PC78MR-6 Sebm030601

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

MAINTENANCE STANDARD......................................................................10-1
20
TESTING AND ADJUSTING .......................................................................20-1
30
DISASSEMBLY AND ASSEMBLY ..........................................................30-1
90
OTHERS ....................................................................................................................90-1
00-2
PC78MR-6
The affected pages are indicated by the use of the

following marks. It is requested that necessary
actions be taken to these pages according to the
table below.
Mark
Indication
Action required
Page to be newly added
Add
Page to be replaced
Replace
( )
Page to be deleted
Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

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

is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
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.
Always wear safety glasses when hitting

parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places.

Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
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.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
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.
Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models
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
Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.
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
Special safety precautions

are necessary when performing the work.
Caution
Special technical precautions or other precautions

for preserving standards
are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary

when selecting hoisting
wire, or when working posture is important, etc.
Tightening
torque
Places that require special

attention for the tightening
torque during assembly.
Coat
Places to be coated with

adhesives and lubricants,
etc.
Oil, water
Places where oil, water or

fuel must be added, and
the capacity.
Drain
Places where oil or water

m u s t b e d r a i n e d , a nd
quantity to be drained.
4
3
2
5
6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
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
Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

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

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the 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
1) Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push

until cover (3) contacts contact surface a of
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.
Disassembly
Type 2
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
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
Main applications, featuresr
Used to prevent rubber gaskets,

rubber cushions, and cock plug
from coming out.
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
Features: Resistance to heat and

chemicals
Used for anti-loosening and sealant purpose for bolts and plugs.
Used as adhesive or sealant for

metal, glass and plastic.
Used as sealant for machined

holes.
Used as heat-resisting sealant for

repairing engine.
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength after 30 minutes)
Used mainly for adhesion of rubbers, plastics and metals.
Resistance to heat, chemicals

Used at joint portions subject to
high temperatures.
Used as adhesive or sealant for

gaskets and packing of power
train case, etc.
Used as sealant for various

threads, pipe joints, flanges.
Used as sealant for tapered
plugs, elbows, nipples of hydraulic piping.
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread.
mab Used as sealant for oil pan,
final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
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 as heat-resisting sealant for

repairing engine.
Used as lubricant for sliding portion (to prevent from squeaking).
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
Ftures: Silicon based, quick hardening type

Used as sealant for flywheel
housing, intake manifold, oil an,
thermostat housing, etc.
General purpose type
Used for normal temperature,

light load bearing at places in contact with water or steam.
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

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

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter
Width across flat
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
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter
Width across flat
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
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
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
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
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 FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
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
Face 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
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13
- 16UN
16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3
1 - 12UNF
16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
02
03
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

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

etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm 2)
0.85
11
0.32
26
CLASSIFICATION BY COLOR AND CODE

Circuits
Priority
Classification
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
Color White & Blue

Code
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
Black & Red Red & Yellow
n
n
n
n
RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
Red & Blue Yellow & White Green & Blue
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
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0.220
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
SPECIFICATION DIMENSIONS DRAWING
SPECIFICATION DIMENSIONS DRAWING
Item
Unit
PC78MR-6
Steel shoe spec.
Road liner spec.
8,270
8,300
Machine weight (with blade)
kg
Bucket capacity
0.28
Engine model
KOMATSU S4D95LE-3-A Diesel engine
kW {HP}/rpm
40.5 {54.0}/1,850
Rated engine output

A
Overall length
mm
6,200
6,230
Overall height
mm
2,730
2,750
Overall width
mm
2,330
Shoe width
mm
450
Tail swing radius
mm
1,310
Overall length of track
mm
Distance between tumbler centers
mm
01-2
2,840
2,900
2,235
Minimum ground clearance
mm
Travel speed (Low/High)
km/h
360
2.8/4.2
400
Continuous swing speed
rpm
10.0
PC78MR-6
GENERAL
WORKING RANGE DRAWING
WORKING RANGE DRAWING
Working range (mm)
Steel shoe spec.
Max. digging reach
6,960
Max. digging depth
4,160
Max. digging height
6,570
Max. vertical wall depth
2,900
Max. dumping height
4,515
Min. swing radius of work equipment
2,775
Min. swing radius at boom swinging
2,125
Max. reach at ground level
6,750
Max. blade lifting height
380
Max. blade lowering depth
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)
Max. digging depth
mm
4,160
Max. vertical wall depth
mm
2,900
Max. digging reach
mm
6,960
Max. reach at ground level
mm
6,750
Max. digging height
mm
6,570
Max. dumping height
mm
4,515
Boom swing (left side/right side)
mm
580/930
Max. blade lifting height
mm
380
Max. blade lowering depth
mm
245
kN {kg}
61.3 {6,250}
Continuous swing speed
rpm
10.0
Max. slope angle for swing
deg.
16.0
Travel speed (Low/High)
km/h
2.8/4.2
Gradeability
deg.
35
Ground pressure
{kg/cm2}
Working range
Performance
SPECIFICATIONS
Max. digging force (Bucket)
kPa
37.3 {0.38}
Overall length (for transport)
mm
6,200
Overall width
mm
2,330
Overall height (for transport)
mm
2,730 (2,750)
Overall height (for operation)
mm
2,710 (2,750)
Ground clearance of counterweight
mm
735 (780)
Min. ground clearance
mm
360 (400)
Tail swing radius
mm
1,310
Min. swing radius of work equipment

(at boom swinging)
mm
2,125
Height of work equipment at min. swing radius
mm
5,210 (5,230)
Overall width of track
mm
2,320
Overall length track
mm
2,840 (2,900)
Distance between tumbler centers
mm
2,235
Track gauge
mm
1,870
Machine cab height
mm
1,745 (1,795)
Blade width height
mm
2,320 470
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
( ) Figures in ( ): Road liner specification
01-4
PC78MR-6
GENERAL
SPECIFICATIONS
Machine model
PC78MR-6
Serial Number
1001 and up
Model
S4D95LE-3-A
Type
4-cycle, water-cooled, in-line, direct injection
No. of cylinders - bore stroke
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}
Max. speed at no load
rpm
2,020
Min. speed at no load
rpm
1,130
Min. fuel consumption
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
Type of radiator core
Assembly-type triple grouser, 39 on each side

Assembly-type road liner, 39 on each side
Unit-type rubber crawler
Variable-capacity piston pump 1
Gear pump 2
(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
Boom swing cylinder
Work equipment cylinder
Hydraulic system
Arm cylinder
Boom cylinder
Type
01-6
Reciprocating piston
Inside diameter of cylinder
mm
115
Diameter of piston rod
mm
65
Stroke
mm
988
Max. distance between pinsmm
mm
2,393
Min. distance between pinsmm
mm
1,405
Type
mm
mm
100
mm
60
Stroke
mm
865
Max. distance between pins
mm
2,193
Min. distance between pins
mm
1,328
Type
mm
mm
90
mm
55
Stroke
mm
710
mm
1,765
mm
1,055
Type
mm
mm
120
mm
60
Stroke
mm
658
mm
1,687
mm
1,029
Type
mm
mm
mm
65
Stroke
mm
130
mm
679
mm
549
130
PC78MR-6
GENERAL
WEIGHT TABLE
WEIGHT TABLE
k This mass list is for reference in handling or transporting these components.

Unit: kg
Machine model
PC78MR-6
Serial Number
1001 and up
Engine assembly (without water and oil)
403
Engine (without water and oil)
300
Engine mount
30
PTO
Hydraulic pump
66
Cooling assembly (without coolant and oil)
29
Radiator (without coolant)
6.3
Oil cooler (without oil)
5.2
Revolving frame
1,220
Operator's cab
260
Operator's seat
18
Fuel tank (without fuel)
8.3
Hydraulic tank (without hydraulic oil)
70
Control valve
62
Counterweight
950
Additional counterweight
220
Swing motor (Including brake valve)
22
Swing circle
104
Swing machinery
47
Center swivel joint
16
Track frame assembly (without track shoe)

Track frame
1,067 [1,048]
704
Idler assembly
54 x 2
Recoil spring assembly
40 x 2
Carrier roller
3.4 x 2
Track roller
13 x 10
Travel motor (with reduction gears)
81 x 2
Sprocket
19 x 2
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
[ ] Figures in [ ]: Rubber shoe specification
PC78MR-6
01-7
GENERAL
WEIGHT TABLE
Unit: kg
Machine model
PC78MR-6
Serial Number
1001 and up
Track shoe assembly

City pad shoe (450 mm)
410 X 2
Road liner (450 mm)
450 X 2
Rubber shoe (450 mm)
385 X 2
Triple grouser (600 m)
495 X 2
Boom assembly
365
Swing bracket
234
Arm assembly
147
Bucket link assembly
56
Bucket assembly (with side cutter)
210
Blade assembly
374
Boom cylinder assembly
95
Arm cylinder assembly
72
Bucket cylinder assembly
51
Boom swing cylinder assembly
65
Blade cylinder assembly
46
Figures are common to the all specifications unless otherwise specified.
01-8
PC78MR-6
GENERAL
LIST OF LUBRICANTS AND COOLANT
LIST OF LUBRICANTS AND COOLANT
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
Engine oil pan
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
*1: ASTM D975 No. 1

Reservoir
PC78MR-6
Specified capacity
Refill capacity
Engine oil pan
7.5
7.0
PTO gear case
0.4
0.4
2.0
2.0
Final drive case (each)
1.3
1.3
Hydraulic system
120
64
Fuel tank
125
Cooling system
10.5
PC78MR-6
01-9
10 STRUCTURE, FUNCTION AND

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

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
Fin pitch (mm)
4.0/2
4.5/2
Total heat dissipation area

(m2)
16.53
6.15
Pressure valve cracking

pressure (kPa {kg/cm})
88.314.7
(0.90.15)
Vacuum valve cracking

4.9
(0.05)
10-3

POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
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.
Boom RAISE stop EPC valve

Arm IN stop EPC valve
Left offset stop EPC vaolve
Swing holding brake solenoid valve
2-stage travel speed selector solenoid valve
PPC lock solenoid valve
Swing machinery
Swing circle
PC78MR-6

SWING CIRCLE
SWING CIRCLE
Unit: mm
2.
3.
4.
5.
6.
7.
No.
Item
Axial clearance of bearing
Greasing for swing circle bearing

Greasing for swing circle pinion
Outer race
Inner race
Ball
Seal
PC78MR-6
Criteria
Remedy
Standard clearance
Allowable clearance
0.20 0.80
2.0
Replace
a. Position of inner race soft zone

b. Position of outer race soft zone
Specifications
Reduction ratio
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.
Swing pinion (Number of teeth: 10)

No. 2 planetary carrier
Ring gear (Number of teeth: 58)
No. 2 sun gear (Number of teeth: 14)
No. 1 planetary carrier
No. 1 sun gear (Number of teeth: 14)
Swing motor
Oil filler
Level gauge
No. 1 planetary gear (Number of teeth: 22)
No. 2 planetary gear (Number of teeth: 22)
Drain plug
10-6
Specification
Reduction ratio
(14+58)/14X(14+58)/14 =
26.45
Swing reduction ratio
26.45X8.0 = 211.59
Swing speed (rpm)
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
Backlash between No.

1 sun gear and No. 1
planetary gear
0.10 0.27
0.6

1 planetary gear and
ring gear
0.12 0.38
0.6

1 planetary carrier and
No. 2 sun gear
0.10 0.26

2 sun gear and No. 2
planetary gear
0.10 0.27
0.6

2 planetary gear and
ring gear
0.12 0.38
0.6

2 planetary carrier and
swing pinion
0.07 0.21
Backlash between
swing pinion and swing
circle
0.27 0.83
2.0
Wear of sliding surface

of swing pinion collar
against oil seal
PC78MR-6
Replace
Basic dimension
75
Allowance
0
- 0.074
Allowable Limit
74.8
Plating with hard

chromium or replace
10-7

TRACK FRAME AND IDLER CUSHION
10-8
PC78MR-6

Unit: mm
No.
Item
Criteria
Basic dimension
Allowable limit
Vertical width of Track frame

idler guide
Idler
support
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
Quantity of grease (cc)
96 (Steel shoe, road liner)

233 (Rubber shoe)
PC78MR-6
10-9

IDLER
IDLER
Unit: mm
No.
1
Item
Outside diameter of
projected part
Outside diameter of tread
Depth of tread
Width of projected part
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
Clearance between idler

shaft and bushing
Interference between idler

and bushing
Side clearance of idler
(Each side)
10
Thickness of tread (at center of width of tread)
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
Outside diameter of tread
120
113
Width of flange
43
Overall width
129
Width of tread
43
47.3
Overlay or replace
Clearance between idler

shaft and bushing
Interference between idler

and bushing
Side clearance of track
roller (Each side)
Thickness of tread (at center of width of tread)
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
Interference between shaft

and bearing
Interference between roller

and bearing
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
47 52 cc (Grease: ALVANIA EP-2)
Replace
Overlay or replace
PC78MR-6

SPROCKET
SPROCKET
Unit: mm
No.
Item
Criteria
Basic dimension
Wear of root diameter
Allowance
433.004
+1.0
-2.0
2.0
Remedy
Allowable limit
421
Wear of tip diameter
483.7
Wear of dip width
28
23
Wear of root width
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
*1. City pad shoe

Triple shoe (OPT)
*2. Road liner (OPT)

a Part P is the link on the press fitting side of bushing.
10-14
PC78MR-6

TRACK SHOE
Unit: mm
No.
Item
Criteria
Basic dimension
Allowable limit
154.25
157.25
41.2
37.2
Height of link
74
70
Thickness of link (Press fitting part of bushing)
20
16
Link pitch
Outside diameter of bushing
3
4
5
6
Shoe bolt pitch
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
Projection of regular bushing
3.15
13
Overall length of pin
131
14
Overall length of bushing

(Master bushing)
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
19.6 98.1 kN {2 10 ton}
Regular
pin
49.0 117.7 kN {5 12 ton}
Master pin
39.2 78.5 kN {4 8 ton}
Items marked with * are for the dry track.
PC78MR-6
10-15

TRACK SHOE
Unit: mm
No.
Item
Criteria
Tightening torque
(Nm {kgm})
a. Regular
link
Shoe bolt
20
b. Master link
Retightening angle (deg.)
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.)
Lower limit torque
Number of shoes
(Each side)
21
22
23
*24
*25
26
39
Interference between regular pin

and link
Clearance between regular pin
and bushing
Interference between master pin

and link
Clearance between master pin

and bushing
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
Items marked with * are for the dry track.
10-16
PC78MR-6

TRACK SHOE
TRIPLE SHOE AND CITY PAD SHOE
Unit: mm
No.
Item
Height of grouser
Overall height of shoe
Thickness of plate
4
5
Length of base of grouser
6
7
Criteria
Remedy
Basic dimension
Allowable limit
20
12
26
18
6
20
Overlay or replace
16
14
Length of upper side of grouser
PC78MR-6
10
12
10-17

TRACK SHOE
RUBBER SHOE (OPTIONAL)
Unit: mm
No.
Item
Wear of lug height
Wear of roller guide
Wear of meshing part of

sprocket
10-18
Criteria
Remedy
Basic dimension
Allowable limit
30
42
58
Replace
Basic dimension
Allowance
Allowable limit
22.5
0.5
27
PC78MR-6

ARRANGEMENT OF HYDRAULIC COMPONENTS
ARRANGEMENT OF HYDRAULIC COMPONENTS
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.
Blade PPC valve

Right work equipment PPC valve
Center swivel joint
Service PPC valve (Machine to which attachments can be installed)
Travel PPC valve
6-spool solenoid valve
Boom swing PPC valve
Blade cylinder
Boom hydraulic anti-burst valve (For EU spec.)
10-19
(1)

HYDRAULIC TANK AND OIL FILTER
HYDRAULIC TANK AND OIL FILTER
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
Quantity of oil in tank ( )
64
Bypass valve set

0.15 0.03
{1.53 0.3}
Pressure valve cracking

38 15
{0.39 0.15}
Vacuum valve cracking

05
{0 0.05}
PC78MR-6

CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
A1: From right travel control valve
A2: To right travel motor
B1: From right travel control valve
B2: To right travel motor
C1: From left travel control valve
C2: To left travel motor
D1: From left travel control valve
D2: To left travel motor
E1: From blade control valve
E2: To blade cylinder bottom
F1: From blade control valve
F2: To blade cylinder head
G1: From 2-stage travel speed selector solenoid valve
G2: To 2-stage travel speed selector solenoid valve
DR1: To tank
DR2: From travel motor drain port
1. Cover
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.
From travel control valve

From travel control valve
To tank
From 2-stage travel speed selector solenoid
valve
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
Brake releasing pressure

(MPa {kg/cm})
0.47
{4.8}
Speed changeover pressure

(MPa {kg/cm})
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.
4. 2-stage travel speed changeover mechanism

The 2-stage travel speed changing mechanism
consists of a changeover valve and a piston,
which change the displacement of the hydraulic
motor to either of 2 stages.
5. Parking brake
The parking brake is a friction plate brake, which
is built as a part of the hydraulic motor.
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.

Regulator valve
Spring
Check valve
End cover
Regulator piston
Swash plate
Pump merge-divider valve
Travel control valve
Brake valve
PC78MR-6
Since 2-stage travel speed selector solenoid

valve (1) is de-energized, the hydraulic oil from
the control pump does not flow into port Pi.
Accordingly, regulator valve (2) is pressed to the
left by spring (3).
Under this condition, the main hydraulic oil from
the control valve pushes check valve (4) and
flows into end cover (5) and then is shut off by
regulator valve (2).
The hydraulic oil in control chamber (a) flows
through passage (b) of regulator valve (2) into
the motor case.
As a result, swash plate (7) is pushed toward the
maximum swash plate angle by the main hydraulic oil in chamber (P) of the cylinder and the
motor capacity is increased to the maximum and
the travel speed lowers.
10-25

TRAVEL MOTOR
At high speed (With swash plate angle at minimum)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Regulator valve
Spring
Check valve
End cover
Regulator piston
Swash plate
Travel control valve
Brake valve
10-26
If 2-stage travel speed selector solenoid valve

(1) is energized, the pilot pressure from the control pump flows into port Pi and pushes regulator
valve (2) to the right.
Accordingly, the main hydraulic oil from the control valve flows through passage (c) of regulator
valve (2) into control chamber (a) and pushes
regulator piston (6) to the left.
As a result, swash plate (7) is pushed toward the
minimum swash plate angle and the motor
capacity is decreased to the minimum and the
travel speed rises.
PC78MR-6

TRAVEL MOTOR
Operation of brake valve
Operation when oil is supplied
The brake valve consists of check valves (1a)

and (1b) and counterbalance valve spool (2) as
shown in the following figure.
If the travel lever is operated, the hydraulic oil

from the control valve flows in port PA, pushes
valve (1a) open, and flows through motor input
port MA to motor outlet port MB.
At the same time, the hydraulic oil also flows
through orifice c of spool (2) to chamber D. If its
pressure becomes higher than the pressure of
spring (3), spool (2) is pushed to the left. As a
result, port MB is connected to port PB and the
motor outlet side opens and the motor starts revolution.
Since port PA is connected to port E, too, the
hydraulic oil operates parking brake piston (4) to
release the parking brake force.
Function
When the machine travels downhill, its speed

may become higher than the motor speed
because of its momentum. If the engine speed is
low at this time, the motor runs idle and the
machine runs away, and this situation is very
dangerous. The brake valve prevents this phenomenon and limits the travel speed according
to the engine speed (pump discharge).
PC78MR-6
10-27

TRAVEL MOTOR
Operation when oil is shut off
Operation of brake during downhill travel
If the control lever is returned to neutral, the

hydraulic oil from the control valve is shut off and
spool (2) is returned to the right by the reaction
force of spring (3).
At this time, the oil flows through orifice (c) of
chamber D into port PA and back pressure is
generated by the throttle effect of orifice (c). This
back pressure controls the speed of spool (2)
returning to the right.
Even after the hydraulic oil in port PA is shut off,
the motor continues revolution by inertia.
At this time, the returning oil is reduced gradually
according to the changing speed and shape of
spool (2) to stop the motor smoothly.
The motor continues revolution by inertia and
can cause cavitation. Since valve (1a) is operated by very slight negative pressure, however, it
opens ports PA and MA to prevent cavitation.
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
Operation of parking brake

When travel lever is operated
If the travel lever is operated, the hydraulic oil
from the pump moves spool (1) to the left and
flows through port E into chamber A of brake piston (2), then pushes brake piston (2) to the left.
As a result, the pressing force of spring (5) given
to plate (3) and disc (4) is lost, then plate (3) and
disc (4) are separated and the brake force is
released.
PC78MR-6
When travel lever is set to neutral position

If the travel lever is set to the neutral position, the
hydraulic oil from the pump is shut off.
The hydraulic oil in chamber (a) of brake piston
(2) is drained into the case and piston (2) is
pushed to the right by spring (5).
As a result, plate (3) and disc (4) are pressed
and the braking force is applied.
10-29

WORK EQUIPMENT CYLINDER

Boom cylinder
Arm cylinder
Bucket cylinder
10-30
PC78MR-6

Boom swing cylinder
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
961 96.1 Nm {98 9.8 kgm}

785 78.5 Nm {80 8.0 kgm}
Procedure 1) Tighten to 1.18 1.37 kNm {120 140 kgm}.
2) Loosen to 0 Nm {0 kgm}.
3) Tighten to 0.39 kNm {40 kgm}.
4) Control tightening of cylinder head by
turning angle (Turning distance: 3.5 4.5 mm).
Boom
swing
981 98.1 Nm {100 10.0 kgm}
Blade
1.030 103.0 Nm {105 10.5 kgm}
Boom
3.33 0.33 kNm {340 34.0 kgm} (2 Width across flats: 70 mm)
Arm
Bucket
Boom
swing
Blade
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
From control pump

Plug
From left work equipment PPC valve "ARM IN"
From right work equipment PPC valve "BOOM RAISE"
To PPC valve
To 2-stage travel speed selection valve
To swing holding brake
Plug
To control valve "ARM IN"
To control valve "BOOM RAISE"
To hydraulic tank
Left boom swing stop EPC valve
Right boom swing stop EPC valve
Not used
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
Serial No.: 1095 and up
10-35-1
(1)
PC78MR-6

A:
A5:
A6:
B1:
B2:
B3:
B4:
B5:
B6:
T:
1.
2.
3.
4.
5.
SOLENOID VALVE
From control pump

From left work equipment PPC valve "ARM IN"
From right work equipment PPC valve "BOOM RAISE"
To PPC valve
To 2-stage travel speed selection valve
To swing holding brake
Plug
To control valve "ARM IN"
To control valve "BOOM RAISE"
To hydraulic tank
Solenoid valve
6. Coil (ON-OFF type)
7. Push pin
8. Valve spool
9. Return spring
10. Valve body
EPC valve
11. Return spring
12. Guide
13. Valve spool
14. Push pin
15. Coil (Proportional)
Check valve
16. Plug
17. Spring
18. Ball
19. Adjustment screw
20. Locknut
21. Guide
22. Return spring
23. Valve spool
PC78MR-6
10-35-2
(1)

SOLENOID VALVE
PPC LOCK SOLENOID VALVE

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

If a signal current flows from the PPC hydraulic
lock switch or travel speed boost pedal to solenoid (1), solenoid (1) is energized.
Accordingly, spool (2) is pushed down by push
pin (4).
Under this condition, the pilot hydraulic oil flows
through port A, spool (2), and port B into the
actuator.
At the same time, port T is closed and the oil
does not flow into the tank.
PC78MR-6

SOLENOID VALVE
LEFT BOOM SWING STOP EPC VALVE

RIGHT BOOM SWING STOP EPC VALVE
Operation
When signal current is maximum (When coil is
energized and circuit pressure is maximum)
If the signal current flows from the controller into
coil (1), coil (1) is energized.
At this time, the thrust of coil (1) is maximum.
As a result, spool (2) is pushed down by push pin
(3).
Accordingly, all the pressurized oil from the PPC
valve flows through port A, spool (2), and port B
to the control valve.
At this time, port T is closed and any oil does not
flow in the tank.
PC78MR-6
When signal current is reduced (When coil is

energized and circuit pressure is low)
If the signal current flowing from the controller
into coil (1) is reduced, coil (1) is still energized
but its thrust is lowered in proportion to the signal
current.
As a result, push pin (3) pushes down spool (2)
and the pressurized oil from port A flows to port
B.
If the pressure in port B rises and the force
applied to face "a" of spool (2) becomes larger
than the thrust of coil (1), spool (2) is pushed up
and port A is disconnected from port B and connected to port T.
Accordingly, spool (2) moves up and down so
that the thrust of coil (1) will be balanced with the
pressure in port B.
As a result, the circuit pressure between the
PPC valve and control valve is controlled in proportion to the signal current.
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.
Signal current is 0 o increased o maximum

The valve operates in the order of 3, 2, and 1
explained above.
10-38
PC78MR-6

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)
(1) JIS Pattern

(2) Backhoe Pattern
* Operation pattern selection drawing (Port names correspond to symbols in drawing)
10-40
PC78MR-6

ACCUMULATOR FOR BRAKE
ACCUMULATOR FOR BRAKE

(If equipped)
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
Sealed gas pressure
(MPa {kg/cm})
0.1 {1} (at 80 C)
Max. actuating pressure
(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
10-42
PD2 : Pump drain (plug)

PDA : Air bleeder
PEN : Control pressure pickup port
PLS : LS pressure input (From control valve)
PPT : PTO oil filler
PS1 : Main pump suction
PEPC : EPC main pressure pickup port
PPLS : Pump pressure input (From control valve)
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
:
:
:
:
:
:
:
Pump average pressure

Drain (Plug)
EPC drain
Control pressure input
PTO oil filler
Pump suction
EPC main pressure pickup port
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
PC78MR-6
PD2 : Pump drain (plug)

PDA : Air bleeder
PEN : Control pressure pickup port
PGS : Gear pump suction
PLS : LS pressure input (From control valve)
PPT : PTO oil filler
PS1 : Main pump suction
PEPC :EPC main pressure pickup port
PPLS :Pump pressure input (From control valve)
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
PDE: EPC drain

1. EPC valve
PC valve
T: Drain
P3: Gear pump pressure input
PH: Pump shuttle pressure
PAV: Pump average pressure
PPL: PC valve output pressure
PEPCOUT: EPC output pressure
2. Lever
3. Spring
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
The oil in each cylinder of cylinder block (7) can

be drawn and discharged through valve plate (8).
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
Shaft (1) and cylinder block (7) revolve together

and shoe (5) slides on plane A. As rocker cam
(4) slants around ball (12) at this time, angle ( )
between the center line X of rocker cam (4) and
axis of cylinder block (7) changes. Angle ( ) is
called the swash plate angle.
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.
If the angle between the center line X of rocker

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

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
At this time, ports F and G of the LS valve are

connected to each other. As a result, the pressure in port J becomes drain pressure PT and
servo piston (6) moves to the left.
Consequently, the pump discharge is increased.
As servo piston (6) moves, lever (1) moves to the
left and spring (2) expands and its spring load is
decreased. Consequently, spool (3) moves to
the left to break the connection of ports C and D,
and then pump discharge ports B and C are connected.
As a result, the pressure in port C rises and the
piston pressure is increased and servo piston (6)
stops moving to the left.
(3) When pump pressure PAVE is high

The pressure of spool (4) is increased and spool
(3) is a little to the left (Fig. 2 and Fig. 5). At this
time, ports C and B are connected to each other
and the pressure in the LS valve is pump pressure PP.
At this time, ports F and G of the LS valve are
connected to each other. As a result, the pressure in port J becomes pump pressure PP and
servo piston (6) moves to the right.
Consequently, the pump discharge is decreased.
As servo piston (6) moves, lever (1) moves to the
right and spring (2) is compressed and its spring
load is increased. Consequently, spool (3)
moves to the right to break the connection of
ports C and B, and then drain pressure ports D
and C are connected.
As a result, the pressure in port C lowers and the
piston pressure is decreased and servo piston
(6) stops moving to the right.
Accordingly, the stopping position (= pump discharge) of servo piston (6) is decided by the
position where the pressure caused by pressure
PP applied to spool (4) is balanced with the force
of spring (2) applied through spool (3) (Fig. 3 and
Fig. 6).
(4) When swing gear pump pressure rises/lowers
The pressure of spool (4) changes and the pump
discharge changes similarly to the case where
the PAVE rises/lowers.
The PC-EPC valve changes the output pressure
according to the input current from the controller,
then the pressure of spool (5) changes and the
pump discharge changes similarly to the case
where the PAVE rises/lowers.
PC78MR-6

HYDRAULIC PUMP
When load is light
When load is heavy
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 load is heavy
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
(2) Sectional view
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Safety-suction valve (Blade head)

Suction valve (Left travel)
Suction valve (Right travel)
Suction valve (Boom swing head)
Suction valve (Boom bottom)
Suction valve (Arm head)
Suction valve (Bucket head)
Suction valve (Attachment)
Suction valve (Attachment)
Suction valve (Bucket bottom)
Suction valve (Arm bottom)
Suction valve (Boom head)
Suction valve (Boom swing bottom)
Suction valve (Right travel)
Suction valve (Left travel)
Suction valve (Blade bottom)
Main relief valve
10-58
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31
32.
33.
34.
Gear pump relief valve

Safety valve
Cooler bypass valve
Spool (Boom raise merge)
Spool (Blade)
Spool (Swing)
Spool (Left travel)
Spool (Right travel)
Spool (Boom swing)
Spool (Boom)
Spool (Arm)
Spool (Bucket)
Spool (Attachment)
Unload valve (P1)
Unload valve (P2)
LS pressure pickup plug (LS1)
PC78MR-6

CONTROL VALVE
Unit: mm
No.
Item
Criteria
Basic dimensions
35
Cooler bypass valve

spring
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
Spool return spring

(Work equipment)
41.1 X 19.3
40.5
34.3 N
{3.5 kg}
27.4 N
{2.8 kg}
37
Spool return spring

(Arm out)
42.3 X 19.2
38.9
103.9 N
{10.6 kg}
83.2 N
{8.48 kg}
38
Spool return spring

(Trave)
29.0 X 17.5
25.0
180.5 N
{18.02 kg}
14.5 N
{14.74 kg}
39
Unload valve spring
40.9 X 15.1
33.5
129 N
{13.2 kg}
103 N
{10.6 kg}
40
Boom RAISE merge

valve spring
42.4 X 19.0
13
287.3 N
{29.3 kg}
230 N
{23.44 kg}
41
Spool return spring

(Blade)
29.01 X 18.3
27.5
89.5 N
{9.1 kg}
71.6 N
{7.28 kg}
42
Spool return spring

(Boom raise)
41.13 X 19.3
38.5
136.4 N
{13.91 kg}
109 N
{11.13 kg}
43
Spool return spring

(Bucket curl,
Boom lower)
41.47 X 19.3
38.5
135.53 N
{13.82 kg}
108 N
{11.06 kg}
44
Spool return spring

(Boom swing)
29.20 X 17.5
25.0
162.54 N
{16.57 kg}
130 N
{13.26 kg}
45
Spool return spring

(Swing)
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.
Spool (Pump merge-divider valve)

Pressure compensation valve F (Left travel)
Pressure compensation valve F (Right travel)
Pressure compensation valve F (Boom swing)
Pressure compensation valve F (Boom)
Pressure compensation valve F (Arm)
Pressure compensation valve F (Bucket)
Pressure compensation valve F (Attachment)
Pressure compensation valve R (Attachment)
Pressure compensation valve R (Bucket)
Pressure compensation valve R (Arm)
Pressure compensation valve R (Boom)
Pressure compensation valve R (Boom swing)
Pressure compensation valve R (Right travel)
Pressure compensation valve R (Left travel)
10-60
CONTROL VALVE
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Pump pressure pickup plug (P2)

LS bypass plug (LS2)
LS bleed valve
Travel junction valve, LS bleed valve
Logic valve
Boom hydraulic drift prevention valve
Check valve (Blade)
Check valve (Swing)
Check valve (Boom bottom)
Check valve (Arm)
Check valve (Bucket)
Check valve (Attachment)
F: Flow control valve

R: Pressure reducing valve
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
valve spring
30.9 X 5.2
27
9.8 N
{1.0 kg}
7.85 N
{0.8 kg}
32
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
Check valve spring
27.2 X 6.9
22
3.92 N
{0.4 kg}
3.14 N
{0.32 kg}
35
Check valve spring
12.3 X 11.4
10.5
3.92 N
{0.4 kg}
3.14 N
{0.32 kg}
36
Check valve spring
21.9 X 5.0
15.8
1.96 N
{0.2 kg}
1.57 N
{0.16 kg}
37
Check valve spring
13.0 X 6.5
9.5
1.96 N
{0.2 kg}
1.57 N
{0.16 kg}
38
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
Check valve spring
Travel junction valve

spring
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
Pump pressure pickup plug (P1)

LS bypass plug (LS1)
Check valve (P1)
Check valve (P2)
Unit: mm
No.
Item
Criteria
Basic dimensions
Check valve spring
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}
Hydraulic drift prevention valve spring
16.6 X 13.0
13
11.2 N
{1.14 kg}
8.96 N
{0.91 kg}
Hydraulic drift prevention valve spring
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
1. Pump pressure pickup plug (P2)

2. Check valve (Boom head)
3. Pressure release plug
Unit: mm
No.
Item
Criteria
Basic dimensions
Logic valve spring
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)
If LS differential pressure EPLS becomes lower

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

2. Pressure compensation control

A pressure compensation valve is installed to the
inlet port side of the control valve spool to balance the load.
When to actuators are operated together, this
valve acts to make pressure difference EP
between the upstream (inlet port) and down-
10-70
CLSS
stream (outlet port) the same, regardless of the

size of the load (pressure). In this way, the flow
of oil from the pump is divided (compensated) in
proportion to the area of openings S1 and S2 of
each valve when it is operated.
PC78MR-6

CLSS
OPERATION FOR EACH FUNCTION AND VALVE

Hydraulic circuit diagram and name of valves
10-72
PC78MR-6

CLSS
1. Unload valve (P1)

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

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
2. During fine control of work equipment valve

Work equipment valve: Boom, arm, bucket,
boom swing, or attachment.
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}.
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
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
3. When work equipment valve is operated

boom swing, or attachment
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.
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
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
4. During fine control of both travel valves
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}.
kg/cm2}), unload spool (1) opens, so excessive
oil (maximum pump discharge mount - demand
flow) flows into the tank circuit.
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.
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
5. When both travel valves are operated
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.
PP1 and PP2 are separated. LS pressures PLS1
and PLS2 are also separated.
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.
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).
PP2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
PC78MR-6

CLSS
6. When either travel valve is operated
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.
PP1 and PP2 are separated. LS pressures
PLS1 and PLS2 are also separated.
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
When this happens, the area of the openings of

both travel valve spools is large, so LS pressures
PLS1 is not so different from pump discharge
pressures PP1.
discharge pressure PP1 and LS pressure PLS1
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).
tank circuit T are shut off, and all pump discharge amount QP1 on the P1 side flows to the
left travel circuit.
Since the right travel valve is at HOLD, LS pressure PLS2 is not generated, so only pump discharge pressure PP2 acts.
When pump discharge pressure PP2 reaches
the load of spring (4) (2.45 MPa {25.0 kg cm2}),
spool (3) moves to the right, and all pump discharge amount QP2 on the P2 side flows into
tank circuit T.
10-79

CLSS
Pump merge-divider valve and logic valve

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

(including compound operation of work
equipment + travel).
boom swing, or attachment.
Function
Pump merge-divider valve spool (3) merges
As the LS pressure, PLS1, PLS2, and PLS3 are
output.
When the work equipment valve is operated,

changeover pressure for spool (3) is not generated, so spring (4) pushes spool (3) to the right.
Pump discharge pressures PP1 and PP2 are
merged. LS pressures PLS1, PLS2, and PLS3
are also merged (PP1 = PP2, PLS1 = PLS2 =
PLS3).
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
3. When either or both travel valves are operated
Function
Pump merge-divider valve spool (3) separates
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.
PP2 and LS pressures PLS1 and PLS2 are separated respectively.
10-82
Furthermore, PP1 and PLS1 are separated for

the left travel circuit and PP2 and PLS2 are separated for the right travel circuit.
The higher pressure of pump discharge pressures PP1 and PP2 is output as the LS pressure
and the swash plate angle of the pump becomes
becomes maximum.
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
When this happens, LS circuit PLS is connected

to tank circuit T from LS bypass plug (4) (See the
section on the LS bypass plug).
The areas at both ends of reducing valve (3) are
the same (SA = SLS), and actuator circuit pressure PA acts on the SA end. The reduced pump
discharge pressure PP acts on SLS at the other
end.
As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure PA and
the pressure of spring chamber PLSS are the
same. Pump discharge pressure PP reduced at
notch (c) becomes actuator pressure A and is
introduced into LS circuit PLS.
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
When both travel valves are 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
(a) of LS bypass plug (2) through orifice (b)

to tank circuit T.
2. When either or both travel valves are operated
Since pump merge-divider spool (1) is at the
separate position, LS circuits PLS1, PLS2,
and PLS3 are separated.
The hydraulic oil PLS1 flows from tip filter (a)
of LS bypass plug (3) on the P1 side through
orifice (b) to tank circuit T.
The hydraulic oil PLS2 flows from tip filter (a)
of LS bypass plug (2) on the P2 side through
orifice (b) to tank circuit T.
10-85

CLSS
Boom raise merge valve

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

When the machine swings and boom is
raised simultaneously, the signal pressure of
the boom RAISE PPC circuit is applied to
pilot port BP.
When pilot pressure BP acts on spool (1)
and increases above the force of spring (2),
spool is pushed to the right. Then, check
valve (3) in spool (1) is pushed open and oil
in gear pump circuit P3 is merged into that in
main pump circuit PP to heighten the boom
raising speed.
PC78MR-6

CLSS
Area ratio of pressure compensation valve
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
Area ratio (S1:S2) and compensation characteristics

When ratio is 1.00: [Pump discharge pressure
PP - spool notch upstream
pressure PPB] = [LS circuit
pressure PLS - actuator circuit pressure PA (= A)] and
oil flow is divided in proportion to area of opening of
spool.
When ratio is more than 1.00:PP PPB > PLS
PA ( = A ) a nd oi l fl o w i s
divided in a proportion less
tha n ar ea of ope ning of
spool.
When ratio is less than 1.00:PP PPB < PLS
PA ( = A ) a nd oi l fl o w i s
divided in a proportion more
tha n ar ea of ope ning of
spool.
10-87

CLSS
Pressure compensation valve
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
Boom hydraulic drift prevention valve

Function
This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) to cause
hydraulic drift of the boom while the boom control lever is not operated.
1. When boom is raised
Operation
When the boom is "raised", the main pressure
from the control valve pushes up puppet (2). As
a result, the hydraulic oil from the control valve
flows through the valve into the boom cylinder
bottom.
PC78MR-6
10-89

CLSS
2. When boom is held
When the boom control lever is returned to the

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

CLSS
3. When boom is lowered
When the boom is lowered, pilot pressure P1

from the PPC valve pushes pilot spool (3) and
the hydraulic oil in chamber (b) in the puppet is
drained.
The pressure in port (Ab) is heightened by the
hydraulic oil from the boom cylinder bottom, but
the pressure in chamber (b) is lowered by orifices (a1) and (a2).
When the pressure in chamber b lowers below
that in port (Ab), puppet (2) opens and the
hydraulic oil from port (Ab) flows through port
(Aa) into the control valve.
PC78MR-6
10-91

CLSS
Boom regeneration circuit

1. When boom is lowered by its weight.
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.
When this happens, a part of the return oil on the

bottom side flows through regeneration passages (a) of bottom spool (2), pushes check
valve (3) open, and flows into the head side.
As a result, the boom lowering speed is heightened.
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
2. When boom is lowered under a load.
Function
While the boom is being lowered under a load, if
head pressure B of cylinder (1) is higher than
bottom pressure A, check valve (3) is closed to
shut off the head side and bottom side from each
other.
Operation
While the boom is being lowered under a load,
pressure B on the head side of boom cylinder (1)
is higher than pressure A on the bottom side.
When this happens, check valve (3) is closed by
pressure B on the head side and spring (4) to
shut off the head side and bottom side from each
other.
PC78MR-6
10-93

CLSS
Travel junction valve

(L.H., R.H. travel junction circuit)
1. When traveling in a straight line
10-94
PC78MR-6

CLSS
2. When steered during travel
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
Travel LS bleed circuit and travel junction valve

PC78MR-6
10-97

CLSS
2. When travel actuator and another actuator

are operated
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
For this reason, LS circuit pressure PLS,

which is the same pressure as boom circuit
pressure A, flows to travel circuit B to reduce
the pressure.
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
B: From swing brake solenoid valve

S: From tank
T: To tank
MA: From control valve
MB: From control valve
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}
1. Reverse prevention valve
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
Check valve spring
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}
Valve return spring
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
2. When machine stops swinging

If the swing control lever is returned to the
neutral position, oil is not supplied from the
pump to port MB any more. Since the return
circuit for the oil from the motor outlet to the
tank is closed by control valve (1), the pressure in port MA rises and revolution resistance is generated in the motor, then the
motor is braked.
The pressure in port MA rises to the set pressure of the safety valve. As a result, high
braking torque is generated in the motor,
then the motor stops.
While the safety valve is operating, the oil
discharged from the safety valve and the oil
from port S are supplied through check valve
CB to port MB so that cavitation will not
occur in port MB.
PC78MR-6

SWING MOTOR
MODULATING RELIEF VALVE

Function
The relief valve for the swing motor prevents the
relief pressure from rising sharply to reduce shocks
when the machine starts and stops swinging.
Operation
1. When circuit pressure is P0
The relief valve does not operate.
2. When circuit pressure rises sharply
When circuit pressure rises to P1, the
hydraulic pressure acts on the area 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
2. When solenoid valve is 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
REVERSE ROTATION PREVENTION LEVEL
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
EFFECT EXPLANATION DRAWING
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).
1. When brake pressure is being generated at

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

The motor is reversed by the closing pressure
generated at port MB. (1st reversal)
When this happens, reversal pressure is generated at port MA. Pressure MA goes to chamber
a, compresses spring (3), spool (2) moves to the
right, and MA o b is connected.
At the same time, b o f is connected through the
drill hole in spool (5), so the reversal pressure at
port MA is bypassed to port T to prevent the 2nd
reversal.
PC78MR-6
10-107

WORK EQUIPMENT AND SWING PPC VALVE
P
T
P1
P2
P3
P4
:
:
:
:
:
:
From main pump

To tank
Left - Arm OUT/Right - Boom LOWER
Left - Arm IN/Right - Boom RAISE
Left - Swing RIGHT/Right - Bucket CURL
Left - Swing LEFT/Right - Bucket DUMP
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)
2. During fine control (neutral o fine control)

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

3. During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is connected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f
in the valve on the side that is not working. The
oil passes through port P2 and enters chamber
B to fill the chamber with oil. (Fig. 3)
4. At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil passes through
fine control hole f and flows to chamber A from
port P1, and pushes the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f and flows to
drain chamber D. (fig. 4)
PC78MR-6
10-113

TRAVEL PPC VALVE
TRAVEL PPC VALVE
P
T
P1
P2
P3
P4
:
:
:
:
:
.
From main pump

To tank
Left travel reverse
Left travel forward
Right travel reverse
Right travel forward
10-114
PC78MR-6

1.
2.
3.
4.
TRAVEL PPC VALVE
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

TRAVEL PPC VALVE
OPERATION
1. At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
2. During fine control (neutral o fine control)

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

TRAVEL PPC VALVE
3. Fine control (control lever returned)

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

BOOM SWING PPC VALVE, BLADE PPC VALVE
BOOM SWING PPC VALVE

BLADE PPC VALVE
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

For Boom Swing

Unit: mm
No.
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).
2. In the fine control mode

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

3. In the fine control mode (when the operation

lever is shifted back to its original position)
As the lever (5) starts returning, the spool (1)
is pushed up by force of the centering spring
(3) and P1 port pressure. By this move, the
fine control hole f is connected to the drain
room D and relieves pressurized oil of P1
port to it.
If P1 port pressure goes excessively low, the
spool (1) is pushed down by the metering
spring (2), and passage between fine control
hole f and drain room D is shut down. And,
almost at the same time, the hole is connected to the pump pressure room PP and
starts supplying pump the pressure. This
supply continues until the P1 port pressure is
recovered to the level equivalent to the lever
position.
When the operation valve spool returns, oil
in the drain room D flows in through the fine
control hole f on the not moving side valve.
Oil is then conducted via P2 port to the room
B to fill it up.
4. In the full stroke mode
When the disk (5) pushes down piston (4)
and the retainer (7) pushes down the spool
(1), connection of the fine control hole f is
switched from the drain room D, to the pump
pressure room PP.
Thus, pilot pressurized oil from the control
pump passes through fine control hole f and
conducted to A room via P1 port to push the
operation valve spool.
Return oil from B room is conducted from P2
port to the drain room D via the fine control
hole f.
PC78MR-6
10-121

BOOM HYDRAULIC ANTI-BURST VALVE
BOOM HYDRAULIC ANTI-BURST VALVE (FOR EU SPEC.)
V : From control valve

T
: To hydraulic tank
CY : To hydraulic cylinder
PI : From PPC valve
PCY: For pressure pickup and equalizer circuits
10-121-1
(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
Check valve spring
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}
Spool return spring
19.1 8
13.5
24.7 1.5 N
{2.52 0.15 kg}
18.6 N
{1.9 kg}
Spool return spring
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

2. When oil is sent from main valve to cylinder

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

3. When oil is returned from work equipment

cylinder to main valve
The work equipment cylinder holding pressure is applied to chamber b and check valve
(5) closes.
The pilot pressure from the PPC valve is
applied to port PI. If it is higher than the force
of spring (2) (area of d), spool (1) moves to
the right standby position (1st-stage stroke).
At this time, chambers a and b are not connected to each other.
If the pilot pressure rises higher than the
force of spring (3) (area of d), spool (1)
moves further to the right and chambers a
and b are connected to each other (2ndstage stroke).
Accordingly, the oil is returned from the work
equipment cylinder to the main valve.
If piping A between the main valve and work
equipment cylinder bursts, the oil in chamber
a flows out through the burst part. Since oil
supplied from chamber b to chamber a flows
through opening c of spool (1), however, the
work equipment does not fall suddenly.
If the PPC valve is returned to the neutral

position, spool (1) returns to the left end to
shut off chambers a and b from each other.
Accordingly, the work equipment stops.
10-121-5
(1)
PC78MR-6

WORK EQUIPMENT
WORK EQUIPMENT
Unit : mm
Item
No.
Clearance between swing

bracket and revolving frame
mounting pin and bushing
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
Clearance between boom and

swing bracket mounting pin
and bushing
65
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Clearance between boom and

arm mounting pin and bushing
60
-0.030
-0.100
+0.174
+0.100
0.130
0.274
1.0
Clearance between arm and

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

link mounting pin and bushing
50
-0.225
-0.285
-0.062
-0.120
0.105
0.223
1.0
Clearance between link and

link mounting pin and bushing
60
-0.030
-0.100
+0.173
+0.100
0.130
0.273
1.0
Clearance between bucket

and link mounting pin and
bushing
50
-0.225
-0.285
-0.040
-0.094
0.131
0.245
1.0
Clearance between blade and

track frame mounting pin and
bushing
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

DIMENSIONS OF EACH PART OF WORK EQUIPMENT

1. ARM SECTION
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

AIR CONDITIONER PIPING
AIR CONDITIONER PIPING (OPTIONAL)
A: Hot/Cool air outlet

B: Inside air circulation opening
C: Fresh air inlet
10-128
1.
2.
3.
4.
5.
6.
7.
8.
Hot water take-out piping

Air conditioner compressor
Hot water return piping
Refrigerant piping
Condenser
Receiver drier
Air conditioner unit
Duct
PC78MR-6

ELECTRIC CONTROL SYSTEM

Engine control function
Engine and pump compound

control function
Overheat prevention function
Swing control function
Travel control function
PPC lock function

(*1)
Electric
control system
Overload alarm function
Error code display and alarm function

Self-diagnosis function
Error code memory func
*1. For EU spec. machine only.
PC78MR-6
10-129
(1)

GENERAL SYSTEM DIAGRAM (FOR STD SPEC.)
10-130
(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

GENERAL SYSTEM DIAGRAM (FOR EU SPEC.)
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 boom swing operating and swing
holding brake release switch
9. Resistor
(For emergency boom swing operating)
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)
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
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
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
40. Engine stop solenoid
41. Engine stop solenoid relay
42. Starting motor
45. Hydraulic pump
45a. Servo piston
45b. LS valve
45c. TVC valve
46. Control valve
47. Travel motor
48. Swing motor
49. Overload alarm actuation switch
50. Overload alarm pressure switch
PC78MR-6
10-131-2
(1)

ENGINE CONTROL FUNCTION
1.
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
Function of preventing engine stop solenoid

from burning
Engine stop solenoid relay (18) is installed to
prevent engine stop solenoid (17) from burning.
The time to supply the suction current is limited
to 3 seconds after starting switch (4) is turned to
the ON position by replacing the 2-wire engine
stop solenoid (17) (which uses the same wire for
the suction and holding currents) with the 3-wire
one (which uses independent wires for the suction and holding currents) and adding a timer
function and engine stop solenoid relay (18) to
controller (6).
A:
B:
C:
t:
Operation of starting switch

Suction coil current
Holding coil current
3 seconds
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:
One-touch deceleration switch [ON]

One-touch deceleration switch [OFF]
Engine speed set with fuel control dial
Low idling
Max. 1 sec
10-134
PC78MR-6

ENGINE AND PUMP COMPOUND CONTROL FUNCTION
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency pump drive switch
9. Monitor panel
10. TVC-EPC valve
13. Control 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

Control method in each mode

Active mode
Matching point of active mode:
Active mode
40.5 kw / 1.850 rpm

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

rises, engine speed lowers.
At this time, the pump discharge is reduced to
heighten the engine speed to near the full output
point. On the other hand, if the pressure lowers,
engine speed is heightened to near the full output point to increase the pump discharge.
The engine is constantly used near the full output
point by repeating this control.
PC78MR-6
10-137

E mode
Matching point of E mode: 85% partial output
point
E mode
37.5 kw / 1.660 rpm

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

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

Driving pump in an emergency
Even if the controller, etc. has a problem and the

hydraulic pump does not operate normally, the
operator can work temporarily by operating the
emergency pump drive switch (S).
(1) Auto: Normal state
(2) Cancel: Abnormal state
a The emergency pump drive switch (S) is of 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".
If the coolant temperature rises too high, the

pump load is lowered to prevent the engine from
overheatin
Operation
Operating condition
Coolant temperature
is above 99C
PC78MR-6
Pump absorption torque is reduced according to torque control system to reduce

engine load.
(Matching point: 90% partial output point)
Engine speed is kept as it is.
Resetting condition
Coolant temperature is
below 95C
10-139

SWING CONTROL FUNCTION
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Swing holding brake release switch
9. Swing motor
13. Engine
14. Hydraulic pump
15. Control valve
10-140
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

When the machine stops swinging, the swing
holding brake is applied automatically to prevent
hydraulic drift on a slope, etc.
When the arm is moved in, the swing holding
brake is released to reduce the load on the swing
unit during digging work.
The swing holding brake is released automatically when the boom swings to reduce the
shocks made at each start and stop of swinging.
a If the swing holding brake is released, only the
hydraulic brake of the safety valve is used to
stop swinging. Accordingly, if the machine stops
swinging on a slope, etc. the boom may drift
hydraulically. Take care.
Swing holding
brake cancel
switch
Releasing swing holding brake

Even if the controller, etc. has a problem and the
swing holding brake does not operate normally
and the machine does not swing, the operator
can swing the machine by releasing the swing
holding brake with the swing holding brake cancel switch (S).
(1) Auto: Normal state
(2) Cancel: Abnormal state
a Emergency swing holding brake cancel switch
(S) is of alternative type. If it is set to the "CANCEL (2)" position while the machine is normal,
user code "E03" or "E41" are displayed on the
display unit.
PC78MR-6
Operation
If swing control lever or arm IN

lever is set to neutral position,
swing holding brake is applied
about 5 seconds later.
If swing control lever or arm IN
Auto
lever is operated, swing holding
(Normal state)
brake is released and machine
can swing freely.
The swing holding brake is applied
and released according to boom
swing operation.
Cancel
(Abnormal
state)
When swing holding brake system

has trouble, if swing holding brake
cancel switch (S) is set to "Cancel
(2)", swing holding brake is
released and machine can swing.
Even if swing control lever or arm
IN lever is set to neutral position,
swing holding brake does not operate, however.
The swing holding brake does not
work even if the boom swing pedal
is in neutral.
Time chart of input and output signals
10-141

TRAVEL CONTROL FUNCTION
10-142
a When the engine is started, the travel speed

boost selector switch is set to the low speed
position automatically.
a The travel speed boost pedal is effective only
while the "Lo" lamp of the travel speed boost
selector switch is lighting. Even if the pedal is
pressed while the "Hi" lamp is lighting up, the
travel speed does not change.
Travel speed boost
selector switch
Released
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
Left travel motor
Right travel motor
Travel PPC valve
Travel PPC oil pressure switch
Travel alarm (If equipped)
Engine
Hydraulic pump
Control valve
Travel speed boost pedal
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

PPC LOCK FUNCTION
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
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
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

OVERLOAD ALARM FUNCTION (FOR EU SPEC.)
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
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

BOOM SWING END CUSHION FUNCTION
When the boom is swung, the boom swing speed is reduced before each stroke end to reduce the shock
made at the stroke end. This function reduces the spillage of soil and the load on the chassis.
1. Decelerating function
If the boom swings and enters area (B) from

area (A), its swing speed is lowered gradually to reduce the shock made at the stop
position.
At this time, the output pressure from the
boom swing PPC valve to the boom swing
control valve is reduced by controlling the
EPC valve according to the angle sensor signal.
As a result, the shock made at the stroke end
is reduced.
2. Correction function
If the potentiometer is replaced or the work

equipment is replaced, an input signal error
is made because of the error of the installation of the potentiometer.
With the correction function, this error can be
corrected easily without measuring the output voltage or adjusting the potentiometer
finely.
If the boom is swung to each stroke and the
set angle (0) is input, the difference between
angle (A) calculated from the actual output
voltage of the potentiometer and standard
angle (B) set in the computer (installation
error) is saved as "correction value (C)".
A. Ordinary area
B. Deceleration area
10-144
PC78MR-6

SELF-DIAGNOSTIC FUNCTION
1. Error code display and alarm function
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
2. Error code memory function

If a problem occurs in the leading system, it
is detected by the self-diagnostic function
and its error code is stored in memory.
a For details of the display and resetting
method, see TESTING AND ADJUSTING.
10-145

SYSTEM COMPONENTS
SYSTEM COMPONENTS
Fuel control dial

10-146
PC78MR-6

SYSTEM COMPONENTS
Fuel control motor
1. Motor assembly
2. Cable
3. Connector
Input and output signals

SWP-6P [CN-K27]
Pin
No.
PC78MR-6
Signal name
Input/Output
signal
Motor acceleration signal
Power source
Input
One-touch deceleration signal
Motor deceleration signal
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
*1. Serial No.: 1001 1094

*2. Serial No.: 1095 and up
10-148
(1)
PC78MR-6

SYSTEM COMPONENTS
DEUTSCH-40P (1) [CN-M96]

Pin
No.
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
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
DEUTSCH-40P (2) [CN-M97]

Pin
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
Controller power
Solenoid power
GND (Solenoid)
NC
NC
One-touch deceleration switch
Air conditioner compressor signal
Controller power
Solenoid power
GND (Solenoid)
Key signal
TVC-EPC vlave
Swing and travel alarm
NC
Acceleration signal
(*1) NC
(*2) Alarm actuation switch
*1 Serial No.: 1001 1094

*2 Serial No.: 1095 and up
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 ( )
For TVC-EPC valve of

hydraulic pump
30
For right boom swing stop

EPC valve
For left boom swing stop
EPC valve
Function
When the emergency pump drive switch is
turned ON, this resistor is used to supply a
proper current to EPC valve according to the
condition of the work equipment.
a Current does not flow under the normal condition.
PC78MR-6
10-151

SYSTEM COMPONENTS
PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Contact composition:
N.O. contact
Operation (ON) pressure: 490 98.1 kPa
{5.0 1.0 kg/cm2}
Reset (OFF) pressure:
294 49.0 kPa
{3.0 0.5 kg/cm2}
Function
The control valve has 5 PPC oil pressure
switches, which sense the operating condition of each actuator from the PPC pressure
and send it to the controller.
10-152
PC78MR-6

SYSTEM COMPONENTS
Overload alarm pressure switch (For EU spec.)
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
Engine speed sensor

a See SENSOR.
TVC-EPC valve
a See HYDRAULIC PUMP.


a See EPC SOLENOID VALVE.
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.

a. Power source
b. Switch signal
c. Caution signal
d. Sensor, switch signal
e. Sensor, switch signal
f. Drive output
10-154
PC78MR-6

MONITOR 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/
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
Engine coolant temperature

Fuel level
Radiator water level
NC
Air cleaner clogged
NC
Engine oil pressure
Engine oil level
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
METER DISPLAY UNIT (FOR STD SPEC.)
No. Display type

1
Display range
Display method
Service meter
0-99999.9 h
Time is measured while engine is running

(alternator is generating) (Lamp always lights
up even if starting switch is at OFF position.)
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
If electric control system has trouble, 3

alphanumerics (user code, service code) is
displayed.
Voltage of boom swing potentiometer is
displayed.
Segment of corresponding level and all segments below it light up.
[Monitor lamp blinks when 8th level lights up
(above 99C). Monitor lamp blinks and alarm
buzzer sounds when 9th level lights up.]
[Monitor lamp blinks and alarm buzzer sounds
when 1st level lights up (below 30 liters).]
Lamp lights up for about 30 seconds when
starting switch is turned to HEAT position, then
blinks (for about 10 seconds) to show that preheating is finished and then goes off.
Display
color
Remarks
Blue
LCD
Red
LED
Blue
LCD
Red
LED
Green
Lamp lights up when one-touch decelerator

operates.
Lamp lights up when starting switch is turned

to ON position and goes off after engine
starts. Lamp is turned off when normal and on
when abnormal.
Below set pressure (If trouble occurs while engine is running,
(49 kPa {0.5 kg/
buzzer sounds.)
cm2})
Lamp
Red
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
10-156
(1)
PC78MR-6

MONITOR SYSTEM
METER DISPLAY UNIT (FOR EU SPEC.)
No. Display type
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
Below set pressure

(12.7 MPa {130 kg/
cm2})
Pilot
Caution
Charge level
When charging
is defective
(charge voltage
< battery voltate)
Engine oil
pressurre
Below set pressure

(49 kPa {0.5 kg/
cm2})
If electric control system has trouble, 3

alphanumerics (user code, service code) is
displayed. In depth 0 set mode, depth from
datum plane is displayed.
[Monitor lamp blinks when 8th level lights up
(above 99C). Monitor lamp blinks and alarm
buzzer sounds when 9th level lights up.]
[Monitor lamp blinks and alarm buzzer sounds
when 1st level lights up (below 30 liters).]
Lamp lights up for about 30 seconds when
starting switch is turned to HEAT position, then
blinks (for about 10 seconds) to show that preheating is finished and then goes off.
Display
color
Remarks
Blue
LCD
Red
LED
Blue
LCD
Red
LED
Green
Lamp lights up when one-touch decelerator

operates.
Lamp
Lamp lights up when starting switch is turned
to ON position and goes off after engine starts.
Lamp is turned off when normal and on when
abnormal.
(If trouble occurs while engine is running,
buzzer sounds.)
Red
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
PC78MR-6
10-156-1
(1)

MONITOR SYSTEM
MONITOR SWITCH UNIT
No. Name
1
Function
Operation
Travel speed selector switch
Switch used to select 1 of 2 travel speeds

When Lo lamp is ON: Low travel speed
When Hi lamp is ON: High travel speed
Working mode
selector switch
Switch used to set movement and power of work

equipment
When E lamp is OFF: Active mode (For heavy load
work)
When E lamp is ON: E mode (For work in which fuel
consumption is more important)
Active (OFF) io E
(Lamp OFF)
Wiper switch
Switch used to operate front glass wiper

When ON lamp is ON: Wiper operates continuously.
When INT lamp is ON: Wiper operates intermittently.
When all lamps are OFF: Wiper is stopped.
OFF (Lamp OFF) o INT (Intermittent) o

ON (Continuous)
Switch used to spout washing liquid over front glass
[When wiper is stopped]

ON: Washing liquid spouts and wiper
operates continuously.
OFF:After switch is released, wiper
operates by 2 cycles continuously
and then stops.
[When wiper is operating intermittently]
ON: Washing liquid spouts and wiper
operates continuously.
OFF:After switch is released, wiper
operates for 2 cycles continuously
and then starts intermittent operation again.
Windshield washer
switch
Lo io Hi
a The boldfaced letters in the operation column

denote the position to which each switch is reset
when the starting switch is turned to the "ON"
position.
PC78MR-6
10-157

SENSORS
SENSORS
The signals from the sensors are input directly to the panel or controller.
The sensors are classified into 3 of contact type, resistance type, and electromagnetic type.
Either of each sensor of contact type must be connected to the chassis ground.
Type of display
Type of sensor
Sensing method
When normal
When abnormal
Caution
Engine oil pressure
Contact
OFF (Open)
ON (Closed)
Coolant temperature
Resistance
Fuel level
Resistance
Engine speed
Electromagnetic
Gauge
Engine oil pressure sensor
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.
Coolant temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
This sensor is installed to the engine cylinder block. It senses changes of temperature by changes of the
resistance of thermistor (3) and sends the change signals to the monitor panel.
10-158
(1)
PC78MR-6

SENSORS
Fuel level sensor
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
Engine speed sensor
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
20 TESTING AND ADJUSTING

STANDARD VALUE TABLE ........................... 20- 2
Standard value table for engine .................. 20- 2
Standard value table for chassis ................. 20- 3
Standard value table for electrical parts .......20- 11
TESTING AND ADJUSTING.......................... 20-101
TROUBLESHOOTING ................................... 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or 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
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Item
Machine Model
PC78MR-6
Engine
S4D95LE-3
Measurement Conditions
Unit
High idling (When mounted on machine)

Revolving speed
Low idling (When mounted on machine)
Standard Value for

New Machine
Service Limit Value
2,020 50
rpm
Rated revolving speed
1,850
Bosch Index
Max. 3.5
Max. 1.0
6.0
2.0
mm
0.35
0.50
Exhaust gas color
At sudden acceleration
At high idling
Valve clearance (At normal temperature)
Air intake valve

Exhaust valve
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)
(Water temperature operating range)

At rated output
Pa
{mmH2O}
Max. 490 {50}

reference value
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
(Water temperature operating range)

(SAE30)
At high idling
(SAE10W)
Oil pressure
MPa
{kg/cm2}
At low idling
Oil temperature
All revolution range (In oil pan)
Fuel injection timing
Before compression top dead center
Tension of fan belt
Deflection under
finger pressure of
approx. 58.8 N {6
kg}
mm
Tension of air compressor belt
20-2
Deflection under
finger pressure of
approx. 58.8 N {6
kg}
PC78MR-6
STANDARD VALUE TABLE FOR CHASSIS

Machine Model
Stroke of control lever, pedal stroke
Engine speed
Category
Item
At relief of 1 pump
Hydraulic oil temperature: 45 55 C

Engine water temperature: Within operating
range
Relief of 1 pump....Arm DUMP relief
Unit
Standard Value
for New Machine
Service Limit
Value
rpm
Min. 1,800
Min. 1,800
Boom control lever
N o RAISE, LOWER
85 10
Max. 95
Min. 75
Arm control lever
N o IN, OUT
85 10
Max. 95
Min. 75
Bucket control lever
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
Swing control lever
Boom swing control

pedal
Blade control lever
Center of
lever grip
End of pedal
Read Max.
value through
stroke end
Stop engine
N o LEFT, RIGHT
mm
N o RAISE, LOWER
Travel control lever
N o FORWARD,
REVERSE
115 12
Attachment control
pedal
N o FORWARD,
REVERSE
Forward 37
Reverse 23
Forward Max.
Min.
Reverse Max.
Min.
Play of control lever
Max. 10
Max. 15
Boom control lever
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
Arm control lever
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}
Blade control lever
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}
Bucket control lever

Operating effort of control lever
PC78MR-6
Swing control lever

Boom swing control
pedal
Measure operating effort of each control lever

by installing push-pull scale to center of its
grip.
Measure operating effort of each control pedal
by installing push-pull scale to its end.
Read Max. value through stroke end.
Stop engine.
N
{kg}
39
35
25
21
Forward Max. 31.0

{Max. 3.2}
Reverse Max. 50.9
{Max. 5.2}
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}
Travel control lever
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

Relief pressure with engine at full throttle (Relieve only circuit to be measured)
Unit
With blade
RAISE
Blade
MPa
{kg/cm2}
LOWER
Travel
Control
Lowering of oil
pressure

Difference between relief pressure at Max. engine speed
and relief pressure at 1/2 of rated engine speed (Pressure at relief of 1 pump)
Position of work equipmentMax. Reach
Overrun of
swing
Swing
Run engine a full throttle

Deviation of swing circle made when it stops after swinging 1 turn
Value in { } is deviation of periphery of swing circle
90
Time required
to start swinging
20-4
Run engine at full throttle

Time required to swing 90 and 180
from starting point
Value in { } is measured under rated
bucket load
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}
Position of work equipment
Max. Reach
Time required to
finish swinging

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

rated load or filled with dirt and sand
(Rated load: 450 kg)
Hydraulic drift of
swing
Leakage from
swing motor

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

Relieve swing circle
Travel speed (1)
Travel

Raise either track and measure time required to
move 5 turns after finishing 1 turn.
{ }: Rubber shoe specification
sec
Travel speed (2)
PC78MR-6

Measure time required to travel 20 m after run-up
of at least 10 m on flat surface
{ }: Rubber shoe specification
20-5
Machine Model
Category
Item
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
Position for measurement
Travel deviation
Travel

Measure deviation made during travel of 20 m after run-up
of at least 10 m on flat surface
Measure on firm and level place
a Measure distance x
Leakage from
swivel joint
(Each port)

Apply relief pressure to port to be measured
Hydraulic drift of
travel
Leakage from
travel motor
20-6
Stop engine
Stop machine on slope of 30 with sprocket up
Measure hydraulic drift of travel made in 5 minutes

Lock shoes and relieve travel circuit
/min.
PC78MR-6
Machine Model
Category
Item
Whole work
equipment
(Hydraulic drift of
bucket tooth tip)
PC78MR-6
Unit
Hydraulic drift
Measure extension and retraction of each cylinder and

hydraulic drift of bucket tooth tip from above position
Measure on level and flat surface
Bucket: Apply rated load of 4,413 N {450 kg}
Set lever in neutral
Stop engine
Start measurement just after setting
Measure hydraulic drift every 5 minutes and judge after
15 minutes
Blade
(Hydraulic drift of
blade tip
Stop engine
Measure hydraulic drift of blade tip from Max. height in
15 minutes
Leakage from cylinder

(Each cylinder)

Apply relief pressure to cylinder to be measured
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

Boom
Bucket tooth on
ground
Work equipment speed
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
(To just before (To just before

cushion)
cushion)
LOWER
Arm
Max. retraction of
cylinder
3.1 0.3
Max. 3.7
3.3 0.3
Max. 4.1

sec
Max. extension of
cylinder
PC78MR-6
RAISE

IN

cushion)
cushion)
DUMP

cushion)
cushion)
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
Unit

Bucket
Max. retraction of
cylinder
Max. extension of
cylinder

Work equipment

Boom swing
Swing (R.H.)
Swing (L.H.)


sec
Blade
Blade on ground
RAISE
1.3 0.3
Max. 2.1
Max. height of blade
LOWER
1.3 0.3
Max. 2.1
Max. 2
Max. 3.9

Time lag
Boom
20-8

Retract arm and bucket cylinder fully and lower boom
from Max. height.
Measure time from when bucket touches ground until
when machine body rises.
PC78MR-6
Machine Model
Category
Item
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

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

Set upside of boom level and retract bucket cylinder fully.
Extend bucket cylinder and measure time from when arm
stops on lower side until when arm starts moving again.
Blade
Discharge of hydraulic pump
PC78MR-6
Piston
pump

Lower blade from Max. height and measure time from
when blade touches ground until when machine body rises.
See following pages
/min.
20-9
PC78MR-6 (With blade)

Main pump discharge
Performance of hydraulic pump
Category
Rated pump speed: 1,850 rpm

Checkpoint
Discharge pressure of test

pump
(MPa {kg/cm2})
Average pressure
(MPa {kg/cm2})
Standard discharge
( /min.)
Lower limit of criterion

( /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
STANDARD VALUE TABLE FOR ELECTRIC PARTS

Sys
tem
Component
Name
Connector
No.
Inspection
Method
Criteria
Source
voltage
M97
Measurement
voltage
If the condition is within the range shown in

the table below, it is normal.
Between (1), (11) chassis ground
20 30 V
Since power is constantly supplied, voltage is detected even if starting switch is

turned OFF.
Between (2), (12) , (22) chassis ground
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.
3) Turn starting
switch ON.
Max. 0 V

M97
M97
M95
Measurement
of current
Controller
Swing
RIGHT stop
solenoid
M97
M13
Between (15) (23)
940 50 mmA

Between (5) (23)
Measurement
of voltage
PPC main
pressure
lock solenoid
Measurement
voltage
Between M97 (38) (13)
1) Turn starting
switch OFF.
3) Turn starting
switch ON.
4) Exclude part near
swing stroke end.
940 50 mmA

Between (22) (21)
5 0.5 V
1) Turn starting
switch OFF.
3) Turn starting
switch ON.
Boom
RAISE
pressure
switch
PC78MR-6
M95
M96
M95
Measurement
of voltage
Model
selection
Measurement
of voltage
If the condition is within the range shown in the table below,

it is normal.
Model
PC78MR-6
Between M96 (37) M95 (10)
Max. 1 V
Between M96 (27) M95 (10)
Min. 7 V
Between M96 (7) M95 (10)
Max. 1 V
Between M96 (30) M95 (10)
Max. 1 V
1) Turn starting
switch OFF.
3) Turn starting
switch ON.
If the condition is within the range shown in the table below,

it is normal
When boom is raised
When in neutral
Between
M95 (12)
chassis
ground
Max. 1V
5 0.5 V
1) Turn starting
switch OFF..
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
If the condition is within the range shown in the table

below, it is normalTurn starting switch OFF.
When machine swings
When arm is moved IN
When machine travels
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

below, it is normal
Between (8) (21)
3.8 4.8 V
Swing
holding
brake clear
solenoid
M97
Measurement
of resistance
Controller

below, it is normal
When swing holding brake
clear switch is OFF
(When normal)
When swing holding brake
clear switch is ON
(When cleared)
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

below, it is normal
Between (C) (B)
0.2 7 kz
Between (B) (A)
0.2 7 kz
Between (C) (A)
4 6 kz

below, it is normal
Between M12 (male) (1) (2)
Between M12 (male) (1), (2) chassis ground
5 25 z
Min. 1 Mz

below, it is normal
Between M11 (male) (1), (2) chassis
ground
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
2nd travel speed

selection solenoid
Inspection
Method
M13
(Male)
M14
(Male)
M15
(Male)
Measurement of
resistance
PPC main pressure lock solenoid
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
Between M13 (Male)

(1), (2) chassis ground
Min. 1 Mz

Between M14 (Male)
(1) (2)
35 80 z
Between M14 (Male)

Min. 1 Mz

Between M15 (Male)
(1) (2)
35 80 z
Between M15 (Male)

Min. 1 Mz
1) Turn starting
switch OFF.
2) Disconnect
adapter.
3) Connect Tadapter.
1) Turn starting
switch OFF.
2) Disconnect
adapter.
1) Turn starting
switch OFF.
2) Disconnect
adapter.
If the monitor panel displays as shown in Tables 1 and 2, it is normal.

Table 1 (Check and caution section).
Machine monitor system
Monitored Item
(Input connector)
Engine oil pressure

P02 (7)
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.
Check and caution

section
Charge level
P02 (11)
Display
1) Connect Tadapter
Start engine.
Stop Engine.
20-13
Component
Name
System
Connector No.
Inspection Method
Criteria
Table 2 (Gauge)
Item indicated by gauge
Display level resistance (kz)

(Monitor panel input
resistance)
Turn starting switch ON
Turn starting switch

OFF
1) Turn starting switch

OFF and insert dummy
resistor or measure
resistance of sensor.
2) Turn starting switch ON
and check indication.
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
a Blink at levels 8 and 9.
Item indicated by gauge
Display level resistance (z)

(Monitor panel input
resistance)
Turn starting switch

OFF

OFF and insert dummy
resistor or measure
resistance of sensor.
2) Turn starting switch ON
and check indication.
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
Fuel level sensor
Alternator
PC78MR-6
Check of continuity
Measurement
Conditions
Criteria
below, it is normal.
Between terminal chassis

ground
Normal
engine oil
pressure
No continuity
Low engine
oil pressure
Normal continuity


M9 (Male)
Between T4
(Terminal
R) chassis ground
M18 (Male)
Coolant temperature sensor
T6
Inspection
Method
Measurement of resistance
Engine oil pressure sensor
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
While engine is running (at 1/2 or more of full throttle) o

27.5 29.5 V
If battery is deteriorated or temperature is low, voltage
may not rise for a while after engine is started.
1) Start engine
2) Disconnect
terminal

OFF
2) Disconnect
connector

OFF
2) Disconnect
connector
1) Start engine
20-15

List of devices for testing, adjusting, & troubleshooting .............................................................................. 20-102
Measuring engine speed............................................................................................................................. 20-103
Measuring exhaust gas color ...................................................................................................................... 20-104
Adjusting valve clearance ........................................................................................................................... 20-105
Measuring compression pressure ............................................................................................................... 20-106
Measuring blow-by pressure ....................................................................................................................... 20-107
Testing and adjusting fuel injection timing................................................................................................... 20-108
Measuring engine oil pressure .................................................................................................................... 20-112
Adjusting engine stop solenoid ................................................................................................................... 20-113
Adjusting fuel control linkage ...................................................................................................................... 20-115
Adjusting engine speed sensor ................................................................................................................... 20-117
Testing and adjusting hydraulic pressure in work equipment, swing, and travel circuits............................. 20-118
Measuring LS differential pressure and adjusting LS valve ........................................................................ 20-121
Adjusting PC valve ...................................................................................................................................... 20-123
Testing TVC-EPC solenoid output pressure ............................................................................................... 20-123
Measuring control circuit pressure .............................................................................................................. 20-124
Measuring PPC valve output pressure ....................................................................................................... 20-125
Testing solenoid valve output pressure ....................................................................................................... 20-126
Adjusting work equipment valve and swing PPC valve .............................................................................. 20-128
Testing travel deviation ............................................................................................................................... 20-129
Testing parts which can cause hydraulic drift of work equipment ............................................................... 20-131
Measuring oil leakage from swing and travel motors .................................................................................. 20-132
Releasing residual pressure from hydraulic circuit ..................................................................................... 20-133
Testing clearance of swing circle bearing ................................................................................................... 20-134
Testing and adjusting track shoe tension .................................................................................................... 20-135
Bleeding air from hydraulic circuit ............................................................................................................... 20-136
Replacement procedure of potentiometers ................................................................................................. 20-138
Procedure for testing diode ......................................................................................................................... 20-139
PC78MR-6
20-101
LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING
LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING

Items to Be
Tested/Adjusted
Engine speed
Symbol
A
Water temperature and oil

temperature
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
Hydraulic tester kit
790-261-1203
Pressure gauge
2.5, 5.9, 39.2, 58.8 MPa

{25, 60, 400, 600 kg/cm2}
Digital hydraulic tester
Pressure gauge
58.8 MPa {600 kg/cm2}
799-401-2320
Hydraulic gauge
Pressure gauge
1.0 MPa {10 kg/cm2}
799-101-5160
Nipple
PT1/8
799-101-5220
Nipple
10 mm P = 1.25
07002-11023
O-ring
799-401-2910
Nipple
(Both male and female) 9/16-18 UNF

(Female: PT1/8)
02896-11008
O-ring
07043-00108
Nipple
PT1/8 (Hexagon hole)
799-401-2701
Differential pressure
gauge
795-502-1590
Compression gauge
0 6.9 MPa {0 70 kg/cm2}

Kit No.: 795-502-1205
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
0 4,900 Pa {0 500 mmH2O}
Valve clearance
Purchased
Filler gauge
790-201-9000
Handy smoke checker
Purchased
Smoke meter
Discoloration 0 70% (with standard color)

(Discoloration % x 1/10
Bosch index)
Exhaust gas color
Operating effort
Purchased
Push-pull scale
Stroke and hydraulic drift
Purchased
Scale
Purchased
Stopwatch
790-601-9320
Box
24-pin
799-601-9310
Plate
Applicable to 40-pole connector
799-601-8000
Adapter assembly
Including 21-pin box
1
2
Troubleshooting for wiring
harnesses and sensors
K
3
Fuel injection timing
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
MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

1. When measuring engine speed during operation
a Measure the engine speed under the following condition.
Cooling water temperature: Within operating range
1) Remove clamp (1) of the high pressure injection pipe and install sensor [1] of multitachometer A to injection pipe (2).
2) Connect the wiring harness of sensor [1] to

amplifier [2] and connect the output wiring
harness of amplifier [2] to tachometer A1.
3) Start the engine and turn dial a of amplifier
[2] so that the value indicated by tachometer
A1 will be stabilized, then measure the following revolving speeds.
i) Low idling speed and high idling speed
Set the fuel control lever to the low idling
and high idling positions and measure
the revolving speeds at the respective
positions.
ii) Revolving speed when pump is relieved
Relieve the pump and run engine at full
throttle and measure its revolving speed.
PC78MR-6
2. When measuring engine speed during measurement of compression pressure

1) Remove the cover for setting the injection
timing of the injection pump from the timing
gear case and install gear box A2.
2) Install bracket [3] of multi-tachometer A1 to

gear box A2 and connect the wiring harness
to tachometer A1.
3) Revolve the engine with the starting motor
according to the procedure for measuring
compression pressure and measure the
revolving speed.
20-103
MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR
When an air source and a power source are not

available in the field, use handy smoke checker
G1. When recording formal data, etc., use
smoke meter G2.
a Before measuring the exhaust gas color,
raise the cooling water temperature to the
operating range.
6) Raise the engine speed sharply and press

accelerator pedal [3] of tool G2 simultaneously to have the filter paper absorb the
exhaust gas.
7) Place the stained filter paper on the unused
filter paper (at least 10 pieces) in the filter
paper holder and read the indicated value.
When installing and removing the measuring

instrument, take care not to touch a hot part.
1. Measuring with handy smoke checker G1
1) Install a piece of filter paper to tool G1.
2) Insert the exhaust gas suction pipe in the
exhaust pipe, then raise the engine speed
sharply and operate the handle of tool G1
simultaneously to have the filter paper
absorb the exhaust gas.
3) Remove the filter paper and compare it with
the attached scale.
2. Measuring with smoke meter G2

1) Insert probe [1] of G2 in the outlet of the
exhaust pipe and tighten the clip to secure
the probe to the exhaust pipe.
2) Connect probe hose [2], cable of accelerator
pedal [3], and air hose [4] to tool G2.
a Set the supplied air pressure below 1.47
MPa {15 kg/cm}.
3) Connect the power cable to an outlet of AC
100 V.
a When connecting the power cable, check
that the power switch of tool G2 is turned
OFF.
4) Loosen cap nut [5] of the suction pump and
fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn ON the power switch of tool G2.
20-104
a The firing order of the engine is as follows

Firing order: 1 2 4 3
a The air intake valves and exhaust valves may be
adjusted in the firing order by revolving the
crankshaft forward by 180 (4 cylinders).
a For the valve clearance, see TESTING AND
ADJUSTING, Failure criteria table.
PC78MR-6
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Method of adjusting valve clearance
1. Remove the cylinder head cover.
2. Turn the crankshaft forward and bring cylinder
No. 1 to the compression top dead center and
match the TOP mark line of crank pulley (5) to
pointer (6), watching the movement of the air
intake valve of cylinder No. 4 (4 cylinders).
a The air intake valve of cylinder No. 4 (4 cylinders) moves (opens) when cylinder No. 1
comes near the compression top dead center.
a Adjust the valve clearance according to the

following procedure. Loosen locknut (8) of
adjustment screw (7). Insert filler gauge A of
the specified thickness between valve stem
(6) and rocker arm (5) and adjust the valve
clearance so that the filler gauge will move
lightly.
5. Tighten the locknut to secure the adjustment

screw.
Locknut: 44 5.0 Nm {4.5 0.5 kgm}
3. Adjust the clearance of the valves marked with q
in the valve arrangement shown below.
4. Turn the crankshaft forward by 1 turn and adjust
the clearance on the valves marked with Q.
PC78MR-6
20-105
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

When measuring the compression pressure,
take care not to touch the exhaust manifold, etc.
to burn yourself or the rotary parts such as the
fan, fan belt, etc. to be caught in them.
1. Adjust the valve clearance accurately. For
details, see Adjusting valve clearance.
2. Warm up the engine until the oil temperature is
40 60 C.
3. Remove nozzle holder assembly (1) of the cylinder to be measured.
4. Install adapter D2 to the fitting part of the nozzle
holder and connect pressure gauge D1.
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}
5. Set the multi-tachometer to the engine.

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

a Measure the blow-by pressure under the following condition.
Cooling water temperature:
Within operating range
Hydraulic oil temperature: 40 60C
1. Install the nozzle of blow-by checker E to blowby hose (2).
a Normally, the blow-by pressure should be

measured while the engine is operated at the
rated output. In the field, however, an
approximate value can be obtained by relieving the hydraulic circuit.
a If it is impossible to run the engine at the
rated output or relieve the hydraulic circuit,
measure while the engine is running at high
idling.
The value obtained in this case is about 80%
of the blow-by pressure at the rated output.
a The blow-by pressure may vary largely with
the engine condition. If the measured value
is judged abnormal, check for increase of oil
consumption, bad exhaust gas color, deterioration of oil, high deterioration speed of oil,
etc. which are related to the abnormal blowby pressure.
2. Connect the nozzle to the gauge by the hose.

3. Set the working mode in the ACTIVE mode, run
the engine at full throttle, and relieve the arm
dump circuit.
4. When the gauge pointer is stabilized, measure
the blow-by pressure.
Do not touch a hot part or a rotary part during measurement.
PC78MR-6
20-107
TESTING AND ADJUSTING FUEL INJECTION TIMING

Adjustment by use of match marks
a Apply this method usually.
(Then installing the fuel injection pump to the
original engine without repairing it, when checking only the injection timing, etc.)
1. Bring cylinder No. 1 to the compression top dead
center.
1) Turn the crankshaft forward and match
1.4Top line (1) on the crank pulley to pointer
(2).
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
2. Remove front cover (3) of the fuel injection

pump.
3. Install the fuel injection pump holder and drive
gear as one unit to the engine.
4. Insert the timing check pin 4.0 4.5 mm in diameter and 80 mm in length on hole a of the front
gear cover and match it to the hole of the drive
gear.
a Check that the timing check pin enters
straight and the hole of the fuel injection
pump holder is aligned with the mounting
hole of the front gear cover (in which the
mounting bolt will be inserted).
a If the holes are deviated from each other,
remove the fuel injection pump and check its
engagement with the drive gear.
5. Remove the timing check pin and tighten each

bolt.
PC78MR-6
Adjustment by delivery valve method

(When installing a repaired or replaced fuel injection
pump, when checking after disassembling or replacing the gear train)
4. Using spring pusher O2, compress the valve

spring and remove valve cotter (5).
5. Loosen spring pusher O2 and remove spring
seat (6) and valve spring (7).
1. Remove the cylinder head cover.

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

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

turn the crankshaft forward or in reverse to set
the dial gauge to 0 when its pointer starts turning
in reverse.
8. Turn the crankshaft about 45 degrees in reverse
from the compression top dead center of cylinder
No. 1.
9. Turn the crankshaft forward so that the dial
gauge indicates standard dimension a.
Standard dimension
BTDC (Deg)
a
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).
10. Disconnect fuel injection pipe (10) of cylinder No.

1.
11. Remove delivery valve holder (11), and remove
delivery valve (12) and spring (13) from its
inside. Then, install delivery valve holder (11)
again.
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
17. Turn the crankshaft forward and check that the

pointer of the dial gauge is in the standard range
shown in the following table when cylinder No. 1
is at the top dead center (when the pointer of the
dial gauge starts moving in reverse). If the
pointer of the dial gauge is out of this range,
repeat the above steps from 7.
Dimension when cylinder is at top dead center: 0 0.08 mm
18. Remove the delivery valve holder (11) and install
delivery valve (12) and spring (13) to it, then
install delivery valve holder (14) again.
a Replace the o-ring and copper gasket of the
delivery valve.
Tighten the delivery valve 3 times to secure
it. (If it is not tightened sufficiently, the gasket may be broken.)
Delivery valve holder:
39.2 44.1 Nm {4 4.5 kgm}
19. Connect fuel injection pipe (3).
Sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}
20. Install valve spring (7) and valve seat (6).
21. Compress the valve spring with spring pusher
O2 and install valve cotter (5).
22. Install air intake rocker arm (4) of cylinder No. 1,
then install snap ring (3).
Install the snap ring securely.
23. Install the cylinder head cover.
Sleeve nut:
7.84 9.8 Nm {0.8 1.0 kgm}
PC78MR-6
20-111
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

a Measure the engine oil pressure under he following condition.
Cooling water temperature: Within operating
range
3. Run the engine at low idling and high idling and

measure the engine oil pressure at each speed.
1. Remove oil pressure pickup plug (1) (PT 1/8)

from the engine block under the alternator.
2. Install oil pressure measuring nipple C3 and connect oil pressure gauge C2 (0.98 MPa {10 kg/
cm}).
20-112
PC78MR-6
ADJUSTING ENGINE STOP SOLENOID

1. Install ball joint (2) to solenoid (1) and tighten
locknut (3).
a a: Approx. 1mm (thread)
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
3. Supply power to solenoid (1) to turn it on.

a If stop lever (6) and rod end (5) of the fuel
injection pump are connected before the
solenoid is turned on, the solenoid cannot
pull sufficiently (the operating current flows
continuously) and the coil will burn. Accordingly, do not connect them at this time.
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
a Stop lever (6) touches the lever end on the

service side (inside the fuel injection pump).
a Play: 0 mm
5. Tighten nut (7) of the joint of stop lever (6) and

rod end (5) and insert the cotter pin.
a Install the rod end with grease hole (8) up.
Rod end: Grease (G2-LI)
6. Lengthen rod (4) to give play to the stop lever

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

apply force so strongly that stop lever (6) will
be pulled up more than the lever end.
a Adjust the length of the rod as shown below.
20-114
PC78MR-6
7. Tighten locknut (8).

a At this time, take care that rod (4) will not turn
together with locknut (9). Do not twist stop
lever (6) forcibly.
8. Start and stop the engine 2 3 times and check
that solenoid (6) operates smoothly to stop the
engine.
PC78MR-6
ADJUSTING ENGINE STOP SOLENOID,

ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL

LINKAGE
1. Adjusting control linkage
1) If any part was replaced, connect the cable
to the fuel injection pump governor lever
securely.
a Connect the cable to the hole at the end
of the injection pump governor lever.
2) Turn the starting switch to the ON position
and set the fuel control dial to the FULL position.
3) Bring fuel injection pump governor lever (1)
in contact with stopper (2) on the FULL side.
4) Under this condition, pull cable (3) with force
of about 98 N {about 10 kg} and tighten nuts
(4) and (5) temporarily.
a Tighten the nuts while pulling the cable to
eliminate play.
5) Return nut (4) by 2 turns and tighten nut (5)
by 2 turns retighten them.
6) Start the engine and check that it runs at the
specified speed.
20-115
2. Adjusting control linkage finely

If the control linkage cannot be adjusted by the
method in 1. above, adjust it finely with the turnbuckle above the cable.
When the engine speed (high idling speed) is
below the specified level
1) Turn the starting switch to the ON position
and set the fuel control dial to the FULL position.
2) Loosen nut (6) (right-hand screw) and nut (7)
(left-hand screw).
3) Turn bolt (8) counterclockwise, seeing from
the governor lever side, to eliminate the
clearance between injection pump governor
lever (1) and full stopper (2).
4) Tighten nuts (6) and (7).
ADJUSTING FUEL CONTROL LINKAGE
4) Tighten nuts (6) and (7).

Nut: 8.8 10.8 Nm {0.9 1.1 kgm}
a At this time, check that clearance A and
B between bolt (8) and nuts (6) and (7)
are 5 3.5 mm (1.5 8.5 mm).
a At this time, check that the rubber boot
(10) of the cable is not twisted.
5) Start the engine and check that it runs at the
specified speed.
Nut: 8.8 10.8 Nm {0.9 1.1 kgm}
5)
1)
2)
3)
a At this time, check that clearance A and

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

a Adjust the engine speed sensor for the pump
controller according to the following procedure.
a The engine G speed and engine Ne speed sensor for the engine controller cannot be adjusted.
1. Screw in sensor (1) until its tip touches the tooth
tip of flywheel ring gear (2).
a Before installing the sensor check that its tip
is free from steel chips and flaws.
Threads: Hydraulic sealant
2. Return sensor (1) by 1/2 2/3 turns.
a A clearance of 0.75 1.00 mm is made
between the sensor tip and gear tooth tip.
3. Secure sensor (1) with nut (3).
Nut: 69 74 Nm {7.0 7.5 kgm}
PC78MR-6
20-117
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN

WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, AND TRAVEL CIRCUITS
a Hydraulic oil temperature for measurement:
45 55 C
Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure of the hydraulic tank. Set the safety valve
lock lever to the LOCK position.
Measuring hydraulic pressure in boom arm,
bucket, travel, and swing circuits
1. Measuring
1) Installing pressure gauge
i) Open the top cover of the valve and
remove the side cover.
ii) Remove pressure pickup plug (1) or (2)
(10 mm, P = 1.25) and install nipple C3,
then connect oil pressure gauge C1
(58.8 MPa {600 kg/cm}
a Use plug (1) to measure the hydraulic
pressure in boom, arm, and bucket circuits and use plug (2) to measure the
hydraulic pressure in the swing and
travel circuits.
2) Measuring unload pressure
Measure the hydraulic pressure while the
engine is running at full throttle and the control lever is in neutral.
3) Measuring pump relief pressure
Measure the hydraulic pressure when each
actuator is relieved while the engine is running at full throttle.
Measuring hydraulic pressure in swing and
blade circuits
1. Measuring pump relief pressure
1) Remove the top cover of the valve.
2) Remove pressure pickup plug (3) (10 mm, P
= 1.25) and install nipple C3, then connect oil
pressure gauge (58.8 MPa {600 kg/cm}).
a See the photo.
3) Measure the hydraulic pressure when swing
or blade lower actuator is relieved while the
engine is running at full throttle.
20-118
PC78MR-6

2. Adjusting
Adjusting main relief valve for boom, arm,
bucket, swing, and travel circuits.
Remove cap (2) of main relief valve (1) and
loosen locknut (3), then adjust with 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
screw: 12.5 MPa {128 kg/cm}.
Locknut : 39 49 Nm {4 5 kgm}
Cap
: 39 49 Nm {4 5 kgm}
20-120
Adjusting main relief valve for blade (RAISE)

circuits
screw: 19.6 MPa {200 kg/cm}.
Locknut : 39 49 Nm {4 5 kgm}
Cap
: 39 49 Nm {4 5 kgm}
PC78MR-6
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING

LS VALVE
1. Measuring LS differential pressure
1) Measuring with main relief differential pressure gauge
i) Remove pump pressure pickup plug (1)
(on the high pressure side) and disconnect LS pressure hose (2). Install nipple
C3 to the high pressure side and nipple
C4 to the LS pressure side.
ii) Connect differential pressure gauge C5.
a Connect the high pressure side of
the differential pressure gauge to the
main relief pressure side and connect the low pressure side to the LS
pressure side.
iii) Measure the LS differential pressure
under the condition in Table 1.
Table 1
Fuel Control
Dial
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
2) Measuring with oil pressure gauge

a Measure with the same gauge.
i) Remove pump pressure pickup plug (1)
(on the high pressure side) and disconnect LS pressure hose (2) (on the low
pressure side) and install adapter C3.
ii) Connect pressure gauge C1 (39.2 MPa
{400 kg/cm}).
a Use a pressure gauge having unit
divisions of 1.0 MPa {10 kg/cm}. (If a
pressure gauge of 39.2 MPa {400 kg/
cm} is not available, one of 58.8
MPa {600 kg/cm} will do.)
iii) Measure the pump discharge pressure
under the condition in Table 1.
Read the pointer correctly, facing the
gauge.
iv) Measure the LS pressure under the condition in Table 1.
a Read the pointer correctly, facing the
gauge.
a LS differential pressure = (Pump discharge pressure) (LS pressure)
20-121
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
Adjusting
1. Adjusting LS valve
a If the differential pressure is abnormal, adjust
the LS valve according to the following procedure.
a Before loosening the locknut, be sure to
make match marks.
1) Loosen locknut (3) and adjust with adjustment screw (4).
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
TESTING TVC-EPC SOLENOID

OUTPUT PRESSURE
Measuring
a Hydraulic oil temperature for measurement: 45
55 C
1) Remove pump pressure pickup plug (1) (10
mm, P = 1.25) and install nipple C3 of the oil
pressure gauge kit and connect oil pressure
gauge kit and connect oil pressure gauge C1
(5.9 MPa {60 kg/cm}).
Locknut: 29.4 39.2 Nm {3 4 kgm}
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
MEASURING CONTROL CIRCUIT PRESSURE
MEASURING CONTROL CIRCUIT PRESSURE

Measuring
55 C
filler cap slowly to release the internal pressure
of the hydraulic tank. Set the safety valve lock
lever to the LOCK position.
1) Remove the front cover front guard plate of
the valve.
2) Remove pressure pickup plug (1) (10 mm, P
= 1.25) from the top of the solenoid valve
block.
4) Start and run the engine at full throttle and

measure the circuit pressure.
Adjusting
If the control circuit pressure is abnormal, adjust
the control relief valve according to the following
procedure.
1) Loosen locknut (2) of relief valve (1) and
adjust with adjustment screw (3).
screw: 0.32 MPa {3.3 kg/cm}.
a After adjusting, check the set pressure
according to the procedure in 1.
3) Connect nipple C3 and install oil pressure

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

45 55 C
1. Measuring PPC valve output pressure
1) Disconnect hose (1) of the circuit to be measured.
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
e. LEFT REVERSE travel
n. Arm IN
f.
o. Bucket DUMP
LEFT FORWARD travel
Boom LOWER
g. RIGHT REVERSE travel
p. Bucket CURL
h. RIGHT FORWARD travel
q. Service
i.
r.
RIGHT swing
Service
2) Install adapter C4 between hose (1) and

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

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

45 55 C
1. Measuring output pressure of boom swing
stop EPC solenoid valve
1) Disconnect EPC solenoid valve output hose
(1) and install oil pressure gauge C1 (5.9
MPa {60 kg/cm}), using nipples C3 and C4
in the oil pressure gauge kit.
a The EPC solenoid valve is installed in the
6-spool solenoid valve assembly under
the floor plate.
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.
2) Measure the output pressure under the condition in Table 1.
Table 1
Oil pressure
MPa {kg/cm}
Remarks
While boom is swinging to right
3.14 0.49
{32 5}
Stroke end
1.13 0.29
{11.5 3}
While boom is swinging to left
3.14 0.49
{32 5}
Stroke end
1.13 0.29
{11.5 3}
Solenoid Name
Measurement Condition
Swing right stop EPC
Boom swing stop

EPC
20-126
PC78MR-6
Table 2
Solenoid Name
PPC
1 oil pressuressure lock
Swing hold2
ing brake
Travel speed
3
selector
Operation of Oil pressure

solenoid
MPa {kg/cm}
Measurement Condition
Operating Condition
Remarks
Set safety lock lever in

FREE position.
Oil pressure is
applied to PPC valve
circuit.
ON
3.14 0.29
{32 3}
Set safety lock lever in

LOCK position.
Oil pressure is not

applied to PPC valve
circuit.
OFF
Operate swing or boom

swing or arm-in lever.
Brake is released.
ON
3.14 0.49
{32 5}
Set swing or arm-in lever

in neutral (5 sec after
Brake is applied.
setting in neutral)
OFF
Set travel speed selector Travel speed is

switch in Hi.
increased.
ON
3.14 0.49
{32 5}
Set travel speed selector Travel speed is

switch in Lo.
decreased.
OFF
Note: Operation of solenoid valve is as follows;

When ON: Power is applied (Hydraulic oil is generated).
When OFF: Power is not applied (Hydraulic oil is 0).
PC78MR-6
20-127
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE

If the work equipment control lever or swing control
lever has excessive play, adjust it according to the
following procedure.
of the hydraulic tank. Set the safety valve lock
lever to the LOCK position.
1. Remove the PPC valve.
2. Remove bolt (1).
3. Loosen locknut (2) and screw in disc (3) until it
touches the heads of 4 pistons (4).
a At this time, do not move the pistons.
4. Fix disc (3) and tighten locknut (2) to the specified torque.
5. Install boot (1).
a The clearance between disc (3) and piston
(4) is eliminated by the above adjustment.
20-128
PC78MR-6
TESTING TRAVEL DEVIATION

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

4 mm) in adjustment plug (1) or (2).
a Insert the hexagonal wrench securely.
3. Loosen locknut (3), leaving the hexagonal
wrench inserted.
a Before adjusting, mark the position of the
locknut with paint.
a Loosen the locknut, securing the hexagonal
wrench.
Loosening angle of locknut: Approx. 90
180
If the adjustment plug is loosened more than

the adjustment limit, high pressure oil spurts
out. Take care extremely.
of the hydraulic tank.
1. Check the position of each adjustment plug of
the main pump.
When the machine deviates to the right:
Loosen adjustment plug (1).
When the machine deviates to the left:
Loosen adjustment plug (2).
a Loosen only either plug. Do not loosen both
plugs at the same time.
4. Correct the travel deviation by loosening adjustment plug (1) or (2).

Quantity of correction of travel deviation per
turn of adjustment plug: 150 mm (For reference)
a When the machine is shipped, the adjustment plugs are tightened fully. Adjust the correction angle by the loosening angle of the
adjustment plugs.
a If the adjustment plug is dragged when the
locknut is loosened, tighten it again.
a The adjustable range of each adjustment
plug is 2 turns / 720 degrees from the tightened position.
5. Tighten locknut (3).
Locknut:2.94 4.9 Nm {0.3 0.5 kgm}
6. Check for travel deviation again. If the machine
still deviates, adjust again according to the
above procedure.
a Do not loosen the adjustment plugs more
than the adjustable range (2 turns / 720
degrees).
20-130
PC78MR-6
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT

OF WORK EQUIPMENT
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF

WORK EQUIPMENT
55 C
1. Work equipment cylinder
a If the hydraulic drift of the work equipment
exceeds the standard value, measure the leakage in the cylinder according to the following procedure to see if the cause of the hydraulic drift is
on the cylinder side or control valve side.
If the leakage is less than the standard value,
the cause is on the control valve side.
If the leakage is above the standard value,
the cause is on the cylinder side.
1) Extend the rod of the cylinder to be measured and stop the engine.
2) Disconnect hoses (1) (4) on the head side
and block the pipes on the machine side with
plugs.
1. Boom cylinder head hose
2. Arm cylinder head hose
3. Bucket cylinder head hose
4. Swing cylinder head hose
3) Run the engine at full throttle and apply relief

pressure to the cylinder bottom.
Take care not to disconnect the bottom hoses.
4) After 30 seconds, measure the oil leakage in

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

MOTORS
55 C
1. Swing motor
1) Disconnect drain hose (1) of the swing motor
(on the hydraulic tank side).
a Plug the hydraulic tank.
2) Stick the bucket into the ground to lock the
swing mechanism.
3) Run the engine at full throttle and relieve the
swing circuit.
1 minute.
a After measuring 1 time, swing 180 degrees
and measure again.
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.
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
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

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

Method of testing clearance of swing circle bearing on machine
1. Fix dial gauge with magnet (1) to the swing circle
outer ring (2) (or inner ring) (3) and apply the
probe to the end face of the inner ring (or outer
ring). Set the dial gauge to the front or rear part.
4. Set the arm at about right angles to the ground

and lower the boom until the front part of the
undercarriage floats.
At this time, the front part of the upper structure
rises and the rear part lowers.
5. Read the dial gauge. The indicated value is the
clearance of the swing circle bearing.
Do not put your hand or foot under the undercarriage during measurement.
2. Extend the work equipment to the maximum

reach and set the bucket tip to the height of the
underside of the revolving frame.
At this time, the front part of the upper structure
lowers and the rear part rises.
3. Set the dial gauge to the zero point.
20-134
6. Set the machine in the position explained in 2

above again and check that the dial gauge indicates zero. If the dial gauge does not indicate
zero, repeat Steps 2 5.
PC78MR-6
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

Testing
1. Run the engine at low idling and move the
machine forward by the length of the track on the
ground and stop slowly.
2. Place square wood bar (3) over idler (1) and carrier roller (2).
3. Measure the maximum distance between the top
of the track and the underside of the wood bar.
If the standard slack a is in the following
range, the shoe tension is normal.
Specification
Standard Slack a
Road liner, steel shoe
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
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
3) Test the track shoe tension again. If it is still
not normal, adjust it again.
PC78MR-6
20-135
BLEEDING AIR FROM HYDRAULIC CIRCUIT

Contents of work and procedures for bleeding air
Air bleeding item
Procedure for Bleeding Air

1
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
Replacing return filter element

Replacing or repairing pump
Removing suction pipe
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 or repairing control

valve
Replacing cylinder
Removing cylinder piping
Replacing swing motor

Removing swing motor piping
Replacing travel motor and swivel

Removing travel motor and swivel
Replacing or removing swing

PPC circuit parts (Swing PPC
valve, piping, pressure switch,
etc.)
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.
2. Bleeding air between pump and hydraulic tanks.

a If the pump is operated without bleeding air
from the circuit between the pump and
hydraulic tank, it is heated abnormally and
may be broken soon. Accordingly, bleed all
air.
1) Run the engine at medium speed (approx.
1,650 rpm)
2) Operate the work equipment slowly for about
5 minutes to bleed air.
Bleeder: 7.8 9.8 Nm {0.8 1.0 kgm}

3. Bleeding air from LS circuit
a Bleed air only after the hoses of the pump,
valve, and LS circuit are replaced.
a If air is not bled from the LS circuit, the work
equipment may malfunction.
1) Loosen air bleeder (2) installed to the LS port
of the pump.
2) Run the engine at low idling for 2 minutes.
3) Operate the bucket (dump and curl bucket to
the stroke ends) for about 2 minutes.
4) After bleeding air, tighten air bleeder (2).
20-136
PC78MR-6
4. Bleeding air from hydraulic cylinder

a If the engine speed is heightened or the cylinder is moved to the stroke end at first, the
air in the cylinder will damage the piston
packing, etc.
1) Run the engine at medium speed (approx.
1,650 rpm) and move each cylinder to about
100 mm before each stroke end 4 5 times.
a Never relieve the oil.
2) Move each cylinder to each stroke end 3 4
times.
3) Move each cylinder to each stroke end 4 5
more times to bleed air.
5. Bleeding air from swing motor
a Bleed air from the swing motor only after the
oil is drained from the swing motor case.
a If the swing motor is operated without bleeding air from it, its bearings may be broken.
1) Run the engine at low idling and loosen drain
hose (2). If oil oozes out, tighten the drain
hose.
a Do not swing the machine while bleeding
air.
2) Keep the engine speed at low idling and
swing evenly at least 2 turns in each direction.
7. Bleeding air from swing PPC circuit

1) Stick the bucket into the ground to lock the
swing mechanism.
2) Run the engine at low idling.
3) Loosen air bleeders (4) and (5) of the control
valve.
4) Move the swing control lever through the full
stroke repeatedly to check that all air is bled
through bleeders (4) and (5).
5) Tighten bleeders (4) and (5).
Bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}
6. Bleeding air from travel motor

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

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

diode according to the following procedure.
Use a digital tester having a diode range.
1. Apply the red (+) test pin to the anode (P) side of
the diode, and the black (-) test pin to the cathode (N) side.
a The current flow mark is printed on the diode
body.
PC78MR-6
2. Set the tester in the diode range, and the voltage

of the battery in it is indicated. If this voltage
does not change, the diode doesn't have
continuity.
changes, the diode has continuity (normal)
(Note).
0 or near 0, the diode is shorted in it.
Note: A normal silicon diode indicates 450 600.
20-139
TROUBLESHOOTING
Points to remember when troubleshooting.................................................................................................. 20-202
SEQUENCE of events in troubleshooting ................................................................................................... 20-203
Point to remember when carrying out maintenance ................................................................................... 20-204
Checks before troubleshooting ................................................................................................................... 20-212
Type and location of connectors ................................................................................................................. 20-214
Connector arrangement diagram ................................................................................................................ 20-216
Connection table for connector pin numbers .............................................................................................. 20-219
Explanation of functions of electric system control mechanism .................................................................. 20-242
Display and special functions of monitor panel ........................................................................................... 20-243
TVC valve current adjustment table ............................................................................................................ 20-254
Adjusting service meter............................................................................................................................... 20-255
Method of using judgement table ................................................................................................................ 20-256
How to read flow of troubleshooting............................................................................................................ 20-258
Contents and procedure of troubleshooting ................................................................................................ 20-260
Troubleshooting for engine (S mode).......................................................................................................... 20-301
Troubleshooting for communication system (N mode)................................................................................ 20-401
Troubleshooting for controller (governor control system) (E mode)............................................................ 20-501
Troubleshooting for controller (pump control system) (C mode)................................................................. 20-601
Troubleshooting for controller (input signal system) (F mode).................................................................... 20-701
Troubleshooting for hydraulic and mechanical systems (H mode) ............................................................. 20-801
Troubleshooting for machine monitor system (M mode) ............................................................................. 20-901
PC78MR-6
20-201
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait
for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some
idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry
to disassemble the components. If components
are disassembled immediately after a failure
occurs:
Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
It will become impossible to find the cause of
the failure.
It will also cause a waste of man hours, parts, or
oil and grease. At the same time, it will also lose
the confidence of the user or operator. For this
reason, when carrying out troubleshooting, it is
necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator.
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred
before?
4) Check the stroke of the control valve spool.

5) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
4. Confirming the failure.
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as a
problem with the method of operation, etc.
a When operating the machine to re-enact the
troubleshooting symptoms, do not carry out
any investigation or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Steps 2 4 to narrow down the causes of
the failure, then use the troubleshooting flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting is as
follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure.
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the problem occurred. Then, remove the root cause.
3. Check before troubleshooting.

1) Check the oil level.
2) Check for any external leakage of oil from the
piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202
PC78MR-6
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180
TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first
ask the following points.
Name of customer
Type, serial number of machine
Details of jobsite, etc.
2) Ask questions to gain an outline of the 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
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
tools.
T-adapter
Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the necessary replacement parts.
Step 7
Pinpoint locations of failure (carry out
troubleshooting)
Decide action to take
TEW00186
1) Before starting troubleshooting, locate and

repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
Step 4
Go to jobsite
Step 5
Ask operator questions to confirm details of
failure.
TEW00189
PC78MR-6
Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
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
POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric equipment
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire,
and protectors or tubes used for protecting the wiring.
Compared with other electrical components fitted in
boxes or cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again,
so they are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when
handling wiring harnesses.
Main failures occurring in wiring harness

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

The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if
there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause improper connection or breakage.
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.
4) High-pressure water entering connector

The connector is designed to make it difficult for water to
enter (drip-proof structure), but if high-pressure water is
sprayed directly on the connector, water may enter the
connector, depending on the direction of the water jet.
As already said, the connector is designed to prevent
water from entering, but at the same time, if water does
enter, it is difficult for it to be drained. Therefore, if water
should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately
dry the connector or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and an oil film
is formed on the mating surface between the male and
female pins, the oil will not let the electricity pass, so
there will be defective contact.
If there is oil or grease stuck to the connector, wipe it off
with a dry cloth or blow it dry with compressed air and
spray it with a contact restorer.
a When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and
water from the compressed air completely before
cleaning with compressed air.
PC78MR-6
20-205
TROUBLESHOOTING
2) Removing, installing, and drying connectors and

wiring harnesses
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.
3) Action to take after removing connectors

After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from getting in the connector portion.
a If the machine is left disassembled for a long
time, it is particularly easy for improper contact to
occur, so always cover the connector.
20-206
PC78MR-6
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
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off
with a dry cloth. Avoid washing it in water or using
steam. If the connector must be washed in water, do not
use high-pressure water or steam directly on the wiring
harness.
If water gets directly on the connector, do as follows.
Disconnect the connector and wipe off the water with
a dry cloth.
a If the connector is blown dry with compressed
air, there is the risk that oil in the air may cause
defective contact, so remove all oil and water
from the compressed air before blowing with air.
Dry the inside of the connector with a dryer.

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

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

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

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

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

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

With the increase in pressure and precision of hydraulic
equipment, the most common cause of failure is dirt (foreign
material) in the hydraulic circuit. When adding hydraulic oil,
or when disassembling or assembling hydraulic equipment,
it is necessary to be particularly careful.
1) Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or repairing
the machine in rain or high winds, or places where there
is a lot of dust.
2) Disassembly and maintenance work in the field
If disassembly or maintenance work is carried out on
hydraulic equipment in the field, there is danger of dust
entering the equipment. It is also difficult to confirm the
performance after repairs, so it is desirable to use unit
exchange. Disassembly and main-tenance of hydraulic
equipment should be carried out in a specially prepared
dustproof workshop, and the performance should be
confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the openings
should be sealed with caps, tapes, or vinyl bags to 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.
4) Do not let any dirt or dust get in during refilling operations.

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

When hydraulic oil or other oil is warm, it flows easily. In
addition, the sludge can also be drained out easily from
the circuit together with the oil, so it is best to change the
oil when it is still warm. When changing the oil, as much
as possible of the old hydraulic oil must be drained out.
(Drain the oil from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the circuit.) If
any old oil is left, the contaminants and sludge in it will
mix with the new oil and will shorten the life of the
hydraulic oil.
6) Flushing operations
After disassembling and assembling the equipment, or
changing the oil, use flushing oil to remove the 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
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Value
Action
1. Check fuel level, type of fuel
Add fuel
2. Check for impurities in fuel
Clean, drain
3. Check hydraulic oil level
Add oil
4. Check hydraulic oil strainer
Clean, drain
5. Check swing machinery oil level
Add oil
6. Check engine oil level, type of engine oil
Add oil
7. Check coolant level
Add coolant
8. Check dust indicator for clogging
Clean or replace
9. Check hydraulic oil filter
Replace
1. Check for looseness, corrosion of battery terminal, wiring
Tighten or replace
2. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring
Tighten or replace
1. Check for abnormal noise, smell
Repair
2. Check for oil leakage
Repair
3. Carry out air bleeding
Bleed air
20 - 30 V
Replace
2. Check battery electrolyte level
Add or replace
3. Check for discolored, burnt, exposed wiring
Replace
4. Check for missing wiring clamps, hanging wire
Repair
5. Check for water leaking on wiring (Pay particular attention to water leaking
on connectors or terminals)
Disconnect
connector and dry
6. Check for blown, corroded fuses
Replace
After running for several minutes:

27.5 ~ 29.5 V
Replace
Hydraulic,
mechanical
equipment
Electrical
equipment
Lubricating oil, coolant
Item
Electrical equipment
1. Check battery voltage (Engine stopped)
7. Check alternator voltage (Engine running at 1/2 throttle or above)

8. Sound of actuation of battery relay (When starting switch is turned ON,
OFF)
20-212
PC78MR-6
TROUBLESHOOTING
TYPE AND LOCATION OF CONNECTORS

a The addresses in the follwing table are the addresses used in the connector arrangement drawing
(3-dimensional drawing).
Connector
No.
Type
No.
of
Pins
Address
Connector
No.
Type
No.
of
Pins
A/C
Air conditioner compressor
L7
K20
Cab inlet
R6
D4
SWP
Diode (Engine stop solenoid)
H1
K21
Cab inlet
R6
D5
SWP
Diode (Battery relay BR)
G1
K23
Starting motor cut-out relay
R8
D6
SWP
Diode (Battery relay BR)
G1
K26
090
Horn switch
M7
D11
SWP
Diode (TVC solenoid)
R7
K27
SWP
Fuel governor control motor
N7
D12
SWP
Diode (TVC solenoid)
R8
K28
PPC hydraulic lock switch
P2
D13
SWP
Diode (PPC basic pressure

lock solenoid)
Q8
K32
Accelerator relay
O8
D22
SWP
Diode (Air conditioner compressor)
H1
K33
Decelerator relay
N8
D25
SWP
Diode (Engine stop solenoid

relay)
G1
K42
SUMITOMO
16
Intermediate connector
(Reset switch)
P8
D26
SWP
Diode (Engine stop solenoid

relay)
H9
K45
Ground (Radio)
Q3
D30
SWP
Diode (PPC basic pressure

lock solenoid)
R7
K51
090
20
(Starting, light switch)
M7
D31
SWP
Diode (Swing RIGHT stop

circuit)
R7
K52
Light switch
N8
D32
SWP
Diode (Swing RIGHT stop

circuit)
R6
K53
Buzzer cancel switch
O8
D33
SWP
Diode (Swing LEFT stop circuit)
Q8
K54
Revolving warning lamp

(Optional)
P8
D34
SWP
Diode (Swing LEFT stop circuit)
P8
M1
(Power supply, ground)
M4
EU1
Overload warning cancel

switch (*1)
R5
M2
(Power supply)
M4
Fuse box
R3
M3
DT (Gr)
(Rotation sensor, etc.)
M4
FB1
Location
Address
Location
GND Terminal
Key stop solenoid
L2
M4
DT (G)
(Swing angle sensor, etc.)
M4
HOLD Terminal
Key stop solenoid
L2
M5
DT (Gr)
(TVC solenoid)
M3
K1
12
(Monitor panel)
M7
M6
DT (B)
(Related to pressure switch)
M3
K2
16
(Monitor panel)
N7
M7
DT (G)
For connection of boom

pressure sensor (*1)
M3
K3
DT
2nd travel speed selection

solenoid valve
O2
M9
DT
Fuel sensor
I2
K11
SWP
12
Auto A/C unit
O2
M11
DT
Boom swing LEFT stop solenoid
N2
K12
Resister
P8
M12
DT
Boom swing RIGHT stop

solenoid
N2
K17
Optional power supply unit
P2
M13
DT
PPC hydraulic lock solenoid
M2
K18
090
Decelerator switch
Q2
M13
Speaker (Right)
I9
K19
PA
Radio
R3
M14
DT
Parking brake solenoid
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
Travel speed shifting solenoid
M2
P15
040
Sunlight sensor (Optional)
M6
Engine speed sensor
J3
Key stop solenoid
L3
Glow plug
K8
T1
Terminal
Revolving frame ground

(Controller system)
I2
M18
DT
Engine water temperature

sensor
L8
T2
Terminal
H2
M20
DT
TVC/EPC solenoid
K8
T3
Terminal

(Controller SIG system)
H1
M21
Pressure switch
(Boom RAISE)
G9
T4
Terminal
Alternator (Terminal R)
L6
M22
Pressure switch (Swing)
I9
T5
Terminal
Alternator (Terminal B)
L6
M23
Pressure switch (Swing)
G9
T6
Terminal
Engine oil pressure switch
L5
M24
Pressure switch (Arm IN)
H9
T9
Terminal
Battery relay (Terminal E)
A4
M25
Pressure switch (Travel)
I9
T10
Terminal
Battery relay (Terminal BR)
A3
M26
Fusible link
C8
T11
Terminal
Battery relay (Terminal M)
A6
M27
Fusible link
B8
T12
Terminal
Battery relay (Terminal B)
A5
M28
DT
(Working lamp)
J9
T16
Terminal
K3
M30
Safety relay (S, R)
J3
T17
Terminal
K3
M31
KES
Windshield washer
C8
T31
Terminal
Safety relay (Terminal B)
K3
M32
DT
Travel/Swing alarm
J2
T32
Terminal
Safety relay (Terminal C)
L5
M35
Junction wiring harness
K1
T33
Terminal
Starting motor (Terminal B)
L7
M36
DT
Engine stop solenoid
J2
T34
Terminal
Starting motor (Terminal C)
L6
M71
Room light
J9
W04
Wiper motor
M5
M73
Speaker (Left)
J9
W19
Cigarette lighter
M5
M75
DT
Working lamp
D9
Terminal
Starting switch (Terminal B)
M9
M80
040
Horn
M2
BR
Terminal
Starting switch (Terminal BR)
M8
M92
DT
Boom bottom pressure sensor (*1)
D2
ACC
Terminal
Starting switch (Terminal

ACC)
M8
M95
DRC23
24
Controller
R8
Terminal
Starting switch (Terminal C)
M9
M96
DRC23
40
Controller
Q8
R1
Terminal
Starting switch (Terminal R1)
N8
M97
DRC23
40
Controller
Q8
R2
Terminal
Starting switch (Terminal R2)
N8
M101
DT
Boom swing angle potentiometer
F1
P01
040
12
Monitor panel
M6
P02
P040
20
Monitor panel
M6
Location
PULL Terminal
Address
Location
PC78MR-6
20-215
(1)
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM

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

a The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
X-Type Connector
Number of
Pins
Male (Female Housing)
Female (Male Housing)
T-adapter Part
Number
Part Number: 08055-00181
799-601-7010
BWP04702
2
799-601-7020
BWP04703
3
BWP04704
BWP04705
799-601-7030
BWP04706
799-601-7040
Terminal part number: 79A-222-3370

Wire size: 0.85
Grommet: black
Quantity: 20 pieces

Wire size: 0.85
Grommet: black
Quantity: 20 pieces

Wire size: 2.0
Grommet: red
Quantity: 20 pieces

Wire size: 2.0
Grommet: red
Quantity: 20 pieces
PC78MR-6
20-219
TROUBLESHOOTING
Number of
Pins
SWP-Type Connector
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
Terminal part number:

Wire size: 0.85
Grommet: black
Quantity: 20 pieces

Wire size: 0.85
Grommet: black
Quantity: 20 pieces

Wire size: 1.25
Grommet: red
Quantity: 20 pieces

Wire size: 1.25
Grommet: red
Quantity: 20 pieces
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
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
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
T-adapter Part
Number
Body Part Number: 79A-222-2640

(Quantity: 5 pieces)

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
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
BWP04751
12
BWP04753
16
BWP04755
20
BWP04757
PC78MR-6
T-adapter Part
Number
BWP04752
799-601-7180
Housing Part Number: 79A-222-3430
BWP047544
799-601-7190
BWP04756
799-601-7210
BWP04758
799-601-7220
20-227
TROUBLESHOOTING
Number of
Pins
10
AMP070-Type Connector
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
BWP04769
BWP04770
Number of
Pins
T-adapter Part
Number
PA-Type Connector
BWP04771
BWP04772
Number of
Pins
10
BENDIX MS-Type Connector
BWP04773
PC78MR-6
T-adapter Part
Number
T-adapter Part
Number
BWP04774
799-601-3460
20-229
TROUBLESHOOTING
Number of
Pins
KES1 Automobile-Type Connector

BWP04775
Part Number: 08027-10210 (Natural color)

08027-10220 (Black)
BWP04777
BWP04779

08027-10420 (Black)
BWP04781

08027-10620 (Black)
20-230
T-adapter Part
Number
BWP04776

08027-10270 (Black)
BWP04778
BWP04780

08027-10470 (Black)
BWP04782

08027-10670 (Black)
PC78MR-6
TROUBLESHOOTING
Number of
Pins
KES1 Automobile-Type Connector

BWP04783

08027-10820 (Black)
PC78MR-6
T-adapter Part
Number
BWP04784

08027-10870 (Black)
20-231
TROUBLESHOOTING
Number of
Pins
Socket-Type Connector for Relay

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
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
HD30 Series Connector

Body (Plug)
Body (Receptacle)
Pin (Male Terminal)
Pin (Female Terminal)
Part Number: 08191-11201, 08191-11202,

08191-11205, 08191-11206
Part Number: 08191-14101, 08191-14102,

08191-14105, 08191-14106
Pin (Male Terminal)
Part Number: 08191-12201, 08191-12202,

08191-12205, 08191-12206
Part Number: 08191-13101, 08191-13102,

08191-13105, 08191-13106
Pin (Male Terminal)
Part Number: 08191-21201, 08191-12202,

08191-21205, 08191-12206
Part Number: 08191-24101, 08191-24102,

08191-24105, 08191-24106
Pin (Male Terminal)
Part Number: 08191-22201, 08191-22202

08191-22205, 08191-22206
Part Number: 08191-23101, 08191-23102,

08191-23105, 08191-23106
T-adapter Part
Number
799-601-9210
799-601-9220
PC78MR-6
TROUBLESHOOTING
Type
(Shell
Size
Code)
18-20
(3)
18-21
(4)
PC78MR-6

Body (Plug)
Body (Receptacle)
Pin (Male Terminal)
Part Number: 08191-31201, 08191-31202
Part Number: 08191-34101, 08191-34102
Pin (Male Terminal)
Part Number: 08191-32201, 08191-32202
Part Number: 08191-33101, 08191-33102
Pin (Male Terminal)
Part Number: 08191-41201, 08191-42202
Part Number: 08191-44101, 08191-44102
Pin (Male Terminal)
Part Number: 08191-42201, 08191-42202
Part Number: 08191-43101, 08191-43102
T-adapter Part
Number
799-601-9230
799-601-9240
20-235
TROUBLESHOOTING
Type
(Shell
Size
Code)
24-9 (5)
24-16
(6)
20-236

Body (Plug)
Body (Receptacle)
Pin (Male Terminal)
Part Number: 08191-51201, 08191-51202
Part Number: 08191-54101, 08191-54102
Pin (Male Terminal)
Part Number: 08191-52201, 08191-52202
Part Number: 08191-53101, 08191-53102
Pin (Male Terminal)
Part Number: 08191-61201, 08191-62202,

08191-61205, 08191-62206
Part Number: 08191-64101, 08191-64102,

08191-64105, 08191-64106
Pin (Male Terminal)
Part Number: 08191-62201, 08191-62202,

08191-62205, 08191-62206
Part Number: 08191-63101, 08191-63102,

08191-63105, 08191-63106
T-adapter Part
Number
799-601-9250
799-601-9260
PC78MR-6
TROUBLESHOOTING
Type
(Shell
Size
Code)

Body (Plug)
Body (Receptacle)
Pin (Male Terminal)
Part Number: 08191-71201, 08191-71202,

08191-71205, 08191-71206
Part Number: 08191-74101, 08191-74102, 0819174105,

08191-74106
Pin (Male Terminal)
Part Number: 08191-72201, 08191-72202,

08191-72205, 08191-72206
Part Number: 08191-73101, 08191-73102,

08191-73105, 08191-73106
Pin (Male Terminal)
Part Number: 08191-81201, 08191-81202, 0819181203, 08191-81204, 08191-81205, 08191-81206
Part Number: 08191-84101, 08191-84102, 0819184103, 08191-84104, 08191-84105, 08191-84106
Pin (Male Terminal)
Part Number: 08191-82201, 08191-82202, 0819182203, 08191-82204, 08191-82205, 08191-82206
Part Number: 08191-83101, 08191-83102, 0819183103, 08191-83104, 08191-83105, 08191-83106
24-21
(7)
24-22
(8)
PC78MR-6
T-adapter Part
Number
799-601-9270
799-601-9280
20-237
TROUBLESHOOTING
Type
(Shell
Size
Code)
24-31
(9)
20-238

Body (Plug)
Body (Receptacle)
Pin (Male Terminal)
Part Number: 08191-91203, 08191-91204,

08191-91205, 08191-91206
Part Number: 08191-94103, 08191-94104,

08191-94105,08191-94106
Pin (Male Terminal)
Part Number: 08191-92203, 08191-92204,

08191-92205, 08191-92206
Part Number: 08191-93103, 08191-93104,

08191-93105, 08191-93106
T-adapter Part
Number
799-601-9290
PC78MR-6
TROUBLESHOOTING
No.
of
Pins
DT Series Connector
Body (Plug)
Body (Receptacle)
799-601-9020
Part Number: 08192-12200 (Normal type)

08192-22200 (Fine wire type)

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
Part Number: 08192-1820T (Normal type)

08192-2820T (Fine wire type)

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
No.
of
Pins
DTM Series Connector

Body (Plug)
Body (Receptacle)
T-adapter Part
Number
799-601-9000
No.
of
Pins
DTHD Series Connector

Body (Plug)
Body (Receptacle)
Part Number: 08192-31200 (Contact size #12)

08192-41200 (Contact size #8)
08192-51200 (Contact size #4)
Part Number: 08192-31100 (Contact size #12)

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

CONTROL MECHANISM
Machine model: PC78MR-6
The control mechanism of the electric system consists of the monitor panel, governor, and pump controller.
Those components receive signals necessary to them. The governor and pump controller output or input the
necessary signal according to the signals selected by the monitor panel to control the absorption torque, engine
output, etc.
Network information
1) Working mode (Standard, E) information
2) One-touch slow-down (ON/OFF) signal
3) Travel Hi/Lo signal
4) Coolant temperature (Water temperature) information
(Monitor panel o Controller)

(Monitor panel i Controller)
(Monitor panel i Controller)
(Monitor panel o Controller)
20-242
(1)
PC78MR-6
TROUBLESHOOTING
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL

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

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

User Code
Abnormal system
E02
TVC-EPC system
E03
Swing holding brake system
E05
Governor control system
E40
Angle sensor input system
E41
EPC solenoid output system
PC78MR-6
20-243
TROUBLESHOOTING
3. Function of displaying "service code"

All trouble information items of the controller are sent to the monitor panel. All of the information items which
must display "user codes" and those which do not need display "user codes" are saved as "service codes"
in the monitor panel.
If the following operation is executed, the service code is displayed on the display of the monitor panel and
the letter "E" to indicate that the trouble is happening currently and the lapse time (service meter reading)
are displayed on the service meter unit.
1) Method of displaying and deleting service
code
i) The service code is displayed by the following procedure:
(1) Push and hold the "Buzzer cancel
switch (8)" and "Working mode selector switch (7)" for 2.5 seconds.
(2) Push the "Buzzer cancel switch (8)"
and "Mode selector switch (UP) (3)"
[or Mode selector switch (DOWN)
(4)] and set "01" tothe 2nd and 3rd
columns from the left on service
meter unit (2).
(1) Display
(3) Mode selector switch
(UP)
(DOWN)
(5) Set switch

(6) Travel speed switch
(7) Working mode
selector switch
(8) Buzzer cancel
switch
(3) Push the "Set switch (5)".

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

ago.
a If "E213" is still happening, the letter
"E" is displayed in the 2nd column of
service meter unit (2). If "E213" has
been repaired, "E" is not displayed.
a The lapse time is displayed in the 3
columns from the right of service
meter unit (2).
20-244
PC78MR-6
TROUBLESHOOTING
Example 3) If any service code is not

saved, "-" is displayed in
every column of display (1)
and service meter unit (2).
ii) To see the next displayed service code,
push the "Buzzer cancel switch (8)" and
"Mode selector switch (UP)" (3).
iii) To see the previous displayed service
code, push the "Buzzer cancel switch (8)"
and "Mode selector switch (DOWN) (4)".
iv) To stop display of the service code, push

the "Buzzer c ancel switch (8)" and
"Working mode selector switch (7)".
v) To delete the saved service codes, press
the "Buzzer cancel switch (8)" and turn
OFF the "starting switch" simultaneously,
then turn ON the "starting switch" again
and push and hold the "Buzzer cancel
switch (8)" for 5 seconds.
a If the number of service codes
exceeds 20, they are deleted one by
one from the oldest one.
2) Service codes list

Error Code
Abnormal System
User Code
E101
Error history data are abnormal
E108
Engine coolant temperature is 105C
E112
Short circuit in forward system of wiper motor drive
E113
Short circuit in reverse system of wiper motor drive
E114
Short circuit in windshield washer drive system
E115
Wiper does not start wiping in 10 seconds
E116
Wiper is not retracted in 10 seconds
E203
Short circuit or grounding fault in swing holding brake solenoid system
E03
E206
Short circuit or grounding fault in 2nd travel speed selection solenoid system
E03
E213
Disconnection in swing holding brake solenoid system
E216
Disconnection in 2nd travel speed selection solenoid system
E218
Abnormality in communication between monitor panel and controller
E227
Short circuit or grounding fault in engine speed sensor system
E232
Short circuit or grounding fault in TVC-EPC Solenoid system
E02
E233
Disconnection in TVC-EPC Solenoid system
E02
(*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
Grounding fault on power source side of angle sensors
E304
Short circuit or grounding fault in engine stop solenoid relay system
E314
Disconnection in engine stop solenoid relay system
E323
Grounding fault in governor control accelerator relays system
E05
E325
Grounding fault in governor control decelerator relays system
E05
E328
Abnormality in governor control motor stal
E05
E412
Abnormality in boom swing angle sensor (Short circuit in power supply)
E40
E413
Abnormality in boom swing angle sensor (Disconnection)
E40
E414
Defective correction of boom swing angle sensor
E451
Short circuit in boom swing LEFT stop EPC system
E41
E452
Disconnection in boom swing LEFT stop EPC system
E41
E453
Short circuit in boom swing RIGHT stop EPC system
E41
E454
Disconnection in boom swing RIGHT stop EPC system
E41
E501
Machine model not set
E502
Defective machine model selection signal
PC78MR-6
20-245
(1)
TROUBLESHOOTING
4. Function of displaying "monitoring code"

The input signals from the sensors to each component and the output signals to drive the solenoids can be
checked in real time with the monitoring codes.
If the following operation is executed, the monitoring code No. is displayed in the 3rd column through the 5th
column from the left on service meter unit (2) of the monitor panel and the monitoring information is displayed on display (1).
1) Method of displaying monitoring code

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

(6) Travel speed switch
(7) Working mode
selector switch
(8) Buzzer cancel
switch
Example 1) A numerical monitoring

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

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

and "Mode selector switch (UP) (3)".
iii) To see the previous displayed monitoring
and "Mode selector switch (DOWN) (4)".
iv) To stop display of the monitoring code,
push and hold the "Buzzer cancel switch
(8)" and "Working mode selector switch
(5)" for 2.5 seconds.
2) Monitoring codes list
a For details of a code marked with "(6 bit)" in the Unit column, see the bit patterns table.
Code No.
Item
Unit
Component Name
Controller
(6bit)
Controller
0001
Monitor model code
0008
S-NET connection state
0041
Water temperature sensor voltage
10 mA
Controller
0042
Fuel level sensor voltage
10 mA
Controller
0043
Charge voltage
100 mA
Controller
0045
Sensor input 1
(6bit)
Controller
0046
Sensor input 2
(6bit)
Controller
0047
Output state
(6bit)
Controller
0048
Wiper state
(6bit)
Controller
0049
Spare
Controller
0200
Software version No. (Monitor)
Controller
1000
Software version No.

(Controller)
If 1.0 is displayed, version No. of controller is 1.0.
Controller
1001
Attachment selection
00: Standard arm
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
Boom swing angle sensor voltage
Controller
1050
EPC output current (TVC)
10 mA
Controller
1052
EPC output current

(Boom swing LEFT stop)
Controller
1053
EPC output current

(Boom swing RIGHT stop)
If 55 is displayed, current is 55 mA. If cur- 10 mA

rent is 1 A, however, FF is displayed.
10 mA
Controller
1060
ON/OFF output
(6bit)
Controller
PC78MR-6
20-247
TROUBLESHOOTING
3) Bit patterns list (Bits of corresponding Nos.

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

speed)
(5)
Travel/Swing alarm (Alarm is output)
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
Attachment Selection (1)
GND
OPEN
OPEN
Standard specification
Standard arm
20-250
PC78MR-6
TROUBLESHOOTING
Procedure for correcting angle sensor

Back mode (When SP monitor is used)
Table 2 Method of selecting back mode and ordinary display

Back Mode
Mode
Code
(Note 3)
PC78MR-6
B Buzzer cancel
a
Working mode
selection
Travel
SET/CLEAR
Model selection (E)
Model selection (R)
01
Emergency
Trouble
(Note 4)
02
06
These modes are set to 2 levels (Note 8)

Error
Memory
Display
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)
Limited to 5 seconds after the power is turned ON.

Displayed on the service meter unit.
A flag from the controller is a trigger.
Used to save monitoring error.
Select with Buzzer cancel + Working mode selection. Select next or previous items with Buzzer cancel + E/R. Enter each mode with the SET/CLEAR switch.
Since the suitches "c, d and e" are not indicated on the panel of model MR, operate the same parts as
the panel of model MR.
PC78MR-6
20-251
TROUBLESHOOTING
"06" Correction of boom swing angle sensor

The stroke end is saved for initial setting of each cylinder (portion where the angle sensor is installed).
No.
Operation
Display
"S-1" is displayed on the display section.
(1) Set the starting switch to the ON position or run the

engine, and then hold warning buzzer cancel switch (B)
and working mode selector switch (a) for 2.5 seconds or
longer.
(2) Set the code of the service meter section to "06".
(B) + (d): Increase code.
(B) + (e): Decrease code.
(3) Press switch (c).
Set the machine in "position 1" and press switch (c).
(Position 1)
Boom swing RIGHT end
After switch (c) is pressed, "ooo" is displayed, and

then "S-2" is displayed on the display section.
If the system is not reset normally, " " flashes.
When abnormal
Set the machine in "position 2" and press switch (c).

(Position 2)
Boom swing LEFT end
After switch (c) is pressed, "ooo" is displayed, and

then " " is displayed on the display section.
When normal
When normal
(Completion of setting)
3
If the system is not reset normally, " " flashes.
When abnormal
(Flashing)
To finish monitoring, perform the operation of 1-(1), and the

monitor panel returns to the ordinary display state.
a If the system is not reset normally, the data

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

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

Adjust the TVC current in this mode to reduce the pump absorption torque and improve the exhaust gas
color at high altitude.
a The work equipment speed, travel speed, and swing speed are lowered by the following operation.
a The following operation is not necessary for the normal work.
No.
Operation
1) Turn the starting switch ON or run the engine and hold

buzzer cancel switch (B), travel speed shifting switch (b),
and switch (c) for 2.5 seconds.
2) Adjustment code (3) is displayed (flashed) at the left 2
positions and set value (4) is displayed (lighted) at the
right 1 position on display unit (1). "5-5E7" (S-SET) is displayed on service meter unit (2).
Although switches are not indicated on b, c, and d of the
panel, the functions are installed to the parts at the tips of
the arrows.
Adjustment code "20" flashes. Set the adjustment code with

switch (c).
The flashing adjustment code lights up.
The lighting set value flashes.
Increase or decrease the set value with switches (d) or (e)

and set it with switch (c).
(d): Code is increased.
(e): Code is decreased.
The lighting adjustment code flashes again.
The flashing set value lights up again.
For details of the adjustment code and set value, see the
TVC valve current adjustment table.
To finish adjustment of the TVC valve current, perform Step

1-1), and the monitor panel returns to the normal display
state.
The set value is saved when the monitor panel returns to
the normal display state.
Caution: If the mode is reset forcibly by turning the starting
switch OFF, the set value is not changed.
Display
Change of setting is completed.
[ 1] Flashing: Code/Set value can be changed.

[ 2] Lighting: Code is selected/set.
To initialize the set value of the TVC valve current adjustment

mode, set the adjustment code and the set value to "40" and
"1" respectively with switches (d) and (e), and then finish the
adjustment mode.
Note) If switch (d) or (e) is pressed at Step 2, the

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

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

Adjustment code
Set value
Initial
(Left 2 positions of (Right 1 position of
value
display unit)
display unit)
20
20-254
Contents
Increase pump absorption torque by +2.0 kgm

(-100 mA).

(-75 mA).

(-50 mA).

(-25 mA).
Exhaust gas
color
Bad
Initial value
Decrease pump absorption torque by -0.5 kgm

(+25 mA)

(+50 mA)

(+75 mA)

(+100 mA)
Good
PC78MR-6
TROUBLESHOOTING
ADJUSTING SERVICE METER
ADJUSTING SERVICE METER
Adjust the service meter when the monitor panel

is replaced.
1. Turn the starting switch ON.

2. To set the monitor panel in the service meter
adjustment mode, hold buzzer cancel switch (8)
and press the following switches on the monitor
panel in the order of 1) - 4).
1) Travel speed switch (6)
2) Set switch (5)
3) Working mode selector switch (7)
4) Mode selector (UP) switch (3)
a If the monitor panel is set in the adjustment
mode, both ends of service meter (2) flash
alternately.
3. To select a digit to be corrected, press the buzzer
cancel switch (8), working mode selector switch
(7), and set switch (5) simultaneously. Each time
those switches are pressed, the selected position
moves to the left. (The selected position moves
to the left only. After it reaches to the left end, it
returns to the right end again.)
The monitor panel of the MR specification also

has switches (3) (5).
4. To set or change the figure, press the buzzer

cancel switch (8), working mode selector switch
(7), and mode selector (UP) switch (3) simultaneously.
5. To finish the service meter adjustment mode,
repeat Step 2.
a The currently saved service meter value cannot be reduced (returned to a smaller value).
When the service meter adjustment is finished after the service meter is set to a large
value, that value cannot be reduced either.
Take care.
PC78MR-6
20-255
TROUBLESHOOTING
METHOD OF USING JUDGEMENT TABLE

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

When a service code is displayed on the monitor panel, advance to the troubleshooting code (C-OO) of
the lowermost step of the decision table.
(A q is marked to the point where a failure mode and a service code match.)
If a service code is not displayed and a nature of trouble appears in the monitor panel, check the display
of an input signal that matches the failure mode of the decision table (display the location marked with a
circle (O)) and
When an input signal is displayed normally, advance to the diagnostic code (H-OO) at the right of the
decision list.
When an input signal is not displayed, advance to the diagnostic code (F-OO) at the lowermost step of
the decision list.
<Example> Failure mode "Swing is not performed"
[Procedure] Test that a service code is displayed on the monitor panel.
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the controller
(pump control) system "C:OO".
2) When a service code is not displayed on the monitor panel and "Swing is not performed":
Check controller input
When the signal is provided:
signal.
.... Advance to mechanical system troubleshooting "H-34" and "C-38".
(Check it in the 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
HOW TO READ FLOW OF TROUBLESHOOTING

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

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

Before starting the work, check the Nos., inspection points, types, and locations of the wiring connectors
which appear in the flow of the troubleshooting for each failure mode (trouble) with the table of locations and
Nos. of connector pins.
<Example>
(1) M-1[E101](Error history data are abnormal) is displayed
(2) a This error is displayed when the connector P01, connector K1, fuse 18, connector M6, connector M2,
battery relay terminal B, or battery terminal in the monitor panel power supply system is disconnected or
connected for troubleshooting. This phenomenon does not indicate an error.
(When the power supply circuit of the monitor panel is cut out while the starting switch is at the OFF position.)
a If the service code is displayed again after the resetting operation is performed, carry out the troubleshooting according to the following procedure.
Cause
After resetting operation,
operate machine normally
and observe its condition for
a while. (See Note 1.)
Remedy
1
NO
After "resetting operation", is

service code displayed again?
Normal
Disconnection, defective contact,

or short circuit with chassis
ground in wiring harness
between battery battery relay B
M27 (1), (2) P01 (Female) (8)
Repair or
replace
Defective monitor panel
Replace
YES
2
Turn starting switch OFF
20 30 V
Is voltage between P01 (8)

chassis ground normal?
YES
PC78MR-6
NO
20-259
TROUBLESHOOTING
CONTENTS AND PROCEDURE OF TROUBLESHOOTING
CONTENTS AND PROCEDURE OF TROUBLESHOOTING

If a trouble occurs, carry out troubleshooting according to the judgment table, controller (governor control system), and controller (pump control system). For the detailed contents and procedure of the troubleshooting,
however, see the following flow.
Before starting the troubleshooting, ask the operator about the trouble as long as possible and check the following items in advance. (1) Connecting condition of the controller (Check with monitoring code 0001), (2) Breakage of the fuses, (3) Battery voltage, (4) Generating (charge input) voltage (Monitoring code 0043 "H-34").
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)
Carry out troubleshooting in corresponding mode.
YES
E300 group: Troubleshooting for pump controller (Governor control system) (E-mode)
2
NO
Is service code displayed on

monitor panel?
Operate and check service code.
YES
Carry out troubleshooting

by engine (in S-mode).
5
Engine system
4
YES
3
NO
Is input/output
signal of controller normal?
Check by
monitoring
code.
Is trouble in engine system or hydraulic

(Mechanical) system?
Adjust hydraulic pressure, then judge by
engine speed.
Is work equipment
always heavy and
does engine speed
lower under heavy
load?
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

by electric system of
engine (in E-mode).
(Flow of part where there
is no indication) (E-6 E8)
(Carry out troubleshooting in Hmode).
Troubleshoot by input signal system (F-mode).
a Judge the details by judgment table for controllers (governor control system) (pump control system).
For the No. and contents of monitoring, see the monitoring codes table.
20-260
PC78MR-6
TROUBLESHOOTING OF ENGINE (S MODE)

Method of using troubleshooting chart........................................................................................................ 20-302
S- 1 Starting performance is poor (Starting always takes time) ............................................................... 20-306
S- 2 Engine does not start ....................................................................................................................... 20-308
(1) Engine does not turn.................................................................................................................. 20-308
(2) Engine turns no but exhaust smoke comes out (Fuel is not being injected) .............................. 20-309
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ........................... 20-310
S- 3 Engine does not pick up smoothly (Follow-up is poor) ......................................................................20-311
S- 4 Engine stops during operations ........................................................................................................ 20-312
S- 5 Engine does not rotate smoothly (Hunting) ...................................................................................... 20-313
S- 6 Engine lacks output (or lacks power) ............................................................................................... 20-314
S- 7 Exhaust smoke is black (Incomplete combustion) ........................................................................... 20-315
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-316
S- 9 Oil becomes contaminated quickly ................................................................................................... 20-317
S-10 Fuel consumption is excessive......................................................................................................... 20-318
S-11 Oil is in cooling water, or water spurts back, or water level goes down............................................ 20-319
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)................................................................ 20-320
S-13 Oil level rises (Water, fuel in oil) ....................................................................................................... 20-321
S-14 Water temperature becomes too high (Overheating) ....................................................................... 20-322
S-15 Abnormal noise is made ................................................................................................................... 20-323
S-16 Vibration is excessive ....................................................................................................................... 20-324
PC78MR-6
20-301
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHART

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

chart is as follows.
Items listed for [Questions] and [Check items]
that have a relationship with the Cause items
are marked with Q, and of these, causes that
have a high probability are marked with w.
Check each of the [Questions] and [Check
items] in turn, and marked the Q or w in the
chart for items where the problem appeared.
The vertical column (Causes) that has the highest number of points is the most probable
cause, so start troubleshooting for that item to
make final confirmation of the cause.
1. For (Confirm recent repair history) in
the [Questions] Section, ask the user,
and mark the Cause column with E to
use as reference for locating the cause
of the failure. However, do not use this
when making calculations to narrow
down the causes.
2. Use the E in the Cause column as reference for [Degree of use (Operated
for long period)] in the [Questions] section as reference. As a rule, do not use
it when calculating the points for locating the cause, but it can be included if
necessary to determine the order for
troubleshooting.
PC78MR-6
Confirm recent repair history
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
Operatred for long period
20-303
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black

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

General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel
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

Degree of use
Operated for long period
Questions
Suddenly became black

Color of exhaust gas
Gradually became black

Blue under light load
Engine oil must be added more frequently

Power was lost
Suddenly
Gradually
Non-specified fuel has been used

Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low

Speed of some cylinders does not change when operating
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
20-304
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does

not return
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
S-1 Starting performance is poor (Starting always takes time)

Possible causes of the engine not starting though exhaust gas
being discharged.
Electrical system is defective.
Fuel supply is insufficient.
Air intake is insufficient.
Fuel selection is improper.
(Under the ambient temperature of 10C or lower, use
ASTM D975 No.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
a Battery charging rate

Ambient
temperature
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
A battery can be used if the specific gravity shows 70% or

higher charging rate shown in the above table.
In cold weather, 75% or higher charging rate is required.
Wor
100 %
Questions

Degree of use of machine
Ease of starting
Gradually became worse

Starts when warm
Preheat indicator lamp does not light up.

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

Match marks on fuel injection pump are not matched.
Mud is sticking to the fuel tank cap.
When the engine is cranked by the starter motor;
1) Even if the injection pump sleeve nut is loosened, little fuel comes out.
2) Even if the fuel filter air bleeding plug is loosened, little fuel comes out.
Leakage from the fuel piping
Engine hunting (rotation is irregular).
Compression pressure measurement found low pressure.
Direct inspection of the air element found clogging.
Troubleshooting
Direct inspection of the fuel filter and strainer found clogging.

Direct inspection of the feed pump strainer found clogging.
Heater mount section is not heated.
Yes
Is voltage 2630V between alternator terminal R and terminal E

with engine at low idling?
No
Either specific gravity or voltage of the battery is low.

Speed of some cylinders does not change when operating on reduced
cylinders.
When pushed, the control rack is heavy, or does not return.
(Remove the blind cover at the rear of the pump. Plunger control sleeve does
not move.)
20-306
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
Direct inspection of the fuel cap found clogging.

Legend
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
S-2 Engine does not start

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

Internal parts of engine seized
a If internal parts of the engine are seized, carry
out troubleshooting for "Engine stops during
operations".
Defective electrical system
Questions

Horn does not sound

Condition of horn when
starting switch is turned ON Horn volume is low
Speed of rotation is low
When starting switch is
turned to START, pinion
moves out, but
Makes grating noise

Soon disengages again
Makes rattling noise and does not turn
When starting switch is turned to ON, there is no clicking

sound
20-308
Replace
Replace
Replace
Replace
Remedy
Replace
Troubleshooting
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are
3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and
terminal E
When ring gear is inspected directly, tooth surface is found to be
chipped
Cannot be moved by hand even when linkage of fuel cut solenoid
is disconnected
Replace
When battery is checked, battery electrolyte is found to be low
Replace
When starting switch is turned ON, linkage is not actuated
Troubleshooting of defective wiring in starting circuit
Battery terminal is loose
Replace
Check items
When starting switch is turned to START, pinion does not

move out
PC78MR-6
TROUBLESHOOTING
S-2
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Causes
a Standards for use of fuel

-4
-20
14
-10
32
0
50
10
68
20
86 F
30
ASTM
D975
No. 2
ASTM
D975
No.2
Diesel fuel
ASTM D975 No.1
Legend
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

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Mud is stuck to fuel tank cap
When starting switch is turned ON, linkage is not actuated
Check items
When fuel filter is drained, fuel does not come out

When engine is cranked with starting motor,
1) Injection pump coupling does no rotate.
2) No fuel comes out even when fuel filter air bleed plug is
loosened
3) No fuel spurts out even when injection pump sleeve nut is
loosened
Rust and water are found when fuel tank is drained
Troubleshooting
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
PC78MR-6
Replace
Replace
Correct
Correct
Add
Clean
Clean
Replace
Replace
Remedy
Replace
Even though the linkage of the fuel cut solenoid is

disconnected, it doesnot work
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
Causes
Defe
General causes why exhaust smoke comes out but

engine not start
Lack of rotating force due to defective electrical
system
Insufficient supply of fuel
Improper selection of fuel and oil
Questions
Suddenly failed to start

When engine is cranked, abnormal noise is heard from
around head
Non-specified fuel is being used
Operation Manual
Dust indicator lamp is red
Indicator lamp does not light up
Starting motor cranks engine slowly
Check items

When fuel lever is placed at FULL position, it does not contact stopper
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve nut
is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Troubleshooting
When fuel filter is drained, no fuel comes out

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

General causes why engine does not pick up smoothly
Improper condition of fuel injction
Improper fuel used
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
Causes
Questions

Operation Manual
Engine pick-up suddenly became poor

Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
Troubleshooting

When air cleaner element is inspected directly, it is found to
be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
When fuel tank cap is inspected directly, it is found to be clogged
PC78MR-6
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
20-311
S-4
TROUBLESHOOTING
S-4 Engine stops during operations
Legend
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
)
General causes why engine stops during operations

Seized parts inside engine
Overheating
a If there is overheating and the engine stops,
carry out troubleshooting for overheating.

Questions
Abnormal noise was heard and

engine stopped suddenly
Condition when engine
stopped
Engine overheated and stopped

Engine stopped slowly
There was hunting and engine stopped
Fuel level lamp lights up

Replacement of filters has not been carried out according
to Operation Manual
Engine rotates, but stops when power train is operated
Check items
Does not turn at all

When it is attempted to
turn by hand using
barring tool
Turns in opposite direction

Moves amount of backlash
Shaft does not turn

Metal particles are found when oil is drained
Remove oil pan and inspect directly
Troubleshooting
Remove head cover and inspect directly

When gear train is inspected, it does not turn
Rotates when pump auxiliary equipment is removed
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
20-312
Replace
Clean
Correct
Replace
Clean
Clean
Add
Replace
Replace
Replace
Replace
Replace
Remedy
Replace

does not return
PC78MR-6
S-5
TROUBLESHOOTING
S-5 Engine does not rotate smoothly (Hunting)
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
Causes
Defe
General causes why engine does not rotate smoothly

Air in fuel system
Defective governor mechanism
Defective electric governor mechanism
(engine with electric governor)
a If hunting stops when electric governor rod is
disconnected, carry out troubleshooting for
the chassis.

Questions
Occurs at a certain speed range

Condition of hunting
Occurs at low idling

Occurs even when speed is raised
Occurs on slopes

to Operation Manual
Rust, water are found when fuel tank is drained
Leakage from fuel piping
Check items
When feed pump is operated,

1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Troubleshooting
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
PC78MR-6
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust

found to be clogged
20-313
S-6
TROUBLESHOOTING
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overtaking
a If there is overheating and lack of output,
carry out troubleshooting for overheating.
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
Causes

Questions
Power was lost

Suddenly
Gradually

to Operation Manual
Black

Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

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

General causes why exhaust smoke is black
Legend
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


Suddenly became black
Questions
Gradually became black


Power was lost
Suddenly
Gradually

Check items

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Timing lock on fuel injection pump does not match
Exhaust noise is abnormal
Muffler is crushed
When air cleaner is inspected directly, it is found to be clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
PC78MR-6
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace

does not return
20-315
S-8
TROUBLESHOOTING
S-8 Oil consumption is excessive (or exhaust smoke is blue)

a Do not run the engine at idling for more than 20
minutes continuously. (Both low and high idling)
Legend
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
General causes why oil consumption is excessive

Abnormal combustion of oil
External leakage of oil
Wear of lubrication system
Causes
Questions

Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Amount of blow-by gas
Excessive
None
Check items
Area around engine is dirty with oil

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

When breather element is inspected, it is found to be
clogged with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
20-316
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be

dirty with oil
PC78MR-6
S-9
TROUBLESHOOTING
S-9 Oil becomes contaminated quickly
Legend
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
General causes why oil becomes contaminated quickly

Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
Improper oil used
Operation under excessive load
Questions


Non-specified oil is being used

Black
None
Carry out troubleshooting for Exhaust smoke is black.
Check items
Excessive
Amount of blow-by gas
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly
When breather element is inspected directly, hose is

broken or is found to be clogged with dirty oil
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
PC78MR-6
Replace
Clean
Clean
Replace
Replace
Remedy
Clean
Excessive play of turbocharger shaft

When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Troubleshooting
20-317
S-10
TROUBLESHOOTING
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Leakage of fuel
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
Causes
Questions

Condition of fuel
consumption

More than for other machines of same
model
Gradually increased
Suddenly increased
Exhaust smoke color
Black
Check items
There is irregular combustion

When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Speed does not change when operation of certain cylinders is stopped

When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found
to be incorrect
Remove feed pump and inspect directly
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
Injection pump measurement shows that injection amount is excessive
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
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

Oil level

Suddenly increased
Gradually increased
Check
items
Engine oil level has risen, oil is cloudy white
Troubleshooting
Hard water is being used as cooling water
Excessive air bubbles inside radiator, spurts back
Pressure-tightness test of cylinder head shows there is leakage
PC78MR-6
Replace
Replace
Replace
Remedy
Replace
20-319
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)

General causes why oil pressure lamp lights up
Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating
a Standards for engine oil selection
Wor
Clog
Legend
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

Operation Manual
Caution lamp lights up
Lights up at low idling
Condition when oil
pressure lamp lights up
Lights up at low, high idling

Lights up on slopes
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 stuck to oil filter element

for Oil level rises.
Oil is cloudy white or smells of diesel oil

Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
20-320
Replace
Replace
Correct
Adjust
Adjust
Add
Replace
Correct
Clean
Clean
Remedy
Clean
When oil pressure is measured, it is found to be within

standard value
Clean
Troubleshooting
When oil filter is inspected, it is found to be clogged
PC78MR-6
S-13
TROUBLESHOOTING
S-13 Oil level rises (Water, fuel in oil)

a If there is oil in the cooling water, carry out troubleshooting for Oil is in cooling waterE
Questions
Legend
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
General causes why oil level rises

Water in oil (milky white)
Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component
Causes

There is oil in radiator cooling water

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

Oil level goes down or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel must be added more frequently
Water temperature is low
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

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

General causes why water temperature becomes too high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature in power train
a Carry out troubleshooting for chassis.
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
Causes
Questions

Condition of overheating

Suddenly overheated
Always tends to overheat
Water temperature
gauge
Rises quickly
Does not go down from red range
Radiator water level sensor lights up

Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Check items
Excessive air bubbles inside radiator, water spurts back

Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
Troubleshooting
When belt tension is inspected, it is found to be loose

Temperature difference between top and bottom radiator tanks
is excessive
Temperature difference between top and bottom radiator tanks
is slight
When water filler port is inspected, core is found to be clogged
When function test is carried out on thermostat, it does not
open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
20-322
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
PC78MR-6
S-15
TROUBLESHOOTING
S-15 Abnormal noise is made

a Judge if the noise is an internal noise or an external noise.
Legend
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)
General causes why abnormal noise is made

Abnormality due to defective parts
Abnormal combustion
Air sucked in from intake system
Causes
Questions

Condition of abnormal
noise
Gradually occurred
Suddenly occurred


Black
Metal particles are found in oil filter

Check items
Engine pickup is poor and combustion is abnormal

Abnormal noise is loud when accelerating engine
Vibrating noise is heard from around muffler
Troubleshooting
Remove gear cover and inspect directly

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

Defective parts (abnormal wear, breakage)
Improper alignment
Abnormal combustion
Legend
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

Condition of vibration

Suddenly increased
Gradually increased

Metal particles are found in oil filter
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black
Troubleshooting

Remove side cover and inspect directly
Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
Remove front cover and inspect directly
Remove head cover and inspect directly
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
N-1 Defective communication

Cause
Remedy
1
NO
Is operation of monitor display switch

normal?
YES

Min. 0.75 V
Disconnect M96 and measure
voltage on wiring harness side
Condition is normal
Defective controller
Replace
2
NO
Is voltage between M96 (Female) (21)

YES
3
Is resistance between P02 (Female) (9),
(10) M96 (Female) (21) normal?
YES
NO
Disconnection or defective contact in

Repair or
wiring harness between P02 (Female)
replace
(9), (10) M96 (Female) (21)
Replace
If the communication becomes defective, the following troubles occur.

The working mode cannot be changed.
The travel speed cannot be changed with the panel switches.
The monitor lamp does not light up when the one-touch slow-down mechanism is turned on.
Normal figures are not displayed on the display and service meter unit.
A mode cannot be selected.
N-1 Electrical circuit diagram of each system
20-402
PC78MR-6
TROUBLESHOOTING FOR CONTROLLER

(GOVERNOR CONTROL SYSTEM)
(E MODE)
Precautions for troubleshooting for controller (governor control system).................................................... 20-502
Action taken by controller when trouble occurs and problems on machine ............................................... 20-504
Judgment table for controller (governor control system) and engine .......................................................... 20-506
E-1 Controller power supply is defective (LED of controller is turned off)................................................. 20-508
E-2 [E323] (Short circuit in accelerator relay system) is displayed ........................................................... 20-509
E-3 [E325] (Short circuit in decelerator relay system) is displayed........................................................... 20-510
E-4 [E328] (Stall of motor) is displayed......................................................................................................20-511
E-5 [E227] (Trouble in engine speed sensor) is displayed........................................................................ 20-513
E-6 One-touch slow-down mechanism does not work.............................................................................. 20-514
E-7 Engine does not start ......................................................................................................................... 20-515
a) [E304] Short circuit in engine stop solenoid relay system is displayed .......................................... 20-515
b) [E314] Disconnection in engine stop solenoid relay system is displayed ...................................... 20-515
c) Engine stop solenoid system.......................................................................................................... 20-516
d) Starting system............................................................................................................................... 20-518
E-8 Engine does not stop.......................................................................................................................... 20-522
PC78MR-6
20-501
TROUBLESHOOTING
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER


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

PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS

AND PROBLEMS ON MACHINE
User Code
Service Code
Troubled System
E323
Short circuit in accelerator relay system
E325
Short circuit in decelerator relay system
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)
Short circuit of M97 pin 19 with power source.

Trouble in motor.
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
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
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

PROBLEMS ON MACHINE
TROUBLESHOOTING
Action taken by controller

when trouble occurs
Between M97 pin 25 chassis ground: Min.: 1 Mz K32 pin 1 If trouble is detected, motor
Resistance between K32 relay pin 1 pin 2: 290 z 10% drive relay output, accelerator
Resistance between K32 relay pin 1, 2 pin 3, 5, 6
relay output, and decelerator
: Min. 1 Mz
relay output are stopped.
Between M97 pin 35 chassis ground: Min. 1 Mz K33 pin 1
Resistance between K33 relay pin 1 pin 2: 290 z 10%
Resistance between K33 relay pin 1, 2 pin 3, 5, 6
: Min. 1 Mz
Normal condition
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,
and decelerator relay output

are stopped.
Relay
M97 (female)
M36 (male)
Resistance
(4) Chassis ground
(1) (2)
68 z 10%
Stop solenoid output is

stopped.
When signal system is troubled

Motor operates but stalls soon.
Then, it does not operated even if
dial is moved.
When motor is troubled
Motor stalls from the first, then it
does not operate even if dial is
moved.
1. Stop solenoid cannot be pulled
(Engine cannot be started).
Engine governor control system
PC78MR-6
20-505
TROUBLESHOOTING
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)

AND ENGINE
JUDGMENT TABLE FOR CONTROLLER

(GOVERNOR CONTROL SYSTEM) AND ENGINE
Controller and Engine
User
Code
Engine does not start easily
Engine does not start
Engine speed does not rise sharply (Does not follow up accelerator pedal)
Engine stops
Engine hunts
Engine output (Power) is low
Exhaust gas color is bad (Imperfect combustion)
Much oil is consumed (or exhaust gas color is bad)
Oil becomes dirty soon

Much fuel is consumed
11
Cooling water contains oil or blows back or its level lowers
12
Oil pressure caution lamp lights up

Oil level rises
14
Water temperature rises too high (Overheating)
15
Abnormal sound is heard
16
Many vibrations are made
17
Engine speed does not follow up throttle valve
One-touch slow-down mechanism does not work
19
When working mode is changed, engine speed does not

change
20
Engine does not stop
Decelerator relay output
Accelerator relay output
Auto deceleration signal

1024
E-1 E-2 E-3 E-4 E-7 E-7 E-5
Diagnosis code displayed when trouble is detected by monitoring or

with machine monitor
Deceleration signal
Trouble in engine speed sensor system
Monitoring Code
314 227
323 325 328 (304
2) ( 2)
18
Diagnosis code displayed when service code is displayed
Short circuit in engine stop solenoid

relay
Disconnection in engine stop solenoid
relay
Stall of motor
10
13
Short circuit in decelerator relay system
E05
Service
Code
1
Short circuit in accelerator relay system
Trouble in controller power supply
Self-diagnosis Display
Acceleration signal
Items Checked/Inspected
by
monitoring
q: Items corresponding to service codes.

Q: Items checked by monitoring or with machine monitor.
: Items checked by monitoring.
20-506
PC78MR-6
TROUBLESHOOTING
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)

AND ENGINE
Is value in red range?
Diagnosis code displayed

when service code is not displayed
95 Series
Min. 105 C
Engine water temperature voltage
Engine speed
One-touch slow-down signal
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
E-1 Controller power supply is defective (LED of controller is turned off)

a Check that fuse 20 is not broken.
a Carry out the following troubleshooting when the starting motor revolves normally (If the starting motor does
not revolve, see E-8, 19).
Cause
Remedy
1
20 30 V
Is voltage between M96 (Female) (1), (11) NO

(21), (31), (32), (33), chassis ground
normal?
YES
Replace
2
20 30 V
Is voltage between fuse 20 and chassis

ground normal?
YES
NO
Disconnection or defective
Repair or
contact in wiring harness between
fuse 20 battery relay terminal B replace
Repair or
fuse 20 M97 (Female) (1), (11) replace
E-1 Electrical circuit diagram of each system
20-508
PC78MR-6
E-2
TROUBLESHOOTING
E-2 [E323] (Short circuit in accelerator relay system) is displayed

Cause
Remedy
1
Operate dial
NO

(23) normal?
YES
Replace
Short circuit with chassis ground

or negative (-) wire in wiring
harness between M97 (Female)
(25) K32 (Female) (1)
Repair or
replace
Defective Relay
Repair or
replace
2
Disconnect M97 and K32
Min. 1 Mz
Is resistance between M97 (Female) (25)

and chassis ground normal?
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.
PC78MR-6
20-509
E-3
TROUBLESHOOTING
E-3 [E325] (Short circuit in decelerator relay system) is displayed

Cause
Remedy
1
Operate dial (to lower)
NO

(23) normal?
YES
Replace

(35) K33 (Female) (1)
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.
20-510
PC78MR-6
E-4
TROUBLESHOOTING
E-4 [E328] (Stall of motor) is displayed

a Stall of the motor ias displayed when the motor does not follow up the operation of the dial in 10 seconds. In
this period, the input signal and relay output are checked by monitoring.
Cause
Remedy
For state of bit, see Action

taken by controller when
trouble occurs and problems
on machine.
Is monitored value normal?

Max. 4 A when normal
When dial is raised
(1) side: (+), (4) side: (-)
When dial is lowered
(1) side: (-), (4) side: (+)
Is current between K27 (Female) (1) NO

(Motor (+) and (4) (Motor (-)
normal?
NO
YES
YES
Resistance between (1) (2)

of each relay: 290 z 10%
Operation of each relay
(when starting switch is ON)
When in neutral, (3) (6) are
connected.
When dial is raised, K32 (3),
(5) are connected.
When dial is lowered, K33
(3), (5) are connected.
Do relay of K32, K33 operate

normally?
Disconnect M97 and K27.

Resistance between pins:
Max. 1 z
Resistance between pin and
chassis and ground:
Min. 1 Mz
Is resistance between M97

(Female) (19) K27 (Female) (5),
between M97 (29) K27
NO
(Female) (6), between M97
(Female) (39) K27 (Female) (3)
normal? Is resistance between
each wiring harness and chassis
ground normal?
Defective motor
(Drive system)
Replace motor
Defective relay
Replace
3
NO
YES
Repair or
K27 (Female) (1), (4) K32
replace
(Female) (3),
K33 (Female) (3)
4
contact in wiring harness between Repair or
M97 (Female) (19), (29), (39)
replace
K27 (Female) (5), (6), (3)
YES
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?
Defective motor (Signal system)
Replace
Replace
YES
20-511
TROUBLESHOOTING
E-4
20-512
PC78MR-6
E-5
TROUBLESHOOTING
E-5 [E227] (Trouble in engine speed sensor) is displayed

Cause
1
When starting switch is OFF: 0

When engine speed is
+5
slow: 113 0
When engine speed is at full
throttle: 202 5
Remedy
NO
Is monitored engine speed normal?
YES
Replace
Defective engine speed

sensor
Repair or
replace
2
Disconnect M16
500 1,000 z
Is resistance between M16 (Male) (1) (2) NO

normal?
YES
Disconnect M16
500 1,000 z

(40) normal?
YES
3
NO
M96 (Female) (39) M16
replace
(Female) (1), (2)
Defective installation of engine
speed sensor
Test/Adjust
PC78MR-6
20-513
E-6
TROUBLESHOOTING
E-6 One-touch slow-down mechanism does not work

Cause
Remedy
1
NO
Does deceleration monitor light up

normally?
YES
Disconnect K18
When switch is ON: Max. 1z
When switch is OFF:
Min. 1 Mz
Disconnect K18
20 30 V
See troubleshooting in E-5
Defective one-touch decelerator

switch
Replace lever
assembly
2
Is resistance between K18 (Male) (1) (2) NO
normal?
YES
Is voltage between K18 (Male) (1)
YES
3
NO
K18 (Female) (1) fuse (11) or
replace
breakage of fuse (11)
K18 (Female) (2) M97 (Female) replace
(9)
20-514
PC78MR-6
E-7
TROUBLESHOOTING
E-7 Engine does not start

a
a
a
a
a)
b)
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.
(male) (1) (2): 68 z 10%
(male) (1), (2) chassis
ground: Min. 1 Mz
Disconnect D26
(with M36 disconnected).
(female) (4) chassis
ground: Min. 1 Mz
Remedy
1
NO
Is resistance between M97 (female) (4)

YES
Replace
Defective stop solenoid relay
Replace
Defective wiring harness

(Grounding fault)
Repair or
replace
Defective diode D26
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)
YES
NO
E-7 a), b) Electrical circuit diagram of each system
PC78MR-6
20-515
E-7
TROUBLESHOOTING
c) Engine stop solenoid system

a Check that fuse 15 is normal.
a Check that service codes [E304] and [E314] are not recorded in the history.
Cause
Remedy
1
See TESTING AND
ADJUSTING
NO
When engine stop solenoid linkage is

adjusted, does engine start?
YES
Defective adjustment of
linkage
Adjust
2
20 29 V
YES
Max. 1 z
Disconnect T8
Is resistance between engine stop

solenoid terminal GND chassis ground
normal?
YES
20 29 V
Disconnect PULL terminal.
For only 3 seconds after
starting switch is turned ON.
NO
Is voltage between engine stop solenoid

terminal chassis ground normal?
NO
engine stop solenoid terminal
replace
GND chassis ground

PULL terminal and chassis ground
normal?
NO
YES
engine stop solenoid PULL
terminal fusible link M26 (male) replace
(2)
Defective engine stop solenoid
Replace
5
20 29 V
NO
Is voltage between outlet of fuse (15)

YES
outlet of fuse (15) M3 (3)
replace
solenoid terminal HOLD
6
20 29 V
Is voltage between starting switch terminal NO

ACC chassis ground normal?
YES
20-516
Defective starting switch

(Between B ACC)
Replace
starting switch terminal ACC
replace
inlet of fuse (15)
PC78MR-6
TROUBLESHOOTING
E-7
E-7 c) Electrical circuit diagram of each system
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
When starting switch is turned OFF, does

battery relay make sound?
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?

20 29 V
YES
Defective contact in wiring

harness between battery
(+) terminal battery relay Repair or
terminal B battery relay
replace
terminal M starting motor
terminal B
(including battery relay)
Defective starting motor
(Body)
Repair or
Replace

(Between terminals B and
C)
Replace

(Electromagnetic switch)
Repair or
replace
5
Turn starting switch to
START position.
20 29 V
Is voltage between starting switch terminal NO

C and chassis ground normal?
YES
Is voltage between safety relay terminal S NO

Conditions are same as 5
YES
7
Is voltage between starting motor terminal NO
C chassis ground normal?
YES
8
Is voltage between safety relay terminal C NO
YES
9
Is voltage between safety relay terminal R NO

Max. 13 V
YES
To page 20-520
contact in wiring harness
Repair or
between starting motor
replace
safety relay terminal C
starting motor terminal C
Defective alternator
Repair or
replace

safety relay
Replace
To page 20-519
20-518
PC78MR-6
E-7
TROUBLESHOOTING
From page 20-518, 6
Cause
Remedy
10
20 29 V
START.
NO
Is voltage between V2 (8) chassis

ground normal?
Repair or
between safety relay terminal S
replace
M30 (1) M5 (4) V2
(Female) (8)
YES
11
20 29 V
START
NO
Is voltage between V2 (7) chassis

ground normal?
YES
between V2 (Male) (7) (8)
12
20 29 V
START
NO
Is voltage between K23 (3) chassis

ground normal?
Repair or
between K23 (Female) (3) V3
replace
(Female) (3)
YES
13
20 29 V
START
YES
20 29 V
Lock PPC lock switch
14
between K23 (Female) (5)
K51 (6) starting switch
terminal C
Repair or
replace
NO

ground normal?
YES
Max. 1 z
Disconnect K23
NO

ground normal?
15
Is resistance between K23 (Female) (2) NO

YES
Repair or
between K23 (Female) (2) M1 replace
(2) chassis ground
Defective K23 relay
Replace
between K28 (Male) (3) K23
(Female) (1) chassis ground
Repair or
replace
16
20 29 V
Lock PPC lock lever
Is voltage between k28 (3) chassis

ground normal?
YES
NO
To page 20-520
PC78MR-6
20-519
E-7
TROUBLESHOOTING
Cause
From page 20-519, 16
Remedy
17
20 29 V
NO

ground normal?
YES
between K28 (Male) (1) fuse
(14)
Repair or
replace
K23 (Female) (1)
Repair or
replace
From page 20-518, 2
Cause
18
Connect (-) pin of tester to (-)
terminal of battery
20 29 V
Is voltage at starting switch terminal B

normal?
YES
Disconnect terminal B
START
NO
19
Is there continuity between starting switch NO

terminals B BR?
YES
20
Set tester in diode range and

apply (+) to starting switch
and (-) to battery relay
Disconnect both starting
switch and battery relay
Is there continuity between starting switch NO

terminal BR battery relay terminal BR?
Is there continuity between chassis

ground and battery relay terminal B?
YES
YES
20-520
21
NO
Remedy
battery (+) terminal M27 (1), (2)
Replace
M2 (1) fuse (20) K51 (1)
starting switch terminal B
(including fusible link)
(between terminal B BR)
Replace
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
Defective battery relay
Replace
PC78MR-6
TROUBLESHOOTING
E-7
E-7 d) Electrical circuit diagram of each system
PC78MR-6
20-521
E-8
TROUBLESHOOTING
E-8 Engine does not stop

Cause
Remedy
1
NO
When engine stop solenoid linkage is

adjusted, does engine stop?
YES
Defective adjustment of
linkage
Adjust
2
Max. 1 V

terminal HOLD and chassis ground
normal?
YES
NO
Contact of (+) wiring harness with

Replace or
wiring harness between starting
switch terminal ACC fuse (15) repair
M3 (3) solenoid terminal HOLD
Defective engine stop solenoid
Replace
20-522
PC78MR-6

PUMP CONTROL SYSTEM
(C MODE)
Precautions for troubleshooting for controller (pump control system) ........................................................ 20-602
Action taken by controller when trouble occurs and problems on machine ................................................ 20-604
Judgement table for controller (pump control system) and hydraulic equipment........................................ 20-608
Electric circuit diagram of C mode system (For STD spec.) ....................................................................... 20-610
Electric circuit diagram of C mode system (For EU spec.)....................................................................... 20-611-1
C- 1 [E232], C-2 [E233] Trouble in TVC-EPC solenoid system.............................................................. 20-612
C- 3 [E203], C-4 [E213] Trouble in swing holding brake solenoid system.............................................. 20-613
C- 5 [E206], C-6 [E216] Trouble in 2nd travel speed selection solenoid system.................................... 20-614
C- 7 [E411] Trouble in boom swing angle sensor correction ................................................................... 20-615
C- 8 [E251] Trouble in boom bottom pressure sensor (overload sensor) system (For EU spec.) ........ 20-615-1
C- 9 [E258] Short circuit in 5V system of sensor power supply (For EU spec.).................................... 20-615-1
C- 9 [E258] Short circuit in 5V system of sensor power supply (For STD spec.) .................................... 20-616
C-10 [E412], C-11 [E413] Trouble in boom swing angle sensor system .................................................. 20-617
C-12 [E451] Short circuit in boom swing LEFT stop EPC solenoid system is displayed .......................... 20-618
C-13 [E452] Disconnection in boom swing LEFT stop EPC solenoid system is displayed ...................... 20-619
C-14 [E453] Short circuit in boom swing RIGHT stop EPC solenoid system is displayed........................ 20-620
C-15 [E454] Disconnection in boom swing RIGHT stop EPC solenoid system is displayed .................... 20-621
C-16 Boom swing LEFT end cushion does not work at all or normally ..................................................... 20-622
C-17 Boom swing RIGHT end cushion does not work at all or normally ................................................... 20-624
C-18 Work equipment still moves after work equipment lock lever is set to LOCK ................................... 20-626
C-19 Machine does not swing ................................................................................................................... 20-627
C-20 Travel speed does not rise................................................................................................................ 20-628
C-21 Trouble in controller power supply (LED of controller is turned OFF)............................................... 20-628
PC78MR-6
20-601
(1)
TROUBLESHOOTING

(PUMP CONTROL SYSTEM)

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


PROBLEMS ON MACHINE
User Code
Service Code
Troubled System
Contents of Trouble
1. Short circuit in wiring harness between M97

pin 16 M20 pin 1
2. Short circuit in EPC solenoid
3. (Wrong operation of switch)
E232
Short circuit in TVC-EPC solenoid system

(When emergency pump drive switch is
turned ON)
E233
1. Disconnection in wiring harness between

M97 pin 16 M20 pin 1
Disconnection in TVC-EPC solenoid system 2. Disconnection in EPC solenoid
E203
Short circuit in swing holding brake solenoid

system

pin 7 M14 pin 2
2. Short circuit in solenoid
E213
Disconnection in swing holding brake

solenoid system (When emergency swing
holding brake reset switch is turned ON)

M97 pin 7 M14 pin 2
2. Disconnection in solenoid
M14 pin 1 M97 pin 3
4. (Wrong operation of switch)
E206
Short circuit in 2nd travel speed selection

solenoid system

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

solenoid system

2. Disconnection in solenoid
M15 pin 1 M97 pin 3
E227
Trouble in engine speed sensor

2. Disconnection in sensor
E414
Trouble in boom swing angle sensor

correction
1. Input voltage is abnormal when angle sensor is corrected (Out of range)

When voltage error is out of 0.5 V Voltage
must be 0.3 4.7 V, however
E258
Short circuit in 5 V system of sensor power

supply

pin 22 M29 pin C, M71 pin C, M72 pin A
E02
E03
E216
20-604
PC78MR-6
TROUBLESHOOTING
Normal Condition

Action Taken by Controller When

Trouble Occurs
Between M97 pin 16 chassis ground: Min.

1 Mz
Between M20 pin 1 solenoid body: Min. 1
Mz
Resistance of M20 EPC solenoid (With
When trouble is detected, TVC-EPC
switch directed down): 3 15 z
solenoid output is stopped.
Resistance between M97 pin 16 M20 pin
1: Max. 1 Mz
Resistance of M20 EPC solenoid: 3 15 z
23: Max. 1 z
Problems on Machine
Current does not flow in TVC-EPC

solenoid.
Accordingly, if load is large, engine
speed may lower to stall.
Between M97 pin 7 chassis ground: Min. 1

Mz
Mz
When trouble is detected, swing
Resistance of M14 solenoid: 35 80 z
Since motor brake is not released,
holding brake reset solenoid output is
machine does not swing.
Resistance between M97 pin 7 M14 pin 2: stopped.
Max. 1 z
Resistance between M14 pin 1 M97 pin 3
(With switch directed down): Max. 1 z
Between M97 pin 27 chassis ground: Min.
1 Mz
Mz
When trouble is detected, 2nd travel
speed selection solenoid output is
Resistance between M97 pin 27 M15 pin stopped.
2: Max. 1 Mz
Resistance between M15 pin 1 M97 pin 3:
Max. 1 z
When speed selector switch pedal is

operated, travel speed does not
change. (It is kept at 1st gear.)

1: Max. 1 z
Resistance of M16 sensor: 500 1,000 z
39: Max. 1 z
When trouble is detected, constant

current flows in TVC-EPC solenoid
(600 mA).
Working mode cannot be changed.
Engine governor control is limited to
operation of fuel control dial.
Since constant current (600 mA) is

output to TVC-EPC solenoid, work
equipment speed and travel speed
are low.
If engine speed is low, engine may
stall.
Boom swing angle sensor voltage for monitoring

At RIGHT swing end: 0.9 V
At LEFT swing end: 4.3 V
When potentiometer is corrected,

"---" is displayed and initial values are
selected.
If machine is operated without normal
correction, it is controlled with initial
values.
Offset end cushion does not work.

Stop position for interference prevention is wrong.
Displayed depth is wrong.
Resistance between M95 pin 22, M29 pin C,

Boom RAISE, arm IN, and offset
M71 pin C, M72 pin A - chassis ground: Min.
LEFT EPC outputs are stopped.
1 Mz
PC78MR-6
Boom RAISE, arm IN, and offset

LEFT operations cannot be executed. (They can be executed if
emergency work equipment operation switch is turned ON, however.)
20-605

TROUBLESHOOTING
User Code Service Code
Troubled System
Contents of Trouble
(*1)
E251
Trouble in boom bottom pressure sensor

(overload sensor) system

M95 pin 22 M92 pin B
2. Short circuit or disconnection in wiring harness between M95 pin 2 M92 pin C
M95 pin 21 M92 pin A
E412
Disconnection on GND side of boom swing

angle sensor

E413

Disconnection on power supply side of boom
pin 8 M101 pin B
swing angle sensor/Short circuit or
disconnection of signal line
M95 pin 8 M101 pin B
4. Defective M101 angle sensor (Internal short
circuit)
E451
Short circuit in boom swing LEFT EPC

solenoid system

pin 5 M11 pin 2
E452
Disconnection in boom swing LEFT EPC

solenoid system

M97 pin 5 M11 pin 2
2. Disconnection in EPC solenoid
E453
Short circuit in boom swing RIGHT EPC

solenoid system

pin 15 M12 pin 2
Disconnection in boom swing RIGHT EPC

solenoid system

2. Disconnection in EPC solenoid
E40
E41
E454
20-606
(1)
PC78MR-6
TROUBLESHOOTING
Normal Condition

Action Taken by Controller When

Trouble Occurs
Resistance between M95 pin 22 M92 pin B:

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

Buzzer sounds.
Caution lamp flashes.

C: Max. 1 z
Resistance between M95 pin 21 M29 pin C:
Max. 1 z
Resistance between M95 pin 20, M101 pin B
chassis ground: Min. 1 M z
B: Max. 1 z
Resistance between M72 angle sensor pin A
pin C: 3 7 k z
Resistance between M72 angle sensor pin A,
C pin B (Which changes as shaft is turned):
07kz
Resistance between M97 pin 5, M11 pin 2
Resistance between M97 pin 5 M11 pin 2: Boom swing LEFT EPC solenoid out- Boom cannot be swing to LEFT.
put is stopped.
Max. 1 z
Max. 1 z
Resistance between M97 pin 15, M12 pin 2
Resistance between M97 pin 15 M12 pin 2: Boom swing RIGHT EPC solenoid
output is stopped.
Max. 1 z
Max. 1 z
PC78MR-6
Boom cannot be swing RIGHT.
20-607
(1)
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM)

AND HYDRAULIC EQUIPMENT
TROUBLESHOOTING

Service Code
Disconnection on power supply side boom swing angle

sensor / short circuit or dsconnection of signal line
Short circuit in 5 V system of sensor power supply
Disconnection on GND side of boom swing angle sensor
(*2)
Trouble in boom bottom pressure sensor (overload sensor) system
Defective correction of boom swing angle sensor
E03
Disconnection in 2nd travel speed selection solenoid system
Short circuit in 2nd travel speed selection solenoid system
Disconnection in swing holding brake solenoid system
Short circuit in swing holding brake solenoid system
Disconnection in TVC-EPC solenoid system
E02
Trouble in engine speed sensor system
User Code
Failure Mode
Short circuit in TVC-EPC solenoid system
Self-diagnosis Display By Controller
Trouble in controller power supply system
Part Which May Cause Trouble
E40
232 233 203 213 206 216 227 414 251 258 412 413
q q q
Boom cannot be swing to LEFT and RIGHT.

Speed or power of 2 or more systems of work equipWork equipment, travel, swing, and blade is low.
ment, travel,
swing, blade Engine speed lowers extremely or engine stalls.
q q
q q
2 or more systems of work equipment, travel, swing,

and blade do not move.
Boom
Speed or power is low.
Arm
Boom swing
Work equipment
Boom
Does not move.
Arm
Boom swing
Travel
q q
Travel speed or power is low.
q q
Travel speed does not change.

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

Hydraulic drift is large.
Electronic
cushion
(*2)
Overload
warning
q
q
Boom swing end cushion does not work well or at all.

Boom swing RIGHT end cushion does not work at all.
Alarm does not stop sounding.

Alarm does not start sounding.
After work equipment lock lever is set to LOCK, work equipment

still moves
Diagnosis code displayed when service code is displayed
E-1 C-1 C-2 C-3 C-4 C-5 C-6 E-6 C-7 C-8 C-9 C-10 C-11
Diagnosis code displayed when trouble is detected by monitoring
20-608
(1)
PC78MR-6

TROUBLESHOOTING
Items Checked By Monitoring
Diagnosis
code displayed
when trouble is not
detected
by monitoring
Boom swing RIGHT EPC current output
Boom swing LEFT EPC current output
TVC-EPC current output
(*2)
Overload warning cancel signal input (2)
(*2)
Boom bottom pressure
Offset boom sensor voltage input
Engine speed input
ATT selection
Model selection and selection cod
2nd travel speed selection (4)
PPC main pressure (2)
Travel speed selector pedal switch input (4)
Deceleration switch signal input (1)
Air compressor signal input (3)
Swing (4)
Travel (3)
Boom LOWER (5)
E41
Swing holding brake (1)
State of
Solenoid
Hydraulic Switch
Boom RAISE (6)
Disconnection in boom swing RIGHT EPC solenoid system
Short circuit in boom swing RIGHT EPC solenoid system
Disconnection in boom swing LEFT EPC solenoid system
Short circuit in boom swing LEFT EPC solenoid system
Self-diagnosis Display By Controller
Monitoring Code
451 452 453 454
1023
1021
1026
1060
1020
1010 1031 1026 1040 1050 1052 1053
(*1)
(*1)
(*1)
(*1) (*1) C-7 C-14
(*1)
(*1)
(*1)
H-1
(*1)
(*1)
(*1)
H-2
(*1)
(*1)
(*1) (*1)
(*1)
H-3
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
C-12 C-13 C-14 C-15
F-3 F-4 F-2 F-1 F-7 F-5 F-6
q : Items corresponding to service codes

*1. Items that can only be cheked by monitoring
PC78MR-6
20-609
(1)
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR STD SPEC.)
20-610
(1)
PC78MR-6
TROUBLESHOOTING
PC78MR-6
20-611
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR EU SPEC.)
20-611-1
(1)
PC78MR-6
TROUBLESHOOTING
PC78MR-6
20-611-2
(1)
C-1, C-2
TROUBLESHOOTING
C-1 [E232], C-2 [E233] Trouble in TVC-EPC solenoid system
a Since this error is displayed when the emergency pump drive switch is turned ON (RAISE), check that this
switch is turned OFF (LOWER).
Cause
Remedy
1
Disconnect M20
3 15 z
Resistance between solenoid
and chassis ground: Min. 1 Mz
Is resistance of EPC solenoid normal

and is EPC solenoid insulated from
chassis?
NO
Defective TVC-EPC solenoid

(Internal short circuit,
disconnection)
Replace
between M97 (Female) (16),
(23) M20 (Female) (1), (2)
Repair or
replace

(16) M20 (Female) (1)
Repair or
replace
Replace
YES
2
Disconnect M97
Resistance: 3 15 z
NO
Is resistance between M97 (Female)

(16) (23) normal?
YES
3
Disconnect M97
Resistance: Min. 1 Mz

(16) chassis ground normal?
YES
NO
C-1, C-2 Electrical circuit diagram of each system
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
and chassis ground: Min. 1 Mz
NO
Is resistance of solenoid normal and is

solenoid insulated from chassis?
Defective swing holding brake

solenoid (Internal short circuit,
disconnection)
Replace
between M97 (Female) (7), (3)
M14 (Female) (2), (1)
Repair or
replace

(7) M14 (Female) (2)
Repair or
replace
Replace
YES
2
Disconnect M97
Resistance: 35 80z
NO

(7) (3) normal?
YES
3
Disconnect M97

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
NO
Is resistance of solenoid normal and is

solenoid insulated from chassis?
Defective 2nd travel speed

selection solenoid (Internal
short circuit, disconnection)
Replace
between M97 (Female) (27), (3)
M15 (Female) (2), (1)
Repair or
replace

(27) M15 (Female) (2)
Repair or
replace
Replace
YES
2
Disconnect M97
Resistance: 35 80 z
NO

(27) (3) normal?
YES
3
Disconnect M97

YES
NO
20-614
PC78MR-6
C-7
TROUBLESHOOTING
C-7 [E411] Trouble in boom swing angle sensor correction

a Check by monitoring that model selection code, and ATT selection code are normal.
a Check that the angle sensor are installed normally.
Cause
Remedy
1
Reset data again according to
potentiometer correction
procedure in back mode
NO
Is error turned off after data are reset

again
Defective correction (Wrong

resetting)
Replace
Defective angle sensor having

abnormal resistance
Replace
contact in wiring harness of
circuit having abnormal
resistance (Between M95
M101) (See circuit diagram)
Repair or
replace
YES
2
NO
Is monitored voltage of angle sensor at

each cylinder end normal?
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)
Is resistance of each angle sensor

normal?
YES
Table 1
NO
Voltage (V)
Position
Boom swing LEFT end

Boom swing RIGHT end
Monitoring Code
Standard Arm
Long Arm
0.9 1.8
0.8 1.8
3.2 4.2
3.2 4.2
1033
C-7 Electrical circuit diagram of each system
PC78MR-6
20-615
C-8, C-9
TROUBLESHOOTING
C-8 [E251] Trouble in boom bottom pressure sensor (overload sensor)

system (For EU spec.)
C-9 [E258] Short circuit in 5V system of sensor power supply (For EU
spec.)
a Check that fuse 10 is not broken.
Cause
Remedy
Disconnection in wiring harness

between M97 (20) fuse box
(10) or defective switch
Repair or
replace
Replace
Disconnection or short circuit in

wiring harness between M95 (2)
M92 (C), M95 (21) M92 (A),
or M95 (22) M92 (B)
Repair or
replace
Defective pressure sensor
Replace
1
When normal: There is a bit.
When reset: There is not a bit.
(Monitoring code 1026 (2))
NO
Is signal input of overload alarm reset

switch normal?
YES
2
0 26.5 MPa
(If boom circuit is relieved at
RAISE end, pressure changes.)
(Monitoring code 1040)
NO
Is boom cylinder bottom pressure

sensor signal normal?
YES
Disconnect M95 and M92.
Is resistance between M95 (2) and

M92 (C), between M95 (21) and M92
(A), and between M95 (22) and M92
(B) below 1 z?
Is resistance between M95 (2),
(22), M92 (C), (B) and chassis ground
above 1 Mz?
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

(Female) (22) (21) chassis
ground normal?
NO
Short circuit with chassis ground in

wiring harness between M95 (Female)
(22) M101 (Female) (C) (Short circuit
of sensor power supply with chassis
ground.)
Repair or
Replace
Short circuit with chassis ground or

negative (-) wire in wiring harness
between M101 (Female) (A), M72
(Female) (C)
Repair or
Replace
Defective angle sensor having abnormal

resistance (Internal short circuit)
Replace
Replace
YES
2
disconnect M95, M101 and
M29.
Min. 1Mz
NO

(Female) (22) (21)normal?
YES
3
turned)
Is resistance of each angle

sensor normal?
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
Is monitored voltage of boom

angle sensor normal?
YES
Replace
Defective boom angle sensor

(Disconnection, short circuit with chassis
ground)
Replace
Disconnection or defective contact in

wiring harness between M95 (Female)
(B), (3) M101 (Female) (C), (B)
Short circuit with chassis ground or
negative (-) wire in wiring harness
between M95 (Female) (8) M101
(Female) (B)
Repair or
replace
2
turned.)
Is resistance of M101 angle

sensor normal?
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?
Turn starting switch OFF.

Disconnect M11.
NO
Defective boom swing LEFT

stop EPC solenoid
(Internal disconnection)
Replace

between D33 (female) (1) M11
(female) (2), M97 (female) (23)
M11 (female) (1)
Repair or
Replace
Grounding fault or internal short

circuit in wiring harness
(female) (5)
Repair or
Replace
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?

Disconnect D33 and M97.
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
Between D33 (1) chassis

ground
Between M11 (male) (2)

chassis ground
Min. 1 z
Between D33 (1) M97 (23)
Table 3
Min. 1 Mz
5 25 z
Between M97 (5) chassis

ground
Min. 1 Mz
Between M97 (5) M97 (23)
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
Disconnect M11.
Resistance: 5 25z
NO

(male) (1) and (2) normal?
Defective boom swing LEFT stop

EPC solenoid
Replace

(female) (2), D15 (female) (2) M97
(female) (5), or M97 (female) (23)
M11 (female) (1)
Repair or
Replace
Defective diode (Disconnection)
Replace
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
Disconnect D33.
* See TESTING AND ADJUSTING.
Is diode D15 normal?
NO
YES
Table 1
Between D33 (1) M97 (23)
5 25 z
Between D33 (2) M97 (26)
Min. 1 z
PC78MR-6
20-619
(1)
C-14
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?

Disconnect M12.
NO
Defective boom swing RIGHT

stop EPC solenoid
(Internal short circuit or
grounding fault)
Replace

(2) or between M97 (23) M12
(1)
Repair or
Replace

(female) (15)
Repair or
Replace
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
Between D31 (1) chassis

ground
Between M12 (male) (2)

chassis ground
Min. 1 z
Between D31 (1) M97 (23)
Table 3
Min. 1 Mz
5 25 z
Between M97 (15) chassis

ground
Min. 1 Mz
Between M97 (15) M97 (23)
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
Disconnect M12.
Resistance: 5 25z
NO

(male) (1) and (2) normal?
Defective boom swing RIGHT stop

EPC solenoid
Replace

between D31 (female) (1) M12 (2),
D31 (female) (2) M97 (15), or M97
(23) M12 (1))
Repair or
Replace
Defective diode (Disconnection)
Replace
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
Disconnect D31.
* See TESTING AND ADJUSTING.
Is diode D31 normal?
NO
YES
Table 1
Between D31 (1) M97 (23)
5 25 z
Between D31 (2) M97 (15)
Min. 1 z
PC78MR-6
20-621
(1)
C-16
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
Defective boom swing angle

sensor
Replace
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
Is resistance of boom swing angle

sensor normal?
YES
3
Normal value: Max. 1 z
Is resistance between M101 (A) and

M95 (21), between M101 (B) and M95
(8), and between M101 (C) and M95
(22) normal?
NO
YES
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
Defective boom swing angle

sensor
Replace
resistance
Repair or
replace
Replace
2
Between (A) and (C): 3 7 kz
Between (A), (C) and (B): 0 7
kz (If shaft is rotated, resistance
changes.)
NO
Is resistance of boom swing angle

sensor normal?
YES
3
Normal value: Max. 1 z
Is resistance between M101 (A) and

M95 (21), between M101 (B) and M95
(8), and between M101 (C) and M95
(22) normal?
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
Is PPC hydraulic lock switch

normal?
Defective hydraulic lock switch
Replace
Short circuit with positive (+) wire in

wiring harness between K28 (2)
M13 (2)
Repair or
replace wiring
harness
Defective PPC lock solenoid valve
Replace
YES
2
When locked: 0 V
When released: 20 29 V
Is voltage between M13 (2)

NO
YES
20-626
(1)
PC78MR-6
C-19
TROUBLESHOOTING
C-19 Machine does not swing

a Carry out the following troubleshooting when [E-203] and [E-213] are not displayed.
Cause
Remedy
1
Check swing control lever.
Is bit pattern 1023 (4)

displayed?
NO
Go to F-1
Go to H-34
YES
PC78MR-6
20-627
(1)
C-20, C-21
TROUBLESHOOTING
C-20 Travel speed does not rise

a Carry out the following troubleshooting when [E-206] and [E-216] are not displayed.
Cause
Remedy
1
20 29 V
Disconnect K3
NO
Is voltage between K3 (Female) (2)

YES
In 1-spool mode: Max. 1Mz

In 2-spool mode: Max. 1Mz
Disconnect K3
NO
Is resistance between K3 (Male) (2)

(1) normal?

selection switch
Replace
chassis ground
Repair or
replace
Replace
between M95 (Female) (5) K3
(Female) (2)
Repair or
replace
YES
3
20 29 V
Disconnect K3
Is voltage between M95 (5)

YES
NO
C-21 Trouble in controller power supply (LED of controller is turned OFF)

a See E-1.
20-628
(1)
PC78MR-6

(INPUT SIGNAL SYSTEM)
(F MODE)
F-1
F-2
F-3
F-4
F-5
F-6
F-7
Bit pattern 1023-(4)

Swing pressure switch does not light up........................................................... 20-702

Travel pressure switch does not light up........................................................... 20-703
Boom RAISE pressure switch does not light up ............................................... 20-704
Arm IN pressure switch does not light up ......................................................... 20-705
Deceleration switch of left knob does not light up............................................. 20-706
2nd travel speed selection switch (pedal) does not light up.............................. 20-707
Compressor signal does not light up................................................................. 20-708
removed and the connector is returned, if the monitoring code is displayed normally, the condition has
returned to normal.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
PC78MR-6
20-701
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.
Is resistance between M22 (Male) (1)

(2) normal and are they insulated from
chassis ground?
Disconnect M23.
Start engine.
neutral: Min. 1 Mz
Move swing control lever to
swing to right: Max. 1 z
See note.

chassis ground?

Disconnect M95, M22, and M23.
Between M95 M22, M23: Max.
1z
Between wiring harness
chassis ground: Min. 1 z

(24) M22, M23 (Female) (2) normal
and are they insulated from chassis
ground?
Start engine.
neutral: 20 30 V
Move swing control lever: Max.
1V
1
NO
Defective left swing pressure

switch
Replace
NO
Defective right swing pressure

switch
Replace
Disconnection, defective
contact, or short circuit with
chassis ground in wiring
(24) M22 (Female) (2), M23
(Female) (2)
Repair or
replace
between M22 (Female) (1), M23
Repair or
replace
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.
F-1 Electrical circuit diagram of each system
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.
neutral: Min. 1 Mz
Move travel lever: Max. 1 z
See note.
Remedy
1
chassis ground?
NO
Defective travel pressure switch
Replace
(18) M25 (Female) (2)
Repair or
replace
between M25 (Female) (1)
chassis ground
Repair or
replace
Replace
YES

Disconnect M95 and M25.
Between M95 M25: Max. 1 z

(18) M25 (Female) (2) normal and
are they insulated from chassis
ground?
NO
YES
Start engine.
Set travel lever in neutral:
20 30 V
Move travel lever: Max. 1 V

ground normal?
YES
Note:
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

ground normal?
YES
Defective governor or pump

controller
Replace
Defective boom RAISE

pressure switch
Replace
(12) M21 (Female) (2)
Repair or
replace
chassis ground
Repair or
replace
2
chassis ground?
NO
YES

Disconnect M95 M21.
Between M95 M21: Max. 1 z

(12) M21 (Female) (2) normal and
are they insulated from chassis
ground?
YES
Note:
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

ground normal?
YES

controller
Replace
Defective arm IN pressure

switch
Replace
(6) M24 (Female) (2)
Repair or
replace
chassis ground
Repair or
replace
2
chassis ground?
NO
YES
3
Disconnect M95 M24.
Between M95 and M24: Max.
1z

(6) M24 (Female) (2) normal and are
they insulated from chassis ground?
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.
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

ground normal?
YES
2
20 30 V
NO
Is voltage between K18 (Male) (2)


controller
Replace
between fuse (11) K18 (1)
knob switch inlet
Repair or
replace
Defective left knob switch
Replace
between K18 (2) M97
(Female) (9)
Repair or
replace
YES
Disconnect knob switch terminal
K18.
Turn knob switch ON: Max. 1z
Turn knob switch OFF: Min. 1
Mz
3
(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
Disconnect 2nd travel speed
selection switch terminal K3.
Turn 2nd travel speed selection
switch ON: Max. 1z
switch OFF: Min. 1 Mz

Disconnect M95 and K3.
Between M95 K3: Max. 1z
Remedy
1
NO

(2) normal?

selection switch (pedal)
Replace
(5) K3 (Female) (2)
Repair or
replace
chassis ground
Repair or
replace
Replace
YES
2
Is resistance between K3 (Female) (2)
M95 (Female) (5) normal and are
they insulated from chassis ground?
NO
YES
3
switch ON: Max. 1 V

YES
NO
.
PC78MR-6
20-707
F-7
TROUBLESHOOTING
F-7 Bit pattern 1021-(3) Compressor signal does not light up
a Before starting measurement, check that the compressor operates normally when the air conditioner is
turned ON.

Disconnect M97.
When compressor operates
(= Just after air conditioner is
turned ON): 20 30 V
When compressor stops
(= After air conditioner is turned
off): Max. 1 V
Cause
Remedy
(10) K11 (Female) (8)
Repair or
replace
Replace
1
NO
YES
.
20-708
PC78MR-6
TROUBLESHOOTING FOR HYDRAULIC AND

MECHANICAL SYSTEMS
(H MODE)
Table of hydraulic failure modes and their causes ...................................................................................... 20-804
H- 1 Speed or power of 2 or more systems of work equipment (boom, arm, bucket), travel, swing,
and blade is low ................................................................................................................................. 20-806
a) Speed or power of all work equipment (including blade), travel, and swing systems is low .......... 20-806
b) Speed or power of all work equipment (excluding blade) and travel is low ................................... 20-807
c) Speed or power of swing and blade is low..................................................................................... 20-807
d) Speed or power of travel and blade is low ..................................................................................... 20-808
e) Speed or power of all work equipment (excluding blade) is low .................................................... 20-808
f) Speed or power of travel and swing is low..................................................................................... 20-808
H- 2 Engine speed lowers extremely or engine stalls................................................................................ 20-809
H- 3 2 or more systems of work equipment (boom, arm, bucket), travel, swing, and blade do not move..........20-811
a) All work equipment (including blade), travel, and swing systems do not move ..............................20-811
b) All work equipment (excluding blade) and travel systems do not move ........................................ 20-812
c) Swing and blade systems do not move ......................................................................................... 20-812
d) Travel and blade systems do not move ......................................................................................... 20-813
e) All work equipment (excluding blade) does not move ................................................................... 20-813
H- 4 Abnormal sound comes out (from around pump) .............................................................................. 20-814
H- 5 Fine controllability or response is low ................................................................................................ 20-815
H- 6 Hydraulic drift is large (all work equipment and blade) ...................................................................... 20-816
H- 7 Boom speed or power is low (other work equipment is normal) ........................................................ 20-817
a) Boom RAISE speed or power is low.............................................................................................. 20-817
b) Boom LOWER speed or power is low ........................................................................................... 20-818
H- 8 Arm speed or power is low (other work equipment is normal) ........................................................... 20-819
a) Arm IN speed or power is low........................................................................................................ 20-819
b) Arm OUT speed or power is low.................................................................................................... 20-820
H- 9 Bucket speed or power is low (other work equipment is normal)....................................................... 20-821
a) Bucket CURL speed or power is low ............................................................................................. 20-821
b) Bucket DUMP speed or power is low ............................................................................................ 20-822
H-10 Boom swing speed or power is low (other work equipment is normal) .............................................. 20-823
a) Swing left speed or power is low ................................................................................................... 20-823
b) Swing right speed or power is low ................................................................................................. 20-824
H-11 Boom does not move ......................................................................................................................... 20-825
a) Boom does not rise........................................................................................................................ 20-825
b) Boom does not lower ..................................................................................................................... 20-826
H-12 Arm does not move............................................................................................................................ 20-827
a) Arm does not move in.................................................................................................................... 20-827
b) Arm does not move out.................................................................................................................. 20-828
H-13 Bucket does not move ....................................................................................................................... 20-829
a) Bucket does not curl ...................................................................................................................... 20-829
b) Bucket does not dump ................................................................................................................... 20-830
H-14 Boom swing does not move .............................................................................................................. 20-831
a) Boom swing LEFT does not move................................................................................................. 20-831
b) Boom swing RIGHT does not move .............................................................................................. 20-832
H-15 Hydraulic drift of boom is large .......................................................................................................... 20-833
H-16 Hydraulic drift of arm is large ............................................................................................................. 20-833
H-17 Hydraulic drift of bucket is large......................................................................................................... 20-834
PC78MR-6
20-801
H-18 Hydraulic drift of swing is large ......................................................................................................... 20-834

a) Hydraulic drift of swing to left is large ............................................................................................ 20-834
b) Hydraulic drift of swing to right is large .......................................................................................... 20-834
H-19 Time lage is large (when engine speed is low) .................................................................................. 20-835
H-20 Part loaded more moves slower in compound operation of work equipment .................................... 20-835
H-21 Boom RAISE speed is low in compound operation of swing and boom RAISE ................................ 20-836
H-22 Travel speed lowers extremely in compound operation of travel and boom RAISE .......................... 20-836
H-23 Speed is low in compound operation of work equipment relief and swing,
work equipment relief and work equipment ....................................................................................... 20-836
H-24 Travel deviation is large ..................................................................................................................... 20-837
a) Travel deviation is large during ordinary travel .............................................................................. 20-837
b) Travel deviation is large when machine starts (but during normal ordinary travel) ........................ 20-838
H-25 Travel deviation is large in compound operation of travel and swing, travel and work
equipment .......................................................................................................................................... 20-839
H-26 Travel speed or power is low (work equipment, swing, and blade operations are normal)................ 20-840
H-27 Machine cannot be steered sharply or steering force is insufficient................................................... 20-842
H-28 Travel speed does not change at all or does not change quickly ...................................................... 20-843
H-29 Machine does not travel..................................................................................................................... 20-844
H-29 Supplement........................................................................................................................................ 20-845
H-30 Overrun of travel is large.................................................................................................................... 20-846
H-31 Travel hydraulic drift is large .............................................................................................................. 20-846
H-32 Fine controllability or response is low ................................................................................................ 20-847
H-33 Swing speed or power is low (work equipment, travel, and blade operations are normal) ................ 20-848
H-34 Machine does not swing (work equipment, travel, and blade operations are normal) ....................... 20-850
a) Swing speed or power is low in both directions ............................................................................. 20-850
b) Swing speed or power is low in either direction ............................................................................. 20-851
H-35 Swing acceleration is low................................................................................................................... 20-852
a) Swing acceleration is low in both directions................................................................................... 20-852
b) Swing acceleration is low in either direction .................................................................................. 20-852
H-36 Overrun of swing is large ................................................................................................................... 20-853
a) Overrun of swing is large in both directions ................................................................................... 20-853
b) Overrun of swing is large in either direction................................................................................... 20-853
H-37 Large shock is made when machine stops swinging ......................................................................... 20-854
H-38 Large abnormal sound is made when machine stops swinging......................................................... 20-854
H-39 Swing hydraulic drift is large .............................................................................................................. 20-855
H-40 Fine controllability more response of swing is low ............................................................................. 20-856
H-41 Blade speed or power is low (work equipment, travel, and swing operations are normal) ................ 20-857
H-42 Blade does not move (work equipment, travel, and swing operations are normal) ........................... 20-858
a) Blade does not rise ........................................................................................................................ 20-858
b) Blade does not lower ..................................................................................................................... 20-859
H-43 Hydraulic drift of blade is large........................................................................................................... 20-860
H-44 Fine controllability or response of blade is low .................................................................................. 20-861
20-802
PC78MR-6
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
TROUBLESHOOTING
Machine model PC78MR-6
Logic valve
Merge valve
Main relief circuit check valve
Main relief valve
Unload valve
LS bypass choke
Pressure compensation valve
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
Part Which May Cause Trouble
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
Hydraulic drift is large (All work equipment and blade)
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
Hydraulic drift Arm

of work equipment is large Bucket
q
q
Boom swing
Time lag is large (When engine speed is low)

Part loaded more moves slower in compound operation of work
equipment
Compound
operation
Boom RAISE speed is low in compound operation of swing and boom

RAISE
Travel speed lowers extremely in compound operation of travel and

boom RAISE
Speed is low in compound operation of work equipment relief and
swing, work equipment relief and other work equipment
q q
q q q
q q
q q
q q q
Machine does not travel
q q
Overrun of travel is large
Travel deviation is large

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

Machine cannot be steered sharply or steering force is insufficient
Travel
Travel speed does not change at all or does not change quickly
Travel hydraulic drift is large
Swing
Fine controllability or response is low
q q
Swing speed or power is low
q q
Machine does not swing
q q
Swing acceleration is low
q q
q q
Overrun or swing is large

Large shock is made when machine stops swinging
Large abnormal sound is made when machine stops swinging

Swing hydraulic drift is large
Blade
20-804
Fine controllability or response of swing is low
q q
Blade speed or power is low
Blade does not move
Hydraulic drift of blade is large
Fine controllability or response of blade is low
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
PPC pressure switch
Hydraulic cylinder
Final drive
Parking brake valve
Parking brake
2nd speed select valve and

piston
Swing Motor
Check valve
Counterbalance valve
Piston motor
Center swivel joint
Swing machinery
Reaction prevention valve
Parking brake
Suction valve
Check valve
Solenoid Valve
Safety valve
Piston motor
Left offset EPC valve
Arm IN EPC valve
Boom RAISE EPC valve
Swing holding brake solenoid

valve
PPC Valve
2nd travel speed selection

solenoid valve
PPC main pressure lock solenoid
q q q
PPC valve (Offset pedal)
PPC valve (Blade bar)
PPC valve (Travel lever)
Control Valve
PPC valve (Left lever) 1 0
PPC valve (Right lever) 1 0
2nd travel speed selection choke
Swing PPC line choke
Swing PPC slow return valve
Pressure release valve
Blade safety valve
Gear pump circuit relief valve
Boom assist valve
Boom lock valve
Suction valve
Centralized safety valve
Travel LS bleed valve
Travel junction variable throttle

valve
PPC circuit check valve
TROUBLESHOOTING
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
H-1 Speed or power of 2 or more systems of work equipment (boom, arm,

bucket), travel, swing, and blade is low
a Before carrying out troubleshooting, check that the oil level in the tank is proper.
a If the engine speed lowers, carry out H-2 first.
a If "individual factor" is indicated, a trouble which occurs less frequently than the detected trouble may have
occurred or several troubles may be combined. Accordingly, carry out troubleshooting for each of those
troubles.
a Select a combination of systems which have low speed or power from Table 1 before going to the next troubleshooting.
a If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators of
each system "which has low speed or power" (H-7 H-10).
Q : Normal
x : Speed or power is low
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
Is suction strainer clogged?
YES
Clogged suction strainer

(Defective suction by pump)
Clean or
replace
Go to H-1, b)
2
3.14 0.3 MPa
{32 3 kg/cm2}
Is output pressure of PPC main pressure lock NO

solenoid valve normal?
YES
3
NO
When control relief valve is adjusted, is

trouble repaired?
YES
Defective adjustment of control valve Adjust
4
When PPC lock solenoid valve is replaced, is NO
trouble repaired?
YES
20-806
Defective pump control
Replace
Defective PPC main pressure lock

solenoid
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}
NO
Is work equipment relief pressure normal?
YES
2
Curl bucket
26.5 1.47 MPa {270 15 kg/cm2}
Is travel relief pressure normal?
NO
Go to corresponding section
in H-7 10, 26
NO
Defective main pump

(Lowering of volumetric
efficiency)
Repair or
replace
Defective boom assist valve
Repair or
replace
in H-7 10, 26
Defective main relief valve
Repair or
replace
Defective unload valve
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}
NO
YES
5
NO
When travel relief valve is adjusted or

replaced, is trouble repaired?
YES
6
NO
Does unload valve move smoothly?
YES
c) Speed or power of swing and blade is low

Cause
Lower blade
21.08 1.47 MPa
{215 15 kg/cm2}
Remedy
1
NO
Is gear pump relief pressure normal?
YES
in H-26, 33
Defective gear pump
Repair or
replace
Defective gear pump relief

pressure
Adjust or
replace
2
When gear pump relief valve is adjusted or NO
YES
PC78MR-6
20-807
H-1
TROUBLESHOOTING
d) Speed or power of travel and blade is low

Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
H-26, 41
H-26, 41
H-26, 41
Defective swivel joint
Repair or
replace
2
21.08 1.47 MPa
{215 15 kg/cm2}
NO
Is blade LOWER relief pressure normal?
YES
3
When hose is disconnected from valve outlet NO
and plugged, is relief pressure normal?
YES
e) Speed or power of all work equipment (excluding blade) is low

Cause
Remedy
1
Is all PPC pressure normal (At PPC pressure NO
inlet of control valve?
YES
2.11 0.1 MPa
{21.5 1 kg/cm2}
Run engine at full throttle and
curl bucket
2
NO
Is LS differential pressure normal?
Defective adjustment of pump

Adjust
LS valve
YES
3
When compound operation of travel, work
NO
equipment, and swing is performed, is trouble
repaired?
YES
in H-7 10
Defective travel pressure

compensation valve
4
NO
Is PPC pressure normal at only 1 place

(When single operation is performed)?
YES
Defective check valve in PPC

circuit having normal PPC
Replace
pressure
5
Is check valve at swing holding brake
pressure inlet of logic valve normal?
YES
f)
NO
Leakage of PPC pressure

caused by defective ball
check valve
in H-7 10
Speed or power of travel and swing is low

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

Cause
Remedy
1
When bucket is relieved in CURL
mode and blade is relieved in RAISE
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
Execute diagnosis No. 4
3
26.5 1.45 MPa
{270 15 kg/cm2}
Is bucket CURL relief pressure normal?
NO
YES
4
12.74 1.47 MPa
{130 15 kg/cm2}
Is blade RAISE relief pressure normal?
NO
YES
5
NO
When gear pump circuit relief valve is

adjusted, repaired, or replaced, is
trouble repaired?
YES
Defective gear pump circuit

relief valve
Adjust or
replace
Defective main relief valve
Repair or
replace
Defective connection
Repair
Defective TVC-EPC valve

(Defective solenoid)
Replace
Repair or
replace
6
NO
When main relief valve is replaced, is

trouble repaired?
YES
7
Does monitor display error code "E02" NO
of TVC trouble?
YES
8
NO
Is TVC connector connected?
YES
9
When engine speed changes, does
TVC current change?
NO
YES
To next page
PC78MR-6
20-809
H-2
TROUBLESHOOTING
Cause
Remedy
From previous page
10
0.54 ~ 0.83 MPa
{5.5 ~ 8.5 kg/cm2}
Is output voltage of TVC-EPC solenoid NO

normal?
YES
11
When PC valve is adjusted, is trouble
repaired?
NO
YES
Defective PC valve
Adjust or
replace
12
NO
When orifice of servo is cleaned, is

trouble repaired?
YES
Clogged orifice
13
When EPC valve of TVC is replaced, is NO
trouble repaired?
YES
Execute diagnosis No. 11
Defective EPC valve
Repair or
replace
Defective engine system
Defective pump or servo
Repair or
replace
14
When pump assembly is replaced, is
trouble repaired?
YES
20-810
NO
PC78MR-6
H-3
TROUBLESHOOTING
H-3 2 or more systems of work equipment (boom, arm, bucket), travel,

swing, and blade do not move
a Before carrying out troubleshooting, check that the oil level in the tank is proper.
a Select a combination of systems which do not move from Table 1 before going to the next troubleshooting.
a If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators of
each system "which does not move" (H-10 13).
Q : Normal
x : Speed or power is low
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
Is suction strainer clogged?
YES
Clogged suction strainer
Clean or adjust
Defective main pump shaft
Replace
Defective damper or spline
Replace
Defective gear pump
Replace
Defective coupling or spline
Replace
4
NO
Is damper or spline damaged?
YES
5
NO
When oil flows out of main pump but

does not flow out of gear pump and
control pump.
YES
6
Is coupling or spline between main
pump and gear pump damaged?
YES
NO
To item No. 5 on next page
PC78MR-6
20-811
H-3
TROUBLESHOOTING
Cause
Remedy
From item 3 on previous page
5
NO
When engine is cranked, does oil flow out of

control pump?
Defective control pump
Repair or
replace
YES
6
3.14 0.3 MPa {32 3 kg/cm2}

YES
Defective PPC main pressure

Repair or
lock solenoid valve or
replace
defective electric system
in H-11 ~ 14, 29, 34, 42
b) All work equipment (excluding blade) and travel systems do not move
Cause
Remedy
1
NO

control?
Defective control
Repair or
replace
YES
2
3.14 0.3 MPa
{32 3 kg/cm2}

Defective PPC main pressure Repair or

lock solenoid valve or
replace
defective electric system
YES
3
NO
Is only 1 part of each of work equipment and

travel normal?
YES
in H-11 14, 29
Repair or
replace
Defective check valve in PPC Repair or

circuit having normal
replace
pressure
c) Swing and blade systems do not move

Cause
Remedy
1
NO

pump?
Defective control pump
Repair or
replace
in H-34, 42
Defective gear pump circuit

relief valve
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
d) Travel and blade systems do not move

Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
H-29
H-42
H-29, 42
Repair or
replace
2
21.08 1.47 MPa
{215 15 kg/cm2}
NO
Is blade relief pressure normal?
YES
3
When hose is disconnected from valve outlet NO
and plugged, is relief pressure normal?
YES
e) All work equipment (excluding blade) does not move

Cause
Remedy
1
3.14 0.5 MPa
{32 5 kg/cm2}
NO
Are all PPC pressures normal

(At connected PPC pressure inlets)?
YES
in H-11 14
in H-11 14
2
NO
Is only 1 place normal?
YES
Defective check valve in PPC

circuit having normal
Replace
pressure
Note: If machine is equipped with an attachment, check that attachment.
PC78MR-6
20-813
H-4
TROUBLESHOOTING
H-4 Abnormal sound comes out (from around pump)

Cause
Remedy
1
NO
Is oil level in hydraulic tank normal?
Low hydraulic oil level
Supply
hydraulic oil
Low hydraulic oil level
YES
2
NO
Are there bubbles in hydraulic tank?
YES
3
NO
When engine is stopped, do bubbles in tank

disappear?
YES
4
Foreign matter: Cloth, etc.
Is suction strainer clogged with foreign matter?
NO
YES
Foreign matter (Cloth, etc.)

clogging suction strainer
Remove
Defective inside pump
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
H-5 Fine controllability or response is low

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

valve
Clean
Defective PC valve or servo

piston
Repair or
replace
Clogging of orifice or piston

pump
Clean
Defective LS valve
Repair or
replace
Defective adjustment of LS
valve
Adjust
3
NO
Is orifice of unload valve clogged?
YES
4
NO
Is orifice of piston pump clogged?
YES
5
When LS valve is adjusted, is trouble repaired?
YES
PC78MR-6
NO
20-815
H-6
TROUBLESHOOTING
H-6 Hydraulic drift is large (all work equipment and blade)

a Before carrying out troubleshooting, check that oil level in the tank is proper.
Cause
Remedy
1
NO
Is pressure release plug of control valve

tightened?
Leakage through pressure

release circuit
Retighten
Leakage through pressure

release circuit
YES
2
NO
Is seal of pressure release plug broken?
YES
3
When centralized safety valve is replaced, is
trouble repaired?
YES
20-816
NO
in H-15 H-18
Defective concentrated
safety valve
Clean
PC78MR-6
H-7
TROUBLESHOOTING
H-7 Boom speed or power is low (other work equipment is normal)

a) Boom RAISE speed or power is low
a When the boom speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
pressure and carry out troubleshooting No. 2.
a Check that the emergency pump drive switch is turned OFF.
Cause
Remedy

set boom in neutral: 410 mA
raise boom: 100 mA
When boom is raised in monitoring mode

1050, does current lower?
0.54 ~ 0.83 MPa

{5.5 8.5 kg/cm2}
Is output pressure of pump TVC-EPC

solenoid normal?
NO
Diagnose by F-3
YES
2
NO
Defective pump TVCEPC solenoid
Replace
NO
Defective operation of
control valve spool
Repair or
replace
NO
pressure compensation
valve
NO
Defective centralized
safety valve
Replace
Defective suction valve

(Boom LOWER side)
Repair or
replace
Defective boom cylinder

packing
Repair or
replace
Defective seat of check

valve of boom assist
valve
Repair or
replace
Defective boom RAISE

PPC valve
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
NO
Is boom relief pressure normal?
YES
4
3.14 0.49 MPa
{32 5 kg/cm2}
Is PPC valve output pressure normal?

(PPC pressure inlet of control valve)
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}
Is boom LOWER relief pressure normal?
YES
8
NO
When pilot hose of boom assist valve is

disconnected, does speed rise?
YES
9
(Move boom RAISE with arm IN
oil.)
When PPC hose is replaced with arm IN hose NO

on control valve side, is trouble repaired?
YES
PC78MR-6
20-817
H-7
TROUBLESHOOTING
b) Boom LOWER speed or power is low

a When the boom speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
Is boom LOWER relief pressure normal?
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
NO
Is PPC valve output pressure normal? (At

control valve PPC pressure inlet)
YES
3
NO
control valve spool
Repair or
replace
Malfunction of lock valve
Repair,
clean, or
replace
Malfunction of spool
Check 3
again
safety valve
Replace

(Boom LOWER side)
Repair or
replace
Defective boom LOWER

PPC valve
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}
NO
Is boom RAISE relief pressure normal?
YES
6
(Move boom LOWER with arm
OUT oil.)
When PPC hose of control valve is replaced NO

with arm DUMP, is trouble repaired? (Return
it immediately after testing.)
YES
20-818
PC78MR-6
H-8
TROUBLESHOOTING
H-8 Arm speed or power is low (Other work equipment is normal)

a) Arm IN speed or power is low
a When the arm speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief pressure and carry out troubleshooting No. 2.
Cause
set arm in neutral: 410 mA
raise boom: 100 mA
Remedy
1
NO
When arm is moved IN in monitoring

mode 1050, does current lower?
Diagnose by F-3
YES
2
0.54 0.83 MPa
{5.5 8.5 kg/cm2}
Run engine at full throttle.
NO
Is output pressure of pump TVC-EPC

solenoid normal?
Defective pump TVC-EPC

solenoid
Replace
Defective arm IN PPC valve
Repair or
replace
YES
3
26.5 1.49 MPa
{270 15 kg/cm2}
NO
Is arm IN relief pressure normal?
YES
4
3.14 0.49 MPa
{32 5 kg/cm2}
NO
Is EPC valve output pressure normal?

YES
5
NO
Defective operation of control Repair or

valve spool
replace
YES
6
Does pressure compensation valve move NO
smoothly?
pressure compensation valve
YES
7
26.5 1.47 MPa
{270 15 kg/cm2}
NO
Is arm OUT relief pressure normal?
YES
Defective centralized safety

valve
Replace
Defective suction valve (Boom Repair or

LOWER side)
replace
8
(Move arm IN with boom
RAISE)
When PPC hose is replaced with boom

RAISE hose on control valve side, is
trouble repaired? (Return it immediately
after testing.)
NO
YES
Repair or
replace
Defective seats of swing

brake circuit check valve and
swing PPC slow-return valve
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
b) Arm OUT speed or power is low

a When the arm speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief pressure and carry out troubleshooting No. 2.
Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
NO

(At control valve PPC pressure inlet)
YES
3
NO
Malfunction of control valve

spool
Repair or
replace

smoothly?
Malfunction of pressure
compensation valve
Repair or
replace
YES
Defective arm cylinder

packing
Repair or
replace
safety valve
Replace

(Arm IN side)
Repair or
replace
Defective arm OUT PPC

valve
Repair or
replace
YES
5
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
6
(Move arm OUT with boom
LOWER oil)
When PPC hose of control valve is

replaced with boom LOWER, is trouble
repaired? (Return it immediately after
testing.)
YES
20-820
NO
PC78MR-6
H-9
TROUBLESHOOTING
H-9 Bucket speed or power is low (Other work equipment is normal)

a) Bucket CURL speed or power is low
a When the bucket speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
NO

YES
3
NO

spool
Repair or
replace

smoothly?
compensation valve
Repair or
replace
YES
Defective arm cylinder

packing
Repair or
replace
safety valve
Replace

(Bucket CURL side)
Repair or
replace
YES
5
26.5 1.47 MPa
{270 15 kg/cm2}
NO
Is bucket DUMP relief pressure normal?
YES
6
(Move bucket CURL with
arm IN oil)

NO
replaced with arm IN, is trouble repaired?
(Return it immediately after testing.)
YES
PC78MR-6
Defective bucket CURL PPC Repair or

valve
replace
20-821
H-9
TROUBLESHOOTING
b) Bucket DUMP speed or power is low

a When the bucket speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
Is bucket DUMP relief pressure normal?
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
NO

YES
3
NO

spool
Repair or
replace
compensation valve
Repair or
replace
Defective bucket cylinder

packing
Repair or
replace
safety valve
Replace

(Bucket DUMP side)
Repair or
replace
YES
4
smoothly?
YES
5
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
6
(Move bucket DUMP with
arm OUT oil)
When PPC hose of control valve is replaced NO

with arm OUT, is trouble repaired? (Return it
immediately after testing.)
YES
20-822
Defective bucket DUMP PPC Repair or

valve
replace
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
Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
Is swing left relief pressure normal?
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Is solenoid valve output pressure normal? NO

YES
3
NO

valve spool
replace

smoothly?
Repair or
pressure compensation valve replace
YES
YES
Defective swing cylinder

packing
Repair or
replace
Defective pressure
compensation valve
Repair or
replace
Defective packing seal near

extraction end of swing
cylinder
Repair or
replace
Go to troubleshooting No. 3
Defective swing left PPC

valve
Repair or
replace
Defective swing left solenoid

valve
Repair or
replace
5
26.5 1.47 MPa
{270 15 kg/cm2}
NO
Is swing right relief pressure normal?
YES
6
(Move swing left by curling
bucket)
When PPC hose and bucket CURL hose

are exchanged at control valve, does
condition become normal?
(Return hoses immediately after testing.)
NO
YES
7
PC78MR-6
NO
20-823
H-10
TROUBLESHOOTING
b) Swing right speed or power is low

a Relieve the swing RIGHT actuator in a position at which the swing end cushion system does not detect the
work equipment.
a When the offset speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
NO

YES
3
NO

valve spool
replace

smoothly?
Repair or
YES
YES
Defective swing cylinder

packing
Repair or
replace
Defective pressure
compensation valve
Repair or
replace

(Right swing side)
Repair or
replace
5
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
6
(Move swing right by dumping
bucket)
When PPC hose and bucket DUMP hose

NO
YES
20-824
Defective swing right PPC

valve
Repair or
replace
PC78MR-6
H-11
TROUBLESHOOTING
H-11 Boom does not move

a Carry out the following troubleshooting, if the boom does not move when operated singly (when the other
work equipment is normal).
a) Boom does not rise
Cause
Remedy
1
kg/cm2}
3.14 0.49 MPa {32 5

NO

YES
2
NO
Does boom lower?

spool
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}
NO
When boom is raised, is pump relief

pressure normal?
YES
4
NO
Does spool move smoothly?
YES
Malfunction of spool in raising Repair or

mode
replace
compensation valve
Repair or
replace
Defective boom RAISE PPC

valve
Repair or
replace
5
(Move boom lower with arm IN oil)

replaced with arm IN, is trouble
testing.)
YES
PC78MR-6
NO
20-825
H-11
TROUBLESHOOTING
b) Boom does not lower

Cause
Remedy
1
2.94 0.49 MPa
{30 5 kg/cm2}
Is PPC valve output pressure normal? NO

YES
2
NO
Does boom rise?

Repair or
spool or seizure of lock valve
replace
poppet
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
When boom is lowered, is pump relief NO

pressure normal?
YES
4
NO
YES
Malfunction of spool in
lowering mode
Repair or
replace
compensation valve
Repair or
replace
5
(Move boom lower with arm
OUT oil)

replaced with arm OUT, is trouble
testing.)
NO
YES
Defective boom LOWER PPC Repair or

valve
replace
6
Is seal drain line of control valve
clogged?
YES
20-826
NO
Defective lock valve
Repair or
replace
Defective lock valve caused

by clogging
Repair or
replace
PC78MR-6
H-12
TROUBLESHOOTING
H-12 Arm does not move

a Carry out the following troubleshooting, if the arm does not move when operated singly (when the other
a) Arm does not move in
Cause
Remedy
1
kg/cm2}
3.14 0.49 MPa {32 5

NO

(At control valve PPC pressure inlet.)
YES
2
NO
Does arm move out?

spool
Repair or
replace
work equipment (Arm does
not move more than
deformed part)
Repair or
replace
Malfunction of spool in IN
mode
Repair or
replace
compensation valve
Repair or
replace
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
NO
When arm is moved in, is pump relief

pressure normal?
YES
4
NO
YES
5
(Move arm out with boom RAISE
oil)

replaced with boom RAISE, is trouble
testing.)
NO
YES
6
When swing operation and arm IN
NO
operation are executed simultaneously,
is trouble repaired?
YES
PC78MR-6
Defective seats of swing

Repair or
brake circuit check valve and
replace
swing PPC slow-return valve
20-827
H-12
TROUBLESHOOTING
b) Arm does not move out

Cause
Remedy
1
3.14 0.49 MPa {32 5 kg/cm2}
NO

YES
2
NO
Does arm move in?

spool
Repair or
replace
work equipment (Arm does
not move more than
deformed part)
Repair or
replace
Malfunction of spool in OUT

mode
Repair or
replace
compensation valve
Repair or
replace
Defective arm OUT PPC

valve
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
NO
When arm is moved out, is pump relief

pressure normal?
YES
4
NO
YES
5
(Move arm out with boom LOWER
oil.)

replaced with boom LOWER, is trouble NO
testing.)
YES
20-828
PC78MR-6
H-13
TROUBLESHOOTING
H-13 Bucket does not move

a Carry out the following troubleshooting, if the bucket does not move when operated singly (when the other
a) Bucket does not curl
Cause
Remedy
1
kg/cm2}
3.14 0.49 MPa {32 5

NO

(At control valve PPC pressure inlet.)
YES
2
NO
Is bucket dumped?

spool
Repair or
replace
work equipment
(Bucket does not move more
than deformed part)
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
NO
When bucket is curled, is pump relief

pressure normal?
YES
4
NO
YES
Malfunction of spool in CURL Repair or

mode
replace
compensation valve
Repair or
replace
Defective bucket CURL PPC

valve
Repair or
replace
5
(Move bucket curl with arm IN oil)

replaced with arm IN, is trouble
testing.)
YES
PC78MR-6
NO
20-829
H-13
TROUBLESHOOTING
b) Bucket does not dump

Cause
Remedy
1
3.14 0.49 MPa {32 5 kg/cm2}
NO

YES
2
NO
Is bucket curled?

spool
Repair or
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
When bucket is dumped, is pump relief NO

pressure normal?
YES
4
NO
YES
work equipment
Repair or
(Bucket does not move more replace
than deformed part)
Malfunction of spool in DUMP Repair or
mode
replace
compensation valve
Repair or
replace
5
(Move bucket dump with arm OUT)

replaced with arm OUT, is trouble
testing.)
YES
20-830
NO
Defective bucket DUMP PPC Repair or

valve
replace
PC78MR-6
H-14
TROUBLESHOOTING
H-14 Boom swing does not move

a Carry out the following troubleshooting when the offset boom does not move when it is operated singly (and
the other work equipment is normal).
a) Boom swing LEFT does not move
Cause
Remedy
1
kg/cm2}
3.14 0.49 MPa {32 5

Is solenoid valve output pressure normal? NO

YES
2
NO
Does boom swing right move?

valve spool
replace
YES
3
26.5 1.47 MPa
{270 15 kg/cm2}
NO
When swing left is operated, is pump

relief pressure normal?
YES
Deformed cylinder or work

equipment
(Work equipment does not
move over deformed part)
Repair or
replace
Defective operation of spool
Repair or
replace
4
NO
YES
Repair or
5
(Move swing left by curling bucket)
When PPC hose and bucket CURL hose

NO
Defective swing left PPC

valve
Repair or
replace
Defective swing left EPC

valve
Repair or
replace
YES
6
YES
PC78MR-6
NO
20-831
H-14
TROUBLESHOOTING
b) Boom swing RIGHT does not move

Cause
Remedy
1
3.14 0.49 MPa {32 5 kg/cm2}
NO

YES
2
NO
Does boom swing left move?

valve spool
replace
YES
26.5 1.47 MPa
{270 15 kg/cm2}
3
NO
When swing right is operated, is pump

relief pressure normal?
YES
4
NO
YES

equipment
(Work equipment does not
move over deformed part)
Repair or
replace
Defective operation of spool
Repair or
replace
Repair or
5
(Move swing right by dumping
bucket)
When PPC hose and bucket DUMP hose

NO
Defective swing RIGHT PPC

valve
Repair or
replace
Defective swing RIGHT EPC

valve
Repair or
replace
YES
6
YES
20-832
NO
PC78MR-6
H-15, H-16
TROUBLESHOOTING
H-15 Hydraulic drift of boom is large

Cause
Remedy
1
NO
Is leakage from hydraulic cylinder

normal?
Defective cylinder piston packing
Repair or
replace
Defective boom lock valve
Repair or
replace
Defective boom lock valve
Replace
YES
2
NO
When centralized safety valve is

YES
H-16 Hydraulic drift of arm is large

Cause
Remedy
1
NO

normal?
Repair or
replace
Defective centralized safety valve
Replace
Defective oil-tightness of control

valve spool
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
H-17 Hydraulic drift of bucket is large

Cause
Remedy
1
NO

normal?
Repair or
replace
Replace

valve spool
Repair or
replace
Repair or
replace
YES
2
NO

YES
3
NO

blind plug, is trouble repaired?
YES
H-18 Hydraulic drift of swing is large

a) Hydraulic drift of swing to left is large
Cause
Remedy
1
NO

normal?
Repair or
replace

valve spool
Repair or
replace
Repair or
replace
YES
2
NO

blind plug, does condition become
normal?
YES
b) Hydraulic drift of swing to right is large

Cause
Remedy
1
normal?
YES
20-834
NO
Repair or
replace

valve spool
Repair or
replace
PC78MR-6
H-19, H-20
TROUBLESHOOTING
H-19 Time lag is large (When engine speed is low)

Cause
Remedy
1
NO
Is suction valve normal (Free from

seizure)?
Replace
Defective back pressure valve
Replace
Defective pump servo piston
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
H-20 Part loaded more moves slower in compound operation of work

equipment
Cause
Remedy
Defective counterbalance valve on

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

boom RAISE
a Carry out the following troubleshooting, if the swing operation and boom RAISE operation are normal when
executed singly (Swing LS pressure is not generated) .
When this operation is executed, the gear pump assists the boom RAISE circuit.
Cause
Remedy
Defective boom assist valve or LS Clean or

select valve
replace
H-22 Travel speed lowers extremely in compound operation of travel and

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

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

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

difference between both
sides
Check rollers for revolution
trouble
Check for deformation and
damage
Above 3.14 0.49 MPa

{Above 32 5 kg/cm2}
Move lever to stroke end
Cause
Remedy
NO
Is undercarriage troubled?
YES
Defective undercarriage
Repair or
replace
Wrong adjustment or breakage of

pump
Adjust, repair
or replace
Defective travel junction variable

choke valve
Clean or
replace
Defective pump merge valve
Repair or
replace
Malfunction of logic valve
Check, clean,
repair or
replace
Defective check valve of main

relief circuit
Repair or
replace
Malfunction of unload valve

(Clogging of hole, etc.)
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
Is pressure at top PP pressure

pickup port of control valve same
as pump pressure?
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
YES
To 12 on next page
PC78MR-6
To 10 on next page
To 13 on next page
20-837
H-24
TROUBLESHOOTING
From 4 on previous page
Cause
Remedy
10
NO
Does pressure compensation

valve move smoothly?
Defective pressure compensation

valve
Repair or
replace
Repair or
replace
Defective travel motor (Motor,

counterbalance valve, final drive)
Check, repair
or replace
Repair or
replace
Defective PPC circuit check valve

of control valve
Repair or
replace
Defective PPC valve
Repair or
replace
Abnormal PPC pressure output

caused by interference
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
Delay of release of parking brake Repair or

(Malfunction of brake, brake valve replace
2
Does counterbalance valve of
travel motor move smoothly?
YES
20-838
NO
Go to diagnosis No. 5 in (a) above

Malfunction of counterbalance
valve
Repair or
replace
PC78MR-6
H-25
TROUBLESHOOTING
H-25 Travel deviation is large in compound operation of travel and swing,

travel and work equipment
a Carry out the following troubleshooting, if the travel operation is normal when executed singly.
Cause
Remedy
1
3.14 0.49 MPa
{32 5 kg/cm2}
Is output pressure of swing holding NO

brake solenoid normal?
YES
PC78MR-6
Defective swing holding brake

solenoid
Replace
Seizure of filter and check valve at

output pressure inlet port of swing
holding brake solenoid of rotary
valve
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.
Cause
and set travel lever in
neutral: 410 mA
Drive machine with engine
at full throttle: 100 mA
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
Is output pressure of TVC-EPC

solenoid normal?
Defective TVC-EPC solenoid
Replace
Omission of connection
Connect
controller
Replace
Malfunction pump merge-divider

valve
Repair or
replace
Malfunction logic valve
Repair or
replace
Large resistance to travel motor

and undercarriage
Repair or
replace
Large leakage through travel

motor or swivel joint
Repair or
replace
Repair or
replace
YES
3
NO
Is travel pressure switch

connected?
YES
4
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
5
as port pressure?
NO
YES
6
Does pump merge-divider spool
from clogging?
NO
YES
When driven on flat

concrete with engine at full
throttle, if pressure is below
11.7 MPa {120 kg/cm2}
7
NO
Is pump pressure normal during

travel?
YES
8
Above 3.14 0.49 MPa
{32 5 kg/cm2}
NO
Is PPC pressure normal? (At PPC

pressure inlet of control valve)
YES
9
NO
YES
To 12 on next page
20-840
To 10 on next page
PC78MR-6
H-26
TROUBLESHOOTING
Cause
Remedy
10
NO
Does pressure compensation


valve
Repair or
replace
Repair or
replace
YES
11
NO
Does unload valve move

smoothly?
YES
Large leakage through travel motor

or swivel joint
12
When PPC circuit check valve is NO
YES
PC78MR-6
Defective PPC valve
Repair or
replace
Replace
20-841
H-27
TROUBLESHOOTING
H-27 Machine cannot be steered sharply or steering force is insufficient

Cause
Remedy
1
Does engine speed lower
(extremely only when machine is
steered during travel)?
NO
YES
Defective pump servo
Repair or
replace
Defective travel junction variable

choke valve
Repair or
replace
Malfunction pump merge-divider

valve
Repair or
replace
Repair or
replace
Defective PPC
Repair or
replace
Repair or
replace
Repair or
replace
2
as port pressure?
NO
YES
3
Does spool of travel junction
NO
variable choke valve move smoothly
YES
4
Does pump merge-divider spool
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
Is inside PPC pressure low?
YES
7
NO
YES
8
When main relief circuit check
valve is replaced, is trouble
repaired?
YES
20-842
NO
Defective counterbalance valve of Repair or

travel motor or swivel joint
replace
Defective main relief circuit check
valve
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}
NO
Is output of 2nd travel speed

selection solenoid valve normal?
Electric trouble in defective 2nd

travel speed selection solenoid
valve, 2nd travel speed selection
switch, etc.
Repair or
replace
Malfunction caused by clogging
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
Defective travel motor or 2nd travel Repair or

speed selection solenoid valve
replace
piston
20-843
H-29
TROUBLESHOOTING
H-29 Machine does not travel

Cause
1
26.5 1.47 MPa
{270 15 kg/cm2}
Remedy
NO
Does pump pressure rise to relief

pressure?
YES
2
Is foreign matter drained from final NO
drive?
YES
Defective final drive
Repair or
replace
Defective counterbalance valve
Repair or
replace
Defective undercarriage
Repair or
replace
Defective travel motor (Motor,

parking brake system)
Repair or
replace
3
NO
Does counterbalance valve of

travel motor operate smoothly?
YES
When driven on flat
concrete with engine at full
throttle, if pressure is below
11.7 MPa {120 kg/cm2}
Above 3.14 0.49 MPa

{Above 32 5 kg/cm2}
Move lever to stroke end
YES
See
NO
Is PPC pressure normal?(At PPC

pressure inlet of control valve)
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?
Does travel spool move smoothly?
NO
YES
7
Does pressure compensation valve NO
move smoothly?

valve
YES
8
NO
Does unload valve move

smoothly?
YES
Drive machine with boom

PPC pressure
(Return piping immediately
after testing)
20-844
Repair or
replace
Defective travel motor or swivel

joint
Repair or
replace
9
When PPC hose is replaced with
boom hose on control valve side,
does PPC pressure rise?
YES
NO
Defective PPC valve
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
H-30 Overrun of travel is large

Cause
Remedy
1
Does PPC pressure lower immediately NO
after lever is returned? (At PPC pressure
inlet of control valve)
Defective PPC
Repair or
replace
Repair or
replace
Repair or
replace
Defective counterbalance valve
Repair or
replace
Defective check valve
Repair or
replace
Defective travel motor
Repair or
replace
YES
2
NO
YES
3
NO
When suction valve is replaced, is

trouble repaired?
YES
4
NO
Does travel motor counterbalance

YES
5
Does travel motor check valve move
smoothly?
YES
NO
H-31 Travel hydraulic drift is large

Cause
Remedy
Defective parking brake or parking Repair or

brake valve of travel motor
replace
20-846
PC78MR-6
H-32
TROUBLESHOOTING
H-32 Fine controllability or response is low

Cause
Remedy
1
When air is bled from PPC, is trouble NO
repaired?
YES
Air in PPC
Bleed PPC
2
Is pressure at top PP pressure pickup NO
port of control valve same as port
pressure?
YES
3
Does spool of pump merge-divider
NO
valve move smoothly and is hole free
from clogging?
YES
Malfunction of pump merge-divider Repair or

valve
replace
Defective logic valve
Repair or
replace
Repair or
replace
compensation valve
Repair or
replace
Repair or
replace
Repair or
replace
Defective PPC
Repair or
replace
4
NO
Does unload valve move smoothly

YES
5
NO
Does pressure compensation valve

move smoothly?
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
a If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
Cause
Remedy
1
NO
When work equipment is relieved,

does speed rise?
YES
Defective boom assist valve
Repair or
replace
NO
Defective motor unit, brake, or

swing machinery circle
Repair or
replace
NO
Defective swing brake release

solenoid
Replace
Malfunction of swing holding brake
Repair or
replace
Malfunction of controller
Replace
Clogging of choke
Malfunction of slow return valve
Clean
repair or
replace
Repair or
replace
Defective swing motor
Repair or
replace
Defective PPC valve
Repair or
replace
Clogging of choke
Clean
repair or
replace
2
21.08 1.47 MPa
{215 15 kg/cm2}
NO
Is swing relief pressure normal?
YES
3
NO
Does pressure rise to near relief

pressure during stable swing?
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}
Is PPC pressure at PPC control valve NO

normal?
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
Defective safety valve
Adjust or
replace
Defective check valve or suction

valve
Repair or
replace
Malfunction of reverse prevention

valve
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
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
Defective LS select valve
Replace

valve
Replace
2
move smoothly and is hole free from
clogging?
NO
YES
3
21.08 1.47 MPa
{215 15 kg/cm2}
NO
YES
4
kg/cm2}
3.14 0.49 MPa {32 5

Is swing holding brake relief pressure NO

normal? (At motor inlet)
YES
Malfunction of swing holding brake

solenoid valve
Malfunction of motor unit, brake, or
swing machinery
5
NO
Is swing motor turning? (Judge by

sound)
YES
Damage of motor shaft or swing

machinery
Repair or
replace
Defective safety valve
Repair or
replace

valve
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
YES
20-850
NO
PC78MR-6
H-34
TROUBLESHOOTING
b) Swing speed or power is low in either direction

Cause
Remedy
1
26.5 1.47 MPa
{270 15 kg/cm2}
NO
YES
2
3.14 0.49 MPa
{32 5 kg/cm2}
Note that swing timer is set to
5 seconds
Are swing brake release pressures on NO

both sides normal? (At solenoid
outlet)
YES
Defective swing motor or swing

machinery circle
Replace
Repair or
replace
Disconnection of wiring harness
Repair or
replace
Repair or
replace

valve
Repair or
replace
3
Since motor may be broken,
operate in fine control mode
When lever is moved to right and left, NO

does work equipment move for 5
seconds?
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
H-35 Swing acceleration is low

a) Swing acceleration is low in both directions
Cause
Remedy
1
When swing motor safety valve is
YES
NO
Execute diagnosis in H-33, H-40
Defective swing motor safety valve Replace
b) Swing acceleration is low in either direction

Cause
Remedy
Execute diagnosis in H-33, H-40
20-852
PC78MR-6
H-36
TROUBLESHOOTING
H-36 Overrun of swing is large

a) Overrun of swing is large in both directions
Cause
Remedy
1
21.08 1.47 MPa
{215 15 kg/cm2}
NO
YES

Repair or
replace
Go to b)
b) Overrun of swing is large in either direction

Cause
Remedy
1
NO
Does control valve spool move

smoothly?
Malfunction of control valve spool
Repair or
replace
Defective swing motor suction

valve
Repair or
replace
Defective reverse prevention valve
Repair or
replace
Defective swing motor check valve
Repair or
replace
Defective PPC valve
Repair or
replace
YES
2
NO
When swing motor suction valve is

YES
3
NO

YES
4
NO
When swing motor check valve is

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
Clogging of swing PPC slow-return Repair or

valve, swing PPC line choke, or
replace
swing PPC circuit choke
20-853
H-37, H-38
TROUBLESHOOTING
H-37 Large shock is made when machine stops swinging

Cause
Remedy
1
NO
Does control valve spool move

smoothly?
Repair or
replace
Go to H-36
Replace
Defective swing motor safety valve
Repair or
replace
YES
2
NO
When swing motor safety valve is

YES
H-38 Large abnormal sound is made when machine stops swinging

Cause
Remedy
1
NO
When safety valve is replaced, is

trouble repaired?
YES
2
NO
When suction valve is replaced, is

trouble repaired?
YES
Defective swing motor suction

valve
Repair or
replace
Defective reverse prevention valve
Repair or
replace
Defective swing motor, swing

machinery, or swing circle
Repair or
replace
Defective swing machinery
Repair or
replace
3
NO

YES
4
Is foreign matter drained from final
drive?
YES
20-854
NO
PC78MR-6
H-39
TROUBLESHOOTING
H-39 Swing hydraulic drift is large

a Check that the emergency swing brake release switch is turned OFF.
Cause
Remedy
1
When connector of swing pressure
switch is disconnected, is trouble
repaired?
NO
YES
Defective swing pressure switch
Replace
Defective controller or wiring
Replace
Defective swing motor brake
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
H-40 Fine controllability or response of swing is low

Cause
Remedy
1
repaired?
YES
Air in PPC
Bleed Air
2
pressure?
YES
3
NO
from clogging?
YES

valve
replace
Repair or
replace
Repair or
replace
compensation valve
Repair or
replace
Repair or
replace
Repair or
replace
Defective PPC valve
Repair or
replace
4
NO

YES
5
clogging?
NO
YES
6
NO
YES
7
trouble repaired?
YES
20-856
NO
PC78MR-6
H-41
TROUBLESHOOTING
H-41 Blade speed or power is low (Work equipment, travel, and swing
a If there is any other trouble in the work equipment, travel system, or swing system, see H-1.
Cause
Remedy
1
kg/cm2}
3.14 0.49 MPa {32 5

NO
Is blade PPC pressure normal?
Defective PPC valve
Repair or
replace
Go to diagnosis 5
Malfunction of check valve in spool

or clogging of hole of spool
Repair or
replace
Flattened or deformed hose
Replace
Execute diagnosis in H-43

(Hydraulic drift of blade is large)
Leakage in control valve (Leakage

from line between swing valve and
blade valve)
Repair or
replace
YES
2
21.08 1.47 MPa
{215 15 kg/cm2}
NO
Is blade LOWER relief pressure

normal?
YES
3
NO
Does pump pressure reach relief

pressure during operation?
YES
4
NO
Is hose between control valve and

cylinder flattened or deformed?
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}
3.14 0.49 MPa {32 5

NO
Is blade PPC pressure normal?
Defective PPC valve
Repair or
replace

equipment
Repair or
replace
Repair or
replace
Replace
YES
2
21.08 1.47 MPa
{215 15 kg/cm2}
NO
Is blade LOWER relief pressure

normal?
YES
3
NO
Is cylinder or work equipment

deformed?
YES
4
NO
Is hose flattened or deformed?
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
b) Blade does not lower

Cause
Remedy
1
NO
Is blade held in air?
YES
2
NO
Is blade PPC normal?
Defective blade PPC valve
Repair or
replace

equipment
Repair or
replace
Repair or
replace
Replace
Execute diagnosis in H-41

(Hydraulic drift of blade is large)
Repair or
replace
YES
3
NO
Is cylinder or work equipment

deformed?
YES
4
NO
Is hose flattened or deformed?
YES
5
Is it impossible to raise machine by
bracing blade on ground?
YES
PC78MR-6
20-859
H-43
TROUBLESHOOTING
H-43 Hydraulic drift of blade is large

Cause
Remedy
1
NO
Is leakage from cylinder normal?
Repair or
replace
Large leakage through swivel

joint
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
Defective centralized safety valve Replace
4
NO

plug, is trouble repaired?
YES
Low oil-tightness of spool
Repair or
replace
Defective suction safety valve
Repair or
replace
Low oil-tightness of spool
Repair or
replace
Defective blade safety valve
Replace
5
If hydraulic drift is large when
machine body is raised with blade
When blade safety valve is replaced,

is trouble repaired?
YES
20-860
NO
PC78MR-6
H-44
TROUBLESHOOTING
H-44 Fine controllability or response of blade is low

Cause
Remedy
1
repaired?
YES
Air in PPC
Bleed Air
2
pressure?
YES
3
NO
from clogging?
YES

valve
replace
Repair or
replace
Repair or
replace
compensation valve
Repair or
replace
Repair or
replace
Repair or
replace
Defective PPC
Repair or
replace
4
NO

YES
5
clogging?
NO
YES
6
NO
YES
7
trouble repaired?
YES
PC78MR-6
NO
20-861
TROUBLESHOOTING FOR MACHINE

MONITOR SYSTEM
(M MODE)
Action taken by controller when trouble occurs and problems on machine ............................................... 20-902
Electric circuit diagram of M mode system ................................................................................................ 20-904
M- 1 [E101] (Error history data are abnormal) is displayed ..................................................................... 20-906
M- 2 [E108] (Engine coolant temperature is 105 C) is displayed ........................................................... 20-907
M- 3 [E112] (Wiper forward output is shorted) is displayed ..................................................................... 20-907
M- 4 [E113] (Wiper reverse output is shorted) is displayed ..................................................................... 20-907
M- 5 [E114] (Contact with washer output of 24 V) is displayed ............................................................... 20-907
M- 6 [E115] (Wiper does not start wiping in 10 seconds) is displayed ..................................................... 20-907
M- 7 [E116] (Wiper is not retracted in 10 seconds) is displayed .............................................................. 20-907
M- 8 Monitor panel segments do not light up at all for 3 seconds after starting switch is turned ON ...... 20-908
a) Monitor panel segments do not light up at all .............................................................................. 20-908
b) Some monitor panel segments do not light up ............................................................................ 20-908
M- 9 When starting switch is set to ON position, all monitor panel segments light up but do not go off ..... 20-910
M-10 While preheating is not executed, "Preheater monitor" lights up ................................................... 20-910
M-11 When starting switch is set to ON position and engine is started, basic check items flash ............. 20-911
a) Alternator system ........................................................................................................................ 20-911
b) Engine oil system ........................................................................................................................ 20-912
M-12 When starting switch is set to ON position (but engine is stopped), caution items and
emergency stop items (excluding battery and engine oil) flash ....................................................... 20-913
a) Alternator system ........................................................................................................................ 20-913
b) Engine oil pressure sensor system ............................................................................................. 20-914
M-13 When starting switch is set to ON position and engine is started, caution items and
emergency stop items flash (When there is not abnormality in inspection items and
engine before troubleshooting, however) ........................................................................................ 20-915
a) "Engine oil" flashes ..................................................................................................................... 20-915
b) "Charge level" flashes ................................................................................................................. 20-915
c) "Coolant temperature" flashes ..................................................................................................... 20-916
d) "Fuel level" flashes ...................................................................................................................... 20-917
M-14 When starting switch is set to ON position (but engine is stopped), buzzer does not sound
for 1 second
While caution item is flashing, buzzer does not sound .................................................................... 20-918
M-15 Monitor plane lamp for nighttime is not turned on (LC display is normal) ....................................... 20-919
M-16 Coolant temperature gauge does not rise ....................................................................................... 20-920
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to 1st line during operation) ..... 20-920
M-18 Fuel level gauge always displays full .............................................................................................. 20-921
M-19 Fuel level gauge is not displayed .................................................................................................... 20-921
M-20 While engine is running, service meter does not advance .............................................................. 20-922
M-21 Trouble in fuel level sensor .............................................................................................................. 20-923
M-22 Trouble in coolant temperature sensor ............................................................................................ 20-924
M-23 Wiper does not operate or operates while wiper switch is turned off .............................................. 20-925
a) Wiper does not operate ............................................................................................................... 20-925
b) Wiper operates while wiper switch is turned off .......................................................................... 20-925
M-24 Washer motor does not operate or operates while washer switch is turned off .............................. 20-928
a) Washer motor does not operate .................................................................................................. 20-928
b) Washer operates while wiper switch is turned off ....................................................................... 20-928
removed and the connector is returned, if the service code "E" is not displayed, the condition has returned to
normal.
a If the starting switch was turned off after the trouble occurred, turn the starting switch ON and check that the
service code displays "E" at the head. (If "E" is not displayed, the condition has returned to normal.)
a Before carrying out the troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
PC78MR-6
20-901
ACTION TAKEN BY CONTROLLER WHEN TROUBLE

OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING

Service
Code
Troubled System
E101
Error history data are abnormal
1.
2.
3.
4.
E108
Engine coolant temperature

is 105 C
1. Coolant temperature sensed by coolant temperature sensor is above 105 C
Short circuit in forward system of wiper motor drive
1. Short circuit or short circuit with chassis ground in

wiring between
wiring between monitor panel P01 (Female) (9)
wiper motor W04 (Female) (3)
3. Defective monitor panel
Short circuit in reverse system of wiper motor drive

wiper motor
wiring between monitor panel P01 (Female) (10)
wiper motor W04 (Female) (1)
Short circuit in windshield

washer drive system
1. Short circuit in washer motor

2. Short circuit with power source in wiring harness
between monitor panel P01(Female) (3) M31
(Female) (1)
Wiper does not start wiping in

10 seconds
1. Defective wiper motor

2. Disconnection, defective contact, short circuit, or
short circuit with chassis ground in wiring harness
between monitor panel P01 (Female) (5) W04
(6)
between monitor panel P01 (Female) (12)
W04(4)
Wiper is not retracted in 10

seconds
1. Defective wiper motor

(6)
(4)
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
ACTION TAKEN BY CONTROLLER WHEN TROUBLE

OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Normal Condition (Voltage, Current, Resistance)
Resistance between M18 (Male) (1) (2):

Min. 3.70 kz
(With engine started)
Problem That Appears on

Machine When There is
Abnormality
1. Service code cannot be

cleared
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.
Voltage between W04 (3) (5): Max. 3 V
a Repeated at regular intervals.
Action Taken By Controller

When Abnormality is
Detected
20 30 V
Stops outputting to wiper

motor
Wiper stops
Same as [E112]
Same as [E112]
Voltage between W04 (1) (5): Max. 3 V
a Repeated at regular intervals.
20 30 V
Voltage between P01 (3) chassis ground

1. Stops outputting to
When washer switch is turned OFF: 20 30 V
washer motor
When washer switch is turned ON: Max. 1 V
1. Stops outputting to washer

motor
Timing chart of setting wiper switch to ON and

INT is conformed to Tables 1 and 2 in M-23
Same as [E112]
Same as [E112]
Timing chart of setting wiper switch to ON and

INT is conformed to Tables 1 and 2 in M-23
Same as [E112]
Same as [E112]
PC78MR-6
20-903
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM

(1/2)
20-904
PC78MR-6
TROUBLESHOOTING
(2/2)
PC78MR-6
20-905
M-1
TROUBLESHOOTING
M-1 [E101] (Error history data are abnormal) is displayed

a If connector P01, connector K1, fuse 18, connector M6, connector M2, connector M27, battery relay terminal B, or battery terminal in the monitor panel power supply system is disconnected or connected for troubleshooting, this error is displayed. This phenomenon does not indicate an actual error, however. (When the
monitor panel power circuit is broken by turning off the starting switch.)
a If the service code is displayed again after the resetting operation, check by the following procedure.
Cause
After resetting operation,
operate machine normally
and observe its condition for
a while. (See Note 1.)
Remedy
1
NO
After "resetting operation", is

service code displayed again?
Normal
Disconnection, defective contact,

or short circuit with chassis
ground in wiring harness
between battery battery relay B
M27 (1), (2) P01 (Female) (8)
Repair or
replace
Replace
YES
2
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
M-2, M-3, M-4, M-5, M-6, M-7
TROUBLESHOOTING
M-2 [E108] (Engine coolant temperature is 105 C) is displayed

Cause
Remedy
1
NO
Does coolant temperature gauge of monitor

indicate red range and is caution lamp flashing?
YES
See M-13, c)
Trouble in engine unit

(See Note 1)
Replace
2
Is "E" attached to head of service code?
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.
M-3 [E112] (Wiper forward output is shorted) is displayed

a See M-23.
M-4 [E113] (Wiper reverse output is shorted) is displayed

a See M-23.
M-5 [E114] (Contact with washer output of 24 V) is displayed

a See M-24.
M-6 [E115] (Wiper does not start wiping in 10 seconds) is displayed

a See M-23.
M-7 [E116] (Wiper is not retracted in 10 seconds) is displayed

a See M-23.
PC78MR-6
20-907
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
20 30 V
Is voltage between P01 (8) and

(6), (7) normal?
NO
YES
2
20 30 V
NO
Is voltage between P01 (1), (2)

and (6), (7) normal?
YES
3
Max. 1 z
Disconnect P01.
Is resistance between P01

(female) (6), (7) and chassis
ground normal?
NO
YES
Disconnection or defective contact

in wiring harness between P01
(female) (6), (7) chassis ground
Repair or replace
Replace

in wiring harness between fuse 13
P01 (female) (1), (2)
Repair or replace

in wiring harness between fuse box
battery relay terminal M
Repair or replace

in wiring harness between fuse 18
P01 (female) (8)
Repair or replace

in wiring harness between fuse box
battery relay terminal B
Repair or replace
4
20 30 V
Is voltage between fuse 13 and

NO
YES
5
20 30 V
Is voltage between fuse 18 and

YES
NO
b) Some monitor panel segments do not light up

Cause
20-908
Remedy
Replace
PC78MR-6
TROUBLESHOOTING
M-8
M-8 a) Electrical circuit diagram of each system
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
M-10 While preheating is not executed, "Preheater monitor" lights up

Cause
Remedy
1
Disconnect terminal R1
Max. 1 V
NO
Is voltage between starting switch R1

Defective starting
switch
Replace
Short circuit with power

source in wiring
harness between
starting switch R1
P02 (Female) (18)
Repair or replace
Defective monitor
panel
Replace
YES
2
Max. 1 V
Is voltage between P02 (18) chassis

ground normal?
YES
NO
20-910
PC78MR-6
M-11
TROUBLESHOOTING
M-11 When starting switch is set to ON position and engine is started,

basic check items flash
a Inspect both alternator system and engine hydraulic system.
a) Alternator system
a Check monitoring code "43". If it is 100 or larger while the engine speed is above the medium level, the
monitor panel is defective.
Cause
Remedy
1
Run engine above medium
speed level
20 30 V
Is voltage between alternator

terminal R chassis ground
normal?
NO
Replace
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
b) Engine oil system

a Carry out the following troubleshooting when the engine oil pressure is normal.
a Check bit (3) of monitoring code "46". If it is lighting up, the monitor panel is defective.
Cause
Remedy
1
Run engine at low speed
When engine speed is low, if oil

pressure sensor terminal T6 is
disconnected, does error disappear?
NO
Defective oil pressure sensor

(Low pressure)
Replace
2
Disconnect sensor wiring
harness and P02
Is there continuity between P02 (7)

YES
NO

Repair or
(Female) (7) sensor terminal T6 replace
Replace
M-11 b) Electrical circuit diagram of each system
20-912
PC78MR-6
M-12
TROUBLESHOOTING
M-12 When starting switch is set to ON position (but engine is stopped),

caution items and emergency stop items (excluding battery and
engine oil) flash
a Inspect both alternator system and engine hydraulic system.
a) Alternator system
a Check monitoring code "43". If it is 100 or larger while the engine speed is above the medium level, the
monitor panel is defective.
Cause
Remedy
1
Disconnect terminal R
Max. 1 V
NO
Is voltage between alternator terminal

R chassis ground normal?
Replace
Short circuit with power source in

wiring harness between P02
(Female) (11) alternator
terminal R
Repair or
replace
Replace
YES
2
Disconnect P02
Max. 1 V
Is voltage between P02 (Female) (11)

YES
NO
PC78MR-6
20-913
M-12
TROUBLESHOOTING
b) Engine oil pressure sensor system

a Carry out the following troubleshooting when the engine oil pressure is normal.
a Check bit (3) of monitoring code "46". If it is lighting up, the monitor panel is defective.
Cause
Remedy
1
Disconnect sensor
terminal T6
NO
Is there continuity between sensor

terminal T6 chassis ground?
Defective oil pressure sensor
Replace
between P02 (Female) (7)
sensor terminal T6
Repair or
replace
Replace
YES
2
Disconnect P02 sensor
terminal T6
Is there continuity between P02

(Female) (11) sensor terminal T6?
NO
YES
M-12 b) Electrical circuit diagram of each system
20-914
PC78MR-6
M-13
TROUBLESHOOTING
M-13 When starting switch is set to ON position and engine is started,

caution items and emergency stop items flash (When there is not
abnormality in inspection items and engine before troubleshooting,
however)
a) "Engine oil" flashes
a Before carrying out the troubleshooting, check that the engine oil pressure is normal.
Cause
See M-11-b)
Remedy
b) "Charge level" flashes

Cause
See M-11-a)
PC78MR-6
Remedy
20-915
M-13
TROUBLESHOOTING
c) "Coolant temperature" flashes

a Before carrying out the troubleshooting, check that the coolant temperature is normal.
Cause
Remedy
1
Start engine
Set engine speed to
medium or higher
NO
Is coolant temperature gauge in red

range?
Replace
Defective coolant temperature

sensor system
(See M-22)

(Female) (1) M18 (Female) (1)
Repair or
replace

in wiring harness between M18
Repair or
replace
YES
2
Start engine
NO
When M18 is disconnected, does gauge

indicate only level 1 (Lowest line)?
YES
3
Disconnect P02 and M18
Max. 1 z
Is resistance between P02 (Female) (1)

M18 (Female) (1) normal?
YES
NO
M-13 c) Electrical circuit diagram of each system
20-916
PC78MR-6
M-13
TROUBLESHOOTING
d) "Fuel level" flashes

a Before carrying out the troubleshooting, check that there is fuel in the fuel tank.
Cause
Remedy
1
Start engine
NO
Is fuel level gauge in red range?
Replace
Defective fuel level sensor

system (See M-21)
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.)
When M9 (Female) (1) is

connected to chassis ground, do
gauge segments light up to level 9
(Right end)?
NO
YES
3
Connect M9 (Female) (1) to
chassis ground
Max. 0.3 V

YES
NO
M-13 d) Electrical circuit diagram of each system
PC78MR-6
20-917
M-14
TROUBLESHOOTING
M-14 When starting switch is set to ON position (but engine is stopped),

buzzer does not sound for 1 second
While caution item is flashing, buzzer does not sound
a Even if the charge level and fuel level among the caution items become abnormal, the buzzer does not
sound.
a The busdzzer is controlled by the monitor panel and turned on when it is required to sound or when the voltage at P01 (11) is 20 30 V.
Cause
Disconnect K53
When buzzer cancel switch
is ON: Max. 1 z
When buzzer cancel switch
is OFF: Min. 1 Mz
Remedy
1
Is resistance between K53 (Female) (1)
(2) normal?
NO
Defective buzzer cancel

switch
Replace
YES
2
Disconnect K53
20 30 V
Is voltage between P02 (16) chassis

ground normal?
YES
NO
Repair or
replace
harness between P02
(Female) (16) K53 (Male) (2)
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
Set monitoring code to "45"
NO
Is bit (4) of monitoring code "45"

turned off?
YES
Replace
Disconnection, defective contact

(Female) (19) K52 (Male) (1)
Repair or
replace
Replace
2
Turn light switch ON
20 30 V

NO
YES
PC78MR-6
20-919
M-16, M-17
TROUBLESHOOTING
M-16 Coolant temperature gauge does not rise

a When the engine coolant temperature does not rise actually, inspect the engine system.
Cause
Remedy
1
Disconnect M18
When short connector is connected to

M18 (Female), does gauge rise 1 level
by 1 and go off at last?
NO
YES

sensor system
(See M-22)
between P02 (Female) (1)
M18 (Female) (1)
Repair or
replace
chassis ground
Repair or
replace
Replace
2
NO

(Female) (1) M18 (Female) (1)?
YES
3
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
NO
When M18 is disconnected, is gauge

displayed?
YES

sensor system
(See M-22)
Replace

Repair or
replace
2
Disconnect P02 and
M18
Is there continuity between P02 (Female)

(1) chassis ground?
YES
NO
M-16, M-17 Electrical circuit diagram of each system
20-920
PC78MR-6
M-18, M-19
TROUBLESHOOTING
M-18 Fuel level gauge always displays full

a Before carrying out the troubleshooting, see if the fuel tank is actually full.
Cause
Wait for 2 minutes. (Since
fuel level fluctuates, its
display is delayed.)
Remedy
1
NO
When M9 is disconnected, does gauge

rise 1 level by 1 and go off at last?
YES
Defective fuel level sensor

system (See M-21)
Replace

Repair or
replace
2
NO

(Female) (2) chassis ground?
YES
M-19 Fuel level gauge is not displayed

a Before carrying out the troubleshooting, check that there is fuel in the fuel tank.
Cause
Remedy
1
Disconnect M9
NO
When M9 (Female) (1) is connected to

chassis ground, does gauge display?
YES
Defective fuel level sensor (See

M-21)
chassis ground
Repair or
replace
Replace
2
Disconnect M9
Is there continuity between M9 (Female)

(2) chassis ground?
NO
YES
M-18, M-19 Electrical circuit diagram of each system
PC78MR-6
20-921
M-20
TROUBLESHOOTING
M-20 While engine is running, service meter does not advance

Cause
Remedy
1
Start engine
Set engine speed to
medium or higher
Does charge level caution lamp flash?
YES
20-922
NO
Replace
See M-13 c)
PC78MR-6
M-21
TROUBLESHOOTING
M-21 Trouble in fuel level sensor

a When carrying out the following troubleshooting, remove the fuel level sensor.
Cause
Remedy
1
When float is moved up and down, does
resistance between connector (1)
flange change as shown in Table 1?
NO
YES
2
NO
Does arm move smoothly?
Defective sensor
(See Note 2)
Replace
Bad contact of connector
Clean or replace
connector
Interference of sensor in tank
Replace (See
Note 2)
Defective sensor
Replace
Breakage of wiring harness

(See Note 3)
(Defective clamp)
(Application of external force)
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
M-22 Trouble in coolant temperature sensor

Cause
Remedy
1
NO
Is resistance between temperature sensor

connector (Male) (1) (2) normal?
YES
Bad contact of connector

(See Note 1)
Clean connector
or replace sensor
Defective sensor
Replace
Breakage of wiring harness

(See Note 2)
(Defective clamp)
(Application of external force)
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
Approx. 3.5 4.0 kz
Note 1. If this error is displayed repeatedly, the connector (Female) on the machine side may be defective.
Accordingly, inspect the connector and wiring harness on the machine side.
Note 2. Check the installation position of the connector for vibration. If it vibrates remarkably, take proper 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 If service code "E112", "E113", "E115", or "E116" is displayed, carry out the following troubleshooting.
Cause
Remedy
1
Close front window
NO
Does bit (3) of monitoring code "49"

light up?
YES
Set wiper switch to "ON" or
"INT" position
2
When wiper switch is set to "ON" or
"INT" position, do bits (4), (5) of
monitoring code "49" go off?
NO
Replace
Defective wiper motor
Replace
Disconnection, defective contact, short circuit, or short circuit

with chassis ground in wiring
having improper resistance
Repair or
replace
Replace
Defective rear limit switch or

opening of front window
Inspection or
replace
having improper resistance
Repair or
replace
Replace
YES
3
NO
Is voltage between pins of W04 as

shown in Table 1?
YES
4
Disconnect P02 and W04
Is voltage between pins of P01

(Female) W04 (Male) as shown in
Table 2?
NO
YES
Max. 1 z
Disconnect terminals (1), (2)
of W03.
5
Is resistance between rear limit
switch terminals W03 (1) (2)
normal?
NO
YES
6
Max. 1 z
Disconnect terminals (1), (2)
of P02 and W03
Is resistance between rear limit

switch terminal W03 (1) P02
(Female) (15), between W03 (2)
NO
YES
b) Wiper operates while wiper switch is turned off

Cause
Remedy
1
Close front window
NO
Does bit (3) of monitoring code

"49" light up?
Replace
Replace
Short circuit with power source in wiring

harness between P01 (Female) (9)
W04 (Female) (3) or between P01
(Female) (10) W04 (Female) (1)
Repair or
replace
YES
2
When wiper switch is set to "ON"

or "INT" position, do bits (4), (5) of
monitoring code "49" go off?
YES
PC78MR-6
NO
20-925
M-23
TROUBLESHOOTING
Table 1
Timing chart of ON-OFF operation of wiper
Symbol
Set Time
Stop time up to next operation
Item
Tia
0.13 sec
Safety circuit during operation of

wiper
[Safety function (1)]
Tsa
10 sec
Stop time up to retraction of

wiper blade
Tip
1.5 sec
Safety circuit during retraction of

wiper
Tsp
10 sec
Item
Symbol
Set Time
Stop time up to next operation
Tia
4 sec
Safety circuit during operation of

wiper
Tsa
10 sec
Stop time up to retraction of

wiper blade
Tip
1.5 sec
Safety circuit during retraction of

wiper
Tsp
10 sec
Table 2
Diagnosis 4
Resistance
Between P01 (Female) (10) W04 (Female) (1)

Max. 1 z
Between P01 (Female) (6), (7) W04 (Female) (5)

Between W04 (Female) (1), (3), (4), (5), (6) GND
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)-1 When [E114] is displayed
Cause
Remedy
1
Max. 1 V

M31 (Female) (1) chassis ground
normal?
NO
Short circuit with power source in

wiring harness between P01
Repair or
replace
Replace
YES
a)-2 When [E114] is not displayed

Cause
1
20 30 V
Disconnect M31
Is voltage between fuse 4 M31

normal?
NO
Remedy
fuse 4 M31 (Female) (2)
Repair or
replace
between P01 (Female) (3) M31
(Female) (1)
Repair or
replace
Defective washer motor
Replace
Replace
YES
2
Max. 1 z
NO
Is resistance between P01 (Female)

(3) M31 (Female) (1) normal?
YES
3
Max. 1 V
Turn washer switch ON

NO
YES
b) Washer operates while wiper switch is turned off

Cause
Remedy
1
Min. 1 Mz

NO

Repair or
replace
Replace
YES
20-928
PC78MR-6
TROUBLESHOOTING
M-24
PC78MR-6
20-929
30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL ...................30- 2
PRECAUTIONS WHEN CARRYING
OUT OPERATION........................................30- 3
SPECIAL TOOL LIST...................................30- 7
COUNTERWEIGHT
Removal and Installation ..........................30-13
INJECTION PUMP
Removal....................................................30-14
Installation.................................................30-15
CYLINDER HEAD
Removal....................................................30-16
Installation.................................................30-19
MAIN PUMP
Removal....................................................30-20
Installation.................................................30-21
CONTROL PUMP
ENGINE AND MAIN PUMP
Removal....................................................30-22
Installation.................................................30-24
HYDRAULIC OIL COOLER
RADIATOR
Removal....................................................30-25
Installation.................................................30-26
SWING MOTOR AND SWING MACHINERY
SWING MACHINERY
Disassembly .............................................30-28
Assembly ..................................................30-30
SWING MOTOR
CENTER SWIVEL JOINT
Removal....................................................30-34
Installation.................................................30-35
Disassembly and Assembly......................30-36
CONTROL VALVE
Assembly ..................................................30-38
WORK EQUIPMENT PPC VALVE
Assembly ..................................................30-39
TRAVEL PPC VALVE
Assembly ..................................................30-40
HYDRAULIC TANK
PC78MR-6
FUEL TANK
Removal ................................................... 30-43
Installation ................................................ 30-44
CONTROLLER
Removal and Installation.......................... 30-44
MONITOR PANEL
AIR CONDITIONER UNIT
Removal ................................................... 30-45
Installation ................................................ 30-46
OPERATORS CAB
FLOOR FRAME
Removal ................................................... 30-48
Installation ................................................ 30-49
REVOLVING FRAME
SWING CIRCLE
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
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
METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked [*1], and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
(Example)
REMOVAL OF O O O ASSEMBLY ....................................... Title of operation
k ........................................................................................ Precautions related to safety when carrying

out the operation
1. XXXX (1)......................................................................... Step in operation
a .................................................................................... Technique or important point to remember
when removing XXXX (1).
2. EEE (2): ..................................................................... [*1] Indicates that a technique is listed for
use during installation
3. T T T T assembly (3)
6 ............................................................................. See Lubricant and Coolant Table
INSTALLATION OF O O O ASSEMBLY ............................... Title of operation

Carry out installation in the reverse
order of removal
[*1] ............................................................................. Technique used during installation
a ................................................................................ Technique or important point to remember
when installing E E E (2).
Adding water, oil......................................................... Step in operation
a ................................................................................ Point to remember when adding water or oil
5 ............................................................................ Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOL LIST given in this manual.
30-2
PC78MR-6
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.

After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installed position, or make match marks in the necessary places
before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, disconnect connectors by grasping the connector, not the wire.
Tag wires and hoses to show their installed position to prevent any mistake when reinstalling.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal.
a Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
Plug (nut end)
Nut (elbow end)
02
07376-70210
02789-00210
03
07376-70315
02789-00315
04
07376-70422
02789-00422
05
07376-70522
02789-00522
06
07376-70628
02789-00628
2) Hoses and tubes using sleeve nuts

Nominal
number
Plug (nut end)
Sleeve nut (elbow end)

Use the two items below as a set
02
07376-50210
07221-20210 (Nut), 07222-00210 (Plug)
03
07376-50315
07221-20315 (Nut), 07222-00312 (Plug)
04
07376-50422
07221-20422 (Nut), 07222-00414 (Plug)
05
07376-50522
07221-20522 (Nut), 07222-00515 (Plug)
06
07376-50628
07221-20628 (Nut), 07222-00616 (Plug)
10
07376-51034
07221-21034 (Nut), 07222-01018 (Plug)
12
07376-51234
07221-21234 (Nut), 07222-01219 (Plug)
3) Split flange type hoses and tubes

Nominal
number
Flange (hose end)
Sleeve head (tube end)
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.
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the coolant water level again.
If the hydraulic equipment has been removed and installed again, add hydraulic oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for
repair, always bleed the air from the system after reassembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
4. Other precautions
To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or
when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are
clean.
To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points
when disassembling or assembling.
Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to
be disassembled.
Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits
of parts that have failed.
When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment
completely.
Do not use the seal tape for the thread of the plug mounts or connectors.
If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment
and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits.
When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping,
always bleed the air before starting the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.
PC78MR-6
30-5
a After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5
times without going to the end of this strike. (Stop approx. 100 mm before the end of the stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the
engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more air
comes out from the plugs.
4. After completing bleeding the air, tighten the plugs
3 Plug: 11.3 1.5 Nm {1.15 0.15 kgm}
a If the engine is run at high speed from the start, or the cylinders are operated to the end of their
stroke, the air inside the cylinder will cause damage to the piston packing.
a After repair or long storage, follow the same procedure.
30-6
PC78MR-6
SPECIAL TOOL LIST
SPECIAL TOOL LIST
Burring of engine
(For Model 102 engine)
Removal, installation of fuel

injection pump assembly
Removal of drive gear

Removal, installation of noz- A

zle holder assembly
Removal, installation of cylinder head assembly
Engine and main pump
assembly
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
Push tool kit
790-101-5281
Plate
790-101-5221
Grip
01010-51225
Bolt
790-101-5201
Push tool kit
790-101-5331
Plate
Part No.
Part Name
795-799-1130
Gear
795-799-1390
or
795-799-1210
Remover
795-799-1170
Puller
Stopping of hydraulic oil

N
Q Removal, installation of spacer

Removal of bearing outer race
Installation of oil seal
1
1
Press fitting of sub bearing outer

race
4
790-101-5221 Grip
01010-51225
Bolt
790-101-5401
Push tool kit
790-101-5431
Plate
790-101-5421
Grip
01010-51240
Bolt
796-765-1110
Push tool
fitting of main bearing

Q Press
inner race
792T-413-1120
Push tool
fitting of sub bearing inner

Q Press
race
796-730-2300
Wrench assembly
795-630-1803
Torque wrench
790-201-2770
Spacer
1
Press fitting of main bearing
outer race
PC78MR-6
Nature of work, remarks
Pulling out of nozzle holder

Tightening of cylinder head bolt
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).
Measurement of running torque

of shaft
Installation of dust seal
30-7
Push tool kit
790-101-5141
Plate
790-101-5021
Grip
01010-50816
Bolt
796-230-1110
Installer
790-101-5001
Push tool kit
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
Push puller kit
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
carrier roller assembly
recoil spring assembly
Expansion, installation of
track shoe assembly
Press fitting of input shaft oil

seal of main pump
Installation of floating seal
Press fitting of bushing
790-105-1100
center swivel joint assembly
Press fitting of bushing
track roller assembly
Sketch
790-101-5001
30-8
Part Name
idler assembly
hydraulic cylinder assembly
Part No.
Qty
Symbol
New/
Remodel
Component
SPECIAL TOOL LIST
Necessity
Q Press fitting of cap
Compression of spring
Pulling out and press fitting of

master pin
Press fitting of oil seal
790-502-1003
Cylinder repair stand
790-101-1102
Pump
Installation of floating seal
Separation of rotor and shaft
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
Socket (Width across t

flats: 80mm)
flats: 70mm)
flats: 60mm)
Boom and blade
Arm and boom

swing
Bucket
Expansion of piston ring
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
Push tool kit
790-101-5021
Grip
01010-50816
Bolt
790-201-1811
Push tool
790-201-1702
Push tool kit
790-101-5021
Grip
01010-50816
Bolt
790-201-1791
Push tool
790-201-1702
Push tool kit
790-101-5021
Grip
01010-50816
Bolt
790-201-1771
Push tool
790-201-1500
Push tool kit
790-201-1620
Plate
790-101-5021
Grip
01010-50816
Bolt
790-201-1500
Push tool kit
790-201-1610
Plate
PC78MR-6
Removal,
installation of
piston nylon
nut
Boom
Arm and boom

swing
Installation of
piston ring
Bucket
Blade
Boom and blade
Sketch
Qty
Symbol
New/
Remodel
Component
SPECIAL TOOL LIST
Necessity
Arm and boom

swing
Press fitting of
cylinder head
bushing
Bucket
Boom and blade
1
1
Press fitting of
cylinder head
dust seal
Arm and boom
swing
30-9
30-10
Grip
01010-50816
Bolt
790-201-1500
Push tool kit
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
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
790-101-1102
Pump
799-703-1200
Service tool kit
799-733-1120
Vacuum pump
(220V)
Vacuum pump
(240V)
799-703-1400
Gas leak tester
Removal of arm cylinder

assembly
Collection and reproduction

of new Freon gas
799-703-1110
X
Sketch
Part Name
790-101-5021
Removal of work equipment and boom assembly
Removal of boom swing

beacket
Part No.
Qty
Symbol
New/
Remodel
Component
SPECIAL TOOL LIST
Necessity
Arm and boom

swing
Press fitting of
cylinder head
dust seal
Bucket
Pulling out of boom foot pin
Pulling out of boom swing

bracket pin
Pulling out of arm cylinder trunnion pin
Collection and supply of air conditioner gas
PC78MR-6
SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special

tools manufactured according to these drawings.
F-1 Push tool
F-6 Push tool
PC78MR-6
30-11
SPECIAL TOOL LIST
F-7 Push tool
L-5 Push tool
30-12
PC78MR-6
COUNTERWEIGHT
COUNTERWEIGHT ASSEMBLY
8. Remove fuel filler mounting cover (9) of the fuel

tank.
REMOVAL
9. Remove clamp (11) and float gauge hose (10).

Loosen the clamp of the hose connected to the
fuel filler tube on the back side of the fuel filler
mounting cover, then remove the tube and cover
together.
a When removing the float gauge hose, check
that the fuel level is below the connecting
position of the hose.
a Stop the machine on a level place and set the

upper structure in parallel with the track, then
swing to the right about 20 degrees (since the
mounting bolts are above the track) and lower
the work equipment to the ground and stop the
engine.
1. Remove cover (1) from the top of the hydraulic
tank.
2. Remove engine cover (2).
3. Remove the bracket of damper case breather
(3).
4. Remove 2 mounting bolts of air cleaner bracket
(4) from the right front end of weight (5).
10. Using sling (1), hang weight (5) temporarily and

remove the 3 weight mounting bolts.
11. Lift off weight assembly (5).
4 Counterweight assembly: 1,170 kg
[*1]
(With auxiliary weight)
5. Remove the bolt of air conditioner hose clamp.

6. Remove radiator support bracket (7) from the
weight.
7. Remove air inlet cover (8) of the radiator, oil
cooler, etc.
INSTALLATION
PC78MR-6
Carry out installation in the reverse order to

removal.
[*1]
4 Weight mounting bolt:

1,150 1,1440 Nm {118 147 kgm}
30-13
INJECTION PUMP ASSEMBLY

REMOVAL
a Disconnect the wiring harness from the negative
terminal of the battery.
a Remove the counterweight. (See REMOVAL OF
COUNTERWEIGHT.)
1. Remove the nut (1) of the engine stop solenoid
rod and the nut of the accelerator cable (2) from
the lever side of the pump, then remove the rod
and cable assembly.
INJECTION PUMP
4. Remove the engine stop solenoid (8) and

bracket together.
5. Remove the injection pipe clamp, and loosen the
4 sleeve nuts each on the pump side and nozzle
side of the injection pipe (9), then remove the
injection pipe (9).
[*1]
6. Disconnect the inlet and outlet hoses (10) of the
feed pump and lubrication tube (11).
7. Remove the rear bracket (12) of the pump.
[*2]
2. Disconnect the 3 terminals (PULL, HOLD, GND)

(3) from the engine stop solenoid.
8. Remove the 6 bolts (14) used to install the pump

holder (13) to the front cover (12).
3. Disconnect the connector (M19) (4) of the air

conditioner compressor, water temperature sensor (M18) (5), glow plug (M17) (6) and harness
clamp (7).
30-14
9. Remove the bolt (15) used to install the holder

from the pump side, then remove the pump
assembly and holder drive gear together.
[*3]
a When drive gear and idler gear are installed,
their marks C must be matched to each
other. Since those marks are not seen actually, however, mark match marks on the gear
and pump in white paint when the pump is
removed.
PC78MR-6
INJECTION PUMP
INSTALLATION

removal.
[*1]
3 Sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}
[*2]
3 Outlet and inlet tube bolts of feed pump:

19.6 24.5 Nm {2 2.5 kgm}
[*3]
1. When installing holder (13) to pump (16), match
the engraved lines (17) on them to each other.
When installing the pump to the front cover,
match the match marks made on the gear and
pump when the pump was removed. Furthermore, match the engraved lines (18) of holder
(13) and plate to each other and tighten the
mounting bolts temporarily.
2. When the engraved line of 1.4TOP of the clamp

is matched to the pointer, timing check holes (20)
(the bolt hole on this side and the through hole
under it) of tachometer removing opening (19) on
front cover (12) must be matched to each other.
Insert round bar about 100 mm long (21) in the
holes to check that those holes are matched,
then tighten each bolt to the specified torque.
PC78MR-6
30-15
CYLINDER HEAD
CYLINDER HEAD ASSEMBLY
8. Remove the air intake connector (6) between the

turbocharger and the air intake manifold.
REMOVAL
k WARNING! Disconnect the battery () terminal

in advance.
1. Remove the engine hood (See REMOVAL OF
COUNTERWEIGHT).
2. Drain the coolant.
6 Coolant: 10.5 l
3. Remove the air intake hose (1) between the air

cleaner and the turbocharger.
9. Disconnect the wiring harness connectors (M17)

(7), (M18) (8) and (M19) (9).
10. Remove the guard (10).
11. Remove the filler pipe (11).
4. Remove the muffler protector (2).

5. Remove the 2 U-clamps (3).
[*1]
6. Remove the clamp (4) between the turbocharger

and muffler, and then loosen the 4 mounting nuts
of the turbocharger side of the exhaust pipe. [*2]
7. Remove the muffler (5).
30-16
PC78MR-6
12. Loosen the 2 mounting bolts of the air compressor and adjustment bolt, and remove the air
compressor belt (12).
CYLINDER HEAD
17. Disconnect the blow-by hose (19).

18. Remove the fuel injection pipe clamp (20) and
then remove the fuel injection pipes (21).
[*3]
13. Disconnect the 3 hoses (13) from the fuel filter.

19. Disconnect the spill pipe (22).
14. Remove the air conditioner compressor (14), the
bracket and the fuel filter together.
20. Remove the inspection cover of the turbocharger

back side.
15. Disconnect the 3 terminals (PULL, HOLD, GND)
(16) and linkage mounting nut (17) from the
engine stop solenoid (15).
21. Disconnect the turbocharger lubrication tubes

(23) and (24).
[*4]
16. Remove the engine stop solenoid (15) and the

bracket (18) together.
22. Remove the turbocharger and exhaust manifold

assembly (25).
[*5]
PC78MR-6
30-17
23. Remove the cylinder head cover (26).
CYLINDER HEAD
[*6]
29. Remove the 8 mounting bolts and the rocker arm

(35), then remove the push rod.
[*7]
30. Remove the lead (36) of the glow plug.
24. Loosen the 2 mounting bolts of the alternator

(27) and remove the fan belt (28).
26. Disconnect the heater hoses (30) and (31).
31. Remove the 17 mounting bolts of the cylinder

head (37), and lift off the cylinder head assembly.
[*8]
27. Disconnect the radiator upper hose (32) and

lower hose (33).
32. Remove the air intake manifold (38) from the cylinder head assembly.
25. Remove the fan (29).
28. Remove the water pump assembly (34).
30-18
PC78MR-6
INSTALLATION
Carry out the installation in the reverse order to

removal.
[*1]
3 U-clamp nut:
7.8 9.8 Nm {0.8 1.0 kgm}
[*2]
[*3]
[*4]
[*5]
[*6]
[*7]
CYLINDER HEAD
a (1): Exhaust side, (2): Air intake side,

(3): Front, (4): Rear
3 Mounting bolt of clamp between turbocharger and muffler:

1st time: 39.2 49 Nm {4 5 kgm}
2nd time:68.6 122.5 Nm {7 12.5 kgm}
3 Mounting nut of exhaust pipe turbocharger
side: 27 34 Nm {2.8 3.5 kgm}
3 Fuel injection pipe sleeve nut:

19.6 24.5 Nm {2 2.5 kgm}
3 Joint bolt of turbocharger lubrication inlet
tube: 9.8 12.7 Nm {1.0 1.3 kgm}
3 Mounting bolt of turbocharger and exhaust

manifold: 34.3 53.9 Nm {3.5 5.5 kgm}
a Insert the cylinder head cover O-ring in the
O-ring groove, taking care not to expand or
contact it, and fit it to cylinder head. Apply
adhesive, if necessary.
3 Head cover mounting bolt:
7.84 9.8 Nm {0.8 1.0 kgm}
5) Mark marks (f) on the bolt heads and seats

on the cylinder head in paint, then tighten the
bolts in the order of [1] [17] shown in figure
until the angle between the mark of each bolt
and the seat is 90 + 30
0 .
a After tightening the bolts, make 1 punch
mark (g) on each bolt head.
a If there are 5 or more punch marks on a
bolt head, do not use that bolt again but
replace it.
3 Rocker arm shaft mounting bolt

: 19.6 29.4 Nm {2 3 kgm}
3 Rocker arm adjustment nut
: 39.2 49 Nm {4 5 kgm}
[*8]
1. Tighten the cylinder head mounting bolts in the
following order.
1) Apply molybdenum disulphide LM-P all over
the threads and seating face of each bolt and
the seats of the cylinder head holes.
2) Turn the bolts in the order of [1] [17] shown
in figure with the fingers until they are
screwed in the holes of the cylinder head to 2
3 threads.
3) Tighten the bolts in the order of [1] [17]
shown in figure to the torque of 68.6}9.8 Nm
{7}1 kgm}.
4) Tighten the bolts in the order of [1] [17]
shown in figure to the torque of 107.8}4.9 Nm
{11}0.5 kgm}.
PC78MR-6
30-19
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).
k Loosen the oil filler cap of the hydraulic tank

gradually to release the residual pressure from
the hydraulic tank.
1. Remove air cleaner (1) and its bracket and air
intake hose (2).
2. Remove oil splash protector (3) from the top of
the pump and bottom plate (4) from the bottom of
the pump.
a Cover the manifold from which the air intake
pipe is removed.
3. Remove drain plug (6) from the bottom of the

suction tube of pump (5) to drain the oil.
5. Remove protector (9), joint (10), and 2 U-bolts

(11) from muffler (8), then remove muffler (8) and
bracket (12).
[*1]
(Since the engine mount is an obstacle to
removal of the pump, remove the bracket.)
6. Remove the wiring harness connector of TVC

solenoid (13). Remove 6 hoses (14) from the
pump.
[*2]
a Mask the removed connector and fit male or
female plugs to the hoses and nipple elbows.
4. Remove drain plug (7) from the PTO case to

drain the oil.
6 Hydraulic oil: Approx. 80 l
6 PTO: 0.5 l
30-20
PC78MR-6
7. Lift pump (5) temporarily and remove suction

tube (15) and pump mounting bolts, then remove
pump (5).
[*3]
4 Main pump assembly: 75 kg
CONTROL PUMP
CONTROL PUMP ASSEMBLY

REMOVAL
a Remove the counter weight (See REMOVAL OF
COUNTER WEIGHT).
1. Remove the right side cover.
2. Remove hose (2) of control pump (1).
3. Remove the 4 mounting bolt and the control
pump assembly (1).
a Fit male or female plugs to the removed
hoses and elbows.
INSTALLATION

removal.
a When assembling, take care fully so that dirt,
rust, flaw, etc. will not cause a trouble.
[*1]
1. Tighten the mounting bolts of clamp (10) of the
joint between exhaust muffler (8) and exhaust
pipe to 39.2 49 Nm {4 5 kgm} first, then
tighten to 68.6 122.5 Nm {7 12.5 kgm}.
2. Tighten the nuts of mounting U-bolts (11) of
exhaust muffler (8) to 7.8 9.8 Nm {0.8 1.0
kgm}.
INSTALLATION

removal.
[*2]
When installing the rubber hoses, be careful not
to twist them.
[*3]
After supplying hydraulic oil and before starting
the engine, bleed air from the main pump.
PC78MR-6
30-21

ASSEMBLY
6. Remove the 2 bolts from the bottom of the

engine to remove centralized wiring harness
bracket (8) from the engine block.
REMOVAL
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).

the hydraulic tank.
a Disconnect the cable from the negative () terminal of the battery.
1. Remove bottom plate (2) from the bottom of
main pump (1) and drain plug (3) from the bottom of the suction tube to drain the hydraulic oil.
2. Loosen plug (4) of the remote hose to drain the
cooling water from the radiator.
a If the cooling water contains antifreeze, handle it as harmful liquid. Do not handle it illegally.
7. Remove the adjustment bolt of alternator (9).

8. Loosen the alternator mounting bolts through the
hole of the partition and remove the V-belt.
9. Remove the mounting bolts to remove the alternator.
(This work is required since the engine mount
bolts cannot be removed.)
6 Hydraulic oil: 80 l
6 Cooling water: 8 l
10. Remove the wiring harnesses and connectors of

air conditioner compressor (10), stop solenoid
(11), TVC solenoid (12), water temperature
gauge, glow plug, starting motor, etc.
3. Remove the covers from the boom foot, swing

motor top, and inspection hole on the engine
side.
4. Remove wiring harness (6) of alternator (5).
5. Remove the wiring harness of hydraulic switch
(7) and the rotation sensor connector.
30-22
PC78MR-6
11. Remove guard (13) of air conditioner compressor (10) from the fan guard.
12. Remove the mounting bolt of the adjustment bolt
and air conditioner compressor (10).
20. Remove protector (25) of exhaust muffler (24).

Remove the clamp of the muffler and exhaust
pipe to remove the muffler. Remove the exhaust
pipe from the exhaust manifold.
[*2]
13. Remove return hose (15) for the tank from fuel
filter (14).
14. Remove the 2 mounting bolts and fuel filter (14).
15. Remove 2 heater hoses (16) from the valves on
the thermostat side and engine block side.
21. Remove protector (26) of the pump hose.

Remove the mounting bolts and suction tube
(27) from the pump.
16. Loosen the clamps and disconnect upper hose

(17) and lower hose (18) of the radiator from the
engine.
17. Remove the 6 mounting bolts and fan (19).
18.Remove fuel hose (20) connected to the feed
pump. Remove accelerator wire (21) from the
governor lever. Loosen the locknut of bracket
(22) and remove the wire.
[*1]
22. Remove the 6 hoses (28) of pump (1).

23. Remove the 4 bolts of engine support (29).
hoses and elbows.
19. Remove air cleaner (23), bracket, and air intake

hose together from the air intake manifold.
PC78MR-6
30-23
24. Install the hook to engine assembly (30) and a

sling to main pump (1) and lift off the engine and
pump assembly, hanging it by 3 points.
INSTALLATION

removal.
[*1]
3 Fuel hose bolt:

19.6 24.5 Nm {2 2.5 kgm}
[*2]
1. Tighten the mounting bolts of the clamp of the
joint between exhaust pipe and muffler to 39.2
49 Nm {4 5 kgm} first, then tighten to 68.6
122.5 Nm {7 12.5 kgm}.
2. Tighten the nuts of the mounting U-bolts of the
muffler to 7.8 9.8 Nm {0.8 1.0 kgm}.
[*3]
After installing the engine mount to the revolving
frame, apply clear lacquer to the unpainted
engine mount fitting face.
3 Mounting bolt:
249 309 Nm {25 31.5 kgm}
2 Mounting bolt:
Apply liquid adhesive LT-2
30-24
PC78MR-6
HYDRAULIC OIL COOLER

ASSEMBLY
REMOVAL
1. Disconnect the hose of reserve tank (1) from the
radiator and remove it together with the tank
bracket.
HYDRAULIC OIL COOLER, RADIATOR
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. Remove receiver tank (2) from the frame.

3. Remove condenser (3) and arrange it and
receiver tank so that they will not be obstacles.
4. Remove net (4) of the oil cooler.
2. Loosen remote plug (3) on the bottom of the 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
5. Remove the bottom plate of oil cooler (5) and

prepare an oil receiving container, then remove
cooler inlet hose (6) and outlet hose (7).
a If the cooling water contains antifreeze, handle it as harmful liquid. Do not handle it illegally.
6. Remove condenser bracket (8). Remove the 4

bolts used to secure the brackets on the top and
bottom of the oil cooler, then remove the oil
cooler.
INSTALLATION

removal.
PC78MR-6
30-25
3. Remove the 6 mounting bolts and fan (5).

Loosen the clamps on the engine side and
remove upper hose (6) and lower hose (7). [*2]
RADIATOR
INSTALLATION

removal.
[*1]
When installing the radiator and oil cooler, check
that the sealing material (sponge) between them
is not deformed or broken but normal.
[*2]
1. When inserting each hose, apply LG-6 to the
adapter of the mating part. When tightening
each clamp, check that it is not over the tube
lock part.
3 Hose clamp: 8.8 Nm {0.9 kgm}
4. Remove the 2 bolts and bracket (8) installed to

the partition under the operator's cab. Remove 2
mounting bolts (9) on the underside and radiator
(1).
30-26
PC78MR-6
SWING MOTOR AND SWING

MACHINERY ASSEMBLY
SWING MOTOR AND SWING MACHINERY
4. Remove the (9) swing machinery mounting bolts.
REMOVAL
5. Pull the plugs out of the forcing screw holes of

the swing machinery and hang the body of the
swing machinery with 2 slings wound onto it.
a Extend the work equipment to the maximum

reach and lower it to the ground and stop the
engine.
6. Using 2 forcing screws, disconnect the swing

motor and swing machinery assembly (6) from
the frame.

the hydraulic tank.
7. Lift off swing motor and swing machinery assembly (6).

[*1]
4 Swing motor and
assembly: 77 kg
1. Remove the top cover of the swing motor
swing
machinery
2. Remove the level gauge bracket (7) and disconnect the hose (8).
hoses and elbows.
INSTALLATION
3. Disconnect hoses (1), (2), (3), (4), and (5) of the
swing motor.
hoses and elbows.
a Record the disconnected hoses to prevent a
mistake in re-connecting them.

removal.
[*1]
2 Contact faces on underside of swing

machinery case and frame:
Apply gasket sealant (LG-6)
3 Swing machinery case mounting bolt:

245 308.7 Nm {25 31.5 kgm}
a When installing the assembly, take care not
to break the drain tube of the swing machinery case.
a Refilling with oil (Hydraulic tank)
Run the engine to circulate the oil through
the piping. Then, check the oil level again
and add new oil to the specified level.
PC78MR-6
30-27
SWING MACHINERY
SWING MACHINERY
ASSEMBLY
3) Disassemble No. 1 carrier assembly according to the following procedure.

i) Remove snap ring (4), thrust washer (5),
gear (6), bearing (7), and thrust washer
(8).
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
6 Swing machinery case: Approx. 2 l
2. Swing motor assembly

Remove swing motor assembly (1).
4) Drive in pin (9) to push out shaft (10).

a After removing the shaft, remove pin (9).
5) Remove thrust washer (11) from carrier (12).
3. No. 1 sun gear and No. 1 carrier assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 2 carrier (3).
30-28
PC78MR-6
4. No. 2 sun gear

Remove No. 2 sun gear (13).
5. Ring gear
Remove ring gear (14).
6. No. 2 carrier assembly
1) Remove No. 2 carrier assembly (15).
2) Disassemble No. 2 carrier assembly according to the following procedure.

i) Remove snap ring (16), thrust washer
(17), gear (18), bearing (19), and thrust
washer (20).
ii) Drive in pin (21) to push out shaft (22).
a After removing the shaft, remove pin
(21).
iii) Remove thrust washer (23) from carrier
(24).
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).
3) Set the shaft assembly to the press. Using

push tool (3), remove main bearing (29) and
collar (30) from shaft (31).
PC78MR-6
30-29
9. Dust seal, oil seal, and bearing outer race

1) Remove dust seal (32) and oil seal (33) from
case (34).
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)
3 Periphery of oil seal:

Gasket sealant (LG-6)
2) Using tool F2, remove bearing outer races

(35) and (36) from case (34).
2. Sub bearing outer race

Using tool F4, press fit outer race (36) to case
(34).
a Press fitting force: Max. 8.82 kN {Max. 0.9
tons}
3. Main bearing outer race
Using tool F5, press fit outer race (35) to case
(34).
a Press fitting force: Max. 19.6 kN {Max. 2.0
tons}
30-30
PC78MR-6
4. Shaft assembly
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}
3) Set case assembly (37) to shaft assembly

(28).
a Press fitting force: Max. 27.4 116.6 kN
{Max. 2.8 11.9 tons}
4) Using tool F7 and the press, press fit sub
bearing (25) until the 2-piece collar can be
installed.
a Press fitting force: Max. 27.4 116.6 kN
{Max. 2.8 11.9 tons}
a Turning the case, press fit the bearing
slowly.
5) Install 2-piece collar (26).
PC78MR-6
SWING MACHINERY
6) Using tool (8) and the press, press fit shaft

(31) until 2-piece collar (26) is secured.
7) Using tool F8, measure the running torque of
the shaft.
a Running torque: Max. 19.6 Nm {Max. 2.0
kgm}
5. Dust seal
Using tool F9, press fit dust seal (32).
a Replace the dust seal with new one.
30-31

1) Assemble No. 2 carrier assembly according
to the following procedure.
i) Install thrust washer (23) to carrier (24).
ii) Match shaft (22) to the pin hole of the
carrier and install it by hitting it lightly with
a plastic hammer.
iii) Insert pin (21).
a After inserting the pin, bend the pin of
the carrier.
iv) Install thrust washer (20), bearing (19),
gear (18), thrust washer (17), and snap
ring (16).
SWING MACHINERY

1) Assemble No. 1 carrier assembly according
to the following procedure.
i) Install thrust washer (11) to carrier (12).
ii) Match shaft (10) to the pin hole of the
carrier and install it by hitting it lightly with
a plastic hammer.
iii) Insert pin (9).
a After inserting the pin, bend the pin of
the carrier.
iv) Install thrust washer (8), bearing (7),

gear (6), thrust washer (5), and snap ring
(4).
2) Install No. 2 carrier assembly (15) to the
shaft and case assembly.
7. Ring gear
Install ring gear (14).
2 Fitting face of ring gear:

3 Ring gear mounting bolt:

58.5 73.5 Nm {6 7.5 kgm}
8. No. 2 sun gear

Install No. 2 sun gear (13).
a Take care not to install the sun gear and
planetary gear upside down.
30-32
2) Install No. 1 carrier assembly (3).

3) Install No. 1 sun gear (2).
PC78MR-6
SWING MACHINERY
10. Swing motor assembly

Install swing motor assembly (1).
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
2 Fitting face of motor:

11. Supplying oil and grease

Tighten the drain plug and supply engine oil
through the oil filler.
6 Swing machinery case: Approx. 2 l
2 Swing machinery case (Main bearing):

Grease (G2-LI), approx. 115 g
a Apply LG-5 to the fitting part of the drain
tube.
3 Drain plug:
44.1 93.1 Nm {4.5 9.5 kgm}
a When mounting the assembly on the
machine, apply gasket sealant LG-6 to the
fitting face of the revolving frame.
PC78MR-6
30-33
SWING MOTOR ASSEMBLY

REMOVAL
a Remove the hoses of the swing motor. For
details, see REMOVAL OF SWING MOTOR
AND SWING MACHINERY ASSEMBLY.
1. Remove the 8 swing motor mounting bolts (1).
2. Remove the swing motor assembly.
a After removing the swing motor, cover the
swing machinery.
SWING MOTOR, CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

ASSEMBLY
REMOVAL
engine.

the hydraulic tank.
1. Remove the top cover of the center swivel joint.
2. Remove travel drain hose (1) and swing motor
hose (2).
3. Remove 5 hoses (3) of the control valve, travel
forward/reverse, lateral hose, and 2nd travel
speed selection from the top one.
hoses, nipples, and elbows.
INSTALLATION

removal.

Run the engine to circulate the oil through the
piping. Then, check the oil level again and add
new oil to the specified level.
30-34
PC78MR-6
CENTER SWIVEL JOINT
4. Remove the bottom plate of the center swivel.
INSTALLATION
5. Remove the 4 travel forward/reverse and lateral

hoses, 2 2nd travel speed selection hoses, 2
drain hoses, etc. (4) from the underside of the
swivel.
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.

removal.
a When installing the rubber hoses, be careful not
to twist them.
7. Hang the center swivel joint temporarily and

remove the 4 mounting bolts from plate (5).
hoses, nipples, and elbows and record the
disconnected hoses to prevent a mistake in
re-connecting them.
8. Lift off center swivel joint assembly (6).
4 Center swivel joint assembly: 18.5 kg
PC78MR-6
30-35
CENTER SWIVEL JOINT
DISASSEMBLY
ASSEMBLY
1. Remove cover (1).
1. Install slipper seal (7) and O-ring (6) to swivel

shaft (5).
2. Remove snap ring (2).

3. Using tool T, pull swivel rotor (4) and ring (3) out
of swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7).
2. Set swivel shaft (5) to the block. Using the push

tool, hit swivel rotor (4) with a plastic hammer
lightly to install it.
a Apply grease (G2-LI) to the contact surfaces
of swivel shaft (5) and swivel rotor (4).
a When installing the rotor, take care fully not
to damage the lips of the slipper seal and oil
seal.
3. Install ring (3) and secure it with snap ring (2).
4. Install the O-ring and cover (1).
3 Mounting bolt:
31.4 2.94 Nm {3.2 0.3 kgm}
a When assembling, take care fully so that dirt,
a After assembling, seal each port with a polyethylene plug.
30-36
PC78MR-6
CONTROL VALVE ASSEMBLY

REMOVAL
k Lower the work equipment to the ground and

stop the engine, then loosen the oil filler cap
the hydraulic tank.
CONTROL VALVE
7. Remove hoses (8) on the operator's cab side of

the control valve in order from the top one. [*1]
hoses and nipples.

() terminal of the battery.
1. Remove the top cover of the hydraulic tank.
2. Remove the right side cover.
3. Remove the tool box and the washer tank.
4. Remove 5 connectors (1) of the hydraulic
switches and the wiring harness bracket.
8. Remove the 4 control valve mounting bolts from

the underside of control valve stand (9) and lift
off control valve assembly (10), using sling (1).
4 Control valve assembly: 65 kg
5. Remove each pilot hose (2).

6. Remove hoses (3) between the pump and
merge-divider valve.
a Mask the removed connectors.
INSTALLATION

removal.
[*1]
1. When assembling, take care fully so that dirt,
2. When installing the rubber hoses, take care fully
not to twist them.
3. Bleed all air from the swing PPC circuit.
4. After assembling, flush the all piping circuit.
a The number of the control valves and pipes
of a machine equipped with an attachment
and those of Model UU are different from the
above.
PC78MR-6
30-37
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}
3. When loosening or tightening plug (10) of spool

(9) of bucket valve (8), be sure to put spool (9) in
valve chest (8).
4. When loosening or tightening plugs (13) and (14)
of spool (12) of arm valve (11), be sure to put
spool (12) in valve chest (11).
5. When loosening or tightening plugs (17) and (18)
of spool (16) of boom valve (15), be sure to put
spool (16) in valve chest (15).
a When tightening each of the orifices and
plugs described above, apply 1 drop (approx.
0.02 g) of LOCTITE (No. 638) to it. Thoroughly degrease and dry the plug and the
f e m a l e s c r e w o f t h e v a l v e c h e s t wi t h
DRYSOL. Do not apply pressure to them for
2 hours after they are tightened.
3 Orifice and plug:
14.7 19.6 Nm {1.5 2.0 kgm}
2. When loosening or tightening orifice (5) and plug

(6) of merge-divider valve (4), be sure to put
spool (7) in valve chest (4) (to prevent deformation of the spool).
30-38
PC78MR-6
6. Tighten the combination bolts (1) and (2) in the

order of (1) (4) gradually in 3 times.
1) Combination bolt (1) tightening torque.
1st tightening torque:
19.6 29.4 Nm {2 3 kgm}
2nd tightening torque:
39.2 49.0 Nm {4 5 kgm}
3rd tightening torque:
58.8 73.5 Nm {6 7.5 kgm}
2) Combination bolt (2) tightening torque
29.4 34.3 Nm {3 3.5 kgm}
WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT PPC

VALVE ASSEMBLY
ASSEMBLY
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
etc. will not cause a trouble.
1. When installing piston (1), apply grease (G2-LI)
to its outside and the inside of the body hole.
2. When installing disc (2), adjust it so that the play
of the lever end will be 0.5 ~ 3 mm (at 200 mm
from the center of rotation of the lever).
a For the tightening torque of the auxiliary valves

(Relief valve, suction safety valve, pressure
compensation valve, etc.), see STRUCTURE
AND OPERATION, MAINTENANCE STANDARD.
a After assembling, seal each port with a nylon
cap, etc.
a When hanging the valve assembly, use eyebolts
(04530-10815).
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
4. Install spring (5) with its small diameter side on

the shim (6) side.
Diameter of spring (Inside diameter)
Small diameter side: 4.9,
Large diameter side: 5.55
5. When installing plug (7) to body (4), take care
that its tip will not enter the hole of the body 20
mm in diameter.
PC78MR-6
30-39
6. Apply grease (G2-LI) to the rocking part of joint

(3) and the contact surfaces of disc (2) and piston (1).
Quantity of grease
1) Rocking part of joint: 2 4 cc/periphery
2) Contact surfaces of disc and piston:
0.3 0.8 cc/place
7. Seal the ports (P1 - P4, T, P) with nylon caps,
etc.
8. Tighten each part to the following torque.
Joint (3): 39 49 Nm {4 5 kgm}
Bolt (8): 11.8 14.7 Nm {1.2 1.5 kgm}
Nut (9): 98 127 Nm {10 13 kgm}
Plug (10): 6 11 Nm {0.6 1.1 kgm}
TRAVEL PPC VALVE
TRAVEL PPC VALVE

ASSEMBLY
ASSEMBLY
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
etc. will not cause a trouble.
1. When installing piston (1), apply grease (G2-LI)
to its outside and the inside of the body hole.
2. Install spring (2) with its small diameter side on
the shim (3) side.
Diameter of spring (Inside diameter)
Small diameter side: 4.9,
Large diameter side: 5.55
3. Use the insertion jig to insert bushing (4). (Do
not drive in the bushing with impact loads of a
hammer, etc.)
4. Use the insertion jig to insert pin (5). (Do not
drive in the pin with impact loads of a hammer,
etc.)
5. Apply grease (G2-LI) to the rocking part of shaft
(6) and the contact surfaces of lever (7) and piston (1) and the contact surfaces of plate (8) and
pin of lever (9).
2 Quantity of grease (G2-LI)

Rocking part of shaft:4 8 cc/periphery
Contact surfaces of lever and piston:
0.3 0.8 cc/place
Contact surfaces of plate and pin:
0.3 0.8 cc/place
6. Install washer (10) 1.6 mm thick first. If the 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
TRAVEL PPC VALVE
8. Tighten each part to the following torque.

Plug (11): 6 11 Nm {0.6 1.1 kgm}
Bolt (12): 3.9 4.9 Nm {0.4 0.5 kgm}
(Apply LOCTITE #262.)
Screw (13): 7.8 9.8 Nm {0.8 1.0 kgm}
Plug (14): 4 9 Nm {0.4 0.9 kgm}
Bolt (15): 25 30 Nm {2.5 3.2 kgm}
Bolt (16): 27 34 Nm {2.8 3.5 kgm}
PC78MR-6
30-41
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
6. Remove return hose (5), including the swing

hose.
7. Remove hose (6) from the oil cooler and the
other hoses.
hoses, elbows, etc.
k Stop the engine and loosen the hydraulic oil

filler cap gradually to release the residual pressure from the hydraulic tank.
1. Drain the oil from the hydraulic tank.
2. Remove the top cover and right side cover of the
hydraulic tank.
3. Remove the wiring harness clamp and washer
tank (1).
4. Loosen the clamp and remove pump suction
hose (2).
6 Hydraulic tank: 64 l
8. Using sling [1], remove the mounting bolts and

lift off hydraulic tank assembly (7).
5. Disconnect the return hose (8).
INSTALLATION

removal.
a When installing the rubber hoses, be careful not
to twist them.
30-42
PC78MR-6
FUEL TANK ASSEMBLY

REMOVAL
FUEL TANK
7. Remove the inspection cover of fuel suction

hose (7) and drain hose (8) from the underside of
the revolving frame under the fuel tank, then
remove the suction hose and drain hose.

a Drain the fuel through the drain valve.
6 When fuel tank is full: 125 l
1. Remove the front and left deck covers.

2. Remove the mounting bolts of fuel filler mounting
cover (1) and loosen the hose clamp of the fuel
filler tube and pull out the tube.
3. Remove the clamp and hose (2) of the fuel spill
prevention gauge and take out cover (1).
4. Loosen the clamp of fuel supply hose (3) on the
fuel tank (4) side and remove the hose from the
tank.
8. Remove the 2 mounting bolts of fuel tank bracket

(9) on this side from the underside of the revolving frame.
5. Remove the clamp of PPC hose (5) from the

underside of the floor.
9. Remove the mounting bolt of the valve (10) and

move them to the left side (to secure winder work
space).
6. Remove the fuel sensor top cover of the floor

and disconnect sensor connector (6).
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

removal.
3. Loosen the mounting bolts and remove connectors (4), (5), and (6) of controller (3).
[*1]
3 Nut of tank band:

5.9 0.49 Nm {0.6 0.05 kgm}
4. Remove the 4 mounting bolts and controller

assembly (3).
INSTALLATION

removal.
a Do not tighten the mounting bolts of connectors
too strongly.
30-44
PC78MR-6
MONITOR PANEL ASSEMBLY

REMOVAL
1. Pull cover (2) of monitor panel (1) and remove
the claw stopper.
2. Remove side cover (3).
3. Remove the stopper of cover (4).
MONITOR PANEL, AIR CONDITIONER UNIT

ASSEMBLY
REMOVAL
a Connect a hose to the compressor charge unit
and collect the refrigerant gas. (If the charge tool
is available, this work becomes easy.)
[*1]
1. Remove floor mat (1).
2. Remove dust covers (2) and (3).
3. Remove air conditioner unit cover (4).
4. Remove the 3 mounting bolts of monitor panel

(1) and connectors (5) and (6) on the back side,
then remove monitor panel assembly (1).
4. Remove duct (5) and the rear duct.

5. Remove cover (6) and the rear duct.
6. Remove 2 tubes (7) and push them in under the
floor.
[*2]
tubes.
INSTALLATION

removal.
PC78MR-6
30-45
7. Loosen the clamp and remove heater hose (8)

under the rear part of the operator's seat.
11. Remove the 3 front mounting bolts and 3 rear

ones and air conditioner unit assembly (12).
8. Remove 3 wiring harness connectors (9) for the

air conditioner under the rear part of the operator's seat.
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.

removal.
[*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
11.8 14.7 {1.2 1.5}
# 11
20 x 1.5
24
19.6 24.5 {2.0 2.5}
# 14
22 x 1.5
27
29.4 34.3 {3.0 3.5}
PC78MR-6
OPERATORS CAB
OPERATORS CAB
ASSEMBLY
7. Remove wiring harness connectors (6) and (7) of

the radio system at the left rear and disconnect
radio cable (8) from the jack.
REMOVAL
8. Remove connectors (9), (10), and (11) of the

monitor panel at the right rear.
1. Remove the floor mat.
9. Remove the washer tank hose.
2. Remove air conditioner unit cover (1).

3. Remove rear cover (3) of monitor panel (2) and
air conditioner duct.
10. Install a sling to the top of operator's cab assembly (12) and lift off the assembly.
4 Operator's cab assembly: 280 kg
4. Remove the mounting bolts used to install the

operator's cab to the floor.
5. Remove the 4 nuts from the left front, rear, and
right front and 1 bolt from the right rear of the
operator's cab mount.
6. Remove the controller storage cover, wiring harness connectors of controller (4), and clamps (5).
INSTALLATION
PC78MR-6

removal.
30-47
FLOOR FRAME ASSEMBLY

REMOVAL
a Remove the operator's cab assembly. (See
REMOVAL OF OPERATOR CAB.)
a Connect a hose to the compressor charge unit
and collect the refrigerant gas. (If the charge tool
is available, this work becomes easy.)
[*1]
FLOOR FRAME
7. Remove the 4 hoses connected to travel right

and left control valves (9).
8. Remove the 2 hoses connected to the attachment control valve (10).
9. Disconnect the hoses connected to swing control
valve and blade control valve.
1. Remove front deck cover (1) and left deck cover

(2).
2. Remove 8 wiring harness connectors (3) of
engine and pump control systems.
3. Remove 3 solenoid connectors (4) and cable
clamp (5).
4. Remove the wiring harness connector of horn
(6).
10. Loosen the clamps and remove 2 heater hoses

(11). (At the rear of the operator's seat)
5. Remove 2 air conditioner gas tubes (7). (Fit

male or female plugs to the removed tubes.)
11. Remove the 4 mounting bolts used to install the

floor frame to floor mount (12).
6. Remove 8 hoses (8) of the work equipment control valve from the couplers.
12. Remove the accelerator wire from the injection

pump and pull it out through the hole of the
revolving frame to the floor side.
30-48
PC78MR-6
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]

removal.
a See INSTALLATION OF AIR CONDITIONER
UNIT.
PC78MR-6
30-49
REVOLVING FRAME
REVOLVING FRAME
ASSEMBLY
6. Remove receiver drier (5) and bracket together

from the revolving frame and place them on their
side.
REMOVAL
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.
7. Remove the all mounting bolts used to install

swing circle outer race (6) to the revolving frame.
3. Remove engine ventilator cover (2).
4. Hang boom cylinder assembly (3) temporarily

and remove the hoses on the head side and bottom side. Pull out the mounting pin on the bottom side and lift off the cylinder assembly.
5. Remove fuel filler mounting cover (4).
8. Install a sling to the boom foot mounting unit and

both sides of counterweight (7) and lift off the
revolving frame assembly, hanging it by 3 points.
a Use the hole of the revolving frame on the
left rear side from which the receiver drier
was removed.
INSTALLATION
30-50

removal.
PC78MR-6
SWING CIRCLE
SWING CIRCLE ASSEMBLY
INSTALLATION
REMOVAL

removal.
1. Remove the revolving frame assembly. For

details, see REMOVAL OF REVOLVING FRAME
ASSEMBLY.
[*1]
2 Threads of swing circle mounting bolt:

Liquid adhesive (LT-2)
3 Swing circle mounting bolt:
245 309 Nm {25 31.5 kgm}
Target: 279.5 Nm {28.5 kgm}
2. Hang swing circle assembly (1) temporarily and

remove the 24 mounting bolts.
[*1]
3. Remove swing circle assembly (1).
4 Swing circle assembly: 115 kg
[*2]
[*2]
a Hang swing circle assembly (1) and install it

to the track frame, directing mark S of the
inner race to the just right s ide of the
machine body as shown below.
2 Quantity of grease to be applied to

circle: Apply sufficient quantity of
grease (G2-LI).
PC78MR-6
30-51
WORK EQUIPMENT
WORK EQUIPMENT
ASSEMBLY
REMOVAL
engine.

the hydraulic 6tank.
1. Remove the top cover of the hydraulic tank.
2. Disconnect the working lamp connector (1), then
disconnect the wiring harness (7) from the hose.
3. Remove the handrail (8).
4. Loosen the sleeve nut and disconnect the work
equipment hose (2).
[*1]
a Move the removed hoses to the swing motor
side.
hoses and tubes.
k Since an accumulator is not installed,

loosen the sleeve nut of each hose gradually and check that oil will not spout out,
then remove the hose.
7. Remove the lock plate (9) of the boom foot pin

and handrail (10).
8. Lift the work equipment assembly (5) temporarily.
9. Pull out the boom hoot pin (6).
[*3]
a Check the quantity and positions of the
inserted shims.
5. Remove the rod pin stopper used to lift boom cylinder (3) temporarily and pull out rod pin (4). [*2]
6. Lift off the boom cylinder (3) onto a stable stand
of proper heght.
inserted shims.
30-52
PC78MR-6
10. Lift off the work equipment assembly (5).

inserted shims.
2 Work equipment assembly: 1,100kg
WORK EQUIPMENT
INSTALLATION

removal.
[*1]
1. Check that the O-rings are fitted to the sealing
parts of each hose.
2. When installing the rubber hoses, take care not
to twist them.
[*2]
1. When assembling, apply GT2-T to the sliding
surfaces of the pins.
2. Supply grease until it comes out through the dust
seals on both sides of each bushing.
k When aligning the pin holes, never insert

your fingers in the pin holes.
a Adjust the shims so that the clearance
between the cylinder rod head and bracket
will be less than 1 mm.
[*3]
1. When assembling, apply GT2-T to the sliding
surfaces of the pins.
2. Supply grease until it comes out through the dust
seals on both sides of each bushing.
3. After supplying grease, change the position of
the boom and supply grease further.
k When aligning the pin holes, never insert

your fingers in the pin holes.
a Adjust the shims so that the clearance

between the boom and bracket will be less
than 1 mm.
PC78MR-6
30-53
SWING BRACKET
SWING BRACKET ASSEMBLY

REMOVAL
1. Remove the work equipment assembly (See
REMOVAL OF WORK EQUIPMENT ASSEMBLY).
2. Disconnect the 2 boom cylinder hoses (1). [*1]
hoses and elbows.
3. Lift the boom cylinder assembly (2), then pull out
the bottom pin (3) and remove the boom cylinder
assembly (2).
[*2]
inserted shims.
4 Boom cylinder assembly: 112kg
6. Remove the cover (6) and disconnect the connector (7).

7. Remove the bolt of the upper and lower brackets, then remove the potentiometer assembly
(8).
[*5]
a After removing the potentiometer assembly,
do not swing it around the lever or turn the
lever unnecessarily.
8. Remove the work equipment hose clamp (9). [*4]

a Make marks on the disconnected hoses so
that you can connect them again in the original order.
4. Set the block under the swing cylinder, and

remove the head pin (4).
[*3]
inserted shims.
k Start the engine and retract the cylinder.
5. Remove the boom cylinder hose clamp (5). [*4]
30-54
PC78MR-6
9. Lift the swing bracket (10) temporarily, and

remove the mounting bolts of the swing pin
upper side and lower side.
a Plate (11) will be removed from the lower pin.
10. Pull out the pins (12) and (13) toward upper or
lower.
a If the pins are difficult to pull out, use puller
V2.
11. Pull out the work equipment hoses and the boom
cylinder hose, and remove the swing bracket
assembly (10).
[*6]
a Check the quantity of the shims installed to
the top of pin (13).
4 Swing bracket assembly: 234kg
SWING BRACKET
INSTALLATION
Carry out the installation in the reverse order to

removal.
[*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]
a When installing the hoses, be careful not to

twist them.
a Referring to TROUBLESHOOTING, Procedure for correcting angle sensor, correct the
sensor.
[*6]
1) When assembling, apply G2-T to the sliding
surface of the pins.
2) Use G2-T HYPER WHITE GREASE.
3) Adjust the shims so that the clearance
between the swing bracket and the bracket
on the chassis side (the clearance on the
upper side of the lower pin) will be 0.5 mm or
less.
a Shims of 3 thicknesses of 0.5, 1.0, and
2.0 mm are prepared.
k When aligning the pin holes, never
insert your fingers in the pin holes.
a After installing, check that the hydraulic oil level

is normal.
a After installing, check that the electric system
works normally.
PC78MR-6
30-55
STEEL SHOE, RUBBER PAD SHOE, ROAD LINER
STEEL SHOE, RUBBER PAD

SHOE, ROAD LINER
ASSEMBLY
4. Remove tool R and move the machine forward

so that the temporary pin will be in front of the
idler and set block [1].
EXPANSION
5. Pull out the temporary pin and move the

machine in reverse to expand track shoe (2).
1. Stop the machine so that the master pin will be

between the idler and carrier roller and the track
shoe can be expanded forward and backward.
2. Lower the work equipment to the ground and
loosen lubricator (1) to lower the track shoe tension.
[*1]
k Since the internal pressure of the adjustment

cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not
come out easily, move the machine forward and
in reverse.
INSTALLATION

removal.
[*1]
a Adjust the tension of the steel shoe and road
liner. For details, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
3. Using tool R, pull out the master pin.
30-56
PC78MR-6
RUBBER SHOE, FINAL DRIVE
RUBBER SHOE ASSEMBLY
FINAL DRIVE ASSEMBLY
REMOVAL
REMOVAL
1. Lower the work equipment to the ground and

loosen lubricator (1) to lower the track shoe tension.
[*1]
1. Expand the track shoe assembly. (See EXPANSION OF TRACK SHOE.)
k Since the internal pressure of the adjustment

cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not
come out easily, move the machine forward and
in reverse.
2. Swing the work equipment by 90 degrees and

raise the machine body a little.
3. Put steel pipes in rubber shoe (2) and turn the
sprocket in the reverse direction. If the rubber
shoe is floated from the idler by the steel pipes,
slide off the rubber shoe sideways.
2. Swing the work equipment by 90 degrees from

the parking position and raise the machine body
by pressing the work equipment against the
ground and set block (1) between the track
frame and track link to float sprocket (1) above
the link tread.
k Lower the work equipment to the ground

and stop the engine. Loosen the oil filler
cap of the hydraulic tank to release the
residual pressure from the hydraulic tank.
3. Remove travel motor side cover (2).
INSTALLATION

removal.
[*1]
a Adjust the rubber shoe tension. For details, see
TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
PC78MR-6
30-57
4. Hang final drive assembly (3) temporarily.
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}
5. Remove 4 travel motor hoses (4).

6. Remove 14 final drive assembly mounting bolts
(5).
[*1]
7. Lift off the final drive assembly.
hoses and nipples.
INSTALLATION

removal.
[*1]
2 Final drive assembly mounting bolt:

Liquid adhesive (LT-2)
2. Fit the O-ring and install support (7) to shaft (5)

with dowel pin (8).
3. Using tool L2, install floating seal (6) to idler (4)

and assembly of shaft (5) and support (7).
a Apply oil to the sliding surface of the floating
seal and take care that dirt will not stick to
that surface.
a Bleed air from the travel motor. For details,

see TESTING AND ADJUSTING, Bleeding
air from each part.
Add oil through the oil filler to the specified level.
system. Then, check the oil level again.
30-58
PC78MR-6
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).
IDLER
4. Install the assembly of shaft (5) and support (7)

to idler (4).
5. Supply oil between shaft (5) and idler (4).

a When inserting the floating seal assembly in
the housing, use the push jig. This push jig
must push the load ring.
[1]: Cylindrical push jig
6 Quantity of oil: 60 cc (EO-30CD)
a The metallic faces of the floating seal which

are in contact with each other must be free
from dirt.
a After the floating seal is inserted, check that
it does not slant more than 1 mm and its projection is as follows.
PC78MR-6
30-59
6. Using tool L2, install floating seal (3) to idler (4)

and support (2).
a Apply oil to the sliding surfaces of the floating
seal and take care that dirt will not stick to
the floating seal.
a Degrease the contact faces of the floating
seal and O-ring.
RECOIL SPRING
RECOIL SPRING ASSEMBLY

DISASSEMBLY
1. Remove lubricator (1).
2. Remove yoke piston assembly (3) from recoil
spring assembly (2).
3. Disassembly of recoil spring assembly
1) Remove set bolt (4).
2) Set recoil spring assembly (2) to tool M.
k Since the installing load of the spring is

heavy and dangerous, set the spring
securely.
a Installing load of spring:
69.2 kN {7,061 kg} (Rubber shoe)
47.4 kN {4,837 kg} (Steel shoe)
7. Fit the O-ring and install support (2) with dowel

pin (1).
30-60
PC78MR-6
3) Apply hydraulic pressure slowly. After the

spring is compressed, remove nut (5).
a Compress the spring until the nut is loosened.
a Release the hydraulic pressure slowly to
eliminate the spring force.
4) Remove pilot (7) and cylinder (8) from spring
(6).
a Remove O-ring (13) from the cylinder.
RECOIL SPRING
3) Set recoil spring (2) to tool M.
4. Disassembly of yoke piston assembly

1) Remove wear ring (10) from yoke piston (9).
2) Remove snap ring (11) and U-packing (12).
4) Apply hydraulic pressure slowly to compress
the spring. Tighten nut (5) so that the installing length of the spring will be a.
a Installing length a of spring:
283 mm (Rubber shoe)
323 (Steel shoe)
2 Nut:
Lubricant containing
num disulphide (LM-P)
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
5) Remove recoil spring assembly (2) from tool

M.
6) Install set bolt (4).
3 : 58.8 73.5 Nm {6 7.5 kgm}
7) Fill cylinder (8) with grease (G2-LI).

a Quantity of grease (G2-LI):
Approx. 232 cc (Rubber shoe)
Approx. 96 cc (Steel shoe)
8) Loosen lubricator (1) and insert yoke piston
assembly (3) in recoil spring assembly (4)
until grease comes out through part B.
TRACK ROLLER
TRACK ROLLER ASSEMBLY

DISASSEMBLY
1. Remove pin (2) from track roller assembly (1),
then remove collar (3).
3 Sliding parts of yoke piston and wear

ring: Grease (G2-LI)
9) Tighten lubricator (1).
3: 58.8 88.2 Nm {6.0 9.0 kgm}

a Install the valve so that the fitting will be
on the outside.
2. Remove floating seal (4a) from collar (3).
3. Remove floating seal (4b) from roller (5).
4. Remove shaft and collar assembly (6) from roller

(5).
30-62
PC78MR-6
5. Remove floating seal (7a) from roller (5), then

remove floating seal (7b) from shaft and collar
assembly (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).
a When inserting the floating seal assembly in the

housing, use the push jig. This push jig must
push the load ring.
[1]: Cylindrical push jig
a After the floating seal is inserted, check that it

does not slant more than 1 mm and its projection
is as follows.
PC78MR-6
30-63
a The metallic faces of the floating seal which are

in contact with each other must be free from dirt.
a Supply GO140 oil.
Quantity of oil: 210 230 cc
a Thoroughly clean the parts to be in contact with
the supplied oil. After cleaning them, the dirt
remaining on these parts of 1 roller assembly
must be below 25 mg and the size of the dirt
must be below 0.3.
a Set plug (2) on the outside of the machine body.
TRACK ROLLER
3. Using tool L4, press fit floating seal (7b) to shaft

(9).
4. Using tool L4, press fit floating seal (7a) to roller
(5).
a Press fit floating seal (4b) similarly.
5. Install shaft and collar assembly (6) to roller (5).

6. Turn over the assembly of roller (5) and shaft (6).
1. Using tool L3, press fit bushing (12) to roller (5).
a Press fit bushing (11) similarly.
2. Fit the O-ring to shaft (9), then install collar (10)
and pin (8) to shaft (9).
7. Using tool L4, install floating seal (4a) to collar

(3).
30-64
PC78MR-6
8. Install collar (3) to shaft (9), then install pin (2).

9. Fill the roller with oil and tighten plug (13).
5 Track roller: 210 230 cc (GO-140)
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).
3) Pull out piston rod assembly (3).

a Place an oil pan, etc. under the cylinder
to receive the oil.
PC78MR-6
30-65
HYDRAULIC CYLINDER
2. Piston rod assembly

1) Set piston rod assembly (3) to tool U1.
and tool U3, remove nylon nut (4).
a Width across flats of nut:
Cylinder Boom
Width
across
80
flats
Arm
Bucket
Swing
Blade
75
60
70
75
3. Disassembly of piston assembly

1) Remove wear ring (9).
2) Remove piston ring (10).
a Apply a screwdriver, etc. to the piston
ring and hit it with a hammer to break off
the piston ring.
3) Remove piston assembly (6) from piston rod

(5).
4) Remove head assembly (2).
5) Remove cap (6) and take out 9 balls (7), then

remove plunger (8).
Perform this work for only arm cylinder.
30-66
4. Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (11).
2) Remove O-ring (12).
3) Remove snap ring (13) and dust seal (14).
4) Remove rod packing (15).
5) Remove bushing (16).
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
2. Assembly of piston assembly

1) Using tool U4, expand piston ring (10).
a Set the piston ring to tool U4 and revolve
the handle by 8 - 10 turns to expand the
piston ring.
2) Using tool U5, contract piston ring (10).
1. Assembly of cylinder head assembly

1) Using tool U6, press fit bushing (16).
2) Install rod packing (15).
3) Using tool U7, install dust seal (14) and
secure it with snap ring (13).
4) Fit O-ring (12).
5) Fit the backup ring and O-ring (11).
3) Install wear ring (9).

a Take care not to open the closed gap of
the ring too much.
PC78MR-6
30-67
HYDRAULIC CYLINDER
5. Piston rod assembly

1) Set plunger (8) to the piston rod and install 9
balls (7) and secure them with cap (6).
a Check that there is some play at the
plunger tip.
Perform this work for only arm cylinder.
6. Cylinder assembly
1) Set the cylinder to tool U1.
2) Install piston rod assembly (3).
a Push in the piston rod to the end.
2) Install head assembly (2) to piston rod (5).
3) Install piston assembly (6) to piston rod (5).

and tool U2, tighten head assembly (2).
4) Set piston rod assembly (3) to tool U1.
5) Using tool U3, tighten nylon nut (4).
2 Nylon nut: Liquid adhesive (Equivalent to LOCTITE 262)
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
{405 40.5 kgm}

{420 42.0 kgm}
{220 22 kgm}
{320 32.0 kgm}
{265 26.5kgm}
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}
a After assembling, clean each part and mask the

piping ports and pin hole
30-68
PC78MR-6
90 OTHERS
Hydraulic circuit diagram (For STD spec.) ............... 90- 3
Hydraulic circuit diagram (For EU spec.) .................. 90- 5
Electrical circuit diagram (For STD spec.) (1/2) ........ 90- 7
Electrical circuit diagram (For STD spec.) (2/2) ........ 90- 9
Electrical circuit diagram (For EU spec.) (1/2)........... 90-11
Electrical circuit diagram (For EU spec.) (2/2)........... 90-13
PC78MR-6
90-1
(1)
HYDRAULIC CIRCUIT DIAGRAM (FOR STD SPEC.)
PC78MR-6
90-3
(1)
HYDRAULIC CIRCUIT DIAGRAM (FOR EU SPEC.)
PC78MR-6
90-5
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC.) (1/2)
PC78MR-6
90-7
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC.) (2/2)
PC78MR-6
90-9
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC.) (1/2)
PC78MR-6
90-11
(1)
ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC.) (2/2)
PC78MR-6
90-13
(1)

PC78MR-6 Sebm030601

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

PC78MR-6 Sebm030601

Încărcat de

Drepturi de autor:

Formate disponibile

SEBM030601

STRUCTURE AND FUNCTION,

TESTING AND ADJUSTING .......................................................................20-1

DISASSEMBLY AND ASSEMBLY ..........................................................30-1

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised

LIST OF REVISED PAGES

To prevent injury to workers, the symbol

Always wear safety glasses when hitting

3. If welding repairs are needed, always have a

6. Decide a place in the repair workshop to keep

PRECAUTIONS DURING WORK

19.Be sure to assemble all parts again in their original places.

STRUCTURE AND FUNCTION

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

Chassis volume: Issued for every machine model

Revised pages are shown in the LIST OF REVISED

Special safety precautions

Special technical precautions or other precautions

Weight of parts of systems. Caution necessary

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

Slinging near the edge of the hook may cause

3) Do not sling a heavy load with one rope alone,

4) Do not sling a heavy load with ropes forming a

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

1) Hold the mouthpiece of the tightening portion

1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

2) Hold in the condition in Step 1), and push

3) Hold in the condition in Steps 1) and 2), and

3) Hold in the condition in Steps 1) and 2), and

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening portion

Main applications, featuresr

Used to prevent rubber gaskets,

Used in places requiring an immediately effective, strong adhesive.

Features: Resistance to heat and

Used as adhesive or sealant for

Used as sealant for machined

Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Resistance to heat, chemicals

Used as adhesive or sealant for

Used as sealant for various

Features: Silicon based, resistance to heat, cold

Main applications, featuresr

Used as heat-resisting sealant for

Used as lubricant for sliding portion (to prevent from squeaking).

Ftures: Silicon based, quick hardening type

General purpose type