travel deviation adjustment orifice
: Travel deviation adjustment orifice
10-42
PC78MR-6
T
P1
P2
P3
P5
PD
PH
:
:
:
:
:
:
:
Drain
Pump discharge
Pump discharge
Gear pump pressure input
Gear pump pressure pickup port
Drain
Pump shuttle
PC78MR-6
HYDRAULIC PUMP
PAV
PD2
PDE
PEN
PPT
PS1
PEPC
:
:
:
:
:
:
:
10-43
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
HYDRAULIC PUMP
Shaft
Flange
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
Servo piston
Oil seal
10-44
PC78MR-6
HYDRAULIC PUMP
With blade
Model: LPD45 + 45
P1
P2
P3
P4
P5
PD
PM
P1T
P2T
: Pump discharge
: Pump discharge
: Gear pump discharge
: Pilot pump discharge
: Gear pump pressure pickup port
: Drain
: PC mode changeover pressure pickup port
: Travel deviation adjustment orifice
: Travel deviation adjustment orifice
PC78MR-6
10-45
T
P1
P2
PD
PH
PAV
PD2
: Drain
:Pump discharge
: Pump discharge
:Drain
:Pump shuttle
:Pump average pressure
:Drain (Plug)
10-46
HYDRAULIC PUMP
PD3 :Drain
PDE :EPC drain
PEN :Control pressure input
PPT :PTO oil filler
PS1 :Pump suction
PEPC :EPC main pressure pickup port
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
HYDRAULIC PUMP
Shaft
Flange
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
Servo piston
Oil seal
PC78MR-6
10-47
HYDRAULIC PUMP
10-48
4. Retainer
5. Seat
6. Spool
7. Sleeve
8. Piston
9. Seal
10. Piston
11. Plug
LS valve
PE: Control piston pressure
PH: Pump shuttle pressure
PLS: LS pressure input
PPL: PC valve output pressure
PPLS: LS pump pressure input
12. Spool
13. Plug
14. Seat
15. Spring
16. Seat
17. O-ring
18. Backup ring
19. Nut
20. Plug
PC78MR-6
Function
This pump converts the revolution and torque of
the engine transmitted to its shaft into hydraulic
energy and discharges hydraulic oil according to
the load.
The discharge can be changed by changing the
swash plate angle.
HYDRAULIC PUMP
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-pressure 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
HYDRAULIC PUMP
Operation
1. Operation of pump
If center line X of rocker cam (4) is in the direction of the axis of cylinder block (7) (Swash plate
angle = 0), the difference between volumes E
and F in cylinder block (7) is 0 and oil is not
sucked or discharged (The swash plate angle is
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.
10-50
PC78MR-6
HYDRAULIC PUMP
2. Control of discharge
LS valve
Function
The LS valve controls the discharge of the pump
according to the stroke of the control lever, or the
demand flow for the actuator.
The LS valve calculates the demand flow for the
actuator from differential pressure EPLS
between inlet pressure PPLS and outlet pressure PLS of the control valve, and controls discharge Q of the main pump.
(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 constant.
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 discharge Q changes as shown below.
If swash plate angle ( ) is increased, the difference between volumes E and F, or discharge Q,
is increased. Swash plate angle ( ) is changed
with servo piston (11).
Servo piston (11) is reciprocated linearly by the
signal pressure of PC and LS valves. This linear
motion is transmitted to rocker cam (4) supported on flange (2) through ball (12). Then,
rocker cam (4) slides in the revolutionary direction.
PC78MR-6
10-51
PC valve
Function
The PC valve limits the oil flow to a certain level
(according to the discharge pressure) even if the
stroke of the control valve is increased so that
the horsepower absorbed by the pump will not
exceed the engine horsepower, as long as pump
discharge pressure PP is high. That is, the PC
valve performs constant-horsepower control.
In other words, the PC valve decreases the
pump discharge when the load is increased and
the pump discharge pressure rises and
increases it when the pump discharge pressure
lowers.
This pump has 2 discharge openings and the
average of discharge pressures P1 and P2 at
those openings is sensed.
The average of P1 and P2 is called the PAVE.
The relationship between this average and pump
discharge (discharge from the 2 discharge openings) is shown below.
Operation
1. With blade
(1) Function of spring
The spring load of spring (2) at the PC valve is
decided by the position of the swash plate.
If servo piston (6) moves to the right, spring (2) is
compressed through lever (1) and its spring load
changes. The spring constant of this spring
changes to 2 levels.
(2) When pump pressure PAVE is low
The pressure of spool (4) is decreased and spool
(3) is a little to the right (Fig. 1 and Fig. 4). At this
time, ports C and D are connected to each other
and the pressure in the LS valve is drain pressure PT.
10-52
HYDRAULIC PUMP
PC78MR-6
HYDRAULIC PUMP
PC78MR-6
10-53
HYDRAULIC PUMP
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
HYDRAULIC PUMP
When balanced
PC78MR-6
10-55
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
CONTROL VALVE
10-57
CONTROL VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
10-58
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31
32.
33.
34.
PC78MR-6
CONTROL VALVE
Unit: mm
No.
Item
Criteria
Basic dimensions
35
Remedy
Allowable limit
Free length x
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
34.5 X 17.7
25
73.5 N
{7.5 kg}
58.8 N
{6.0 kg}
36
41.1 X 19.3
40.5
34.3 N
{3.5 kg}
27.4 N
{2.8 kg}
37
42.3 X 19.2
38.9
103.9 N
{10.6 kg}
83.2 N
{8.48 kg}
38
29.0 X 17.5
25.0
180.5 N
{18.02 kg}
14.5 N
{14.74 kg}
39
40.9 X 15.1
33.5
129 N
{13.2 kg}
103 N
{10.6 kg}
40
42.4 X 19.0
13
287.3 N
{29.3 kg}
230 N
{23.44 kg}
41
29.01 X 18.3
27.5
89.5 N
{9.1 kg}
71.6 N
{7.28 kg}
42
41.13 X 19.3
38.5
136.4 N
{13.91 kg}
109 N
{11.13 kg}
43
41.47 X 19.3
38.5
135.53 N
{13.82 kg}
108 N
{11.06 kg}
44
29.20 X 17.5
25.0
162.54 N
{16.57 kg}
130 N
{13.26 kg}
45
29.03 X 18.4
26.0
173.2 N
{17.66 kg}
139 N
{14.13 kg}
PC78MR-6
If damaged or
deformed,
replace spring.
10-59
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
10-60
CONTROL VALVE
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
PC78MR-6
CONTROL VALVE
Unit: mm
No.
Item
Criteria
Basic dimensions
29
Free length x
Pressure compensation Outside diamvalve spring
eter
Remedy
Allowable limit
Installed
length
Installed
load
Free length
Installed
load
28.0 X 14.4
14.5
13.7 N
{1.4 kg}
11.0 N
{1.12 kg}
30
Pressure compensation
valve spring
33.4 X 14.4
21.5
55.9 N
{5.7 kg}
44.7 N
{4.56 kg}
31
Pressure compensation
valve spring
30.9 X 5.2
27
9.8 N
{1.0 kg}
7.85 N
{0.8 kg}
32
Pressure compensation
valve spring
20.0 X 8.4
12
6.86 N
{0.7 kg}
5.49 N
{0.56 kg}
33
Pump merge-divider
valve spool
return spring
33.2 X 14.2
22.5
49.0 N
{5.0 kg}
39.2 N
{4.0 kg}
34
27.2 X 6.9
22
3.92 N
{0.4 kg}
3.14 N
{0.32 kg}
35
12.3 X 11.4
10.5
3.92 N
{0.4 kg}
3.14 N
{0.32 kg}
36
21.9 X 5.0
15.8
1.96 N
{0.2 kg}
1.57 N
{0.16 kg}
37
13.0 X 6.5
9.5
1.96 N
{0.2 kg}
1.57 N
{0.16 kg}
38
Pressure compensation
valve spring
28.0 X 14.4
14.5
13.72 N
{1.4 kg}
11.0 N
{1.12 kg}
PC78MR-6
If damaged or
deformed,
replace spring.
10-61
10-62
CONTROL VALVE
PC78MR-6
CONTROL VALVE
Unit: mm
No.
Item
Criteria
Basic dimensions
PC78MR-6
Remedy
Allowable limit
Free length x
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
21.9 X 5.0
15.8
1.96 N
{0.2 kg}
1.57 N
{0.16 kg}
19.3 X 7.5
14
15.7 N
{1.6 kg}
12.6 N
{1.28 kg}
If damaged or
deformed,
replace spring.
10-63
10-64
CONTROL VALVE
PC78MR-6
1.
2.
3.
4.
CONTROL VALVE
Unit: mm
No.
Item
Criteria
Basic dimensions
Remedy
Allowable limit
Free length x
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
13.0 X 6.5
9.5
1.96 N
{0.2 kg}
1.57 N
{0.16 kg}
16.6 X 13.0
13
11.2 N
{1.14 kg}
8.96 N
{0.91 kg}
13.0 X 8.8
7.5
10.8 N
{1.1 kg}
8.64 N
{0.88 kg}
PC78MR-6
If damaged or
deformed,
replace spring.
10-65
10-66
CONTROL VALVE
PC78MR-6
CONTROL VALVE
Item
Criteria
Basic dimensions
PC78MR-6
Remedy
Allowable limit
Free length x
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
11.0 X 6.2
9.5
5.5 N
{0.56 kg}
4.4 N
{0.45 kg}
If damaged or
deformed,
replace spring.
10-67
CLSS
CLSS
OUTLINE OF CLSS
Features
CLSS stands for Closed center Load Sensing System, and has the following featues.
Fine control not influenced by load
Control enabling digging even with fine control
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
Structure
The CLSS consists of a variable capacity single
piston pump, control valve, and actuators.
The pump body consists of the main pump, PC
valve and LS valve.
PC78MR-6
CLSS
BASIC PRINCIPLE
1. Control of pump swash plate angle
The pump swash plate angle (pump discharge
amount) is controlled so that LS differential pressure EPLS (the difference between pump (discharge) 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)
PC78MR-6
10-69
10-70
CLSS
PC78MR-6
CLSS
10-72
PC78MR-6
CLSS
PC78MR-6
10-73
CLSS
Unload valve
1. When control valve is at HOLD
Function
When the control valve is at HOLD, pump discharge amount Q discharged by the minimum
swash plate angle is released to the tank circuit.
At this time, pump discharge pressure PP1/PP2
is set at 2.45 MPa {25.0 kg/cm2} by spring (2) in
the valve. (LS pressure PLS1/PLS2: 0 MPa {0
kg/cm2})
Since the pump merge-divider valve is at the
merge position, pump discharge pressures PP1
and PP2 are merged. LS pressures PLS1,
PLS2, and PLS3 are also merged.
When the control valve is at HOLD, LS pressures PLS1 and PLS2 are not generated, so only
pump discharge pressures PP1 and PP2 act,
and PP1 and PP2 are set by only the load of
spring (2).
As pump discharge pressure PP1/PP2 rises and
reaches the load of spring (2) (2.45 MPa {25.0
kg/cm2}), spool (1) is moved to the right. Pump
discharge pressures PP1 and PP2 are connected to tank circuit T through the cut of spool
(1)
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
CLSS
Function
During fine control of the work equipment valve,
when the demand flow for the actuator is within
the amount discharged by the minimum swash
plate angle of the pump, pump discharge pressure PP1/PP2 is set to LS pressure PLS1/PLS2
+ 2.45 MPa {25.0 kg/cm2}. When the difference
between pump discharge pressure PP1/PP2 and
LS pressure PLS1/PLS2 reaches the load of
spring (2) (2.45 MPa {25.0 kg/cm 2 }), unload
spool (1) opens, so LS differential pressure
EPLS becomes 2.45 MPa {25 kg/cm2}.
Since the pump merge-divider valve is at the
merge position, pump discharge pressures PP1
and PP2 are merged. LS pressures PLS1, PLS2,
and PLS3 are also merged.
PC78MR-6
Operation
When fine control is carried out on the work
equipment valve, LS pressures PLS1 and PLS2
are generated and act on the right end of spool
(1) (PP1 = PP2, PLS1 = PLS2). When this happens, the area of the opening of the work equipment valve spool is small, so LS pressures PLS1
and PLS2 are very different from pump discharge pressures PP1 and PP2.
When the difference between pump discharge
pressure PP1/PP2 and LS pressure PLS1/PLS2
reaches the load of spring (2) (2.45 MPa {25.0
kg/cm2}), spool (1) moves to the right, and pump
discharge pressures PP1 and PP2 are connected to tank circuit T.
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 differential pressure DPLS becomes 2.45 MPa
{25.0 kg/cm2}.
10-75
CLSS
Function
When any work equipment valve is operated if
the demand flow for the actuator becomes
greater than the pump discharge from the minimum swash plate angle, the oil flow to tank circuit T is cut off, and all pump discharge amount
Q flows to the actuator circuit.
Since the pump merge-divider valve is at the
merge position, pump discharge pressures PP1
and PP2 are merged. LS pressures PLS1,
PLS2, and PLS3 are also merged.
Operation
When any work equipment valve is operated for
a long stroke, LS pressures PLS1 and PLS2 are
generated and act on the right end of unload
spool (1) (PP1 = PP2, PLS1 = PLS2). When this
happens, the area of the opening of the work
equipment valve spool is large, so LS pressures
PLS1 and PLS2 are not so different from pump
discharge pressures PP1 and PP2.
10-76
PC78MR-6
CLSS
Function
During fine control of both travel valves, when
the demand flow is below the maximum pump
discharge amount, pump discharge pressure
PP1/PP2 is set to LS pressure PLS1/PLS2 +
2.45 MPa {25.0 kg/cm2}.
When the difference between pump discharge
pressure PP1/PP2 and LS pressure PLS1/PLS2
reaches the load of spring (2) (2.45 MPa {25.0
kg/cm2}), unload spool (1) opens, so excessive
oil (maximum pump discharge mount - demand
flow) flows into the tank circuit.
Since the pump merge-divider valve is at the
separate position, pump discharge pressures
PP1 and PP2 are separated. LS pressures PLS1
and PLS2 are also separated.
The swash plate angle of the pump becomes
maximum, so the pump discharge amount
becomes maximum. (For details, see the sections on the pump merge-divider valve and logic
valve.)
PC78MR-6
Operation
When fine control is carried out on both travel
valves, LS pressures PLS1 and PLS2 are generated and act on the right end of spool (1) (PP1,
PP2, PLS1, and PLS2 are separated).
When this happens, the area of the opening of
both travel valve spools is small, so LS pressures PLS1 and PLS2 are very different from
pump discharge pressures PP1 and PP2.
When the difference between pump discharge
pressure PP1/PP2 and LS pressure PLS1/PLS2
reaches the load of spring (2) (2.45 MPa {25.0
kg/cm2}), spool (1) moves to the right, and pump
discharge pressures PP1 and PP2 are connected to tank circuit T and the excessive oil
(maximum pump discharge mount demand
flow) flows.
In other words, the excessive oil (maximum
pump discharge mount demand flow) above
the strokes of both travel valves flows into tank
circuit T.
10-77
CLSS
Function
During operation of both travel valves, when the
demand flow becomes maximum, the oil flow to
tank circuit T is cut off, and all pump discharge
amount Q flows to both travel circuits.
Since the pump merge-divider valve is at the
separate position, pump discharge pressures
PP1 and PP2 are separated. LS pressures PLS1
and PLS2 are also separated.
The swash plate angle of the pump becomes
maximum, so the pump discharge amount
becomes maximum. (For details, see the sections on the pump merge-divider valve and logic
valve.)
10-78
Operation
When both travel valves are operated to the
stroke ends, LS pressures PLS1 and PLS2 are
generated and act on the right end of unload
spool (1) (PP1, PP2, PLS1, and PLS2 are separated).
When this happens, the area of the openings of
both travel valve spools is large, so LS pressures
PLS1 and PLS2 are not so different from pump
discharge pressures PP1 and PP2.
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.
PC78MR-6
CLSS
Function
The demand flow decided by the valve stroke is
sent to the travel circuit on the operated travel
valve side and the all pump discharge amount is
sent to the tank circuit on the non-operated travel
valve side.
Since the pump merge-divider valve is at the
separate position, pump discharge pressures
PP1 and PP2 are separated. LS pressures
PLS1 and PLS2 are also separated.
The swash plate angle of the pump becomes
maximum, so the pump discharge amount
becomes maximum. (For details, see the sections on the pump merge-divider valve and logic
valve.)
Operation
When left travel valve is operated to stroke end and
right one is at HOLD.
When the left travel valve is operated to the
stroke end, LS pressure PLS1 is generated and
acts on the right end of unload spool (1).
PC78MR-6
10-79
CLSS
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 mergedivider 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
CLSS
Function
Pump merge-divider valve spool (3) merges
pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 respectively.
As the LS pressure, PLS1, PLS2, and PLS3 are
output.
Operation
When any work equipment valve is operated, the
work equipment PPC pressure or the swing holding 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 connected to tank circuit T and changeover pressure
for spool (3) is not generated.
PC78MR-6
10-81
CLSS
Function
Pump merge-divider valve spool (3) separates
pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 respectively.
As the LS pressure, higher pressure of PP1 and
PP2 is output.
Operation
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 pressure 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.
As a result, pump discharge pressures PP1 and
PP2 and LS pressures PLS1 and PLS2 are separated respectively.
10-82
PC78MR-6
CLSS
Introduction of LS pressure
1. Work equipment valve: Boom, arm, bucket,
boom swing, or attachment
Function
The LS pressure is the actuator load pressure at
the outlet port end of the control valve.
Actually, pump discharge pressure PP is
reduced by reducing valve (3) of the pressure
compensation valve to the same pressure as
actuator circuit pressure A and sent to LS circuit
PLS.
In the travel valve, actuator circuit pressure A is
directly introduced to LS circuit PLS.
Operation
When spool (1) is operated, pump discharge
pressure PP flows from flow control valve (2)
through notch (a) in the spool and bridge passage (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 chamber PLSS.
PC78MR-6
10-83
CLSS
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 passage (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 equipment circuit: actuator circuit pressure PA is
directly introduced into LS circuit PLS.
10-84
PC78MR-6
CLSS
LS bypass plug
When work equipment valve is operated
Function
The LS bypass plug releases the residual pressure of LS pressure PLS.
This lowers the rising speed of LS pressure PLS.
In addition, the discarded throttled flow causes a
pressure loss in the throttled flow in the reducing
valve, and that lowers the effective LS differential
pressure to improve the stability.
Operation
1. When work equipment valve is operated (including compound operation of work equipment +
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
CLSS
Function
When the machine swings and the boom is
raised simultaneously, this valve merges discharge amount of the gear pump into that of
main pump to heighten the boom raising speed.
Operation
1. During normal operation
When the boom is not raised, the pilot pressure is not applied to pilot port BP.
Under this condition, gear pump circuit P3
and main pump circuit PP are shut off by
spool (1), so oil in gear circuit P3 is not
merged into that of main pump circuit PP.
10-86
PC78MR-6
CLSS
Function
The pressure compensation valve determines
the compensation characteristics by carrying out
fine adjustment of the area r atio ( S2/S1)
between (left) area S1 of flow control valve (2)
and (right) area S2 of reducing valve (1) to match
the characteristics of each actuator.
S1: Area of flow control valve (2) area of piston (3)
S2: Area of reducing valve (1) area of piston (3)
PC78MR-6
10-87
CLSS
Function
During compound operations, if the load pressure on either actuator becomes lower than the
other actuator and the oil flow is about to
increase, compensation is made. [When this
happens, the other actuator being used for compound operation (right side) is at a high load than
the actuator on this side (left side).]
Operation
When the load pressure on the other actuator
(right side) becomes higher during compound
operations, the oil flow in actuator circuit A on
this side (left side) starts increasing.
When this happens, the LS pressure PLS on the
other actuator acts on spring chamber PLSS,
and reducing valve (1) and flow control valve (2)
are pushed to the left.
10-88
Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream
PPA to cause a pressure loss between PP and
PPA.
Flow control valve (2) and reducing valve (1) are
balanced in a position where the difference
between PLS and PA acting on both ends of
reducing valve (1) and the pressure loss made
between PP and PPA on the sides of flow control
valve (2) will be the same.
In this way, the pressure difference between
upstream pressure PPA and downstream pressure PA of both spools used during compound
operations is the same, so the pump flow is
divided in proportion to the area of opening of
notch (a) of each spool.
PC78MR-6
CLSS
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
CLSS
10-90
PC78MR-6
CLSS
PC78MR-6
10-91
CLSS
Function
While the boom is being lowered by its weight, if
bottom pressure A of cylinder (1) is higher than
head pressure B, this circuit sends the return oil
on the bottom side to the head side to increase
the cylinder speed by that amount.
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
CLSS
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
CLSS
10-94
PC78MR-6
CLSS
PC78MR-6
10-95
CLSS
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 operated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are separated 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 discharge circuits PP1 and PP2 through actuator 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 operated 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 compensated to reduce travel deviation.
2. When steered during travel
Since only both travel valves are operated
and any work equipment valve is not operated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are separated 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
CLSS
PC78MR-6
10-97
CLSS
10-98
PC78MR-6
Function
When the travel actuator and another actuator
are operated at the same time, the amount of oil
discarded through the throttle in LS circuit PLS
increases and the pressure compensation precision 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 easily.
CLSS
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 singly, 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 circuit 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
SWING MOTOR
SWING MOTOR
Model: LMF30AEL
Specifications
Model: LMF30AEL
Capacity: 31 cm3/rev
Set pressure of safety valve: 21 MPa {210 kg/cm2}
Cracking pressure of check valve: Max. 0.03 MPa
{0.30 kg/cm2}
10-100
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
SWING MOTOR
9.
10.
11.
12.
13.
14.
15.
Output shaft
Housing
Shoe
Piston
Cylinder block
Valve plate
Center spring
Swash plate
Safety valve
Check valve
Check valve spring
Brake spring
Brake piston
Disc
Plate
Unit: mm
No.
Item
Criteria
Basic dimension
Free length
Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
15.5 9.0
11.5
0.9 N
{0.09 kg}
0.69 N
{0.07 kg}
33 13.8
19.5
1.8 N
{0.18 kg}
1.41 N
{0.14 kg}
PC78MR-6
Remedy
Allowable limit
If damaged
or deformed,
replace spring.
10-101
SWING MOTOR
BRAKE VALVE
Outline
The brake valve consists of a check valve and a
safety valve.
Function
When the machine stops swinging, control valve
(1) closes the outlet circuit of the motor. Since
the motor continues revolving because of the
inertia, the motor output pressure rises abnormally to break the motor. Accordingly, the abnormally high pressure is released through the
outlet (high pressure side) of the motor to protect
the motor.
Operation
1. When machine starts swinging
When the swing control lever is operated to
swing to the left, the hydraulic oil from the
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
SWING MOTOR
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 difference between D1 and D3 (D1 > D3) and
pushes spring (4) to open valve (3).
At this time, pressure acts on the area difference between D1 and D2 (D2 > D1), so seat
(1) follows valve (3).
As seat (1) moves, the passage for the pressurized 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 MOTOR
SWING BRAKE
1. When solenoid valve is de-energized
Operation
When the solenoid valve of the swing brake is
de-energized, the hydraulic oil from the selfpressure reducing valve is shut off and port B is
connected to the tank circuit.
As a result, brake piston (13) is pushed up by
brake spring (12) to press disc (14) and disc (15)
to apply the brake.
Operation
When the solenoid valve of the swing brake is
energized, the valve is changed and hydraulic oil
from the self-pressure reducing valve flows
through port B into brake chamber A.
The hydraulic oil in chamber A pushes brake
spring (12) and brake piston (13) moves down.
As a result, disc (14) and plate (15) are separated and the brake is released.
10-104
PC78MR-6
SWING MOTOR
MA :
MB :
T1 :
T2 :
Port
Port
Port
Port
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
Valve Body
Spool (MA end)
Spring (MA end)
Plug (MA end)
Spool (MB end)
Spring (MB end)
Plug (MB end)
10-105
SWING MOTOR
10-106
PC78MR-6
SWING MOTOR
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 system, 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 possible to move swiftly to the next job).
PC78MR-6
10-107
P
T
P1
P2
P3
P4
:
:
:
:
:
:
10-108
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Spool
Metering spring
Centering spring
Piston
Disc
Nut (For connection of lever)
Joint
Plate
Retainer
Body
Filter
10-110
PC78MR-6
Unit: mm
No.
Item
Criteria
Basic dimension
12
13
14
Centering spring
(For ports P3 and P4)
Centering spring
(For ports P1 and P2)
Metering spring
PC78MR-6
Remedy
Allowable limit
Free length
Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
42.48 15.5
34.0
17.65 N
{1.80 kg}
14.1 N
{1.44 kg}
44.45 15.5
34.0
29.42 N
{3.0 kg}
23.5 N
{2.40 kg}
26.47 8.20
24.9
16.66 N
{1.70 kg}
13.3 N
{1.36 kg}
If damaged
or deformed,
replace spring.
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)
10-112
PC78MR-6
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
P
T
P1
P2
P3
P4
:
:
:
:
:
.
10-114
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
Plate
Body
Piston
Collar
Metering spring
Centering spring
Valve
Bolt
Unit: mm
No.
Item
Criteria
Basic dimension
10
Metering spring
Centering spring
PC78MR-6
Remedy
Allowable limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
26.53 8.15
24.9
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
52.06 15.5
31.9
135.2 N
{13.8 kg}
108 N
{11.04 kg}
If damaged
or deformed,
replace spring.
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)
10-116
PC78MR-6
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
T
P
P1
P2
:
:
:
:
To tank
From main pump
To right boom swing/blade raise valve
To left boom swing/blade lower valve
1.
2.
3.
4.
5.
Spool
Metering spring
Centering spring
Piston
Lever
10-118
6.
7.
8.
9.
Plate
Retainer
Body
Filter
PC78MR-6
Item
Criteria
Basic dimension
10
11
Centering spring
Metering spring
Remedy
Allowable limit
Free length
Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
33.88 15.3
28.4
124.5 N
{12.7 kg}
100 N
{10.2 kg}
22.73 8.1
22.0
16.67 N
{1.70 kg}
13.3 N
{1.36 kg}
If damaged
or deformed,
replace spring.
For Blade
Unit: mm
No.
Item
Criteria
Basic dimension
10
11
Centering spring
Metering spring
PC78MR-6
Remedy
Allowable limit
Free length
Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
42.36 15.5
32.5
14.7 N
{15 kg}
118 N
{12 kg}
22.73 8.1
22.0
16.67 N
{1.7 kg}
13.3 N
{1.36 kg}
If damaged
or deformed,
replace spring.
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).
10-120
PC78MR-6
PC78MR-6
10-121
10-121-1
(1)
PC78MR-6
1.
2.
3.
4.
5.
6.
Pilot spool
Spring (1st stage of spool)
Spring (2nd stage of spool)
Safety valve
Check valve
Spring
Unit: mm
No.
Item
Criteria
Basic dimension
Remedy
Allowable limit
Free length x
Outside diameter
Installed
length
Installed
load
Free
length
Installed
load
16.4 x 8.9
11
14.7 1.5 N
{1.5 0.15 kg}
10.8 N
{1.1 kg}
19.1 8
13.5
24.7 1.5 N
{2.52 0.15 kg}
18.6 N
{1.9 kg}
24.8 16.8
22.5
55.4 3.0 N
{5.65 0.3 kg}
42.2 N
{4.3 kg}
PC78MR-6
If damaged or
deformed,
replace spring
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 equipment 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 cylinder 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
(1)
PC78MR-6
PC78MR-6
10-121-4
(1)
10-121-5
(1)
PC78MR-6
WORK EQUIPMENT
WORK EQUIPMENT
Unit : mm
Item
No.
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
-0.036
-0.090
+0.204
+0.125
0.161
0.294
1.0
65
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
60
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
50
-0.225
-0.285
-0.062
-0.120
0.105
0.223
1.0
50
-0.225
-0.285
-0.062
-0.120
0.105
0.223
1.0
60
-0.030
-0.100
+0.173
+0.100
0.130
0.273
1.0
50
-0.225
-0.285
-0.040
-0.094
0.131
0.245
1.0
50
-0.025
-0.087
+0.142
+0.080
0.105
0.229
1.0
10-122
Replace pin
and bushing
PC78MR-6
PC78MR-6
WORK EQUIPMENT
10-123
10-124
PC78MR-6
PC78MR-6
No.
Measuring point
Arm side
Cylinder head side
Basic dimension
60
Allowance
Shaft
Hole
-0.030
-0.100
+0.100
0
71.5
+1.0
0
70
1.2
-0.030
-0.100
+0.100
0
60
Boom side
220
+0.5
0
Arm side
220
-0.5
-1.0
142.4
2.0
218.8
1.0
458.6
1.0
1,650
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
17
50
-0.225
-0.285
Link side
200
-1.0
-2.0
Bucket side
200
+2.0
0
50
18
19
PC78MR-6
-0.225
-0.285
0
-0.150
Arm side
188
-0.50
-1.0
Bucket side
211
+3.0
0
Min.
1,055
1.5
Max.
1,765
20
21
0
-0.150
10-125
2. BUCKET PORTION
10-126
PC78MR-6
No.
PC78MR-6
Measuring point
Basic dimension
Allowance
309.8
0.5
38.6
0.5
97.1
312.2
1,057.2
143.7
5.2
50
0
-0.15
10
60
11
70
+0.2
0
12
200
+2.0
0
13
40
14
71
15
296
+1.0
0
16
18
17
100
18
115
19
95
20
211
+3.0
0
21
40
22
24
23
89.3
24
87.9
25
60
26
66
PC78MR-6
10-127
10-128
1.
2.
3.
4.
5.
6.
7.
8.
PC78MR-6
PC78MR-6
10-129
(1)
10-130
(1)
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Emergency pump drive switch
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)
23. PPC lock solenoid valve
24. 2-stage travel speed selector solenoid valve
25. Swing holding brake solenoid valve
26. Left boom swing stop EPC valve
27. Right boom swing stop EPC valve
28. TVC-EPC valve
29. Right work equipment PPC valve
30. Travel PPC valve
31. Left work equipment 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
10-131-1
(1)
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Emergency pump drive switch
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)
23. PPC lock solenoid valve
24. 2-stage travel speed selector solenoid valve
25. Swing holding brake solenoid valve
26. Left boom swing stop EPC valve
27. Right boom swing stop EPC valve
28. TVC-EPC valve
29. Right work equipment PPC valve
30. Travel PPC valve
31. Left work equipment 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
49. Overload alarm actuation switch
50. Overload alarm pressure switch
PC78MR-6
10-131-2
(1)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Safety lock lever
PPC lock switch
Starting motor cut relay
Safety relay
Fuel control dial
Fuel control motor
Fuel control motor relay (For accelerator)
Fuel control motor relay (For deceleration)
One-touch deceleration switch
Monitor panel
Engine stop solenoid
Engine stop solenoid relay
Starting motor
10-132
PC78MR-6
Starting engine
If starting switch (4) is turned to the ON position,
engine stop solenoid (17) moves governor stop
lever to the "RUN" side.
Accordingly, if the electric system has any trouble, the engine stops, that is, a fail-safe mechanism is formed.
If starting switch (4) is turned to the START position while safety lock lever (7) is at the "LOCK"
position, the start signal flows to starting motor
(19) and the engine starts. If safety lock lever (7)
is at the "FREE" position, the start signal to starting motor (19) is cut out by starting motor cut
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
the cable to control the engine speed according
to the drive signal.
PC78MR-6
A:
B:
C:
t:
10-133
Stopping engine
If starting switch (4) is turned to the OFF position, engine stop solenoid (17) moves the governor 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 deceleration 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 onetouch 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 onetouch deceleration switch is pressed
A:
B:
C:
D:
E:
10-134
PC78MR-6
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency pump drive switch
8. Resistor (For emergency pump drive)
9. Monitor panel
10. TVC-EPC valve
11. Engine speed sensor
12. Coolant temperature sensor
13. Control valve
13a. Pump merge-divider valve
14. Hydraulic pump
14a. Servo piston
14b. LS valve
14c. TVC valve
PC78MR-6
Input/Output signals
a. Controller power source
b. Solenoid power source
c. Monitor panel power source
d. S-NET signal
e. Coolant temperature signal
f. Engine speed signal
g. EPC valve drive signal
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 absorption torque is reduced to prevent the engine from
stopping.
10-136
PC78MR-6
PC78MR-6
10-137
E mode
Matching point of E mode: 85% partial output
point
E mode
10-138
PC78MR-6
a The emergency pump drive switch (S) is of alternative type. If it is set to the "CANCEL (2)" position 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".
Operation
Operating condition
Coolant temperature
is above 99C
PC78MR-6
Resetting condition
Coolant temperature is
below 95C
10-139
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Swing holding brake release switch
8. Swing holding brake solenoid valve
9. Swing motor
10. Left work equipment PPC valve
11. Arm IN PPC oil pressure switch
12. Swing PPC oil pressure switch
13. Engine
14. Hydraulic pump
15. Control valve
15a. Pump merge-divider valve
16. Boom swing potentiometer
10-140
Input/Output signals
a. Controller power source
b. Solenoid power source
c. Solenoid valve drive signal
d. Swing PPC oil pressure switch signal
e. Arm IN PPC oil pressure switch signal
f. Boom swing potentiometer signal
PC78MR-6
Function
Relationship between swing holding brake cancel switch and swing holding brake
Swing holding
brake cancel
switch
PC78MR-6
Operation
Cancel
(Abnormal
state)
10-141
10-142
Released
Input/Output signals
a. Controller power source
b. Solenoid power source
c. Monitor panel power source
d. S-NET drive signal
e. Solenoid valve drive signal
f. Travel PPC oil pressure switch signal
g. Travel alarm drive signal
h. 2nd travel speed selection signal
Function
Changing travel speed
If the travel speed boost selector switch is operated or the travel speed boost pedal is pressed,
the motor capacity changes to change the travel
speed.
Pressed
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
2-stage travel speed selector solenoid valve
Left travel motor
Right travel motor
Travel PPC valve
Travel PPC oil pressure switch
Travel alarm (If equipped)
Engine
Hydraulic pump
Control valve
Pump merge-divider valve
Travel speed boost pedal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
16a.
17.
Lo lamp
Hi lamp
lights up
lights up
(Low speed) (High speed)
Motor capacity
(cc/rev)
36.3
24.1
Travel speed
(km/h)
3.0
4.5
Swash plate
angle of travel
motor
Max.
Min.
Motor capacity
(cc/rev)
24.1
24.1
Travel speed
(km/h)
4.5
4.5
Swash plate
angle of travel
motor
Min.
Min.
PC78MR-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Safety lock lever
PPC lock switch
PPC lock solenoid valve
Left work equipment PPC valve
Right work equipment PPC valve
Travel PPC valve
Blade PPC valve
Engine
Hydraulic pump
Boom swing PPC valve
PC78MR-6
Input/Output signals
a. Controller power source
b. Solenoid power source
c. Solenoid valve drive signal
Function
The PPC lock switch is linked with the safety
lock lever. If the safety lock lever is set to the
LOCK position, the PPC lock switch is turned
OFF.
If the PPC lock switch is turned OFF, the current
to the PPC lock solenoid valve is cut out and the
work equipment does not move any more even
if the work equipment control lever is operated.
10-143
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
Overload alarm actuation switch
Overload alarm pressure switch
Input/Output signals
a. Power supply of controller
b. Power supply of solenoids
c. Power supply of monitor panel
d. S-NET signal
e. Overload alarm actuation signal
f. Overload alarm pressure signal
Function
If the pressure in the boom cylinder bottom circuit 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
(1)
PC78MR-6
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
A. Ordinary area
B. Deceleration area
10-144
PC78MR-6
SELF-DIAGNOSTIC FUNCTION
1. Error code display and alarm function
The system of this function consists of the
controller and the electronic components
such as the potentiometers that output input
signals and the solenoid valves and EPC
valves that receive output signals. The controller is constantly checking that those electronic component and itself are functioning
normally.
If a problem occurs in any of these components, the controller carries out troubleshooting 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
SYSTEM COMPONENTS
SYSTEM COMPONENTS
Fuel control dial
10-146
PC78MR-6
SYSTEM COMPONENTS
1. Motor assembly
2. Cable
3. Connector
PC78MR-6
Signal name
Input/Output
signal
Power source
Input
Acceleration signal
Output
Deceleration signal
Output
Output
Input
10-147
SYSTEM COMPONENTS
CONTROLLER
Input/output signals
DEUTSCH-24P [CN-M95]
Pin
No.
1
2
3
4
5
6
7
8
9
10
11
12
Signal name
NC
(*1) NC
(*2) Boom cylinder bottom presser sensor
NC
GND (Signal)
2-stage travel speed selection switch
Arm IN PPC oil pressure switch
NC
Boom swing angle
NC
GND signal
NC
Boom RAISE PPC oil pressure switch
I/O signal
Pin
No.
Input
Input
Input
Input
Input
13
14
15
16
17
18
19
20
21
22
23
24
Signal name
NC
NC
NC
NC
Attachment 1
Travel PPC oil pressure switch
NC
NC
GND (Analog)
Sensor power source (+5 V)
NC
Swing PPC oil pressure switch
I/O signal
Input
Input
Output
Input
10-148
(1)
PC78MR-6
SYSTEM COMPONENTS
Signal name
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
NC
NC
NC
NC
NC
NC
UU/US selection signal
NC
NC
NC
NC
NC
NC
NC
Back-up light signal
Main monitor selection signal
Attachment 3
NC
NC
NC
I/O signal
Pin
No.
Input
Input
Input
Input
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
I/O signal
Pin
No.
Signal name
I/O signal
Input
Input
Output
Output
Output
Input
Input
Input
Input
Input
Output
Output
Output
Input
Input
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
GND (Controller)
Solenoid power source
GND (Solenoid)
Key signal
Governor motor relay (For acceleration)
NC
2-stage travel speed selector solenoid valve
NC
Deceleration signal
NC
GND (Controller)
GND (Controller)
GND (Controller)
NC
Governor motor relay (For deceleration)
NC
NC
NC
Auto-deceleration signal
NC
Input
Input
Output
Output
Input
Output
Input
Signal name
S-NET
NC
NC
NC
Signal for selecting Tire 2
NC
Mode selection 2
GND (Pulse)
MR selection signal
GND (S-NET)
NC
NC
GND (232C)
NC
NC
Model selection 1
NC
GND (Pulse)
Engine speed sensor (+)
I/O signal
Input/Output
Input
Input
Input
Input
Input
Signal name
Controller power
Solenoid power
GND (Solenoid)
Engine stop solenoid relay
Left boom swing stop EPC valve
NC
Swing holding brake solenoid valve
NC
One-touch deceleration switch
Air conditioner compressor signal
Controller power
Solenoid power
GND (Solenoid)
Key signal
Right boom swing stop EPC valve
TVC-EPC vlave
Swing and travel alarm
NC
Acceleration signal
(*1) NC
(*2) Alarm actuation switch
PC78MR-6
10-149
(1)
SYSTEM COMPONENTS
Potentiometer
1. Shaft
2. Housing
3. Bearing
4. Brush
5. Resistor
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 equipment.
Using the resistance value of the variable resistor, potentiometers send angle data to the controller by converting the supply voltage (5V) into
signal voltage according to the angle of the work
equipment.
10-150
PC78MR-6
SYSTEM COMPONENTS
Register
1. Register
2. Connector
Specifications
Model
PC78MR-6
System
Resistance ( )
30
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 condition.
PC78MR-6
10-151
SYSTEM COMPONENTS
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 condition of each actuator from the PPC pressure
and send it to the controller.
10-152
PC78MR-6
SYSTEM COMPONENTS
1. Plug
2. Sensor
3. Connector
Function
One pressure switch is installed to the boom cylinder bottom circuit to sense the hydraulic pressure on the boom cylinder bottom side.
PC78MR-6
10-152-1
(1)
SYSTEM COMPONENTS
TVC-EPC valve
a See HYDRAULIC PUMP.
Monitor panel
a See MONITOR SYSTEM
PC78MR-6
10-153
MONITOR SYSTEM
MONITOR SYSTEM
1.
2.
3.
4.
5.
Monitor panel
Battery
Controller
Sensors and switches
Wiper motor, windshield washer motor
Outline
The monitor system monitors the machine condition by the sensors installed to various parts of
the machine and processes and displays it on
the panel immediately to notify the operator of
the condition of the machine.
10-154
PC78MR-6
MONITOR SYSTEM
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 displayed 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
Pin
No.
1
2
3
4
5
6
7
8
9
10
11
12
Signal name
Starting switch (Battery)
Starting switch (Battery)
Windshield washer motor output
Starting switch (Terminal C)
Wiper W contact
GND
GND
VB+ (24 V)
Wiper motor (+)
Wiper motor (-)
Alarm buzzer ON signal
Wiper P contact
PC78MR-6
Input/
Output
signal
Input
Input
Output
Input
Input
Input
Output
Output
Input
Input
No.
1
2
3
4
5
6
7
8
S-NET signal
10
S-NET signal
11
12
13
14
15
16
17
18
19
20
Charge level
NC
GND (Analog signal)
NC
Pull-up window limit switch
Alarm buzzer cancel
Swing lock
Preheating
Lamp switch
GND (S-NET)
signal
Input
Input
Input
Input
Input
Input
Input
Input
Input/
Output
Input/
Output
Input
Input
Input
Input
Input
Input
10-155
MONITOR SYSTEM
Display range
Display method
Service meter
0-99999.9 h
Display
3 alphanumerics
0 99.9 V
[*1]
2
3a
Display item
Gauge
3b
Monitor
4a
Gauge
Coolant
temperature
Fuel level
4b
Monitor
See above
drawing.
Above set
temperature
(99C)
See above
drawing.
Below set level
(30 liters)
Preheating
During preheating
One-touch
deceleration
When one-touch
decelerator
operates
Charge level
When charging
is defective
(charge voltage
< battery voltate)
Pilot
6
7
Caution
Engine oil
pressurre
Display
color
Remarks
Blue
LCD
Red
LED
Blue
LCD
Red
LED
Green
Lamp
Red
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
10-156
(1)
PC78MR-6
MONITOR SYSTEM
Display item
Display range
Display method
Time is measured while engine is running
(alternator is generating) (Lamp always lights
up even if starting switch is at OFF position.)
Service meter
0-99999.9 h
[*1]
2
Display
3 alphanumerics
3a
Gauge
3b
Monitor
4a
Gauge
Coolant
temperature
Fuel level
4b
Monitor
See above
drawing.
Above set
temperature
(99C)
See above
drawing.
Below set level
(30 liters)
Preheating
During preheating
One-touch
deceleration
When one-touch
decelerator
operates
Overload
Pilot
Caution
Charge level
When charging
is defective
(charge voltage
< battery voltate)
Engine oil
pressurre
Display
color
Remarks
Blue
LCD
Red
LED
Blue
LCD
Red
LED
Green
Red
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
PC78MR-6
10-156-1
(1)
MONITOR SYSTEM
No. Name
1
Function
Operation
Working mode
selector switch
Active (OFF) io E
(Lamp OFF)
Wiper switch
Windshield washer
switch
Lo io Hi
PC78MR-6
10-157
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
Contact
OFF (Open)
ON (Closed)
Coolant temperature
Resistance
Fuel level
Resistance
Engine speed
Electromagnetic
Gauge
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Function
This sensor is installed to the engine cylinder block to sense oil pressure with diaphragm (4). If the oil pressure lowers below the set level, the switch is turned on and the signal is sent to the monitor panel.
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
(1)
PC78MR-6
SENSORS
1. Float
2. Arm
3. Connector
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)
SENSORS
Wire
Magnet
Terminal
Housing
Connector
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
(1)
PC78MR-6
a Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting.
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 people 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
Item
Machine Model
PC78MR-6
Engine
S4D95LE-3
Measurement Conditions
Unit
2,020 50
rpm
1,850
Bosch Index
Max. 3.5
Max. 1.0
6.0
2.0
mm
0.35
0.50
At sudden acceleration
At high idling
Compression pressure
(SAE15W-40 oil)
Oil temperature: 40 60 C
(Engine speed)
MPa
{kg/cm2}
(rpm)
Min. 2.94
{Min. 30}
320 360
2.06
{21}
Blow-by pressure
(SAE30 oil)
Pa
{mmH2O}
980 {100}
reference value
0.34 0.54
{3.5 5.5}
0.25
{2.5}
0.29 0.49
{3.0 5.0}
0.21
{2.1}
(SAE30)
Min. 0.18
{Min. 1.8}
0.15
{1.5}
(SAE10W)
Min. 0.15
{Min. 1.5}
0.13
{1.3}
90 110
120
(Deg.)
5 0.75
5 0.75
6 10
6 10
6 10
6 10
Oil pressure
MPa
{kg/cm2}
At low idling
Oil temperature
Deflection under
finger pressure of
approx. 58.8 N {6
kg}
mm
20-2
Deflection under
finger pressure of
approx. 58.8 N {6
kg}
PC78MR-6
Engine speed
Category
Item
At relief of 1 pump
Measurement Conditions
Unit
Standard Value
for New Machine
Service Limit
Value
rpm
Min. 1,800
Min. 1,800
N o RAISE, LOWER
85 10
Max. 95
Min. 75
N o IN, OUT
85 10
Max. 95
Min. 75
N o CURL, DUMP
85 10
Max. 95
Min. 75
N o LEFT, RIGHT
85 10
Max. 95
Min. 75
21 2
Max. 23
Min. 19
53 6
Max. 59
Min. 47
Max. 127
Min. 103
Center of
lever grip
End of pedal
Read Max.
value through
stroke end
Stop engine
N o LEFT, RIGHT
mm
N o RAISE, LOWER
N o FORWARD,
REVERSE
115 12
Attachment control
pedal
N o FORWARD,
REVERSE
Forward 37
Reverse 23
Forward Max.
Min.
Reverse Max.
Min.
Max. 10
Max. 15
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
78.4 19.6
{8.0 2}
Max. 117.7
{Max. 12}
25.5 6.9
{2.6 0.7}
Max. 39.2
{Max. 4.0}
Attachment control
pedal
Forward 22.54.9
{2.30.5}
Reverse 36.34.9
{3.70.5}
PC78MR-6
N
{kg}
39
35
25
21
Lever
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
Pedal
74.5 18.6
{7.6 1.9}
Max. 107.6
{Max. 11}
PC78MR-6
20-3
Machine Model
Standard
Value for
New
Machine
Service Limit
Value
Boom
26.5 0.98
{270 10}
26.5 1.47
{270 15}
Arm
26.5 0.98
{270 10}
26.5 1.47
{270 15}
Bucket
26.5 0.98
{270 10}
26.5 1.47
{270 15}
Boom swing
26.5 0.98
{270 10}
26.5 1.47
{270 15}
20.5 0.98
{210 10}
20.5 1.47
{210 15}
12.74 + 01.95
{130 15}
12.74 1.47
{130 15}
21.08 0.98
{215 10}
21.08 1.47
{215 15}
26.5 0.98
{270 10}
26.5 1.47
{270 15}
3.14 + 00.2
3.14 + 0.3
0
{32 + 02 }
{32 + 03 }
Max. 20
Max. 20
deg
(mm)
40 10
{297 74}
Max. 60
{Max. 446}
sec
2.2 0.3
{2.6 0.3}
Max. 2.8
{Max. 3.2}
3.7 0.3
{4.1 0.3}
Max. 4.3
{Max. 4.7}
Category
Item
Swing
Oil pressure
PC78MR-6
Measurement Conditions
Unit
With blade
RAISE
Blade
MPa
{kg/cm2}
LOWER
Travel
Control
Lowering of oil
pressure
Overrun of
swing
Swing
90
Time required
to start swinging
20-4
180
PC78MR-6
Machine Model
Category
Item
PC78MR-6
Unit
Standard
Value for
New
Machine
Service
Limit
Value
sec
30 2
Max. 35
mm
(deg)
0
(0)
0
(0)
/
min.
Max. 3.5
Max. 7.0
Low speed
34 3
41
High speed
25 3
{23 2}
30
{28}
Low speed
26 2
{25 2}
28
{20}
High speed
17 2
{15.5 2}
21
{19.5}
Measurement Conditions
Max. Reach
Time required to
finish swinging
Swing
Hydraulic drift of
swing
Leakage from
swing motor
Travel
sec
PC78MR-6
20-5
Machine Model
Category
Item
Measurement Conditions
PC78MR-6
Unit
Standard
Value for
New
Machine
Service
Limit
Value
mm
Max. 300
330
cc/min.
Max. 10
Max. 50
mm
Max. 4.5
Max. 7.0
Travel deviation
Travel
a Measure distance x
Leakage from
swivel joint
(Each port)
Hydraulic drift of
travel
Leakage from
travel motor
20-6
Stop engine
Hydraulic oil temperature: 45 55 C
Stop machine on slope of 30 with sprocket up
Measure hydraulic drift of travel made in 5 minutes
/min.
PC78MR-6
Machine Model
Category
Item
Whole work
equipment
(Hydraulic drift of
bucket tooth tip)
PC78MR-6
Measurement Conditions
Unit
Hydraulic drift
Blade
(Hydraulic drift of
blade tip
Stop engine
Hydraulic oil temperature: 45 55 C
Measure hydraulic drift of blade tip from Max. height in
15 minutes
Max. 350
Max. 600
Max. 8
Max. 12
mm
Max. 41
Max. 62
Max. 25
Max. 38
Max. 20
Max. 30
cc/min.
Max. 1.5
Max. 7.5
3.2 0.3
Max. 4
Work equipment
Bucket cylinder
(Retraction of cylinder)
Service
Limit
Value
Boom cylinder
(Retraction of cylinder)
Arm cylinder
(Extension of cylinder)
Standard
Value for
New
Machine
Max. extension of
cylinder
LOWER
Arm
Max. retraction of
cylinder
3.1 0.3
Max. 3.7
3.3 0.3
Max. 4.1
Max. extension of
cylinder
PC78MR-6
RAISE
IN
DUMP
2.9 0.3
Max. 3.5
20-7
Machine Model
Category
Item
PC78MR-6
Standard
Value for
New
Machine
Service
Limit
Value
CURL
3.2 0.4
Max. 4.0
DUMP
2.3 0.3
Max. 3.1
Swing (R.H.)
6.7 0.4
Max. 7.6
Swing (L.H.)
4.5 0.4
Max. 5.3
Measurement Conditions
Unit
Max. extension of
cylinder
Work equipment
Swing (L.H.)
RAISE
1.3 0.3
Max. 2.1
LOWER
1.3 0.3
Max. 2.1
Max. 2
Max. 3.9
Time lag
Boom
20-8
PC78MR-6
Machine Model
Category
Item
Measurement Conditions
PC78MR-6
Unit
Standard
Value for New
Machine
Service Limit
Value
Max. 1.0
Max. 1.0
Max. 1.0
Max. 2.0
See following
pages
See following
pages
Arm
sec
Bucket
Work equipment
Time lag
Blade
PC78MR-6
Piston
pump
/min.
20-9
Category
Average pressure
(MPa {kg/cm2})
Standard discharge
( /min.)
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
Component
Name
Connector
No.
Inspection
Method
Measurement Conditions
Criteria
Source
voltage
M97
Measurement
voltage
20 30 V
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
20 30 V
Swing LEFT
stop
solenoid
Potentio
powersource
When safety
lock lever is at
FREE
When safety
lock lever is at
LOCK
20 28 V
20 30 V
M13
Between (1) (2)
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
Max. 0 V
M97
M95
Measurement
of current
Controller
Swing
RIGHT stop
solenoid
M97
M13
940 50 mmA
Measurement
of voltage
PPC main
pressure
lock solenoid
Measurement
voltage
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
4) Exclude part near
swing stroke end.
940 50 mmA
5 0.5 V
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
Boom
RAISE
pressure
switch
PC78MR-6
M95
M96
M95
Measurement
of voltage
Model
selection
Measurement
of voltage
PC78MR-6
Max. 1 V
Min. 7 V
Max. 1 V
Max. 1 V
1) Turn starting
switch OFF.
2) Insert T-adapter.
3) Turn starting
switch ON.
Between
M95 (12)
chassis
ground
Max. 1V
5 0.5 V
1) Turn starting
switch OFF..
2) Insert T-adapter.
3) Turn starting
switch ON.
20-11
System
Component
Name
Connector
No.
Inspection
Method
Measurement
Conditions
Criteria
Swing, arm
IN, travel
pressure
switch
M95
Measurement
of voltage
When in neutral
Between
(24) - chassis ground
Between
(6) - chassis
ground
Between
(18) - chassis ground
Max. 1 V
Max. 1 V
Boom swing
angle potentiometer
signal
M95
Measurement
of voltage
3.8 4.8 V
Swing
holding
brake clear
solenoid
M97
Measurement
of resistance
Controller
20 30 V
Between
(7) (13)
Max. 1 V
1) Turn starting
switch OFF.
2) Insert Tadapter.
3) Turn starting
switch ON.
1) Turn starting
switch OFF.
2) Insert Tadapter.
3) Turn starting
switch ON.
4) Move right
swing to stroke
end.
1) Turn starting
switch OFF.
2) Disconnect
connector.
3) Insert Tadapter.
4) Turn starting
switch ON.
5) Swing or move
arm in.
Left swing
stop EPC
solenoid
20-12
M12
(Male)
M11
(Male)
Measurement
of resistance
Right swing
stop EPC
solenoid
M101
(Male)
Measurement
of resistance
Swing
angle potentiometer
Measurement
of resistance
0.2 7 kz
0.2 7 kz
4 6 kz
5 25 z
Min. 1 Mz
5 25 z
Min. 1 Mz
1) Turn starting
switch OFF.
2) Disconnect
connector.
3) Insert Tadapter.
1) Turn starting
switch OFF.
2) Disconnect
connector.
3) Insert Tadapter.
1) Turn starting
switch OFF.
2) Disconnect
connector.
3) Insert Tadapter.
PC78MR-6
Machine control
Swing holding
brake reset solenoid
Inspection
Method
M13
(Male)
M14
(Male)
M15
(Male)
Measurement of
resistance
Connector
No.
Measurement of
resistance
Component Name
Measurement of
resistance
System
Measurement
Conditions
Criteria
If the condition is within the range shown in the
table below, it is normal.
Between M13 (Male)
(1) (2)
35 80 z
Min. 1 Mz
35 80 z
Min. 1 Mz
35 80 z
Min. 1 Mz
1) Turn starting
switch OFF.
2) Disconnect
adapter.
3) Connect Tadapter.
1) Turn starting
switch OFF.
2) Disconnect
adapter.
3) Connect Tadapter.
1) Turn starting
switch OFF.
2) Disconnect
adapter.
3) Connect Tadapter.
Monitored Item
(Input connector)
Measurement
Conditions
Preheater
P02 (18)
PC78MR-6
Sensor
Input
Signal
Light is
ON.
Max. 1 V
Light is
OFF.
20 30 V
Light is
ON.
Max. 5 V
Light is
OFF.
20 30 V
Light is
ON.
20 30 V
Light is
OFF.
Max. 1 V
Start engine.
Display
1) Connect Tadapter
Start engine.
Stop Engine.
20-13
Component
Name
System
Connector No.
Inspection Method
Criteria
Measurement Conditions
Table 2 (Gauge)
Min. Max.
Upper side
I
Measurement of resistance of coolant temperature gauge P02 (1)
(13)
Position of indication
Lower side
Gauge
section
4.00 3.45
3.13 3.75
3.39 3.94
3.56 4.39
3.97 5.18
4.68 6.89
6.23 10.88
10.34 36.86
33.35 37.83
Min. Max.
Upper side
I
Measurement of resistance of fuel level
gauge P02 (2) (13)
Position of indication
Lower side
10 6.8
6.2 13.7
12.4 22.1
20.0 30.5
27.6 41.0
37.1 54.6
49.4 77.7
70.3 101.9
92.2 10
a Level 1 blinks.
20-14
PC78MR-6
Alternator
PC78MR-6
Check of continuity
Measurement
Conditions
Criteria
If the condition is within the range shown in the table
below, it is normal.
Normal
engine oil
pressure
No continuity
Low engine
oil pressure
Normal continuity
M9 (Male)
Between T4
(Terminal
R) chassis ground
M18 (Male)
T6
Inspection
Method
Measurement of resistance
Connector
No.
Measurement of resistance
Component
Name
Measurement of voltage
System
Between
(1) (2)
Between
(1) (2)
Normal
temperature
(25 C)
Approx. 40 kz
105 C
Approx. 3.3
kz
Full
25z
Empty
105 110 z
1) Start engine
2) Disconnect
terminal
1) Start engine
20-15
PC78MR-6
20-101
Symbol
A
Part No.
Part Name
Remarks
Digital indication
799-203-9000
Multi-tachometer
6210-81-4111
Gear box
799-101-1500
Digital thermometer
-50 1,200 C
799-101-5002
790-261-1203
Pressure gauge
Pressure gauge
799-401-2320
Hydraulic gauge
Pressure gauge
799-101-5160
Nipple
PT1/8
799-101-5220
Nipple
10 mm P = 1.25
07002-11023
O-ring
799-401-2910
Nipple
02896-11008
O-ring
07043-00108
Nipple
799-401-2701
Differential pressure
gauge
795-502-1590
Compression gauge
795-502-1370
Adapter
3
Oil pressure
Compression pressure
L: 60 2,000 rpm
H: 60 19,999 rpm
Blow-by pressure
799-201-1504
Blow-by checker
Valve clearance
Purchased
Filler gauge
790-201-9000
Purchased
Smoke meter
Operating effort
Purchased
Push-pull scale
Purchased
Scale
Purchased
Stopwatch
790-601-9320
Box
24-pin
799-601-9310
Plate
799-601-8000
Adapter assembly
1
2
Troubleshooting for wiring
harnesses and sensors
K
3
20-102
799-601-7310
For SWP12
799-601-7050
For SWP6
799-601-7520
Adapter
12 for 070
799-601-7360
Relay 5P
799-601-7370
Relay 6P
799-601-9200
Adapter kit
795-102-2102
Spring pusher
Commercialy
available
Dial guage
PC78MR-6
PC78MR-6
20-103
20-104
PC78MR-6
PC78MR-6
20-105
6. Disconnect wiring harnesses (2) from the terminals of the engine stop solenoid. Revolve the
engine with the starting motor and measure the
compression pressure and engine speed at this
time.
a Read the pressure gauge when its pointer is stabilized.
a When measuring the compression pressure,
measure the engine speed, too, and check that it
is in the range of the measurement conditions.
a After measuring the compression pressure,
install nozzle holder assembly (1).
Nozzle holder mounting bolt:
39.2 49 Nm {4 5 kgm}
20-106
PC78MR-6
PC78MR-6
20-107
2) Check that cylinder No. 1 is at the compressi 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
the idler gear.
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
PC78MR-6
20-109
mm
5 0.75
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).
20-110
14. Turning the injection pump outward and operating 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 injection timing is delayed. If the former is slanted
toward the cylinder block, the latter is
advanced.
15. Tighten injection pump mounting bolts (14) alternately.
16. Tighten the nut at the oblong hole of the injection
pump mounting flange.
PC78MR-6
PC78MR-6
20-111
2. Install oil pressure measuring nipple C3 and connect oil pressure gauge C2 (0.98 MPa {10 kg/
cm}).
20-112
PC78MR-6
2. Install rod (4) and rod end (5) to ball joint (2) temporarily.
a Screwing depth b of rod in ball joint:
Approx. 12.5 mm
a Screwing depth c of rod end in rod:
Approx. 10.0 mm
PC78MR-6
4. Check that solenoid (1) is turned on, then connect 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 connected, the operating current flows continuously and the coil will burn.)
20-113
20-114
PC78MR-6
PC78MR-6
20-115
5)
1)
2)
3)
20-116
PC78MR-6
PC78MR-6
20-117
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 adjustment 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 lowered.
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 swing and
blade (LOWER) circuits
Remove cap (6) of main relief valve (5) and
loosen locknut (7), then adjust with adjustment screw (8).
a As the adjustment screw is
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 adjustment
screw: 12.5 MPa {128 kg/cm}.
Locknut : 39 49 Nm {4 5 kgm}
Cap
: 39 49 Nm {4 5 kgm}
20-120
PC78MR-6
Operation
Differential
Pressure {kg/cm}
FULL
Set lever in
neutral
2.5 4.4
{25 45}
FULL
Curl bucket
(With lever at
FULL position)
2.11 0.1
{21.5 1}
PC78MR-6
20-121
Adjusting
1. Adjusting LS valve
a If the differential pressure is abnormal, adjust
the LS valve according to the following procedure.
a Before loosening the locknut, be sure to
make match marks.
1) Loosen locknut (3) and adjust with adjustment 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
lowered.
a Quantity of adjustment per turn of adjustment 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 differential pressure, referring to Measuring
described above.
a When loosening or tightening the locknut, secure adjustment screw (4) with a
spanner so that it will not be dragged.
20-122
PC78MR-6
ADJUSTING PC VALVE
a When the load is increased, the engine speed
may lower or the engine speed may be normal
and working speed may be lower. If this trouble
occurs and the pump discharge pressure and LS
differential pressure are normal, adjust the pump
PC valve according to the following procedure.
a Before loosening locknut, be sure to make match
marks.
1. Loosen locknut (1) and adjust with adjustment
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).
ADJUSTING PC VALVE
2) Start the engine and measure the oil pressure under the following condition.
Table 1 Measurement Condition
Engine
Speed
PC78MR-6
MeasureMeasured
Monitor Output
ment
Pressure MPa
Current
Condition
{kg/cm}
FULL
Neutral
0.54 0.84
{5.5 8.5}
410 mA
FULL
Float one
side and
run idle
0 0.2
{0 2}
100 mA
SLOW
Neutral
2.74 3.53
{28 36}
900 mA
20-123
20-124
PC78MR-6
a Measuring points
a. Blade RAISE
J. LEFT swing
b. Blade LOWER
k. Boom RAISE
c. RIGHT swing
l.
d. LEFT swing
m. Arm OUT
n. Arm IN
f.
o. Bucket DUMP
Boom LOWER
p. Bucket CURL
q. Service
i.
r.
RIGHT swing
Service
PC78MR-6
20-125
Measuring
1. Measuring output pressure of ON-OFF solenoid valve.
1) Disconnect ON-OFF solenoid valve output
hose and install oil pressure gauge C1 (5.9
MPa {60 kg/cm}), using nipple C3 and C4 in
the oil pressure gauge kit.
2) Measure the output pressure of the solenoid
valve under the condition in Table 2.
a The ON-OFF solenoid valve.
Installed in the 6-spool soleoid valve
assembly at the front under the floor
plate.
Table 1
Oil pressure
MPa {kg/cm}
Remarks
3.14 0.49
{32 5}
Stroke end
1.13 0.29
{11.5 3}
3.14 0.49
{32 5}
Stroke end
1.13 0.29
{11.5 3}
Solenoid Name
Measurement Condition
20-126
PC78MR-6
Table 2
Solenoid Name
PPC
1 oil pressuressure lock
Swing hold2
ing brake
Travel speed
3
selector
Measurement Condition
Operating Condition
Remarks
Oil pressure is
applied to PPC valve
circuit.
ON
3.14 0.29
{32 3}
OFF
Brake is released.
ON
3.14 0.49
{32 5}
OFF
ON
3.14 0.49
{32 5}
OFF
PC78MR-6
20-127
20-128
PC78MR-6
PC78MR-6
20-129
Adjusting
a Travel deviation can be corrected by draining a
part of the oil discharged from the pump which
discharges more oil with the adjustment plugs.
If the travel deviation is corrected by this method,
however, the travel speed, work equipment
speed in the compound operation, and relief
pressure lower since the pump discharge is
reduced.
a The following is the method of correcting deviation applied when the machine deviates to the
right (left) in both travel directions.
a Travel deviation can be corrected by the following method only when it is 200 mm or less.
20-130
PC78MR-6
PC78MR-6
20-131
20-132
2. Travel motor
1) Disconnect drain hose (3) of the travel motor
and plug the hose.
2) Put a block in the grouser of the track shoe
or between the sprocket and the frame to
lock the track shoe.
3) Run the engine at full throttle and relieve the
travel circuit.
Since a wrong operation of a lever can cause
an accident, make signs and confirm the operations security.
4) After 30 seconds, measure the oil leakage in
1 minute.
a Measure the oil leakage several times, moving the motor little by little (shifting the valve
plate and piston from the cylinder).
PC78MR-6
PC78MR-6
20-133
20-134
PC78MR-6
Standard Slack a
10 30 mm
Rubber shoe
1 3 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
1. When tension is too high.
1) Loosen valve (1) to discharge grease.
Since the high pressure grease may spurt out,
do not loosen the valve more than 1 turn.
a If the grease is not discharged sufficiently,
move the machine slowly forward and in
reverse.
2) To check that the track shoe tension is normal, 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.
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 normal, 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
Bleeding
air from
pump
Starting
engine
Contents of work
Replacing hydraulic oil
Cleaning strainer
Bleeding
air from cirBleeding
cuit
between air from LS
circuit
pump and
hydraulic
tank
Bleeding
air from
cylinders
Bleeding
air from
swing
motor
Bleeding
air from
travel
motor
Bleeding
air from
swing PPC
circuit
Starting
operation
Q Note)
Q Note)
Q
Q
Q
Q
Replacing cylinder
Removing cylinder piping
Q
Q
Q
Q
Q
Q
Q
Q
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
a If the pump is operated without filling pump
case with hydraulic oil, it is heated abnormally and may be broken soon. Accordingly,
bleed all air from the pump before operating
the pump.
1) Loosen air bleeder (1) installed to the drain
port and check that oil oozes out.
2) After bleeding air, tighten the air bleeder.
20-136
PC78MR-6
PC78MR-6
20-137
20-138
PC78MR-6
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
20-202
PC78MR-6
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 problem.
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
Step 7
Pinpoint locations of failure (carry out
troubleshooting)
Decide action to take
TEW00186
TEW00187
Step 6
Re-enacting failure
Step 4
Go to jobsite
Step 5
Ask operator questions to confirm details of
failure.
TEW00189
PC78MR-6
Was there anything strange about the machine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
failure?
20-203
TROUBLESHOOTING
20-204
PC78MR-6
TROUBLESHOOTING
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.
PC78MR-6
20-205
TROUBLESHOOTING
Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the connectors 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 connector 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.
20-206
PC78MR-6
TROUBLESHOOTING
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 careful 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 connector until the stopper clicks into position.
Correct any protrusion of the boot and any misalignment of the wiring harness
For connectors fitted with boots, correct any protrusion 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 connectors 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
TROUBLESHOOTING
20-208
PC78MR-6
TROUBLESHOOTING
PC78MR-6
20-209
TROUBLESHOOTING
3) Sealing openings
After any piping or equipment is removed, the openings
should be sealed with caps, tapes, or vinyl bags to prevent 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.
20-210
PC78MR-6
TROUBLESHOOTING
6) Flushing operations
After disassembling and assembling the equipment, or
changing the oil, use flushing oil to remove the contaminants, 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
Action
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add coolant
Clean or replace
Replace
Tighten or replace
Tighten or replace
Tighten or replace
Repair
Repair
Bleed air
20 - 30 V
Replace
Add or replace
Replace
Repair
5. Check for water leaking on wiring (Pay particular attention to water leaking
on connectors or terminals)
Disconnect
connector and dry
Replace
Replace
Hydraulic,
mechanical
equipment
Electrical
equipment
Item
Electrical equipment
20-212
PC78MR-6
TROUBLESHOOTING
Type
No.
of
Pins
Address
Connector
No.
Type
No.
of
Pins
A/C
L7
K20
Cab inlet
R6
D4
SWP
H1
K21
Cab inlet
R6
D5
SWP
G1
K23
R8
D6
SWP
G1
K26
090
Horn switch
M7
D11
SWP
R7
K27
SWP
N7
D12
SWP
R8
K28
P2
D13
SWP
Q8
K32
Accelerator relay
O8
D22
SWP
H1
K33
Decelerator relay
N8
D25
SWP
G1
K42
SUMITOMO
16
Intermediate connector
(Reset switch)
P8
D26
SWP
H9
K45
Ground (Radio)
Q3
D30
SWP
R7
K51
090
20
Intermediate connector
(Starting, light switch)
M7
D31
SWP
R7
K52
Light switch
N8
D32
SWP
R6
K53
O8
D33
SWP
Q8
K54
P8
D34
SWP
P8
M1
Intermediate connector
(Power supply, ground)
M4
EU1
R5
M2
Intermediate connector
(Power supply)
M4
Fuse box
R3
M3
DT (Gr)
Intermediate connector
(Rotation sensor, etc.)
M4
FB1
Location
Address
Location
GND Terminal
L2
M4
DT (G)
Intermediate connector
(Swing angle sensor, etc.)
M4
HOLD Terminal
L2
M5
DT (Gr)
Intermediate connector
(TVC solenoid)
M3
K1
12
Intermediate connector
(Monitor panel)
M7
M6
DT (B)
Intermediate connector
(Related to pressure switch)
M3
K2
16
Intermediate connector
(Monitor panel)
N7
M7
DT (G)
M3
K3
DT
O2
M9
DT
Fuel sensor
I2
K11
SWP
12
O2
M11
DT
N2
K12
Resister
P8
M12
DT
N2
K17
P2
M13
DT
M2
K18
090
Decelerator switch
Q2
M13
Speaker (Right)
I9
K19
PA
Radio
R3
M14
DT
N2
20-214
(1)
PC78MR-6
TROUBLESHOOTING
Connector
No.
Type
No.
of
Pins
M15
DT
M16
DT
M17
Address
Connector
No.
Type
No.
of
Pins
M2
P15
040
M6
J3
L3
Glow plug
K8
T1
Terminal
I2
M18
DT
L8
T2
Terminal
H2
M20
DT
TVC/EPC solenoid
K8
T3
Terminal
H1
M21
Pressure switch
(Boom RAISE)
G9
T4
Terminal
Alternator (Terminal R)
L6
M22
I9
T5
Terminal
Alternator (Terminal B)
L6
M23
G9
T6
Terminal
L5
M24
H9
T9
Terminal
A4
M25
I9
T10
Terminal
A3
M26
Fusible link
C8
T11
Terminal
A6
M27
Fusible link
B8
T12
Terminal
A5
M28
DT
Intermediate connector
(Working lamp)
J9
T16
Terminal
K3
M30
J3
T17
Terminal
K3
M31
KES
Windshield washer
C8
T31
Terminal
K3
M32
DT
Travel/Swing alarm
J2
T32
Terminal
L5
M35
K1
T33
Terminal
L7
M36
DT
J2
T34
Terminal
L6
M71
Room light
J9
W04
Wiper motor
M5
M73
Speaker (Left)
J9
W19
Cigarette lighter
M5
M75
DT
Working lamp
D9
Terminal
M9
M80
040
Horn
M2
BR
Terminal
M8
M92
DT
D2
ACC
Terminal
M8
M95
DRC23
24
Controller
R8
Terminal
M9
M96
DRC23
40
Controller
Q8
R1
Terminal
N8
M97
DRC23
40
Controller
Q8
R2
Terminal
N8
M101
DT
F1
P01
040
12
Monitor panel
M6
P02
P040
20
Monitor panel
M6
Location
PULL Terminal
Address
Location
PC78MR-6
20-215
(1)
TROUBLESHOOTING
20-216
(1)
PC78MR-6
TROUBLESHOOTING
PC78MR-6
20-217
(1)
TROUBLESHOOTING
20-218
(1)
PC78MR-6
TROUBLESHOOTING
Number of
Pins
T-adapter Part
Number
799-601-7010
BWP04702
2
799-601-7020
BWP04703
3
BWP04704
BWP04705
799-601-7030
BWP04706
799-601-7040
PC78MR-6
20-219
TROUBLESHOOTING
Number of
Pins
SWP-Type Connector
Male (Female Housing)
T-adapter Part
Number
BWP04707
6
799-601-7050
BWP04709
BWP04711
12
BWP04713
BWP04710
799-601-7060
BWP04712
BWP04714
14
799-601-7070
20-220
799-601-7310
PC78MR-6
TROUBLESHOOTING
SWP-Type Connector
Number of
Pins
BWP04715
16
BWP04716
T-adapter Part
Number
799-601-7320
PC78MR-6
20-221
TROUBLESHOOTING
M-Type Connector
Number of
Pins
T-adapter Part
Number
799-601-7080
BWP04717
BWP04719
BWP04721
BWP04723
BWP04725
20-222
BWP04718
799-601-7090
BWP04720
799-601-7110
BWP04722
799-601-7120
BWP04724
799-601-7130
BWP04726
799-601-7340
PC78MR-6
TROUBLESHOOTING
Number of
Pins
S-Type Connector
Male (Female Housing)
BWP04727
10
(White)
BWP04729
12
(White)
BWP04731
16
(White)
BWP04733
PC78MR-6
T-adapter Part
Number
BWP04728
799-601-7140
BWP04730
799-601-7150
BWP04732
799-601-7350
BWP04734
799-601-7330
20-223
TROUBLESHOOTING
Number of
Pins
10
(Blue)
S-Type Connector
Male (Female Housing)
BWP04735
12
(Blue)
BWP04737
16
(Blue)
BWP04739
20-224
T-adapter Part
Number
BWP04736
BWP04738
799-601-7160
BWP04740
799-601-7170
PC78MR-6
TROUBLESHOOTING
Number of
Pins
MIC-Type Connector
Male (Female Housing)
T-adapter Part
Number
11
BWP04741
BWP04743
13
BWP04745
PC78MR-6
BWP04742
799-601-2710
BWP04744
799-601-2950
BWP04746
799-601-2720
20-225
TROUBLESHOOTING
Number of
Pins
17
MIC-Type Connector
Male (Female Housing)
BWP04747
21
20-226
BWP04749
T-adapter Part
Number
BWP04748
799-601-2730
BWP04750
799-601-2740
PC78MR-6
TROUBLESHOOTING
Number of
Pins
AMP040-Type Connector
Male (Female Housing)
BWP04751
12
BWP04753
16
BWP04755
20
BWP04757
PC78MR-6
T-adapter Part
Number
BWP04752
799-601-7180
BWP047544
799-601-7190
BWP04756
799-601-7210
BWP04758
799-601-7220
20-227
TROUBLESHOOTING
Number of
Pins
10
AMP070-Type Connector
Male (Female Housing)
BWP04759
12
BWP04761
14
BWP04763
18
BWP04765
20
BWP04767
20-228
T-adapter Part
Number
BWP04760
799-601-7510
BWP04762
799-601-7520
BWP04764
799-601-7530
BWP04766
799-601-7540
BWP04768
799-601-7550
PC78MR-6
TROUBLESHOOTING
Number of
Pins
L-Type Connector
Male (Female Housing)
BWP04769
BWP04770
Number of
Pins
T-adapter Part
Number
PA-Type Connector
Male (Female Housing)
BWP04771
BWP04772
Number of
Pins
10
BWP04773
PC78MR-6
T-adapter Part
Number
T-adapter Part
Number
BWP04774
799-601-3460
20-229
TROUBLESHOOTING
Number of
Pins
BWP04775
BWP04777
BWP04779
BWP04781
20-230
T-adapter Part
Number
BWP04776
BWP04778
BWP04780
BWP04782
PC78MR-6
TROUBLESHOOTING
Number of
Pins
BWP04783
PC78MR-6
T-adapter Part
Number
BWP04784
20-231
TROUBLESHOOTING
Number of
Pins
BWP04785
BWP04787
20-232
T-adapter Part
Number
BWP04786
799-601-7360
BWP04788
799-601-7370
PC78MR-6
TROUBLESHOOTING
Number of
Pins
F-Type Connector
Male (Female Housing)
BWP04785
BWP04786
PC78MR-6
T-adapter Part
Number
20-233
TROUBLESHOOTING
The pin number is also marked on the connector (Electric wire insertion end).
Type
(Shell
Size
Code)
18-8
(1)
18-14
(2)
20-234
Body (Receptacle)
T-adapter Part
Number
799-601-9210
799-601-9220
PC78MR-6
TROUBLESHOOTING
The pin number is also marked on the connector (Electric wire insertion end).
Type
(Shell
Size
Code)
18-20
(3)
18-21
(4)
PC78MR-6
Body (Receptacle)
T-adapter Part
Number
799-601-9230
799-601-9240
20-235
TROUBLESHOOTING
The pin number is also marked on the connector (Electric wire insertion end).
Type
(Shell
Size
Code)
24-9 (5)
24-16
(6)
20-236
Body (Receptacle)
T-adapter Part
Number
799-601-9250
799-601-9260
PC78MR-6
TROUBLESHOOTING
The pin number is also marked on the connector (Electric wire insertion end).
Type
(Shell
Size
Code)
Body (Receptacle)
24-21
(7)
24-22
(8)
PC78MR-6
T-adapter Part
Number
799-601-9270
799-601-9280
20-237
TROUBLESHOOTING
The pin number is also marked on the connector (Electric wire insertion end).
Type
(Shell
Size
Code)
24-31
(9)
20-238
Body (Receptacle)
T-adapter Part
Number
799-601-9290
PC78MR-6
TROUBLESHOOTING
The pin number is also marked on the connector (Electric wire insertion end).
No.
of
Pins
DT Series Connector
Body (Plug)
Body (Receptacle)
799-601-9020
799-601-9030
799-601-9040
799-601-9050
PC78MR-6
T-adapter Part
Number
20-239
TROUBLESHOOTING
No.
of
Pins
DT Series Connector
Body (Plug)
Body (Receptacle)
8GR:799-601-9060
8B:799-601-9070
8G:799-601-9080
8BR:799-601-9080
12GR:799-601-9110
12B:799-601-9120
12G:799-601-9130
12BR:799-601-9140
12
20-240
T-adapter Part
Number
PC78MR-6
TROUBLESHOOTING
The pin number is also marked on the connector (Electric wire insertion end).
No.
of
Pins
Body (Receptacle)
T-adapter Part
Number
799-601-9000
The pin number is also marked on the connector (Electric wire insertion end).
No.
of
Pins
Body (Receptacle)
T-adapter Part
Number
PC78MR-6
20-241
(1)
TROUBLESHOOTING
Network information
1) Working mode (Standard, E) information
2) One-touch slow-down (ON/OFF) signal
3) Travel Hi/Lo signal
4) Coolant temperature (Water temperature) information
20-242
(1)
PC78MR-6
TROUBLESHOOTING
Abnormal system
E02
TVC-EPC system
E03
E05
E40
E41
PC78MR-6
20-243
TROUBLESHOOTING
(1) Display
(2) Service meter unit
(3) Mode selector switch
(UP)
(4) Mode selector switch
(DOWN)
20-244
PC78MR-6
TROUBLESHOOTING
Abnormal System
User Code
E101
E108
E112
E113
E114
E115
E116
E203
E03
E206
Short circuit or grounding fault in 2nd travel speed selection solenoid system
E03
E213
E216
E218
E227
E232
E02
E233
E02
(*1) E251
Short circuit with chassis ground or disconnection on boom bottom pressure sensor (overload sensor) signal side or (+) side or disconnection on (-) side.
E258
E304
E314
E323
E05
E325
E05
E328
E05
E412
E40
E413
E40
E414
E451
E41
E452
E41
E453
E41
E454
E41
E501
E502
PC78MR-6
20-245
(1)
TROUBLESHOOTING
(1) Display
(2) Service meter unit
(3) Mode selector switch
(UP)
(4) Mode selector switch
(DOWN)
20-246
PC78MR-6
TROUBLESHOOTING
Item
Unit
Component Name
Controller
(6bit)
Controller
0001
0008
0041
10 mA
Controller
0042
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
Controller
1000
Controller
1001
Attachment selection
Controller
1010
Engine speed
1020
10 rpm
Controller
ON/OFF input 1
(6bit)
Controller
1021
ON/OFF input 2
(6bit)
Controller
1022
ON/OFF input 3
(6bit)
Controller
1023
ON/OFF input 4
(6bit)
Controller
1024
ON/OFF input/output
(6bit)
Controller
1025
ON/OFF input/output
(6bit)
Controller
1026
ON/OFF input/output
(6bit)
Controller
1033
Controller
1050
10 mA
Controller
1052
Controller
1053
Controller
1060
ON/OFF output
(6bit)
Controller
PC78MR-6
20-247
TROUBLESHOOTING
Code No.
0008
0045
0046
0047
0048
0049
1020
1021
20-248
Item
Sensor input 1
Sensor input 2
State of output
State of wiper
Spare
ON/OFF input 1
For detail of model
selection, see Table 1.
For detail of ATT selection, see Table 2.
ON/OFF input 2
Bit
(1)
ID2 is connected.
(2)
ID3 is connected.
(3)
ID4 is connected.
(4)
ID5 is connected.
(5)
ID6 is connected.
(6)
ID7 is connected.
(1)
(2)
(3)
(4)
(2)
Constant bit
(3)
(6)
(1)
Buzzer output
(2)
(3)
Wiper output 1
(4)
Wiper output 2
(5)
Wiper output 3
(6)
Wiper output 4
(2)
(3)
(4)
(5)
(1)
(2)
(3)
(4)
(5)
(6)
(1)
(3)
Compressor signal
(4)
(5)
PC78MR-6
TROUBLESHOOTING
Code No.
1022
Item
ON/OFF input 3
1023
1024
1025
1026
1060
PC78MR-6
ON/OFF input 4
ON/OFF input/output
ON/OFF input/output
ON/OFF input/output
ON/OFF input/output
Bit
(1)
(2)
(3)
Backup light
(4)
SET/CLEAR switch
(5)
(6)
(3)
(4)
(5)
(6)
(1)
Deceleration signal
(2)
Acceleration signal
(3)
(4)
(5)
(6)
(1)
(2)
(3)
(6)
(1)
Deceleration switch
(2)
Alarm cancel
(3)
(4)
(5)
(1)
(2)
(4)
(5)
20-249
TROUBLESHOOTING
Table 1
Model selection table
PC78MR-6
Model Selection 1
Model Selection 2
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
GND
OPEN
OPEN
Standard specification
Standard arm
20-250
PC78MR-6
TROUBLESHOOTING
PC78MR-6
B Buzzer cancel
a
Working mode
selection
Travel
SET/CLEAR
01
Emergency
Trouble
(Note 4)
02
06
Correction
Next Item
Monitoring of potenti(Note 6)
ometer
Previous
Item
(Note 6)
Error
Memory
Deletion
Q
Q
Q
Wiper selection
Washer
Continuous operation time (SEC)
Note 1)
Note 3)
Note 4)
Note 6)
Note 8)
2.5
5 (Note 1)
PC78MR-6
20-251
TROUBLESHOOTING
Operation
Display
"S-1" is displayed on the display section.
When abnormal
When normal
When normal
(Completion of setting)
3
When abnormal
(Flashing)
UU monitor panel
20-252
PC78MR-6
TROUBLESHOOTING
Operation
Display
UU monitor panel
PC78MR-6
20-253
TROUBLESHOOTING
20
20-254
Contents
Exhaust gas
color
Bad
Initial value
Good
PC78MR-6
TROUBLESHOOTING
PC78MR-6
20-255
TROUBLESHOOTING
[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:
.... Advance to mechanical system troubleshooting "S-2".
Check the rotation
When
the starting motor does not rotate:
of a starting motor.
.... Advance to electrical system troubleshooting "E-8".
20-256
PC78MR-6
TROUBLESHOOTING
[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 monitorWhen 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
Service code
S-QQ
Engine body
N-QQ
Communication system
E-QQ
C-QQ
E232, E233
F-QQ
H-QQ
M-QQ
Monitor panel
E1-QQ
20-258
PC78MR-6
TROUBLESHOOTING
Cause
After resetting operation,
operate machine normally
and observe its condition for
a while. (See Note 1.)
Remedy
1
NO
Normal
Repair or
replace
Replace
YES
2
Turn starting switch OFF
20 30 V
YES
PC78MR-6
NO
20-259
TROUBLESHOOTING
YES
1
Is user
code displayed on
monitor
panel?
E02
(PC-EPC system)
E03
(Swing holding
brake and 2nd
travel speed
selection solenoid systems)
E05
(Governor motor
system)
o Go to No. 2
E200 group: Troubleshooting for pump controller (Pump control system) (C-mode)
YES
E300 group: Troubleshooting for pump controller (Governor control system) (E-mode)
2
NO
YES
5
Engine system
4
YES
3
NO
Is input/output
signal of controller normal?
Check by
monitoring
code.
Is electric system
of engine with no
failure code normal?
Flow of part of
judgment table
where no troubles are indicated.
NO
Hydraulic
Mechanical System
NO
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
PC78MR-6
20-301
TROUBLESHOOTING
Causes
Questions
(a)
(b)
(c)
(d)
Check items
(e)
B
Troubleshooting
20-302
ii
iii
PC78MR-6
TROUBLESHOOTING
PC78MR-6
Degree of use
Seiz
ed t
urbo
cha
Clog
rger
ged
, int
air c
erfe
lean
renc
Wor
er e
e
n pi
lem
ston
ent
ring
Clog
, cyl
ged
inde
, se
r
ized
Imp
injec
rope
tion
r inj
noz
ectio
Defe
zle
n tim
ctive
ing
injec
tion
pum
p (e
xces
si
ve in
jecti
on)
Causes
20-303
TROUBLESHOOTING
Seiz
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
ed tu
rboc
Clog
harg
ged
er, in
air c
terfe
Wor
lean
re
n pis
er e
ton
leme nce
Clog
ring
nt
, cyli
ged
,
n
s
d
e
er
Imp
ized
rope
injec
r inje
tion
Defe
ction
nozz
ctive
le
ti
m
ing
injec
Imp
tion
rope
p
ump
r va
Crus
lve c
(
exce
lear
hed
ssiv
ance
, clo
e inje
Lea
gge
kage
ction
dm
u
)
o
ff
f
le
air b
Defe
r
etwe
ctive
e
c
n
onta
Deff
turb
c
ocha
ectiv
t of
valv
e inje
e, va rger and
ction
lve s
hea
pum
d
eat
p (ra
ck, p
lung
er s
eize
d)
Causes
Questions
Suddenly
Gradually
Check items
Troubleshooting
20-304
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
PC78MR-6
TROUBLESHOOTING
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
n pis
ton r
Defe
ing,
cylin
ctive
der
cont
Clog
act o
ging
f valv
a
ir cle
e an
Clog
aner
d va
gibg
elem
lve s
f
u
e
eat
ent
l
Clog
filter
ging
, stra
f
in
e
e
e
d pu
r
Glow
mp s
plug
train
(inclu
aer
ding
preheat
ing c
ircuit
)
Causes
Charging rate
20C
0C
10C
90 %
80 %
75 %
70 %
1.28
1.29
1.30
1.26
1.27
1.28
1.24
1.25
1.26
1.23
1.24
1.25
1.22
1.23
1.24
Wor
100 %
Questions
Ease of starting
Check items
No
20-306
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
PC78MR-6
PC78MR-6
Replace
Replace
Clean
Correct
Replace
Adjust
Replace
Replace
Replace
Replace
Defe
ctive
alter
Defe
nato
ctive
r (ex
a
terna
ltern
Defe
l reg
ator
ctive
ulato
(buil
o
r deg
t-in r
r typ
Defe
egula
e)
rade
ctive
d
tor ty
b
injec
a
t
t
Injec
pe)
e
tion
ry
tion
nozz
timin
le
Defe
g fail
tive
u
re
injec
Leak
tion
age,
pum
p (ra
clog
Clog
ck a
ging
ged
nd p
, or a
air b
lung
ir in
reath
Defe
er st
fuel
uck)
ctive
er ho
pipin
f
g
le
e
ed p
in
Defe
fuel
ump
ctive
syst
em
boos
t com
pens
ator
canc
el
TROUBLESHOOTING
S-1
Causes
20-307
S-2
TROUBLESHOOTING
Causes
Defe
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
ctive
wirin
Defe
g of
ctive
star
or d
ting
Defe
eter
circu
iora
ctive
it
t
e
s
d ba
tarti
Brok
ttery
ng m
en r
otor
in g g
Defe
ear
ctive
safe
Defe
ty re
ctive
lay o
b
r sa
atte
Defe
fety
ry re
ctive
swit
lay
ch
b
a
ttery
Defe
ctive
term
i
n
f
u
a l co
el cu
Defe
nne
t sol
ctive
ction
eno
star
id
ting
swit
ch
Questions
20-308
Replace
Replace
Replace
Replace
Remedy
Replace
Troubleshooting
Replace
Replace
Replace
Check items
PC78MR-6
TROUBLESHOOTING
S-2
14
-10
32
0
50
10
68
20
86 F
30
ASTM
D975
No. 2
ASTM
D975
No.2
Diesel fuel
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Brok
en in
jecti
Defe
on p
ctive
ump
injec
drive
Seiz
tion
shaf
ed,
pum
t, ke
brok
p (ra
y
en f
Clog
ck, p
eed
g ed
lung
p
u
f
uel f
mp
er s
Clog
pisto
ilter,
eize
ged
d)
n
stra
feed
i
n
e
Insu
r
pum
fficie
p
s
train
nt fu
Clog
er
el in
ged
tank
, lea
Clog
king
g ed
fuel
air b
pipin
Defe
reat
g
her
ctive
h
o le i
fuel
Imp
n fu
cut s
rope
el ta
ol
r f ue
nk
l use e n o i d
d
AMBIENT TEMPERATURE
KIND OF
FLUID
Questions
Check items
Troubleshooting
PC78MR-6
Replace
Replace
Correct
Correct
Add
Clean
Clean
Replace
Replace
Remedy
Replace
20-309
S-2
TROUBLESHOOTING
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
ctive
, bro
ken v
Defe
alve
ctive
syste
injec
Wor
m (v
tion
alve,
n pis
p
u
mp
rocke
ton
(
rin g
r
Clog
r leve
a
c
k
, cyl
, plu
ged
r, etc
inde
nge
f
.)
u
e
r line
r stu
Clog
l filte
ck)
g ed
r
r, st
rain
feed
er
Clog
pum
ged
p str
air c
aine
Glow
lean
r
er e
plug
leme
(incl
Defe
n
u
t
d
ing p
ctive
r e -h
or d
Lea
e
e
ating
t
e
kage
riora
circu
, clo
te d
it )
batt
Clog
ggin
ery
g, a
ged
ir in
injec
fuel
Clog
tion
syst
ged
nozz
em
air b
le, d
Imp
reat
efec
rope
h
tive
er h
r f ue
spra
ole i
l use
n fu
y
d
el ta
nk c
ap
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Defe
Questions
Check items
Troubleshooting
20-310
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
PC78MR-6
S-3
TROUBLESHOOTING
air c
lean
er e
leme
f
uel f
Clog
nt
ilter,
ged
stra
f
e
iner
ed p
Clog
ump
ged
stra
injec
iner
Seiz
tion
ed in
nozz
jectio
l
e
, de
Wor
n pu
fecti
n pis
mp
ve s
p
t
o
pray
lu
n
nge
Seiz
ring
r
, cyl
ed t
inde
urbo
r line
char
Imp
rope
ger,
r
r va
inter
lve c
Clog
fe re
lear
ged
nce
ance
air b
reat
C lo g
h
er h
ged
, lea
ole i
Defe
n fu
king
el ta
ctive
fuel
nk c
pipin
cont
ap
act o
g
f val
ve a
nd v
alve
seat
ged
Clog
Clean
ged
C lo g
Clean
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Questions
Check items
Troubleshooting
PC78MR-6
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Remedy
Clean
20-311
S-4
TROUBLESHOOTING
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Brok
en,
seiz
ed p
Brok
iston
en,
seiz
, con
ed c
Brok
nect
rank
en d
in g r
shaf
ynam
od
t be
ic va
Brok
arin
lve s
en,
g
y
s
s
e
t
i
e
z
Brok
m (v
ed g
en p
alve
ear
, roc
train
ump
ker le
Brok
a
u
xilia
ver,
en f
ry e
etc.)
uel p
q
u
Insu
u
i
p
mp
m
fficie
e
drive
nt
nt fu
shaf
C l og
el in
t, ke
ged
tank
y
fuel
Clog
filter
ged
, str
aine
feed
r
Brok
pum
en,
p str
seiz
aine
Clog
ed f
r
eed
ged
pum
, lea
king
p pis
Clog
fuel
ton
ged
pipin
air b
g
Defe
reat
her
ctive
hole
injec
in fu
tion
el ta
pum
nk
p (ra
ck, p
lung
er s
tuck
)
Questions
Check items
Troubleshooting
20-312
Replace
Clean
Correct
Replace
Clean
Clean
Add
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
PC78MR-6
S-5
TROUBLESHOOTING
ctive
ope
Defe
ratio
ctive
n of
adju
gove
Defe
stme
rnor
ctive
nt o
f go
o
pera
Low
v
erno
tion
idlin
r
of co
g sp
Insu
n
e
t
ro l r
e d is
fficie
ack
too
nt fu
low
Clog
el in
g ed
tank
f
e
e
d
Clog
pum
ged
p str
fuel
aine
Clog
f
i
lter,
r
ged,
stra
air in
i
ner
Clog
c
ir
cuit
ged,
betw
air in
een
Clog
circu
fuel
ged
it
t a nk
betw
air b
an d
een
reat
feed
feed
her
pum
pum
hole
p
p an
in fu
d no
el ta
zzle
nk
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Defe
Questions
Check items
Troubleshooting
PC78MR-6
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust
20-313
S-6
TROUBLESHOOTING
ged
air c
le a n
ed t
er e
urbo
leme
char
Wor
nt
ger,
n pis
inter
ton
r in g
f
Clog
eren
, cyl
ged
ce
inde
fuel
r
Clog
f
i
lter,
ged
stra
feed
iner
Clog
pum
ged
p str
i
njec
aine
Seiz
tion
r
ed in
nozz
j
e
le, d
c
t
Imp
i
o
n
efec
rope
pum
tive
p pl u
r va
spra
lve c
Defe
n
g
y
er
lear
ctive
a
n
c
c
onta
e
Ben
ct of
t fue
valv
l lev
e an
Clog
er lin
d va
ged
kage
lve s
, lea
, de
eat
Clog
king
f
e
c
tive
ged
fuel
adju
a
p
i
i
r
p
i
b
stme
Defe
ng
reat
her
ctive
nt
hole
boo
in fu
st co
el ta
mpe
nk
nsat
or d
iaph
ragm
Seiz
C log
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Questions
Black
Blue under light load
Troubleshooting
20-314
Replace
Clean
Correct
Adjust
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
PC78MR-6
S-7
TROUBLESHOOTING
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Seiz
ed t
u rbo
Clog
char
ger,
ged
air c
inter
Wor
lean
fere
n pis
nce
er e
leme
ton
r in g
Clog
nt
,
c
ge d
ylind
, sei
er
Imp
zed
rope
r i n je i n j e c t i o
nn
Defe
ction
ctive
timin ozzle
i
g
n
jecti
Imp
on p
rope
u mp
r va
lve c
Crus
(exc
lear
essi
hed
ance
ve in
, clo
gge
Lea
jecti
dm
kage
on)
u
f
fler
of a
ir be
Defe
twee
ctive
n tu
cont
Defe
rboc
act o
ctive
harg
f val
er a
injec
ve a
nd h
tion
nd v
ead
p um
a
l
v
e se
p (ra
at
ck, p
lung
er s
eize
d)
Causes
Questions
Suddenly
Gradually
Check items
Troubleshooting
PC78MR-6
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
20-315
S-8
TROUBLESHOOTING
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Brok
en p
iston
Wor
ring
n pis
ton
ring
Clog
, cyli
ged
nde
brea
r line
L ea
t
h
e
r
r or
kage
brea
f
r
o
Lea
m
t
h
e
o
r ho
kage
i l f ilt
se
er o
from
r oil
L ea
oil p
cool
kage
ipin g
er
from
L ea
oil d
kage
rain
f
rom
p lug
Brok
oil p
en o
an o
i l co
r
cylin
Wor
oler
der
n se
hea
a l at
d
Wor
turb
ine e
n se
al at
n
d
Wor
blow
n, b
er e
roke
nd
n re
Dus
ar s
Turb
t suc
e
a
ocha
l, se
ked
al su
rger
Wor
in fr
om
n va
r
f
a
ce
intak
lve (
e sy
stem
stem
, gu
ide)
, bro
ken
seal
Causes
Questions
Excessive
None
Check items
Troubleshooting
20-316
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
PC78MR-6
S-9
TROUBLESHOOTING
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
nd
Causes
Wor
n pis
ton
r ing
Clog
, cyl
g ed
inde
brea
r line
Clog
ther
r
, bre
g ed
athe
oil fi
lter
Wor
r ho
se
n va
lve,
Clog
valv
ged
e gu
oil c
ide
oo le
Clog
r
ged
t
urbo
Defe
char
ctive
ger
seal
drai
Exh
n pip
at tu
aust
e
rboc
smo
harg
ke is
er tu
blac
r b in
k
ee
Questions
Check items
Excessive
Amount of blow-by gas
PC78MR-6
Replace
Clean
Clean
Replace
Replace
Remedy
Clean
Troubleshooting
20-317
S-10
TROUBLESHOOTING
Defe
ctive
injec
tion
Defe
pum
ctive
p (ex
nozz
cess
Defe
le ho
ive in
ctive
lder
jectio
spra
injec
n)
y
Defe
tion
p
ctive
ump
fuel
p
lu
nger
injec
Exte
tion
rnal
timin
leak
g
age
Defe
from
ctive
fuel
oil se
pipin
Defe
al in
g, fu
ctive
side
el filt
adju
feed
er
stme
pum
nt of
p (pis
fuel
ton)
cont
rol li
nkag
e
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Questions
Black
Check items
20-318
Adjust
Correct
Correct
Adjust
Replace
Remedy
Replace
When engine speed is measured, low idling and high idling speeds
are found to be high
Adjust
Troubleshooting
PC78MR-6
S-11
TROUBLESHOOTING
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
Internal leakage in lubrication system
Internal leakage in cooling system
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Brok
en o
il coo
ler c
Brok
ore,
en c
O-rin
ylind
g
er he
Hole
ad, h
s ca
used
ea d
g
b
aske
Inter
y pit
nal c
t
ting
rack
s in
cylin
der b
lock
Causes
Questions
Check
items
Troubleshooting
PC78MR-6
Replace
Replace
Replace
Remedy
Replace
20-319
TROUBLESHOOTING
S-12
Wor
Clog
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
ged
oil fi
lter
n be
arin
g, jo
Clog
urna
ged
l
stra
iner
C lo g
insid
ged
e oil
or b
Brok
roke
pan
en s
uctio n oil pip
Defe
e ins
n pip
ctive
i de o
e br
azin
i l pa
oil p
Lack
g
n
ump
of o
i
l
i
n oil
Defe
pan
ctive
regu
Defe
lator
ctive
valv
relie
e
Lea
f val
king
ve
, cru
Defe
shed
ctive
hydr
aulic
oil le
Defe
vel s
pipin
ctive
enso
g
oil p
r
r
essu
Wat
er, f
r
e
s
uel i
enso
n oil
r
Causes
Questions
Check items
Sometimes lights up
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 found when oil is drained
Metal particles are stuck to oil filter element
20-320
Replace
Replace
Correct
Adjust
Adjust
Add
Replace
Correct
Clean
Clean
Remedy
Clean
Troubleshooting
PC78MR-6
S-13
TROUBLESHOOTING
Questions
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Brok
en o
i l co
oler
Defe
core
ctive
, Onozz
ring
Brok
le ho
en cy
lder
linde
slee
r hea
Wor
ve
d, he
n, d
ad ga
ama
sket
ged
Defe
(prec
r
ear
ctive
ombu
seal
pum
stion
Defe
s
u
p
rfac
cham
auxi
ctive
e
ber)
l
i
a
r
p
y
art i
Defe
e
q
uipm
nsid
ctive
e inj
e
n
t
t
herm
ectio
seal
Hole
n pu
osta
s ma
t
mp
de b
Crac
y pit
ks in
ting
side
cylin
der
bloc
k
Causes
Check items
PC78MR-6
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Remedy
Replace
20-321
S-14
TROUBLESHOOTING
Brok
en w
ater
Clog
p um
ged
p
, cru
shed
Clog
ged
radia
radi
tor f
ator
Defe
ins
core
ctive
t
h
Defe
erm
osta
ctive
t (do
wate
es n
Lack
r te m
ot o
of co
p
pen
erat
o ling
)
ure
Fan
wate
gau
belt
ge
r
slipp
Clog
ing,
ged
worn
, bro
fan
ken
Defe
pulle
oil c
ctive
y
o
o
p
ler
ress
Brok
ure
en c
valv
ylind
e
Hole
er h
s ma
ead
, he
de b
ad g
y pit
aske
ting
t
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Questions
Water temperature
gauge
Rises quickly
Does not go down from red range
Check items
Troubleshooting
20-322
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
PC78MR-6
S-15
TROUBLESHOOTING
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Exc
essi
ve w
ear
Seiz
of p
ed t
iston
urbo
char
Miss
ring
, cyl
ger,
ing,
inde
inter
seiz
r line
fere
ed b
Clog
nce
r
ushi
ged
ng
Defe , seized
ctive
injec
tion
injec
Defe
nozz
tion
ctive
le
p um
injec
p (ra
Defo
tion
ck, p
rme
pum
l ung
d fa
p (e
er s
n, fa
Defe
xces
eize
n be
ctive
d)
s
ive i
lt int
a
d
njec
justm
erfe
Brok
tion)
renc
en d
e
n
t of
e
ynam
valv
ic va
Imp
e cle
rope
lve s
aran
ystem
r ge
ce
ar tr
Lea
(valv
kage
ain b
e, ro
ackl
of a
cker
ash
ir be
Defe
lever
twee
ct ins
, etc
ide m
n tu
.)
rboc
uffle
harg
r (div
er a
iding
nd h
boar
ead
d ou
t of p
ositio
n)
Causes
Questions
Condition of abnormal
noise
Gradually occurred
Suddenly occurred
Troubleshooting
PC78MR-6
Replace
Correct
Correct
Replace
Adjust
Correct
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
20-323
S-16
TROUBLESHOOTING
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Causes
Wor
n co
nne
cting
Wor
n ba
rod,
lanc
main
Loo
er, c
bea
se e
am
ring
ngin
bush
em
Brok
in
g
oun
en p
t
ing b
art i
nsid
olts,
Imp
e ou
rope
brok
tput
r ge
en c
ar tr
shaf
ushi
Defe
ain b
t (da
ctive
on
mpe
ackl
dyna
Defe
mic v
ash
r)
a
ctive
lve s
ystem
injec
(valv
tion
e, roc
pu m
ker le
p (e
ver, e
xces
tc. st
sive
uck)
injec
tion)
a If there is abnormal noise together with the vibration, carry out troubleshooting also for Abnormal
noise is made
Questions
Check items
Troubleshooting
20-324
Adjust
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
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
N-1
TROUBLESHOOTING
Remedy
1
NO
YES
Condition is normal
Defective controller
Replace
2
NO
YES
3
Is resistance between P02 (Female) (9),
(10) M96 (Female) (21) normal?
YES
NO
Replace
20-402
PC78MR-6
PC78MR-6
20-501
TROUBLESHOOTING
20-502
PC78MR-6
TROUBLESHOOTING
Service Code
Troubled System
E323
E325
E05
E328
E304
E314
Stall of motor
(When burn preventive function of motor operates)
Contents of Trouble
1) Short circuit in wiring harness between M97
pin 25 K32 pin 1.
2) Short circuit in relay K32.
1) Short circuit in wiring harness between M97
pin 35 K33 pin 1.
2) Short circuit in relay K33.
1)
2)
3)
4)
1) Short circuit or disconnection in wiring harness between M97 (4) M36 (1).
2) Disconnection in wiring harness between
Disconnection engine stop solenoid relay system
M36 (2) chassis ground.
3) Trouble in M36 relay.
Short circuit in engine stop solenoid relay system
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
1. Fuel control dial cannot be operated (For acceleration and deceleration).
2. One-touch slow-down mechanism cannot be operated.
3. When working mode is changed,
engine speed does not change.
Motor starts and stops from slow to full and from full to slow If accelerator, decelerator, or
in 2 seconds.
one-touch slow-down mechanism works for more than 10
seconds, motor drive relay output, accelerator relay output,
M36 (male)
Resistance
(1) (2)
68 z 10%
PC78MR-6
20-505
TROUBLESHOOTING
User
Code
Engine speed does not rise sharply (Does not follow up accelerator pedal)
Engine stops
Engine hunts
11
12
14
15
16
17
19
20
Deceleration signal
Monitoring Code
314 227
323 325 328 (304
2) ( 2)
18
Stall of motor
10
13
E05
Service
Code
1
Self-diagnosis Display
Acceleration signal
Items Checked/Inspected
by
monitoring
20-506
PC78MR-6
TROUBLESHOOTING
95 Series
Min. 105 C
Engine speed
Items
Items checked/
inspected
inspected by with machine
monitoring
monitor
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)
(S-14)
(S-15)
(S-16)
E-4
E-6
E-4, E-5
E-8
M-2
PC78MR-6
20-507
E-1
TROUBLESHOOTING
Remedy
1
Turn starting switch ON
20 30 V
YES
Defective controller
Replace
2
Turn starting switch ON
20 30 V
YES
NO
Disconnection or defective
Repair or
contact in wiring harness between
fuse 20 battery relay terminal B replace
Disconnection or defective
Repair or
contact in wiring harness between
fuse 20 M97 (Female) (1), (11) replace
20-508
PC78MR-6
E-2
TROUBLESHOOTING
Remedy
1
Turn starting switch ON
Operate dial
NO
YES
Defective controller
Replace
Repair or
replace
Defective Relay
Repair or
replace
2
Disconnect M97 and K32
Min. 1 Mz
YES
NO
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.
E-2 Electrical circuit diagram of each system
PC78MR-6
20-509
E-3
TROUBLESHOOTING
Remedy
1
Turn starting switch ON
Operate dial (to lower)
NO
YES
Defective controller
Replace
Repair or
replace
Defective Relay
Repair or
replace
2
Disconnect M97 and K33
Min. 1 Mz
NO
YES
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.
E-3 Electrical circuit diagram of each system
20-510
PC78MR-6
E-4
TROUBLESHOOTING
Remedy
NO
YES
YES
Defective motor
(Drive system)
Replace motor
Defective relay
Replace
3
NO
YES
Disconnection or defective
contact in wiring harness between
Repair or
K27 (Female) (1), (4) K32
replace
(Female) (3),
K33 (Female) (3)
4
Disconnection or defective
contact in wiring harness between Repair or
M97 (Female) (19), (29), (39)
replace
K27 (Female) (5), (6), (3)
YES
Turn starting switch ON
When dial is raised
Between K97 (19), (39) (23):
24 V
When dial is lowered
(slowed)
Between M97 (29) (23):
24 V
PC78MR-6
5
When dial is operated, is each input NO
signal normal?
Replace
Defective controller
Replace
YES
20-511
TROUBLESHOOTING
E-4
20-512
PC78MR-6
E-5
TROUBLESHOOTING
slow: 113 0
When engine speed is at full
throttle: 202 5
Remedy
NO
YES
Defective controller
Replace
Repair or
replace
2
Disconnect M16
500 1,000 z
YES
Disconnect M16
500 1,000 z
YES
3
NO
Disconnection or defective
contact in wiring harness between Repair or
M96 (Female) (39) M16
replace
(Female) (1), (2)
Defective installation of engine
speed sensor
Test/Adjust
PC78MR-6
20-513
E-6
TROUBLESHOOTING
Remedy
1
NO
YES
Disconnect K18
When switch is ON: Max. 1z
When switch is OFF:
Min. 1 Mz
Disconnect K18
Turn starting switch ON
20 30 V
Replace lever
assembly
2
Is resistance between K18 (Male) (1) (2) NO
normal?
YES
Is voltage between K18 (Male) (1)
chassis ground normal?
YES
3
NO
Disconnection or defective
contact in wiring harness between Repair or
K18 (Female) (1) fuse (11) or
replace
breakage of fuse (11)
Disconnection or defective
contact in wiring harness between Repair or
K18 (Female) (2) M97 (Female) replace
(9)
20-514
PC78MR-6
E-7
TROUBLESHOOTING
The signals from battery relay terminal M on the monitor screen, etc. must be normal.
Carry out the following troubleshooting when the starting motor does not revolve.
Before carrying out the troubleshooting, check that fuses 12, 14, 15, and 20 are normal.
Lock the PPC hydraulic lock switch. (Raise the work equipment lever stand.)
[E304] Short circuit in engine stop solenoid relay system is displayed
[E314] Disconnection in engine stop solenoid relay system is displayed
Cause
Disconnect M97.
Resistance between M97
(female) (4) chassis
ground: 68 z 10%
Disconnect M36.
Resistance between M36
(male) (1) (2): 68 z 10%
Resistance between M36
(male) (1), (2) chassis
ground: Min. 1 Mz
Disconnect D26
(with M36 disconnected).
Resistance between M97
(female) (4) chassis
ground: Min. 1 Mz
Remedy
1
NO
YES
Defective controller
Replace
Replace
Repair or
replace
Replace
2
Is resistance between stop solenoid relay NO
M36 (male) (1) (2) and between each
pin and chassis ground normal?
YES
3
Is resistance between M97 (female) (4)
chassis ground normal?
YES
NO
PC78MR-6
20-515
E-7
TROUBLESHOOTING
Remedy
1
See TESTING AND
ADJUSTING
NO
YES
Defective adjustment of
linkage
Adjust
2
20 29 V
Turn starting switch ON
YES
Max. 1 z
Turn starting switch OFF
Disconnect T8
YES
20 29 V
Disconnect PULL terminal.
For only 3 seconds after
starting switch is turned ON.
NO
NO
Disconnection or defective
contact in wiring harness between Repair or
engine stop solenoid terminal
replace
GND chassis ground
NO
YES
Disconnection or defective
contact in wiring harness between Repair or
engine stop solenoid PULL
terminal fusible link M26 (male) replace
(2)
Defective engine stop solenoid
Replace
5
20 29 V
Turn starting switch ON
NO
YES
Disconnection or defective
contact in wiring harness between Repair or
outlet of fuse (15) M3 (3)
replace
solenoid terminal HOLD
6
20 29 V
Turn starting switch ON
YES
20-516
Replace
Disconnection or defective
contact in wiring harness between Repair or
starting switch terminal ACC
replace
inlet of fuse (15)
PC78MR-6
TROUBLESHOOTING
E-7
PC78MR-6
20-517
E-7
TROUBLESHOOTING
d) Starting System
Cause
Remedy
1
Are battery voltage and specific gravity of NO
battery fluid normal?
Min. 24 V
Specific gravity: Min. 1.26
YES
Charge or
replace
2
NO
Insufficient battery
capacity
YES
3
Is engaging sound of starting motor pinion NO
heard?
YES
4
Is voltage between starting motor terminal NO
B chassis ground normal?
YES
Repair or
Replace
Replace
Repair or
replace
5
Turn starting switch to
START position.
20 29 V
YES
YES
7
Is voltage between starting motor terminal NO
C chassis ground normal?
YES
8
Is voltage between safety relay terminal C NO
chassis ground normal?
YES
9
Is voltage between safety relay terminal R NO
chassis ground normal?
YES
To page 20-520
Disconnection or defective
contact in wiring harness
Repair or
between starting motor
replace
safety relay terminal C
starting motor terminal C
Defective alternator
Repair or
replace
Replace
To page 20-519
20-518
PC78MR-6
E-7
TROUBLESHOOTING
Cause
Remedy
10
20 29 V
Turn starting switch to
START.
NO
Disconnection or defective
contact in wiring harness
Repair or
between safety relay terminal S
replace
M30 (1) M5 (4) V2
(Female) (8)
YES
11
20 29 V
Turn starting switch to
START
NO
YES
Disconnection or defective
contact in wiring harness
between V2 (Male) (7) (8)
12
20 29 V
Turn starting switch to
START
NO
Disconnection or defective
contact in wiring harness
Repair or
between K23 (Female) (3) V3
replace
(Female) (3)
YES
13
20 29 V
Turn starting switch to
START
YES
20 29 V
Turn starting switch ON
Lock PPC lock switch
14
Disconnection or defective
contact in wiring harness
between K23 (Female) (5)
K51 (6) starting switch
terminal C
Repair or
replace
NO
YES
Max. 1 z
Turn starting switch ON
Disconnect K23
NO
15
YES
Disconnection or defective
Repair or
contact in wiring harness
between K23 (Female) (2) M1 replace
(2) chassis ground
Defective K23 relay
Replace
Disconnection or defective
contact in wiring harness
between K28 (Male) (3) K23
(Female) (1) chassis ground
Repair or
replace
16
20 29 V
Turn starting switch ON
Lock PPC lock lever
YES
NO
To page 20-520
PC78MR-6
20-519
E-7
TROUBLESHOOTING
Cause
Remedy
17
20 29 V
Turn starting switch ON
NO
YES
Disconnection or defective
contact in wiring harness
between K28 (Male) (1) fuse
(14)
Repair or
replace
Disconnection or defective
contact in wiring harness
between K28 (Female) (3)
K23 (Female) (1)
Repair or
replace
Cause
18
Connect (-) pin of tester to (-)
terminal of battery
20 29 V
YES
Disconnect terminal B
Turn starting switch to
START
NO
19
YES
20
YES
YES
20-520
21
NO
Remedy
Disconnection or defective
contact in wiring harness between
battery (+) terminal M27 (1), (2)
Replace
M2 (1) fuse (20) K51 (1)
starting switch terminal B
(including fusible link)
Defective starting switch
(between terminal B BR)
Replace
Disconnection or defective
contact in wiring harness between
starting switch terminal BR K51 Replace
(3) D51 (2), (1) battery relay
terminal BR (including diode)
Defective contact in wiring
harness between battery relay
terminal E - revolving frame
ground terminal
Repair or
replace
Replace
PC78MR-6
TROUBLESHOOTING
E-7
PC78MR-6
20-521
E-8
TROUBLESHOOTING
Remedy
1
NO
YES
Defective adjustment of
linkage
Adjust
2
Max. 1 V
Turn starting switch OFF
YES
NO
Replace
20-522
PC78MR-6
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
20-602
PC78MR-6
TROUBLESHOOTING
Service Code
Troubled System
Contents of Trouble
E232
E233
E203
E213
E206
E227
E414
E258
E02
E03
E216
20-604
PC78MR-6
TROUBLESHOOTING
Normal Condition
Problems on Machine
PC78MR-6
20-605
TROUBLESHOOTING
Troubled System
Contents of Trouble
(*1)
E251
E412
E413
E451
E452
E453
E40
E41
E454
20-606
(1)
PC78MR-6
TROUBLESHOOTING
Normal Condition
Problems on Machine
PC78MR-6
20-607
(1)
TROUBLESHOOTING
Service Code
(*2)
Trouble in boom bottom pressure sensor (overload sensor) system
E03
E02
User Code
Failure Mode
E40
232 233 203 213 206 216 227 414 251 258 412 413
q q q
q q
q q
Arm
Boom swing
Work equipment
Boom
Does not move.
Arm
Boom swing
Travel
q q
q q
Swing
q q
q q
Electronic
cushion
(*2)
Overload
warning
q
q
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
20-608
(1)
PC78MR-6
TROUBLESHOOTING
Diagnosis
code displayed
when trouble is not
detected
by monitoring
(*2)
Overload warning cancel signal input (2)
(*2)
Boom bottom pressure
ATT selection
Swing (4)
Travel (3)
E41
State of
Solenoid
Hydraulic Switch
Monitoring Code
1023
1021
1026
1060
1020
(*1)
(*1)
(*1)
(*1)
(*1)
(*1)
H-1
(*1)
(*1)
(*1)
H-2
(*1)
(*1)
(*1) (*1)
(*1)
H-3
H-7
(*1)
(*1)
q q q q
H-8
(*1)
H-10
H-11
(*1)
q q q q
H-12
(*1)
(*1)
H-14
H-26
(*1)
(*1)
C-19, H-28
H-33
(*1)
(*1)
C-18, H-34
(*1)
(*1)
H-39
q q
(*1)
q q
(*1)
C-15
(*1)
C-16
(*1) (*1)
(*1) (*1)
C-17
PC78MR-6
20-609
(1)
TROUBLESHOOTING
20-610
(1)
PC78MR-6
TROUBLESHOOTING
PC78MR-6
20-611
TROUBLESHOOTING
20-611-1
(1)
PC78MR-6
TROUBLESHOOTING
PC78MR-6
20-611-2
(1)
C-1, C-2
TROUBLESHOOTING
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
3 15 z
Resistance between solenoid
and chassis ground: Min. 1 Mz
NO
Replace
Disconnection or defective
contact in wiring harness
between M97 (Female) (16),
(23) M20 (Female) (1), (2)
Repair or
replace
Repair or
replace
Defective controller
Replace
YES
2
Disconnect M97
Resistance: 3 15 z
NO
YES
3
Disconnect M97
Resistance: Min. 1 Mz
YES
NO
20-612
PC78MR-6
C-3, C-4
TROUBLESHOOTING
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
35 80 z
Resistance between solenoid
and chassis ground: Min. 1 Mz
NO
Replace
Disconnection or defective
contact in wiring harness
between M97 (Female) (7), (3)
M14 (Female) (2), (1)
Repair or
replace
Repair or
replace
Defective controller
Replace
YES
2
Disconnect M97
Resistance: 35 80z
NO
YES
3
Disconnect M97
Resistance: Min. 1 Mz
YES
NO
PC78MR-6
20-613
C-5, C-6
TROUBLESHOOTING
C-5 [E206], C-6 [E216] Trouble in 2nd travel speed selection solenoid
system
Cause
Remedy
1
Disconnect M14
35 80 z
Resistance between solenoid
chassis ground: Min. 1 Mz
NO
Replace
Disconnection or defective
contact in wiring harness
between M97 (Female) (27), (3)
M15 (Female) (2), (1)
Repair or
replace
Repair or
replace
Defective controller
Replace
YES
2
Disconnect M97
Resistance: 35 80 z
NO
YES
3
Disconnect M97
Resistance: Min. 1 Mz
YES
NO
20-614
PC78MR-6
C-7
TROUBLESHOOTING
Remedy
1
Reset data again according to
potentiometer correction
procedure in back mode
NO
Defective controller
Replace
Replace
Disconnection or defective
contact in wiring harness of
circuit having abnormal
resistance (Between M95
M101) (See circuit diagram)
Repair or
replace
YES
2
NO
See Table 1
YES
3
M101
Between (A) (C): 3 7 kz
Between (A), (C) (B): 0 7 kz
(Resistance changes as shaft is
turned)
YES
Table 1
NO
Voltage (V)
Position
Monitoring Code
Standard Arm
Long Arm
0.9 1.8
0.8 1.8
3.2 4.2
3.2 4.2
1033
PC78MR-6
20-615
C-8, C-9
TROUBLESHOOTING
Remedy
Repair or
replace
Defective controller
Replace
Repair or
replace
Replace
1
When normal: There is a bit.
When reset: There is not a bit.
(Monitoring code 1026 (2))
NO
YES
2
0 26.5 MPa
(If boom circuit is relieved at
RAISE end, pressure changes.)
(Monitoring code 1040)
NO
YES
NO
YES
20-615-1
(1)
PC78MR-6
C-9
TROUBLESHOOTING
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
Disconnect M95
Min. 1Mz
NO
Repair or
Replace
Repair or
Replace
Replace
Defective controller
Replace
YES
2
disconnect M95, M101 and
M29.
Min. 1Mz
NO
YES
3
Between (A) (C): 3 7 kz
Between (A), (C) (B): 0 7 kz
(Resistance changes as shaft is
turned)
NO
YES
20-616
(1)
PC78MR-6
C-10, C-11
TROUBLESHOOTING
C-10 [E412], C-11 [E413] Trouble in boom swing angle sensor system
Cause
Remedy
1
0.3 4.7 V
(Monitoring code 1033)
NO
YES
Defective controller
Replace
Replace
Repair or
replace
2
Between (A) (C): 3 7 kz
Between (A), (C) (B): 0 7 kz
(Resistance changes as shaft is
turned.)
YES
NO
If the wiring harness between M95(3) M101 (B) is shorted actually, the controller output is cut out. Accordingly, if [E402] is displayed, the controller is defective.
PC78MR-6
20-617
(1)
C-12
TROUBLESHOOTING
C-12 [E451] Short circuit in boom swing LEFT stop EPC solenoid system
is displayed
Cause
Remedy
1
Is resistance between M11 (male) (1)
and (2) and between (2) and chassis
ground as shown in Table 1?
NO
Replace
Repair or
Replace
Repair or
Replace
Defective controller
Replace
YES
2
Is resistance between D33 (female) (1)
and chassis ground and between D33
(female) (1) and M97 (female) (23) as
shown in Table 2?
NO
YES
3
Is resistance between M97 (female)
(5) and M97 (female) (23) between
M97 (female) (5) as shown table 3?
NO
YES
Table 1
Table 2
5 25 z
Min. 1 z
Table 3
Min. 1 Mz
5 25 z
Min. 1 Mz
Min. 1 Mz
20-618
(1)
PC78MR-6
C-13
TROUBLESHOOTING
C-13 [E452] Disconnection in boom swing LEFT stop EPC solenoid system is displayed
Cause
Remedy
1
Turn starting switch OFF.
Disconnect M11.
Resistance: 5 25z
NO
Replace
Repair or
Replace
Replace
Defective controller
Replace
YES
2
Is resistance between D33
(female) (1) and M97 (female)
(23) and between D33 (female)
(2) and M97 (female) (5) as
shown in Table 1?
NO
YES
3
Turn starting switch OFF.
Disconnect D33.
* See TESTING AND ADJUSTING.
NO
YES
Table 1
Between D33 (1) M97 (23)
5 25 z
Min. 1 z
PC78MR-6
20-619
(1)
C-14
TROUBLESHOOTING
C-14 [E453] Short circuit in boom swing RIGHT stop EPC solenoid system is displayed
Cause
Remedy
1
Is resistance between M12 (male) (1)
and (2) and between (2) and chassis
ground as shown in Table 1?
NO
Replace
Repair or
Replace
Repair or
Replace
Defective controller
Replace
YES
2
Is resistance between D31 (female) (1)
and chassis ground and between D31
(female) (1) and M97 (female) (23) as
shown in Table 2?
NO
YES
3
Is resistance between M97 (female)
(15) and chassis ground and between
M97 (female) (15) and M97 (female)
(23) as shown in Table 3?
NO
YES
Table 1
Table 2
5 25 z
Min. 1 z
Table 3
Min. 1 Mz
5 25 z
Min. 1 Mz
Min. 1 Mz
20-620
(1)
PC78MR-6
C-15
TROUBLESHOOTING
C-15 [E454] Disconnection in boom swing RIGHT stop EPC solenoid system is displayed
Cause
Remedy
1
Turn starting switch OFF.
Disconnect M12.
Resistance: 5 25z
NO
Replace
Repair or
Replace
Replace
Defective controller
Replace
YES
2
Is resistance between D31
(female) (1) and M97 (female)
(23) and between D31 (female)
(2) and M97 (female) (15) as
shown in Table 1?
NO
YES
3
Turn starting switch OFF.
Disconnect D31.
* See TESTING AND ADJUSTING.
NO
YES
Table 1
Between D31 (1) M97 (23)
5 25 z
Min. 1 z
PC78MR-6
20-621
(1)
C-16
TROUBLESHOOTING
C-16 Boom swing LEFT end cushion does not work at all or normally
a
a
a
a
Check that the boom swing angle sensor voltage input is normal by monitoring code 1033.
(Standard value: 0.9 V when boom swing is at left end)
Check that the boom swing EPC current output is normal by monitoring code 1052.)
Check installation of the boom swing angle sensor for abnormality.
Cause
Remedy
1
When boom swing angle sensor is
corrected again, does condition
become normal?
NO
YES
Defective correction
Replace
Disconnection or defective
contact in wiring harness of
circuit having abnormal
resistance (See circuit diagram)
Repair or
replace
2
Between (A) and (C): 3 7 kz
Between (A), (C) and (B): 0 7
kz (If shaft is rotated, resistance
changes.)
NO
YES
3
Normal value: Max. 1 z
NO
YES
Defective controller
20-622
(1)
PC78MR-6
TROUBLESHOOTING
C-16
PC78MR-6
20-623
(1)
C-17
TROUBLESHOOTING
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
corrected again, does condition
become normal?
NO
YES
Defective correction
Replace
Disconnection or defective
contact in wiring harness of
circuit having abnormal
resistance
Repair or
replace
Defective controller
Replace
2
Between (A) and (C): 3 7 kz
Between (A), (C) and (B): 0 7
kz (If shaft is rotated, resistance
changes.)
NO
YES
3
Normal value: Max. 1 z
NO
YES
20-624
(1)
PC78MR-6
TROUBLESHOOTING
C-17
PC78MR-6
20-625
(1)
C-18
TROUBLESHOOTING
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.
When released, (1) (2) are
connected to each other
(Test on switch unit)
NO
Replace
Repair or
replace wiring
harness
Replace
YES
2
When locked: 0 V
When released: 20 29 V
NO
YES
20-626
(1)
PC78MR-6
C-19
TROUBLESHOOTING
Remedy
1
Check swing control lever.
NO
Go to F-1
Go to H-34
YES
PC78MR-6
20-627
(1)
C-20, C-21
TROUBLESHOOTING
Remedy
1
20 29 V
Turn starting switch ON
Disconnect K3
NO
YES
NO
Replace
Disconnection or defective
contact in wiring harness
between K3 (Female) (1)
chassis ground
Repair or
replace
Defective controller
Replace
Disconnection or defective
contact in wiring harness
between M95 (Female) (5) K3
(Female) (2)
Repair or
replace
YES
3
20 29 V
Turn starting switch ON
Disconnect K3
YES
NO
20-628
(1)
PC78MR-6
F-1
F-2
F-3
F-4
F-5
F-6
F-7
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 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
F-1
TROUBLESHOOTING
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
Disconnect M22.
Start engine.
Set swing control lever in
neutral: Min. 1Mz
Move swing control lever to
swing to left: Max. 1z
See note.
Disconnect M23.
Start engine.
Set swing control lever in
neutral: Min. 1 Mz
Move swing control lever to
swing to right: Max. 1 z
See note.
Start engine.
Set swing control lever in
neutral: 20 30 V
Move swing control lever: Max.
1V
1
NO
Replace
NO
Replace
Disconnection, defective
contact, or short circuit with
chassis ground in wiring
harness between M95 (Female)
(24) M22 (Female) (2), M23
(Female) (2)
Repair or
replace
Disconnection or defective
contact in wiring harness
between M22 (Female) (1), M23
(Female) (1) chassis ground
Repair or
replace
Defective controller
Replace
YES
YES
3
NO
YES
4
Is voltage between M95 (24) chassis
ground normal?
YES
Note:
Remedy
NO
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.
20-702
PC78MR-6
F-2
TROUBLESHOOTING
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
Disconnect M25.
Start engine.
Set swing control lever in
neutral: Min. 1 Mz
Move travel lever: Max. 1 z
See note.
Remedy
1
Is resistance between M25 (Male) (1)
(2) normal and are they insulated from
chassis ground?
NO
Replace
Disconnection, defective
contact, or short circuit with
chassis ground in wiring
harness between M95 (Female)
(18) M25 (Female) (2)
Repair or
replace
Disconnection or defective
contact in wiring harness
between M25 (Female) (1)
chassis ground
Repair or
replace
Defective controller
Replace
YES
NO
YES
Start engine.
Set travel lever in neutral:
20 30 V
Move travel lever: Max. 1 V
YES
Note:
NO
This item may be judged by fitting a short connector. In this case, judge by the voltage between M95
(18) chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
PC78MR-6
20-703
F-3
TROUBLESHOOTING
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
Start engine.
Set boom control lever in
neutral: 20 30 V
Move boom control lever to
lower boom: Max. 1 V
Disconnect M21.
Start engine.
Set boom control lever in
neutral: Min. 1 Mz
Move boom control lever to
lower boom: Max. 1 z
See note.
Remedy
1
NO
YES
Replace
Replace
Disconnection, defective
contact, or short circuit with
chassis ground in wiring
harness between M95 (Female)
(12) M21 (Female) (2)
Repair or
replace
Disconnection or defective
contact in wiring harness
between M21 (Female) (1)
chassis ground
Repair or
replace
2
Is resistance between M21 (Male) (1)
(2) normal and are they insulated from
chassis ground?
NO
YES
YES
Note:
NO
This item may be judged by fitting a short connector. In this case, judge by the voltage between M95
(12) chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
20-704
PC78MR-6
F-4
TROUBLESHOOTING
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
Start engine.
Set arm control lever in neutral:
20 30 V
Move arm control lever to move
arm in: Max. 1 V
Disconnect M24.
Start engine.
Set arm control lever in neutral:
Min. 1 Mz
Move arm control lever to move
arm in: Max. 1 z
See note.
Remedy
1
NO
YES
Replace
Replace
Disconnection, defective
contact, or short circuit with
chassis ground in wiring
harness between M95 (Female)
(6) M24 (Female) (2)
Repair or
replace
Disconnection or defective
contact in wiring harness
between M24 (Female) (1)
chassis ground
Repair or
replace
2
Is resistance between M24 (Male) (1)
(2) normal and are they insulated from
chassis ground?
NO
YES
3
Turn starting switch OFF.
Disconnect M95 M24.
Between M95 and M24: Max.
1z
Between wiring harness
chassis ground: Min. 1 Mz
YES
Note:
NO
This item may be judged by fitting a short connector. In this case, judge by the voltage between M95 (6)
chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
PC78MR-6
20-705
F-5
TROUBLESHOOTING
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.
Turn knob switch ON: 20 30 V
Turn knob switch OFF: Max. 1 V
NO
YES
2
Turn starting switch ON.
20 30 V
NO
Replace
Disconnection or defective
contact in wiring harness
between fuse (11) K18 (1)
knob switch inlet
Repair or
replace
Replace
Disconnection or defective
contact in wiring harness
between K18 (2) M97
(Female) (9)
Repair or
replace
YES
Turn starting switch OFF.
Disconnect knob switch terminal
K18.
Turn knob switch ON: Max. 1z
Turn knob switch OFF: Min. 1
Mz
3
Is resistance between K18 (Male) (1)
(2) normal?
YES
NO
20-706
PC78MR-6
F-6
TROUBLESHOOTING
F-6 Bit pattern 1026-(4) 2nd travel speed selection switch (pedal) does not
light up
Cause
Turn starting switch OFF.
Disconnect 2nd travel speed
selection switch terminal K3.
Turn 2nd travel speed selection
switch ON: Max. 1z
Turn 2nd travel speed selection
switch OFF: Min. 1 Mz
Remedy
1
NO
Replace
Disconnection, defective
contact, or short circuit with
chassis ground in wiring
harness between M95 (Female)
(5) K3 (Female) (2)
Repair or
replace
Disconnection or defective
contact in wiring harness
between K3 (Female) (1)
chassis ground
Repair or
replace
Defective controller
Replace
YES
2
Is resistance between K3 (Female) (2)
M95 (Female) (5) normal and are
they insulated from chassis ground?
NO
YES
3
Turn starting switch ON.
Turn 2nd travel speed selection
switch ON: Max. 1 V
YES
NO
.
F-6 Electrical circuit diagram of each system
PC78MR-6
20-707
F-7
TROUBLESHOOTING
a Before starting measurement, check that the compressor operates normally when the air conditioner is
turned ON.
Cause
Remedy
Disconnection, defective
contact, or short circuit with
chassis ground in wiring
harness between M97 (Female)
(10) K11 (Female) (8)
Repair or
replace
Defective controller
Replace
1
Is voltage between M97 (Female) (10)
chassis ground normal?
NO
YES
.
F-7 Electrical circuit diagram of each system
20-708
PC78MR-6
PC78MR-6
20-801
20-802
PC78MR-6
TROUBLESHOOTING
Logic valve
Merge valve
Unload valve
LS bypass choke
Spool
LS line choke
Control pump
Control Valve
Gear pump
Orifice
Servo valve
EPC valve
LS valve
PC valve
Piston pump
Hydraulic Pump
Strainer
Cap
Hydraulic oil
Failure mode
PTO spline
Tank
Engine system
Standard specification
Failure mode
Speed or power of 2 or more systems or work equipment, travel, and
blade is low
Engine speed lowers extremely or engine stalls
All work equip- 2 or more systems of work equipment, travel, swing, and blade do not
move
ment, travel,
swing, blade
Abnormal sound comes out (From around pump)
Fine controllability or response is low
q
q
q q q q q
q q
q q
q q
q q
q q
q q
q q q
q q
q q q q
q q
q q
q q
q q
q q
Boom
Speed or
Arm
power of work
equipment is
Bucket
low
Work equipment
q q
q q
Boom swing
q q
Boom
q q
q q
Work equipArm
ment does not
move
Bucket
q q
Boom swing
q q
Boom
q
q
q
q
Boom swing
q q
q q q
q q
q q
q q q
q q
q q
q
Travel speed does not change at all or does not change quickly
Swing
q q
q q
q q
q q
q q
Blade
20-804
q q
PC78MR-6
PC78MR-6
q
q
q q
q q q
q q
q
q
q
q
H- 2
q q
q
q
q
q
q
q
q
q
H-11
q
H-12
q
H-13
q
H-14
q q
q
H-15
q
q
H-16
q
q
H-17
q
q
H-18
q
q
q q
q q
q q
q q q q q q
H-35
q q
q q q q
H-36
q q
q
q
q q q q q
q q q
q
q q
q q
q q q
q q q
q
q
q
q
q
q
q
q
H-25
q
q q q q
q q q
q
q q q q
q q q
q
q
q
q
q q q
q q q q q q
q q
q q q q q
Hydraulic cylinder
Final drive
Parking brake
Swing Motor
Check valve
Counterbalance valve
Piston motor
Swing machinery
Parking brake
Suction valve
Check valve
Solenoid Valve
Safety valve
Piston motor
PPC Valve
q q q
Control relief valve
Control Valve
Suction valve
TROUBLESHOOTING
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
Travel Motor
q q
Failure
mode
H- 1
H- 3
H- 4
H- 5
q q q
H- 6
H- 7
q q q
H- 8
q
q
H- 9
q
q
H-10
H-19
H-20
H-21
H-22
H-23
H-24
H-26
H-27
H-28
H-29
q q
H-30
H-31
q q
H-32
H-33
H-34
H-37
H-38
H-39
H-40
H-41
H-42
H-43
H-44
20-805
H-1
TROUBLESHOOTING
Table 1
Work Equipment
Travel
Swing
Blade
Diagnosis Item
Go to a
Go to b
Go to c
Go to d
Go to e
Go to f
a) Speed or power of work equipment (including blade), travel, and swing systems is low
Cause
Remedy
1
NO
YES
Clean or
replace
Go to H-1, b)
2
3.14 0.3 MPa
{32 3 kg/cm2}
Run engine at full throttle
YES
3
NO
YES
4
When PPC lock solenoid valve is replaced, is NO
trouble repaired?
YES
20-806
Replace
Replace
PC78MR-6
H-1
TROUBLESHOOTING
b) Speed or power of all work equipment (excluding blade) and travel is low
Cause
Remedy
1
Curl bucket
26.5 1.47 MPa {270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
Curl bucket
26.5 1.47 MPa {270 15 kg/cm2}
Run engine at full throttle
NO
Go to corresponding section
in H-7 10, 26
NO
Repair or
replace
Repair or
replace
Go to corresponding section
in H-7 10, 26
Repair or
replace
Repair or
replace
Go to diagnosis No. 3
Repair or
replace
YES
3
When blade is relieved in RAISE mode,
does the travel speed rise?
YES
4
Curl bucket
26.5 1.47 MPa {270 15 kg/cm2}
Run engine at full throttle
NO
YES
5
NO
YES
6
NO
YES
Remedy
1
NO
YES
Go to corresponding section
in H-26, 33
Repair or
replace
Adjust or
replace
2
When gear pump relief valve is adjusted or NO
replaced, is trouble repaired?
YES
PC78MR-6
20-807
H-1
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
Go to corresponding section
H-26, 41
Go to corresponding section
H-26, 41
Go to corresponding section
H-26, 41
Repair or
replace
2
21.08 1.47 MPa
{215 15 kg/cm2}
Run engine at full throttle
NO
YES
3
When hose is disconnected from valve outlet NO
and plugged, is relief pressure normal?
YES
Remedy
1
Is all PPC pressure normal (At PPC pressure NO
inlet of control valve?
YES
2.11 0.1 MPa
{21.5 1 kg/cm2}
Run engine at full throttle and
curl bucket
2
NO
YES
3
When compound operation of travel, work
NO
equipment, and swing is performed, is trouble
repaired?
YES
Go to corresponding section
in H-7 10
4
NO
YES
5
Is check valve at swing holding brake
pressure inlet of logic valve normal?
YES
f)
NO
a If the PPC main pressure is judged low by troubleshooting in b) above, this trouble can occur.
20-808
PC78MR-6
H-2
TROUBLESHOOTING
Remedy
1
When bucket is relieved in CURL
mode and blade is relieved in RAISE
mode, does engine speed lower
much?
NO
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
3
26.5 1.45 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
4
12.74 1.47 MPa
{130 15 kg/cm2}
Run engine at full throttle
NO
YES
5
NO
YES
Adjust or
replace
Repair or
replace
Defective connection
Repair
Replace
Defective controller
Repair or
replace
6
NO
YES
7
Does monitor display error code "E02" NO
of TVC trouble?
YES
8
NO
YES
9
When engine speed changes, does
TVC current change?
NO
YES
To next page
PC78MR-6
20-809
H-2
TROUBLESHOOTING
Cause
Remedy
10
0.54 ~ 0.83 MPa
{5.5 ~ 8.5 kg/cm2}
Run engine at full throttle
YES
11
When PC valve is adjusted, is trouble
repaired?
NO
YES
Defective PC valve
Adjust or
replace
12
NO
YES
Clogged orifice
13
When EPC valve of TVC is replaced, is NO
trouble repaired?
YES
Repair or
replace
Repair or
replace
14
When pump assembly is replaced, is
trouble repaired?
YES
20-810
NO
PC78MR-6
H-3
TROUBLESHOOTING
Table 1
Work Equipment
Travel
Swing
Blade
Diagnosis Item
Go to a
Go to b
Go to c
Go to d
Go to e
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
YES
Clean or adjust
Replace
Replace
Replace
Replace
4
NO
YES
5
NO
YES
6
Is coupling or spline between main
pump and gear pump damaged?
YES
NO
PC78MR-6
20-811
H-3
TROUBLESHOOTING
Cause
Remedy
5
NO
Repair or
replace
YES
6
3.14 0.3 MPa {32 3 kg/cm2}
Run engine at full throttle
YES
b) All work equipment (excluding blade) and travel systems do not move
Cause
Remedy
1
NO
Defective control
Repair or
replace
YES
2
3.14 0.3 MPa
{32 3 kg/cm2}
Run engine at full throttle
YES
3
NO
YES
Go to corresponding section
in H-11 14, 29
Repair or
replace
Remedy
1
NO
Repair or
replace
Go to corresponding section
in H-34, 42
Adjust or
replace
YES
2
When gear pump circuit relief valve is
adjusted or replaced, is trouble repaired?
YES
20-812
NO
PC78MR-6
H-3
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
Go to corresponding section
H-29
Go to corresponding section
H-42
Go to corresponding section
H-29, 42
Repair or
replace
2
21.08 1.47 MPa
{215 15 kg/cm2}
Run engine at full throttle
NO
YES
3
When hose is disconnected from valve outlet NO
and plugged, is relief pressure normal?
YES
Remedy
1
3.14 0.5 MPa
{32 5 kg/cm2}
Run engine at full throttle
NO
YES
Go to corresponding section
in H-11 14
Go to corresponding section
in H-11 14
2
NO
YES
PC78MR-6
20-813
H-4
TROUBLESHOOTING
Remedy
1
NO
Supply
hydraulic oil
YES
2
NO
YES
3
NO
YES
Go to diagnosis No. 4
4
Foreign matter: Cloth, etc.
NO
YES
Remove
Repair or
replace
5
Is suction strainer clotted with metallic foreign NO
matter or metal chips?
YES
6
Is hydraulic tank cap clogged?
YES
20-814
NO
Re-inspect
Operate machine and
(according to
observe condition for a while change of
condition)
Negative pressure caused by Clean or
clogging of cap
replace cap
PC78MR-6
H-5
TROUBLESHOOTING
Remedy
1
See TESTING AND
ADJUSTING
NO
YES
2
NO
YES
Clean or
replace
Clean
Repair or
replace
Clean
Defective LS valve
Repair or
replace
Defective adjustment of LS
valve
Adjust
3
NO
YES
4
NO
YES
5
When LS valve is adjusted, is trouble repaired?
YES
PC78MR-6
NO
20-815
H-6
TROUBLESHOOTING
Remedy
1
NO
Retighten
YES
2
NO
YES
3
When centralized safety valve is replaced, is
trouble repaired?
YES
20-816
NO
Go to corresponding section
in H-15 H-18
Defective concentrated
safety valve
Clean
PC78MR-6
H-7
TROUBLESHOOTING
Remedy
NO
Diagnose by F-3
YES
2
NO
Replace
NO
Defective operation of
control valve spool
Repair or
replace
NO
Defective operation of
pressure compensation
valve
NO
Defective centralized
safety valve
Replace
Repair or
replace
Repair or
replace
Repair or
replace
Go to diagnosis No. 3
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
4
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
YES
5
Does control valve spool move smoothly?
YES
6
Does pressure compensation valve move
smoothly?
YES
7
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
YES
8
NO
YES
9
(Move boom RAISE with arm IN
oil.)
YES
PC78MR-6
20-817
H-7
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
NO
YES
3
NO
Defective operation of
control valve spool
Repair or
replace
Repair,
clean, or
replace
Malfunction of spool
Check 3
again
Defective concentrated
safety valve
Replace
Repair or
replace
Go to diagnosis No. 3
Repair or
replace
YES
4
Does poppet of pilot piston of boom lock
valve move smoothly and its orifice free
from clogging?
NO
YES
5
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
6
(Move boom LOWER with arm
OUT oil.)
YES
20-818
PC78MR-6
H-8
TROUBLESHOOTING
Remedy
1
NO
Diagnose by F-3
YES
2
0.54 0.83 MPa
{5.5 8.5 kg/cm2}
Run engine at full throttle.
NO
Replace
Repair or
replace
YES
3
26.5 1.49 MPa
{270 15 kg/cm2}
Run engine at full throttle.
NO
YES
4
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle.
NO
YES
5
Does control valve spool move smoothly?
NO
YES
6
Does pressure compensation valve move NO
smoothly?
Defective operation of
pressure compensation valve
YES
7
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle.
NO
YES
Replace
8
(Move arm IN with boom
RAISE)
NO
YES
Repair or
replace
Go to diagnosis No. 3
Repair or
replace
9
When swing operation and arm IN
NO
operation are executed simultaneously, is
trouble repaired?
YES
PC78MR-6
20-819
H-8
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
NO
YES
3
NO
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
YES
Repair or
replace
Defective concentrated
safety valve
Replace
Repair or
replace
Go to diagnosis No. 3
Repair or
replace
YES
5
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
6
(Move arm OUT with boom
LOWER oil)
YES
20-820
NO
PC78MR-6
H-9
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
NO
YES
3
NO
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
YES
Repair or
replace
Defective concentrated
safety valve
Replace
Repair or
replace
Go to diagnosis No. 3
YES
5
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
6
(Move bucket CURL with
arm IN oil)
YES
PC78MR-6
20-821
H-9
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
NO
YES
3
Does control valve spool move smoothly?
NO
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
Repair or
replace
Defective concentrated
safety valve
Replace
Repair or
replace
Go to diagnosis No. 3
YES
4
Does pressure compensation valve move NO
smoothly?
YES
5
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
6
(Move bucket DUMP with
arm OUT oil)
YES
20-822
PC78MR-6
H-10
TROUBLESHOOTING
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
pressure and carry out troubleshooting No. 2.
a Check that the emergency pump drive switch is turned OFF.
Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
YES
3
NO
Defective operation of
Repair or
pressure compensation valve replace
YES
YES
Repair or
replace
Defective pressure
compensation valve
Repair or
replace
Repair or
replace
Go to troubleshooting No. 3
Repair or
replace
Repair or
replace
5
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
6
(Move swing left by curling
bucket)
NO
YES
7
Is PPC valve output pressure normal?
PC78MR-6
NO
20-823
H-10
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
NO
YES
3
NO
Defective operation of
Repair or
pressure compensation valve replace
YES
YES
Repair or
replace
Defective pressure
compensation valve
Repair or
replace
Repair or
replace
Go to troubleshooting No. 3
5
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
6
(Move swing right by dumping
bucket)
YES
20-824
Repair or
replace
PC78MR-6
H-11
TROUBLESHOOTING
Remedy
1
kg/cm2}
NO
YES
2
NO
Repair or
replace
Deformation of cylinder or
work equipment (Boom does
not rise above the deformed
part
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle.
NO
YES
4
NO
YES
Repair or
replace
Go to diagnosis No. 2
Repair or
replace
5
(Move boom lower with arm IN oil)
YES
PC78MR-6
NO
20-825
H-11
TROUBLESHOOTING
Remedy
1
2.94 0.49 MPa
{30 5 kg/cm2}
Run engine at full throttle.
YES
2
NO
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle.
YES
4
NO
YES
Malfunction of spool in
lowering mode
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
Go to diagnosis No. 2
5
(Move boom lower with arm
OUT oil)
NO
YES
6
Is seal drain line of control valve
clogged?
YES
20-826
NO
Repair or
replace
Repair or
replace
PC78MR-6
H-12
TROUBLESHOOTING
Remedy
1
kg/cm2}
NO
YES
2
NO
Repair or
replace
Deformation of cylinder or
work equipment (Arm does
not move more than
deformed part)
Repair or
replace
Malfunction of spool in IN
mode
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
Repair or
replace
Go to diagnosis No. 2
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
4
NO
YES
5
(Move arm out with boom RAISE
oil)
NO
YES
6
When swing operation and arm IN
NO
operation are executed simultaneously,
is trouble repaired?
YES
PC78MR-6
20-827
H-12
TROUBLESHOOTING
Remedy
1
3.14 0.49 MPa {32 5 kg/cm2}
Run engine at full throttle
NO
YES
2
NO
Repair or
replace
Deformation of cylinder or
work equipment (Arm does
not move more than
deformed part)
Repair or
replace
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
Repair or
replace
Go to diagnosis No. 2
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
4
NO
YES
5
(Move arm out with boom LOWER
oil.)
YES
20-828
PC78MR-6
H-13
TROUBLESHOOTING
Remedy
1
kg/cm2}
NO
YES
2
NO
Is bucket dumped?
Repair or
replace
Deformation of cylinder or
work equipment
(Bucket does not move more
than deformed part)
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
4
NO
YES
Repair or
replace
Go to diagnosis No. 2
Repair or
replace
5
(Move bucket curl with arm IN oil)
YES
PC78MR-6
NO
20-829
H-13
TROUBLESHOOTING
Remedy
1
3.14 0.49 MPa {32 5 kg/cm2}
Run engine at full throttle
NO
YES
2
NO
Is bucket curled?
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
YES
4
NO
YES
Deformation of cylinder or
work equipment
Repair or
(Bucket does not move more replace
than deformed part)
Malfunction of spool in DUMP Repair or
mode
replace
Malfunction of pressure
compensation valve
Repair or
replace
Go to diagnosis No. 2
5
(Move bucket dump with arm OUT)
YES
20-830
NO
PC78MR-6
H-14
TROUBLESHOOTING
Remedy
1
kg/cm2}
YES
2
NO
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle.
NO
YES
Repair or
replace
Repair or
replace
4
NO
YES
Defective operation of
Repair or
pressure compensation valve replace
5
(Move swing left by curling bucket)
NO
Go to troubleshooting No. 2
Repair or
replace
Repair or
replace
YES
6
Is PPC valve output pressure normal?
YES
PC78MR-6
NO
20-831
H-14
TROUBLESHOOTING
Remedy
1
3.14 0.49 MPa {32 5 kg/cm2}
Run engine at full throttle.
NO
YES
2
NO
YES
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle.
3
NO
YES
4
NO
YES
Repair or
replace
Repair or
replace
Defective operation of
Repair or
pressure compensation valve replace
5
(Move swing right by dumping
bucket)
Go to troubleshooting No. 2
Repair or
replace
Repair or
replace
YES
6
Is PPC valve output pressure normal?
YES
20-832
NO
PC78MR-6
H-15, H-16
TROUBLESHOOTING
Remedy
1
NO
Repair or
replace
Repair or
replace
Replace
YES
2
NO
YES
Remedy
1
NO
Repair or
replace
Replace
Repair or
replace
Repair or
replace
YES
2
NO
YES
3
When suction valve is replaced with
blind plug, is trouble repaired?
YES
PC78MR-6
NO
20-833
H-17, H-18
TROUBLESHOOTING
Remedy
1
NO
Repair or
replace
Replace
Repair or
replace
Repair or
replace
YES
2
NO
YES
3
NO
YES
Remedy
1
NO
Repair or
replace
Repair or
replace
Repair or
replace
YES
2
NO
YES
Remedy
1
Is leakage from hydraulic cylinder
normal?
YES
20-834
NO
Repair or
replace
Repair or
replace
PC78MR-6
H-19, H-20
TROUBLESHOOTING
Remedy
1
NO
Replace
Replace
Replace
pump
assembly
Defective LS valve
Replace
YES
2
When poppet and spring of back
NO
pressure valve are replaced, is trouble
repaired?
YES
3
When LS valve is replaced, is trouble NO
repaired?
YES
Remedy
Compound Operation
Heavier Load
Side
Lighter Load
Side
Boom RAISE
Arm IN
Arm OUT
Boom RAISE
Bucket CURL
Arm OUT
Bucket CURL
Arm OUT
Boom LOWER
PC78MR-6
20-835
TROUBLESHOOTING
Remedy
Remedy
Repair or
replace
20-836
Remedy
Replace
PC78MR-6
H-24
TROUBLESHOOTING
Cause
Remedy
NO
Is undercarriage troubled?
YES
Defective undercarriage
Repair or
replace
Adjust, repair
or replace
Clean or
replace
Repair or
replace
Check, clean,
repair or
replace
Repair or
replace
Repair or
replace
2
Are PPC output pressures on both NO
sides normal?
YES
3
When both hoses are exchanged
at pump outlet, does deviating
direction change?
NO
YES
4
When both hoses between control
NO
valve and swivel joint are exchanged,
does deviating direction change?
YES
5
When only travel operation is
executed
NO
YES
6
Does spool of travel junction
NO
variable choke valve move smoothly
and is hole free from clogging?
YES
7
Does spool of pump merge valve
move smoothly and is hole free
from clogging?
NO
YES
8
When both check valves of main
relief circuit are exchanged, does
deviating direction change?
NO
YES
9
Does unload valve move smoothly NO
and is hole free from clogging?
YES
To 12 on next page
PC78MR-6
To 10 on next page
To 13 on next page
20-837
H-24
TROUBLESHOOTING
Cause
Remedy
10
NO
Repair or
replace
Malfunction of spool
Repair or
replace
Go to diagnosis No. 11
Check, repair
or replace
Repair or
replace
Repair or
replace
Repair or
replace
Adjust
YES
11
Does travel spool move smoothly?
NO
YES
12
When both hoses between
swivel joint and travel motor are NO
exchanged, does deviating
direction change?
YES
13
When both PPC hose are
exchanged, does deviating
direction change?
NO
YES
14
Does lever interfere with floor?
NO
YES
b) Travel deviation is large when machine starts (but normal during ordinary travel)
Cause
1
When machine starts, is dragging
sound of brake heard from travel
motor on deviating side?
Remedy
NO
YES
2
Does counterbalance valve of
travel motor move smoothly?
YES
20-838
NO
Repair or
replace
PC78MR-6
H-25
TROUBLESHOOTING
Remedy
1
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
YES
PC78MR-6
Replace
Replace
20-839
H-26
TROUBLESHOOTING
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.
a Check that the emergency pump drive switch is turned OFF.
Cause
Run engine at full throttle
and set travel lever in
neutral: 410 mA
Drive machine with engine
at full throttle: 100 mA
Run engine at full throttle
and set travel lever in
neutral: 0.45 0.83 MPa
{5.5 8.5 kg/cm2}
Drive machine with engine
at full throttle: 0 0.2 MPa
{0 2 kg/cm2}
Remedy
1
When machine is driven in
monitoring mode 1050, does
current lower?
NO
YES
2
NO
Replace
Omission of connection
Connect
Disconnection or defective
controller
Replace
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Malfunction of spool
Repair or
replace
YES
3
NO
YES
4
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
5
Is pressure at top PP pressure
pickup port of control valve same
as port pressure?
NO
YES
6
Does pump merge-divider spool
move smoothly and is hole free
from clogging?
NO
YES
7
NO
YES
8
Above 3.14 0.49 MPa
{32 5 kg/cm2}
NO
YES
9
Does spool move smoothly?
NO
YES
To 12 on next page
20-840
To 10 on next page
PC78MR-6
H-26
TROUBLESHOOTING
Cause
Remedy
10
NO
Repair or
replace
Repair or
replace
YES
11
NO
YES
12
When PPC circuit check valve is NO
replaced, is trouble repaired?
YES
PC78MR-6
Repair or
replace
Replace
20-841
H-27
TROUBLESHOOTING
Remedy
1
Does engine speed lower
(extremely only when machine is
steered during travel)?
NO
YES
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Defective PPC
Repair or
replace
Malfunction of spool
Repair or
replace
Repair or
replace
2
Is pressure at top PP pressure
pickup port of control valve same
as port pressure?
NO
YES
3
Does spool of travel junction
NO
variable choke valve move smoothly
and is hole free from clogging?
YES
4
Does pump merge-divider spool
move smoothly and is hole free
from clogging?
NO
YES
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
YES
7
NO
YES
8
When main relief circuit check
valve is replaced, is trouble
repaired?
YES
20-842
NO
Repair or
replace
PC78MR-6
H-28
TROUBLESHOOTING
H-28 Travel speed does not change at all or does not change quickly
Cause
Remedy
1
31.4 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
NO
Repair or
replace
Repair or
replace
Repair or
replace
YES
2
Is outlet choke of 2nd travel speed NO
selection solenoid valve free from
clogging?
YES
3
Is output pressure of 2nd travel
speed selection solenoid valve at
travel motor inlet normal?
YES
PC78MR-6
NO
20-843
H-29
TROUBLESHOOTING
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
Remedy
NO
YES
2
Is foreign matter drained from final NO
drive?
YES
Repair or
replace
Repair or
replace
Defective undercarriage
Repair or
replace
Repair or
replace
3
NO
YES
When driven on flat
concrete with engine at full
throttle, if pressure is below
11.7 MPa {120 kg/cm2}
YES
See
NO
YES
1
If machine does not travel on
flat concrete with engine at full
throttle and pump pressure
above about 10 MPa
{100 kg/cm2}, perform
diagnosis 2.
NO
Is undercarriage deformed or
damaged?
NO
Malfunction of spool
YES
7
Does pressure compensation valve NO
move smoothly?
YES
8
NO
YES
20-844
Repair or
replace
Repair or
replace
9
When PPC hose is replaced with
boom hose on control valve side,
does PPC pressure rise?
YES
NO
PC78MR-6
TROUBLESHOOTING
H-29
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, H-31
TROUBLESHOOTING
Remedy
1
Does PPC pressure lower immediately NO
after lever is returned? (At PPC pressure
inlet of control valve)
Defective PPC
Repair or
replace
Malfunction of spool
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
YES
2
NO
YES
3
NO
YES
4
NO
YES
5
Does travel motor check valve move
smoothly?
YES
NO
Remedy
20-846
PC78MR-6
H-32
TROUBLESHOOTING
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
valve move smoothly and is hole free
from clogging?
YES
Repair or
replace
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
Malfunction of spool
Repair or
replace
Repair or
replace
Defective PPC
Repair or
replace
4
NO
YES
5
NO
YES
6
NO
YES
7
When PPC valve is replaced, is
trouble repaired?
YES
PC78MR-6
NO
20-847
H-33
TROUBLESHOOTING
H-33 Swing speed or power is low (Work equipment, travel, and blade
operations are normal)
a If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
Cause
Remedy
1
NO
YES
Repair or
replace
NO
Repair or
replace
NO
Replace
Repair or
replace
Malfunction of controller
Replace
Clogging of choke
Malfunction of slow return valve
Clean
repair or
replace
Malfunction of spool
Repair or
replace
Repair or
replace
Repair or
replace
Clogging of choke
Clean
repair or
replace
2
21.08 1.47 MPa
{215 15 kg/cm2}
Run engine at full throttle
NO
YES
3
NO
YES
4
Is swing dragging sound heard?
YES
5
Is swing brake release pressure
output?
YES
6
When controller is replaced, is trouble NO
repaired?
YES
7
3.14 0.49 MPa {32 5 kg/cm2}
Run engine at full throttle.
YES
8
When fixed choke of swing PPC slow- NO
return valve is cleaned, is trouble
repaired?
YES
9
NO
YES
10
When choke of swing PPC line is
cleaned, is trouble repaired?
NO
YES
To 11 on next page
20-848
PC78MR-6
H-33
TROUBLESHOOTING
Cause
Remedy
11
When safety valve of swing motor is
adjusted or replaced, is trouble
repaired?
NO
YES
Adjust or
replace
Repair or
replace
Repair or
replace
12
When check valve and suction valve NO
of swing motor are replaced, is trouble
repaired?
YES
13
When reverse prevention valve is
replaced, is trouble repaired?
YES
PC78MR-6
NO
20-849
H-34
TROUBLESHOOTING
H-34 Machine does not swing (Work equipment, travel, and blade operations 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
Replace
Replace
2
Does pressure compensation valve
move smoothly and is hole free from
clogging?
NO
YES
3
21.08 1.47 MPa
{215 15 kg/cm2}
Run engine at full throttle.
NO
YES
4
kg/cm2}
YES
5
NO
YES
Repair or
replace
Repair or
replace
Go to diagnosis No. 6
Clean
repair or
replace
6
When safety valve of swing motor is
adjusted or replaced, is trouble
repaired?
NO
YES
7
When check valve and suction valve
of swing motor are adjusted or
replaced, is trouble repaired?
YES
20-850
NO
PC78MR-6
H-34
TROUBLESHOOTING
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
Run engine at full throttle
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Run engine at full throttle
Note that swing timer is set to
5 seconds
YES
Replace
Malfunction of spool
Repair or
replace
Repair or
replace
Malfunction of spool
Repair or
replace
Repair or
replace
3
Since motor may be broken,
operate in fine control mode
YES
4
When check valve and suction valve NO
of swing motor are replaced, is trouble
repaired?
YES
PC78MR-6
20-851
H-35
TROUBLESHOOTING
Remedy
1
When swing motor safety valve is
replaced, is trouble repaired?
YES
NO
Remedy
20-852
PC78MR-6
H-36
TROUBLESHOOTING
Remedy
1
21.08 1.47 MPa
{215 15 kg/cm2}
Run engine at full throttle
NO
YES
Go to b)
Remedy
1
NO
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
YES
2
NO
YES
3
NO
YES
4
NO
YES
5
When swing PPC slow-return valve,
swing PPC line, and swing PPC
circuit choke are cleaned, is trouble
repaired?
YES
PC78MR-6
NO
20-853
H-37, H-38
TROUBLESHOOTING
Remedy
1
NO
Repair or
replace
Go to H-36
Replace
Repair or
replace
YES
2
NO
YES
Remedy
1
NO
YES
2
NO
YES
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
3
NO
YES
4
Is foreign matter drained from final
drive?
YES
20-854
NO
PC78MR-6
H-39
TROUBLESHOOTING
Remedy
1
When connector of swing pressure
switch is disconnected, is trouble
repaired?
NO
YES
Replace
Replace
Repair or
replace
Malfunction of solenoid
Replace
valve
assembly
2
When connector of swing brake
release solenoid is disconnected, is
trouble repaired?
NO
YES
3
When hose of swing brake release
line is disconnected, is trouble
repaired?
YES
PC78MR-6
NO
20-855
H-40
TROUBLESHOOTING
Remedy
1
When air is bled from PPC, is trouble NO
repaired?
YES
Air in PPC
Bleed Air
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
valve move smoothly and is hole free
from clogging?
YES
Repair or
replace
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
Malfunction of spool
Repair or
replace
Repair or
replace
Repair or
replace
4
NO
YES
5
Does pressure compensation valve
move smoothly and is hole free from
clogging?
NO
YES
6
NO
YES
7
When PPC valve is replaced, is
trouble repaired?
YES
20-856
NO
PC78MR-6
H-41
TROUBLESHOOTING
H-41 Blade speed or power is low (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.
Cause
Remedy
1
kg/cm2}
NO
Repair or
replace
Go to diagnosis 5
Repair or
replace
Replace
Repair or
replace
YES
2
21.08 1.47 MPa
{215 15 kg/cm2}
Run engine at full throttle
NO
YES
3
NO
YES
4
NO
YES
5
Is hydraulic drift normal?
YES
PC78MR-6
NO
20-857
H-42
TROUBLESHOOTING
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
kg/cm2}
NO
Repair or
replace
Repair or
replace
Repair or
replace
Replace
YES
2
21.08 1.47 MPa
{215 15 kg/cm2}
Run engine at full throttle
NO
YES
3
NO
YES
4
NO
YES
5
Check hydraulic drift by H-41.
YES
If trouble is not repaired by H-41 Leakage in control valve (Large
leakage from line between swing
valve and blade valve)
20-858
Repair or
replace
PC78MR-6
H-42
TROUBLESHOOTING
Remedy
1
NO
YES
2
NO
Repair or
replace
Repair or
replace
Malfunction of spool
Repair or
replace
Replace
Repair or
replace
YES
3
NO
YES
4
NO
YES
5
Is it impossible to raise machine by
bracing blade on ground?
YES
PC78MR-6
20-859
H-43
TROUBLESHOOTING
Remedy
1
NO
Repair or
replace
Repair or
replace
YES
2
When hose is disconnected from
valve outlet and plugged, is hydraulic
drift large?
NO
YES
3
If blade is held in air and hydraulic
drift is large
NO
YES
4
NO
YES
Repair or
replace
Repair or
replace
Repair or
replace
Replace
5
If hydraulic drift is large when
machine body is raised with blade
YES
20-860
NO
PC78MR-6
H-44
TROUBLESHOOTING
Remedy
1
When air is bled from PPC, is trouble NO
repaired?
YES
Air in PPC
Bleed Air
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
valve move smoothly and is hole free
from clogging?
YES
Repair or
replace
Repair or
replace
Malfunction of pressure
compensation valve
Repair or
replace
Malfunction of spool
Repair or
replace
Repair or
replace
Defective PPC
Repair or
replace
4
NO
YES
5
Does pressure compensation valve
move smoothly and is hole free from
clogging?
NO
YES
6
NO
YES
7
When PPC valve is replaced, is
trouble repaired?
YES
PC78MR-6
NO
20-861
20-901
TROUBLESHOOTING
Troubled System
E101
1.
2.
3.
4.
E108
User Code
20-902
E112
E113
E114
E115
E116
Contents of Trouble
Trouble in internal memory
Overvoltage (Above 36 V)
Undervoltage (Above 12 V)
Disconnection of connector
PC78MR-6
TROUBLESHOOTING
1. If abnormality is detected
continuously, coolant temperature caution lamp
flashes and buzzer sounds.
2. If abnormality is detected
continuously, engine
speed is set to low idling.
20 30 V
Wiper stops
Same as [E112]
Same as [E112]
20 30 V
Same as [E112]
Same as [E112]
Same as [E112]
Same as [E112]
PC78MR-6
20-903
TROUBLESHOOTING
20-904
PC78MR-6
TROUBLESHOOTING
(2/2)
PC78MR-6
20-905
M-1
TROUBLESHOOTING
Remedy
1
NO
Normal
Repair or
replace
Replace
YES
2
Turn starting switch OFF
20 30 V
YES
NO
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 service codes saved in the memory are deleted by this operation.)
M-1 Electrical circuit diagram of each system
20-906
PC78MR-6
TROUBLESHOOTING
Remedy
1
NO
YES
See M-13, c)
Replace
2
Turn starting switch ON
NO
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.
PC78MR-6
20-907
M-8
TROUBLESHOOTING
M-8 Monitor panel segments do not light up at all for 3 seconds after starting 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.
20 30 V
NO
YES
2
Turn starting switch ON
20 30 V
NO
YES
3
Turn starting switch OFF.
Max. 1 z
Disconnect P01.
NO
YES
Repair or replace
Replace
Repair or replace
Repair or replace
Repair or replace
Repair or replace
4
Turn starting switch ON.
20 30 V
NO
YES
5
Turn starting switch ON.
20 30 V
YES
NO
20-908
Remedy
Replace
PC78MR-6
TROUBLESHOOTING
M-8
PC78MR-6
20-909
M-9,10
TROUBLESHOOTING
M-9 When starting switch is set to ON position, all monitor panel segments light up but do not go off
Cause
Defective monitor
panel
Remedy
Replace
Remedy
1
Disconnect terminal R1
Turn starting switch ON
Max. 1 V
NO
Defective starting
switch
Replace
Repair or replace
Defective monitor
panel
Replace
YES
2
Turn starting switch ON
Max. 1 V
YES
NO
20-910
PC78MR-6
M-11
TROUBLESHOOTING
Remedy
1
Run engine above medium
speed level
20 30 V
NO
Defective alternator
Replace
Disconnection or defective
contact in wiring harness
between alternator terminal R
P02 (Female) (11)
Repair or
replace
Replace
YES
2
Run engine above medium
speed level
20 30 V
YES
NO
PC78MR-6
20-911
M-11
TROUBLESHOOTING
Remedy
1
Run engine at low speed
NO
Replace
2
Turn starting switch OFF
Disconnect sensor wiring
harness and P02
YES
NO
Replace
20-912
PC78MR-6
M-12
TROUBLESHOOTING
Remedy
1
Disconnect terminal R
Turn starting switch ON
Max. 1 V
NO
Defective alternator
Replace
Repair or
replace
Replace
YES
2
Disconnect P02
Turn starting switch ON
Max. 1 V
YES
NO
PC78MR-6
20-913
M-12
TROUBLESHOOTING
Remedy
1
Turn starting switch OFF
Disconnect sensor
terminal T6
NO
Replace
Disconnection or defective
contact in wiring harness
between P02 (Female) (7)
sensor terminal T6
Repair or
replace
Replace
YES
2
Turn starting switch OFF
Disconnect P02 sensor
terminal T6
NO
YES
20-914
PC78MR-6
M-13
TROUBLESHOOTING
Remedy
PC78MR-6
Remedy
20-915
M-13
TROUBLESHOOTING
Remedy
1
Start engine
Set engine speed to
medium or higher
NO
Replace
Repair or
replace
Repair or
replace
YES
2
Start engine
NO
YES
3
Turn starting switch OFF
Disconnect P02 and M18
Max. 1 z
YES
NO
20-916
PC78MR-6
M-13
TROUBLESHOOTING
Remedy
1
Start engine
NO
Replace
Disconnection or defective
contact in wiring harness
between P02 (Female) (2) M9
(Female) (1)
Repair or
replace
Repair or
replace
YES
2
Start engine
Wait for 2 minutes. (Since
fuel level fluctuates, its
display is delayed.)
NO
YES
3
Connect M9 (Female) (1) to
chassis ground
Turn starting switch ON
Max. 0.3 V
YES
NO
PC78MR-6
20-917
M-14
TROUBLESHOOTING
Remedy
1
Is resistance between K53 (Female) (1)
(2) normal?
NO
Replace
YES
2
Disconnect K53
Turn starting switch ON
20 30 V
YES
NO
Disconnection, defective
contact, or short circuit with
Repair or
chassis ground in wiring
replace
harness between P02
(Female) (16) K53 (Male) (2)
Defective monitor panel
Replace
20-918
PC78MR-6
M-15
TROUBLESHOOTING
M-15 Monitor plane lamp for nighttime is not turned on (LC display is normal)
a Carry out the following troubleshooting when the headlamp and working lamp light up normally.
Cause
Remedy
1
Turn starting switch ON
Set monitoring code to "45"
NO
YES
Replace
Repair or
replace
Replace
2
Turn starting switch ON
Turn light switch ON
20 30 V
NO
YES
PC78MR-6
20-919
M-16, M-17
TROUBLESHOOTING
Remedy
1
Disconnect M18
Turn starting switch ON
NO
YES
Disconnection or defective
contact in wiring harness
between P02 (Female) (1)
M18 (Female) (1)
Repair or
replace
Disconnection or defective
contact in wiring harness
between M18 (Female) (2)
chassis ground
Repair or
replace
Replace
2
Turn starting switch OFF
Disconnect P02 and M18
NO
YES
3
Turn starting switch OFF
Disconnect M18
NO
YES
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to
1st line during operation)
Cause
Remedy
1
Disconnect M18
Turn starting switch ON
NO
YES
Replace
Repair or
replace
2
Turn starting switch ON
Disconnect P02 and
M18
YES
NO
20-920
PC78MR-6
M-18, M-19
TROUBLESHOOTING
Remedy
1
NO
YES
Replace
Repair or
replace
2
Turn starting switch OFF
Disconnect P02 and M9
NO
YES
Remedy
1
Disconnect M9
Turn starting switch ON
NO
YES
Disconnection or defective
contact in wiring harness
between M9 (Female) (2)
chassis ground
Repair or
replace
Replace
2
Turn starting switch OFF
Disconnect M9
NO
YES
PC78MR-6
20-921
M-20
TROUBLESHOOTING
Remedy
1
Start engine
Set engine speed to
medium or higher
YES
20-922
NO
Replace
See M-13 c)
PC78MR-6
M-21
TROUBLESHOOTING
Remedy
1
When float is moved up and down, does
resistance between connector (1)
flange change as shown in Table 1?
NO
YES
2
NO
Defective sensor
(See Note 2)
Replace
Clean or replace
connector
Replace (See
Note 2)
Defective sensor
Replace
Replace sensor
YES
3
Is float cracked, broken off, or scratched
badly?
NO
YES
4
Is breakage of wiring harness detected
by visual inspection?
NO
YES
Table
At upper (FULL)
stopper
Approx. 12 or below
At lower (EMPTY)
stopper
Approx. 85 110z
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 latter 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 measures to suppress the vibration.
PC78MR-6
20-923
M-22
TROUBLESHOOTING
Remedy
1
NO
YES
Clean connector
or replace sensor
Defective sensor
Replace
Replace sensor
2
Is breakage of wiring harness detected by
visual inspection?
NO
YES
Table
Normal
Approx. 37 50 kz
Temperature (25 C)
100 C
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 measures to suppress the vibration.
20-924
PC78MR-6
M-23
TROUBLESHOOTING
M-23 Wiper does not operate or operates while wiper switch is turned off
a) Wiper does not operate
a Check that fuse 14 is normal.
a If service code "E112", "E113", "E115", or "E116" is displayed, carry out the following troubleshooting.
Cause
Remedy
1
Close front window
Turn starting switch ON
Set monitoring code to "49"
NO
YES
Turn starting switch ON
Set wiper switch to "ON" or
"INT" position
Set monitoring code to "49"
2
When wiper switch is set to "ON" or
"INT" position, do bits (4), (5) of
monitoring code "49" go off?
NO
Replace
Replace
Repair or
replace
Replace
Inspection or
replace
Disconnection or defective
contact in wiring harness
having improper resistance
Repair or
replace
Replace
YES
3
Turn starting switch ON
NO
YES
4
Turn starting switch OFF
Disconnect P02 and W04
NO
YES
Max. 1 z
Turn starting switch OFF
Disconnect terminals (1), (2)
of W03.
5
Is resistance between rear limit
switch terminals W03 (1) (2)
normal?
NO
YES
6
Max. 1 z
Turn starting switch OFF
Disconnect terminals (1), (2)
of P02 and W03
NO
YES
Remedy
1
Close front window
Turn starting switch ON
Set monitoring code to "49"
NO
Replace
Replace
Repair or
replace
YES
2
Turn starting switch ON
PC78MR-6
NO
20-925
M-23
TROUBLESHOOTING
Table 1
Timing chart of ON-OFF operation of wiper
Symbol
Set Time
Item
Tia
0.13 sec
Tsa
10 sec
Tip
1.5 sec
Tsp
10 sec
Item
Symbol
Set Time
Tia
4 sec
Tsa
10 sec
Tip
1.5 sec
Tsp
10 sec
Table 2
Diagnosis 4
Resistance
Max. 1 z
20-926
Min. 1 Mz
PC78MR-6
TROUBLESHOOTING
M-23
PC78MR-6
20-927
M-24
TROUBLESHOOTING
M-24 Washer motor does not operate or operates while washer switch is
turned off
a) Washer motor does not operate
a Check that fuse 4 is normal.
a)-1 When [E114] is displayed
Cause
Remedy
1
Max. 1 V
Turn starting switch ON
Disconnect P02 and M31
NO
Repair or
replace
Replace
YES
1
20 30 V
Turn starting switch ON
Disconnect M31
NO
Remedy
Disconnection or defective
contact in wiring harness between
fuse 4 M31 (Female) (2)
Repair or
replace
Disconnection or defective
contact in wiring harness
between P01 (Female) (3) M31
(Female) (1)
Repair or
replace
Replace
Replace
YES
2
Max. 1 z
Turn starting switch OFF
Disconnect P01 and M31
NO
YES
3
Max. 1 V
Turn starting switch ON
Turn washer switch ON
NO
YES
Remedy
1
Min. 1 Mz
Turn starting switch OFF
Disconnect P02 and M31
NO
Repair or
replace
Replace
YES
20-928
PC78MR-6
TROUBLESHOOTING
M-24
PC78MR-6
20-929
FUEL TANK
Removal ................................................... 30-43
Installation ................................................ 30-44
CONTROLLER
Removal and Installation.......................... 30-44
MONITOR PANEL
Removal and Installation.......................... 30-45
AIR CONDITIONER UNIT
Removal ................................................... 30-45
Installation ................................................ 30-46
OPERATORS CAB
Removal and Installation.......................... 30-47
FLOOR FRAME
Removal ................................................... 30-48
Installation ................................................ 30-49
REVOLVING FRAME
Removal and Installation.......................... 30-50
SWING CIRCLE
Removal and Installation.......................... 30-51
WORK EQUIPMENT
Removal ................................................... 30-52
Installation ................................................ 30-53
SWING BRACKET
Removal ................................................... 30-54
Installation ................................................ 30-55
STEEL SHOE, RUBBER PAD SHOE,
ROAD LINER
Expansion and Installation ....................... 30-56
RUBBER SHOE
Removal and Installation.......................... 30-57
FINAL DRIVE
Removal ................................................... 30-57
Installation ................................................ 30-58
IDLER
Assembly.................................................. 30-58
RECOIL SPRING
Disassembly............................................. 30-60
Assembly.................................................. 30-61
TRACK ROLLER
Disassembly............................................. 30-62
Assembly.................................................. 30-63
HYDRAULIC CYLINDER
Disassembly............................................. 30-65
Assembly.................................................. 30-67
30-1
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 operation procedure, see the SPECIAL TOOL LIST given in this manual.
30-2
PC78MR-6
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
02
07376-50210
03
07376-50315
04
07376-50422
05
07376-50522
06
07376-50628
10
07376-51034
12
07376-51234
Split flange
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
number
Part Number
06
07049-00608
Dimensions
D
08
07049-00811
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.
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
Burring of engine
(For Model 102 engine)
Puller
790-331-1110
Wrench
796-732-1311
Oil stopper
796T-226-1120
Push tool
790-101-3400
Bearing puller
790-101-3220
Screw
790-101-5201
790-101-5281
Plate
790-101-5221
Grip
01010-51225
Bolt
790-101-5201
790-101-5331
Plate
Part No.
Part Name
795-799-1130
Gear
795-799-1390
or
795-799-1210
Remover
795-799-1170
Puller
1
1
4
790-101-5221 Grip
01010-51225
Bolt
790-101-5401
790-101-5431
Plate
790-101-5421
Grip
01010-51240
Bolt
796-765-1110
Push tool
792T-413-1120
Push tool
796-730-2300
Wrench assembly
795-630-1803
Torque wrench
790-201-2770
Spacer
1
Press fitting of main bearing
outer race
PC78MR-6
Disassembly, assembly of
swing machinery assembly
Sketch
Qty
Symbol
New/
Remodel
Component
Necessity
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 SPECIAL TOOLS).
30-7
790-101-5141
Plate
790-101-5021
Grip
01010-50816
Bolt
796-230-1110
Installer
790-101-5001
790-101-5111
Plate
790-101-5021
Grip
01010-50816
Bolt
796-230-1120
Installer
790T-230-1110
Push tool
791-685-8005
Compressor (B)
790-201-2860
Spacer
791-635-3160
Extension assembly
790-101-1600
Cylinder
(686kN{70ton})
790-101-1102
Pump
791-616-1030
Remover and
installer
Cylinder
(294kN{30ton})
790-101-1102
Pump
796T-267-1110
Push tool
790-201-2730
Spacer
790-101-2501
790-101-2510
Block
790-101-2520
Screw
791-112-1180
Nut
790-101-2540
Washer
790-101-2630
Leg
790-101-2570
Washer
790-101-2560
Nut
790-101-2650
Adapter
Disassembly, assembly of
carrier roller assembly
Disassembly, assembly of
recoil spring assembly
Expansion, installation of
track shoe assembly
790-105-1100
Disassembly, assembly of
center swivel joint assembly
Disassembly, assembly of
track roller assembly
Sketch
790-101-5001
30-8
Part Name
Disassembly, assembly of
idler assembly
Disassembly, assembly of
hydraulic cylinder assembly
Part No.
Qty
Symbol
New/
Remodel
Component
Necessity
Compression of spring
790-502-1003
790-101-1102
Pump
Disassembly, assembly of
hydraulic cylinder
PC78MR-6
790-102-3802
Wrench assembly
790-330-1100
Wrench assembly
Boom, blade
Removal,
and boom swing installation of
cylinder head
Arm and bucket assembly
790-302-1340
Bucket
Part No.
Part Name
790-102-1470
790-302-1290
790-720-1000
Expander
796-720-1670
Band
07280-01279
Clamp
796-720-1660
Band
07281-01159
Clamp
796-720-1650
Band
07281-01029
Clamp
796-720-1670
Band
07281-01279
Clamp
790-201-1702
790-101-5021
Grip
01010-50816
Bolt
790-201-1811
Push tool
790-201-1702
790-101-5021
Grip
01010-50816
Bolt
790-201-1791
Push tool
790-201-1702
790-101-5021
Grip
01010-50816
Bolt
790-201-1771
Push tool
790-201-1500
790-201-1620
Plate
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
790-201-1610
Plate
Disassembly, assembly of
hydraulic cylinder assembly
PC78MR-6
Removal,
installation of
piston nylon
nut
Boom
Blade
Sketch
Qty
Symbol
New/
Remodel
Component
Necessity
Press fitting of
cylinder head
bushing
Bucket
1
1
Press fitting of
cylinder head
dust seal
Arm and boom
swing
30-9
Disassembly, assembly of
hydraulic cylinder assembly
30-10
Grip
01010-50816
Bolt
790-201-1500
790-201-1580
Plate
790-101-5021
Grip
01010-50816
Bolt
790-441-1802
Remover
790-441-1810
Sleeve
792-900-1530
Screw
790-270-1110
Adapter
01803-13034
Nut
01643-33080
Washer
790-101-4000
Puller (490kN{50ton}) t
790-101-1102
Pump
790-101-2102
Puller (294kN{30ton}) t
790-101-1102
Pump
790-201-2850
Spacer
791-535-1170
Plug
791-520-4140
Screw
790-101-2420
Adapter
790-101-2540
Washer
791-112-1180
Nut
790-101-2102
Puller (294kN{30ton}) t
790-101-1102
Pump
799-703-1200
799-733-1120
Vacuum pump
(220V)
Vacuum pump
(240V)
799-703-1400
799-703-1110
X
Sketch
Part Name
790-101-5021
Part No.
Qty
Symbol
New/
Remodel
Component
Necessity
Press fitting of
cylinder head
dust seal
Bucket
PC78MR-6
PC78MR-6
30-11
30-12
PC78MR-6
COUNTERWEIGHT
COUNTERWEIGHT ASSEMBLY
REMOVAL
[*1]
INSTALLATION
PC78MR-6
[*1]
30-13
INJECTION PUMP
[*2]
30-14
PC78MR-6
INJECTION PUMP
INSTALLATION
[*1]
3 Sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}
[*2]
[*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. Furthermore, match the engraved lines (18) of holder
(13) and plate to each other and tighten the
mounting bolts temporarily.
PC78MR-6
30-15
CYLINDER HEAD
REMOVAL
6 Coolant: 10.5 l
[*1]
30-16
PC78MR-6
12. Loosen the 2 mounting bolts of the air compressor and adjustment bolt, and remove the air
compressor belt (12).
CYLINDER HEAD
PC78MR-6
30-17
CYLINDER HEAD
[*6]
32. Remove the air intake manifold (38) from the cylinder head assembly.
30-18
PC78MR-6
INSTALLATION
[*1]
3 U-clamp nut:
7.8 9.8 Nm {0.8 1.0 kgm}
[*2]
[*3]
[*4]
[*5]
[*6]
[*7]
CYLINDER HEAD
[*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
MAIN PUMP
MAIN PUMPASSEMBLY
REMOVAL
a Remove the engine hood and counterweight
(See REMOVAL OF COUNTERWEIGHT).
a Swing the upper structure from the parking position 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).
6 PTO: 0.5 l
30-20
PC78MR-6
CONTROL PUMP
INSTALLATION
INSTALLATION
[*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
REMOVAL
a Remove the engine hood and counterweight
(See REMOVAL OF COUNTERWEIGHT).
a Swing the upper structure from the parking position 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).
6 Hydraulic oil: 80 l
6 Cooling water: 8 l
30-22
PC78MR-6
11. Remove guard (13) of air conditioner compressor (10) from the fan guard.
12. Remove the mounting bolt of the adjustment bolt
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.
PC78MR-6
30-23
INSTALLATION
[*1]
[*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
RADIATOR ASSEMBLY
REMOVAL
a Remove the hydraulic oil cooler. For details, see
REMOVAL OF HYDRAULIC OIL COOLER. [*1]
1. Move oil cooler (2) removed from radiator (1) to
the left, without disconnecting the inlet and outlet
hoses.
2. Loosen remote plug (3) on the bottom of the radiator to drain the cooling water into a container.
Remove protector (4) of the air conditioner compressor from fan guard (1).
6 Cooling water: Approx. 4 l
a If the cooling water contains antifreeze, handle it as harmful liquid. Do not handle it illegally.
INSTALLATION
PC78MR-6
30-25
RADIATOR
INSTALLATION
[*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}
30-26
PC78MR-6
REMOVAL
swing
machinery
2. Remove the level gauge bracket (7) and disconnect the hose (8).
a Fit male or female plugs to the removed
hoses and elbows.
INSTALLATION
3. Disconnect hoses (1), (2), (3), (4), and (5) of the
swing motor.
a Fit male or female plugs to the removed
hoses and elbows.
a Record the disconnected hoses to prevent a
mistake in re-connecting them.
[*1]
PC78MR-6
30-27
SWING MACHINERY
SWING MACHINERY
ASSEMBLY
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
6 Swing machinery case: Approx. 2 l
30-28
PC78MR-6
SWING MACHINERY
7. Collar
1) Set the shaft and case assembly to a press
and push sub bearing (25) with tool F1.
a Operate the press slowly and push the
bearing until the 2-piece collar can be
removed.
2) Remove 2-piece collar (26).
8. Shaft assembly
1) Set block (1) to shaft and case assembly
(27). Using push tool (2) and the press,
remove shaft assembly (28).
2) Remove sub bearing (25).
PC78MR-6
30-29
SWING MACHINERY
ASSEMBLY
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)
30-30
PC78MR-6
4. Shaft assembly
1) Install collar (30) to shaft (31).
2) Using tool F6 and the press, press fit main
bearing (29).
a Press fitting force: Max. 65.7 ~ 178.4 kN
{Max. 6.7 ~18.2 tons}
PC78MR-6
SWING MACHINERY
5. Dust seal
Using tool F9, press fit dust seal (32).
a Replace the dust seal with new one.
30-31
SWING MACHINERY
30-32
PC78MR-6
SWING MACHINERY
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
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
INSTALLATION
30-34
PC78MR-6
INSTALLATION
6. Remove the cotter pin of the lock pin of the center swivel from above, then pull out the lock pin
and disconnect the lock plate.
PC78MR-6
30-35
DISASSEMBLY
ASSEMBLY
3 Mounting bolt:
31.4 2.94 Nm {3.2 0.3 kgm}
a When assembling, take care fully so that dirt,
rust, flaw, etc. will not cause a trouble.
a After assembling, seal each port with a polyethylene plug.
30-36
PC78MR-6
CONTROL VALVE
INSTALLATION
[*1]
1. When assembling, take care fully so that dirt,
rust, flaw, etc. will not cause a trouble.
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
CONTROL VALVE
ASSEMBLY
a When disassembling and assembling the precision 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 hitting 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
hydraulic system and can cause a trouble.
Accordingly, never wipe the parts with cloths or
paper.
a When assembling, replace the consumable parts
such as the O-rings and seals with new ones, as
a rule. Apply a little amount of clean grease to
the O-rings.
a Take care of the installing direction of each
spool.
1. When loosening or tightening mounting bolt (1)
used to install the retainer of the spool return
spring to each spool, be sure to put spool (2) in
valve chest (3) (to prevent deformation of the
spool).
3: 6.9 9.8 Nm {0.7 1.0 kgm}
30-38
PC78MR-6
3. When installing joint (3) to body (4), apply LOCTITE 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.
Female screw of body
PC78MR-6
30-39
6. Install washer (10) 1.6 mm thick first. If the difference between both sides at the stroke end of
the lever exceeds 0.7, change the washer thickness 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
PC78MR-6
30-41
HYDRAULIC TANK
ASSEMBLY
REMOVAL
a Swing the work equipment to a position at which
the hydraulic oil can be drained easily and lower
the work equipment to the ground.
HYDRAULIC TANK
INSTALLATION
30-42
PC78MR-6
FUEL TANK
10. Remove the nut and fuel tank band (11) on the
deeper side from the tank.
[*1]
PC78MR-6
30-43
11. Pull out fuel tank (4) and remove the clamp and
tank air bleed hose (12), then remove the fuel
tank.
CONTROLLER
CONTROLLER ASSEMBLY
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
3. Loosen the mounting bolts and remove connectors (4), (5), and (6) of controller (3).
[*1]
INSTALLATION
30-44
PC78MR-6
INSTALLATION
PC78MR-6
30-45
INSTALLATION
9. Remove 5 mounting bolts of operator's seat
stand (10).
10. Raise the operator's seat stand to 60 mm above
the floor by using 4 forcing screws (11) having
screwing length of 70 - 80 mm, and the unit can
be taken out.
a If the operator's seat stand is raised too high,
it will interfere with the wiring harnesses on
both sides.
[*1]
1. Connect the power cable for the compressor
after charging the air conditioner with refrigerant
gas (R134a).
2. Do not connect the outlet and inlet hoses of the
receiver drier before the air conditioner is
charged with refrigerant gas.
3. When assembling, take care that water (moisture), 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.
30-46
Size
Dimensions of
thread
Width
across
flats
Tightening torque Nm
{kgm}
# 08
16 x 1.5
19
# 11
20 x 1.5
24
# 14
22 x 1.5
27
PC78MR-6
OPERATORS CAB
OPERATORS CAB
ASSEMBLY
REMOVAL
10. Install a sling to the top of operator's cab assembly (12) and lift off the assembly.
4 Operator's cab assembly: 280 kg
INSTALLATION
PC78MR-6
30-47
FLOOR FRAME
30-48
PC78MR-6
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
[*1]
PC78MR-6
30-49
REVOLVING FRAME
REVOLVING FRAME
ASSEMBLY
REMOVAL
a Disconnect the wiring harness from the negative
terminal of the battery.
a Remove the work equipment assembly. (See
REMOVAL OF WORK EQUIPMENT ASSEMBLY.)
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.
2. Remove air cleaner assembly (1) and bracket
hose together.
INSTALLATION
30-50
SWING CIRCLE
INSTALLATION
REMOVAL
[*1]
[*2]
[*2]
PC78MR-6
30-51
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.
5. Remove the rod pin stopper used to lift boom cylinder (3) temporarily and pull out rod pin (4). [*2]
6. Lift off the boom cylinder (3) onto a stable stand
of proper heght.
a Check the quantity and positions of the
inserted shims.
30-52
PC78MR-6
WORK EQUIPMENT
INSTALLATION
[*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.
[*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.
PC78MR-6
30-53
SWING BRACKET
30-54
PC78MR-6
SWING BRACKET
INSTALLATION
[*1]
1. When installing, check that the O-ring is fitted to
the sealing part of the hose.
2. When installing the rubber hoses, be careful not
to twist them.
[*2] [*3]
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 cylinder and bracket will be 1
mm or less.
k When aligning the pin holes, never
insert your fingers in the pin holes.
[*4]
[*5]
[*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.
PC78MR-6
30-55
EXPANSION
INSTALLATION
[*1]
a Adjust the tension of the steel shoe and road
liner. For details, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
30-56
PC78MR-6
REMOVAL
REMOVAL
INSTALLATION
[*1]
a Adjust the rubber shoe tension. For details, see
TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
PC78MR-6
30-57
IDLER
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}
INSTALLATION
[*1]
30-58
PC78MR-6
IDLER
PC78MR-6
30-59
RECOIL SPRING
30-60
PC78MR-6
RECOIL SPRING
molybde-
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
TRACK ROLLER
30-62
PC78MR-6
TRACK ROLLER
ASSEMBLY
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).
8. Remove bushings (11) and (12) from roller (5).
PC78MR-6
30-63
TRACK ROLLER
30-64
PC78MR-6
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
ASSEMBLY
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).
PC78MR-6
30-65
HYDRAULIC CYLINDER
Arm
Bucket
Swing
Blade
75
60
70
75
30-66
PC78MR-6
ASSEMBLY
a Apply engine oil to the sliding surfaces of each
part and take care not to damage the packing,
dust seals, O-rings, etc.
a Do not insert the backup ring forcibly. Heat it in
water at 50 - 60C, then insert it carefully.
HYDRAULIC CYLINDER
PC78MR-6
30-67
HYDRAULIC 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).
3 Nylon nut:
Cylinder
name
Boom
Arm
Bucket
Blade
Swing
3 Head addembly:
Cylinder
name
Boom
Arm
Tightening torque
3.97 0.4 kNm
4.12 0.41 kNm
2.16 0.22 kNm
3.14 0.31 kNm
2.6 0.26 kNm
Bucket
Blade
Swing
Tightening torque
980 98 Nm{100 10 kgm}
1,107 110 Nm {113 42.0 kgm}
1st time: Tighten to 1,176 1,372 Nm
{120 140 kgm}.
2nd time: Loosen to 0 Nm {0 kgm}.
3rd time: Tighten to 392 Nm {40 kgm}
4th time: Apply angle tightening
(Tighten periphery of cylinder
head by 3.5 4.5 mm).
1.03 0.10 Nm {105 10.5 kgm}
981 98.1 Nm {100 10 kgm}
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)
PC78MR-6
90-3
(1)
PC78MR-6
90-5
(1)
PC78MR-6
90-7
(1)
PC78MR-6
90-9
(1)
PC78MR-6
90-11
(1)
PC78MR-6
90-13
(1)