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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
90 OTHERS ....................................................................................................................90-1
00-2 PC78MR-6
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
PC78MR-6 00-2-1
(1)
Revision Revision Revision Revision Revision
Mark Page number Mark Page number Mark Page number Mark Page number Mark Page number
20-1 20-137 20-250 20-516 20-808
20-2 20-138 20-251 20-517 20-809
20-3 20-139 20-252 20-518 20-810
20-4 20-201 20-253 20-519 20-811
20-5 20-202 20-254 20-520 20-812
20-6 20-203 20-255 20-521 20-813
20-7 20-204 20-256 20-522 20-814
20-8 20-205 q 20-257 (1) q 20-601 (1) 20-815
20-9 20-206 20-258 20-602 20-816
20-10 20-207 20-259 20-604 20-817
20-11 20-208 20-260 20-605 20-818
20-12 20-209 20-301 q 20-606 (1) 20-819
20-13 20-210 20-302 q 20-607 (1) 20-820
20-14 20-211 20-303 q 20-608 (1) 20-821
20-15 20-212 20-304 q 20-609 (1) 20-822
20-101 q 20-214 (1) 20-305 q 20-610 (1) 20-823
20-102 q 20-215 (1) 20-306 20-611 20-824
20-103 q 20-216 (1) 20-307 Q 20-611-1 (1) 20-825
20-104 q 20-217 (1) 20-308 Q 20-611-2 (1) 20-826
20-105 q 20-218 (1) 20-309 20-612 20-827
20-106 20-219 20-310 20-613 20-828
20-107 20-220 20-311 20-614 20-829
20-108 20-221 20-312 20-615 20-830
20-109 20-222 20-313 Q 20-615-1 (1) 20-831
20-110 20-223 20-314 q 20-616 (1) 20-832
20-111 20-224 20-315 q 20-617 (1) 20-833
20-112 20-225 20-316 q 20-618 (1) 20-834
20-113 20-226 20-317 q 20-619 (1) 20-835
20-114 20-227 20-318 q 20-620 (1) 20-836
20-115 20-228 20-319 q 20-621 (1) 20-837
20-116 20-229 20-320 q 20-622 (1) 20-838
20-117 20-230 20-321 q 20-623 (1) 20-839
20-118 20-231 20-322 q 20-624 (1) 20-840
20-119 20-232 20-323 q 20-625 (1) 20-841
20-120 20-233 20-324 q 20-626 (1) 20-842
20-121 20-234 20-401 q 20-627 (1) 20-843
20-122 20-235 20-402 q 20-628 (1) 20-844
20-123 20-236 20-501 20-701 20-845
20-124 20-237 20-502 20-702 20-846
20-125 20-238 20-504 20-703 20-847
20-126 20-239 20-505 20-704 20-848
20-127 20-240 20-506 20-705 20-849
20-128 q 20-241 (1) 20-507 20-706 20-850
20-129 q 20-242 (1) 20-508 20-707 20-851
20-130 20-243 20-509 20-708 20-852
20-131 20-244 20-510 20-801 20-853
20-132 q 20-245 (1) 20-511 20-802 20-854
20-133 20-246 20-512 20-804 20-855
20-134 20-247 20-513 20-805 20-856
20-135 20-248 20-514 20-806 20-857
20-136 20-249 20-515 20-807 20-858
00-2-2 PC78MR-6
(1)
Revision Revision Revision Revision Revision
Mark Page number Mark Page number Mark Page number Mark Page number Mark Page number
20-859 30-19 q 90-1 (1)
20-860 30-20 q 90-3 (1)
20-861 30-21 q 90-5 (1)
20-901 30-22 q 90-7 (1)
20-902 30-23 Q 90-9 (1)
20-903 30-24 Q 90-11 (1)
20-904 30-25 Q 90-13 (1)
20-905 30-26
20-906 30-27
20-907 30-28
20-908 30-29
20-909 30-30
20-910 30-31
20-911 30-32
20-912 30-33
20-913 30-34
20-914 30-35
20-915 30-36
20-916 30-37
20-917 30-38
20-918 30-39
20-919 30-40
20-920 30-41
20-921 30-42
20-922 30-43
20-923 30-44
20-924 30-45
20-925 30-46
20-926 30-47
20-927 30-48
20-928 30-49
20-929 30-50
30-51
30-1 30-52
30-2 30-53
30-3 30-54
30-4 30-55
30-5 30-56
30-6 30-57
30-7 30-58
30-8 30-59
30-9 30-60
30-10 30-61
30-11 30-62
30-12 30-63
30-13 30-64
30-14 30-65
30-15 30-66
30-16 30-67
30-17 30-68
30-18
PC78MR-6 00-2-3
(1)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive () terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
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
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
tank.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
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).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
FOREWORD STANDARD TIGHTENING TORQUE
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 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 Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
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
PC78MR-6 01-1
GENERAL SPECIFICATION DIMENSIONS DRAWING
PC78MR-6
Item Unit
Steel shoe spec. Road liner spec.
Machine weight (with blade) kg 8,270 8,300
Bucket capacity m 0.28
Engine model KOMATSU S4D95LE-3-A Diesel engine
Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850
A Overall length mm 6,200 6,230
B Overall height mm 2,730 2,750
C Overall width mm 2,330
D Shoe width mm 450
E Tail swing radius mm 1,310
F Overall length of track mm 2,840 2,900
G Distance between tumbler centers mm 2,235
Minimum ground clearance mm 360 400
Travel speed (Low/High) km/h 2.8/4.2
Continuous swing speed rpm 10.0
01-2 PC78MR-6
GENERAL WORKING RANGE DRAWING
PC78MR-6 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC78MR-6
Serial Number 1001 and up
Bucket capacity m3 0.28
Machine weight kg 8,270 (8,300)
Max. digging depth mm 4,160
Max. vertical wall depth mm 2,900
Max. digging reach mm 6,960
Working range
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
( ) Figures in ( ): Road liner specification
01-4 PC78MR-6
GENERAL SPECIFICATIONS
Max. torque
Engine
{kgm/rpm} {24.2/1,500}
Max. speed at no load rpm 2,020
Min. speed at no load rpm 1,130
PC78MR-6 01-5
GENERAL SPECIFICATIONS
Bucket cylinder
01-6 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 7
Hydraulic pump 66
Cooling assembly (without coolant and oil) 29
Radiator (without coolant) 6.3
Oil cooler (without oil) 5.2
Revolving frame 1,220
Operator's cab 260
Operator's seat 18
Fuel tank (without fuel) 8.3
Hydraulic tank (without hydraulic oil) 70
Control valve 62
Counterweight 950
Additional counterweight 220
Swing motor (Including brake valve) 22
Swing circle 104
Swing machinery 47
Center swivel joint 16
Track frame assembly (without track shoe) 1,067 [1,048]
Track frame 704
Idler assembly 54 x 2
Recoil spring assembly 40 x 2
Carrier roller 3.4 x 2
Track roller 13 x 10
Travel motor (with reduction gears) 81 x 2
Sprocket 19 x 2
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
[ ] Figures in [ ]: Rubber shoe specification
PC78MR-6 01-7
GENERAL WEIGHT TABLE
Unit: kg
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
01-8 PC78MR-6
GENERAL LIST OF LUBRICANTS AND COOLANT
AMBIENT TEMPERATURE
KIND OF
RESERVOIR FLUID 22 4 14 32 50 68 86 104 122F
30 20 10 0 10 20 30 40 50C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Swing machinery case
Final drive case Engine oil
PTO gear case SAE 30
SAE 10
Hydraulic system
SAE 10W-30
SAE 15W-40
PC78MR-6
Reservoir
Specified capacity Refill capacity
Engine oil pan 7.5 7.0
PTO gear case 0.4 0.4
Swing machinery case 2.0 2.0
Final drive case (each) 1.3 1.3
Hydraulic system 120 64
Fuel tank 125
Cooling system 10.5
PC78MR-6 01-9
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PC78MR-6 10-1
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PTO
PTO
1. Drain plug
2. Coupling
3. Flywheel
4. Pump case
5. Cage
6. Level plug
7. Breather/Oil filler plug
10-2 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
PC78MR-6 10-3
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN SYSTEM
10-4 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
1 Axial clearance of bearing Replace
0.20 0.80 2.0
2. Greasing for swing circle bearing a. Position of inner race soft zone
3. Greasing for swing circle pinion b. Position of outer race soft zone
4. Outer race
5. Inner race Specifications
6. Ball Reduction ratio 80/10=8.0
7. Seal
Grease G2-LI
Quantity of grease ( ) 5.5
PC78MR-6 10-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
10-6 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
No. Item Criteria Remedy
Backlash between Standard clearance Allowable clearance
1 swing motor shaft and
No. 1 sun gear 0.03 0.11
PC78MR-6 10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK FRAME AND IDLER CUSHION
10-8 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK FRAME AND IDLER CUSHION
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
Overlay
Vertical width of Track frame 74 78
1
idler guide Idler Overlay or
73 69
support replace
Track frame 158 162 Overlay
Lateral width of
2 Overlay or
idler guide Idler support 156 152
replace
Basic dimension Allowable limit
Installed Installed Installed
Free length Free length
length load load
3 Recoil spring Road liner, 47.4 kN 42.2 kN Replace
412 323 402
steel shoe {4,835 kg} {4,305 kg}
69.2 kN 61.6 kN
Rubber shoe 412 283 402
{7,061 kg} {6,284 kg}
4. Idler
5. Track frame
6. Carrier roller
7. Travel motor
8. Sprocket
9. Track roller
10. Track shoe
11. Idler cushion
11a.Support
11b.Yoke
11c.Recoil spring
11d.Cylinder
11e.Collar
11f. Lubricator
12. Idler guard (Road liner specification, steel shoe
specification)
13. Bracket to secure machine body for transporta-
tion (for USA spec. only)
Specification
Grease G2-LI
96 (Steel shoe, road liner)
Quantity of grease (cc)
233 (Rubber shoe)
PC78MR-6 10-9
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD IDLER
IDLER
Unit: mm
No. Item Criteria Remedy
Outside diameter of Basic dimension Allowable limit
1
projected part 460
2 Outside diameter of tread 415 407
3 Depth of tread 22.5 26.5 Overlay or replace
4 Width of projected part 43 37
5 Overall width 100 92
6 Width of tread 28.5 32
Basic Allowance Standard Allowable
Clearance between idler dimension Shaft Hole clearance clearance
7
shaft and bushing -0.250 + 0.062
44 0.250 0.352 1.5
-0.290 0
Basic Allowance Standard Allowable
Replace
Interference between idler dimension Shaft Hole interference interference
8
and bushing +0.117 +0.025
50 0.062 0.117
+0.087 0
Side clearance of idler Standard clearance Allowable clearance
9
(Each side) 0.190 0.395 1.5
Thickness of tread (at cen- Basic dimension Allowable limit
10 Overlay or replace
ter of width of tread) 13.8 9.8
Quantity of oil 60 cc (Engine oil: SAE30CD)
10-10 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
No. Item Criteria Remedy
Outside diameter of Basic dimension Allowable limit
1
projected part 149
Overlay or replace
2 Outside diameter of tread 120 113
3 Width of flange 43 36.6
4 Overall width 129
5 Width of tread 43 47.3 Overlay or replace
Basic Allowance Standard Allowable
Clearance between idler dimension Shaft Hole clearance clearance
6
shaft and bushing -0.250 + 0.075
38 0.225 0.345 1.5
-0.270 - 0.025
Basic Allowance Standard Allowable
Replace
Interference between idler dimension Shaft Hole interference interference
7
and bushing +0.117 +0.030
48 0.057 0.117
+0.087 0
Side clearance of track Standard clearance Allowable clearance
8
roller (Each side) 0.38 0.73 1.5
Thickness of tread (at cen- Basic dimension Allowable limit
9 Overlay or replace
ter of width of tread) 36 32.5
Quantity of oil 210 230 cc (Gear oil: G0140)
PC78MR-6 10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No. Item Criteria Remedy
Outside diameter of Basic dimension Allowable limit
1 Overlay or replace
tread 82 72
2 Width of tread 100
Basic Allowance Standard Allowable
Interference between shaft dimension Shaft Hole interference interference
3
and bearing +0.009 0 -0.004
30 Replace
-0.004 - 0.010 0.019
Interference between roller 0 + 0.018 -0.031
4 62
and bearing - 0.013 - 0.012 0.012
Basic dimension Allowable limit
5 Thickness of tread Overlay or replace
10 5
Quantity of oil 47 52 cc (Grease: ALVANIA EP-2)
10-12 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowance Allowable limit
1 Wear of root diameter +1.0
433.004 421
-2.0
2 Wear of tip diameter 483.7 2.0 472
Overlay or
3 Wear of dip width 28 - 23 replace
+0.5
4 Wear of root width 38 33
-2.5
+0.475
5 Thickness of root 84.002 78
-1.150
PC78MR-6 10-13
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
CITY PAD SHOE, ROAD LINER, AND TRIPLE SHOE
10-14 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
1 Link pitch
154.25 157.25 Reverse or replace
2 Outside diameter of bushing 41.2 37.2
3 Height of link 74 70
Thickness of link (Press fit- Repair or replace
4 20 16
ting part of bushing)
5 89
6 Shoe bolt pitch 73 Replace
7 57
Inside
8 45
width
Overall
9 Link 30 Repair or replace
width
Width of
10 26.3
tread
11 Projection of pin 3
Projection of regular bush-
12 3.15
ing
13 Overall length of pin 131
Overall length of bushing Adjust or replace
14 74.6
(Master bushing)
Basic dimension Allowable limit
15 Thickness of bushing
8.4 4.4
16 Thickness of spacer
17 Bushing 19.6 98.1 kN {2 10 ton}
Press fitting Regular
18 49.0 117.7 kN {5 12 ton}
pressure pin
*19 Master pin 39.2 78.5 kN {4 8 ton}
PC78MR-6 10-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
No. Item Criteria Remedy
Tightening torque
Retightening angle (deg.)
(Nm {kgm})
City pad 117.7 19.6
a. Regular 90 10
Triple {12 2}
link
60 10
Shoe bolt 117.7 19.6 Retighten
Road liner (Torque after retightening)
20 {12 2}
Min. 343 Nm {35 kgm}
Tightening Retightening
Lower limit torque
b. Master link torque angle (deg.)
Number of shoes
39
(Each side)
Basic dimen- Allowance Standard
Number of shoes sion Shaft Hole interference
21
(Each side) +0.214 +0.062
41 0.112 0.214
+0.174 0
Interference between regular pin +0.150 -0.198
22 24 0.198 0.400
and link 0 -0.250
Basic dimen- Allowance Standard
Clearance between regular pin sion Shaft Hole clearance
23
and bushing +0.150 +0.830
24 0.180 0.830 Adjust or replace
0 +0.330
Basic dimen- Allowance Standard
Interference between master pin sion Shaft Hole interference
*24
and link +0.020 -0.198
24 0.178 0.270
-0.020 -0.250
Basic dimen- Allowance Standard
Clearance between master pin sion Shaft Hole clearance
*25
and bushing -0.150 +0.630
24 0.380 0.880
-0.250 +0.230
Basic dimension Allowable limit
26 Height of grouser Replace
Road liner 42 19
10-16 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
1 Height of grouser
20 12
2 Overall height of shoe 26 18
3 Thickness of plate 6
4 20 Overlay or replace
Length of base of grouser
5 16
6 14
7 Length of upper side of grouser 10
8 12
PC78MR-6 10-17
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
1 Wear of lug height
30 5
2 Wear of roller guide 42 58 Replace
Wear of meshing part of Basic dimension Allowance Allowable limit
3
sprocket 22.5 0.5 27
10-18 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ARRANGEMENT OF HYDRAULIC COMPONENTS
PC78MR-6 10-19
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC TANK AND OIL FILTER
10-20 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD 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
Unit: mm
No. Item Criteria Remedy
Clearance Basic dimension Standard clearance Allowable clearance
5 between rotor Replace
and shaft 70 0.056 0.105 0.111
PC78MR-6 10-21
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
10-22 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
PC78MR-6 10-23
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
Specification
Model GM09VN-E
Theoretical Hi 24.1
displacement (cm/rev) Lo 36.3
Hi 3,211
Rated speed
Lo 2,154
Brake releasing pressure 0.47
(MPa {kg/cm}) {4.8}
Speed changeover pressure 2.94
(MPa {kg/cm}) {30}
Reduction ratio 66.5
Outline
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
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
OPERATION
Operation of motor
1. 2-stage travel speed selector solenoid valve Since 2-stage travel speed selector solenoid
2. Regulator valve valve (1) is de-energized, the hydraulic oil from
3. Spring the control pump does not flow into port Pi.
4. Check valve Accordingly, regulator valve (2) is pressed to the
5. End cover left by spring (3).
6. Regulator piston Under this condition, the main hydraulic oil from
7. Swash plate the control valve pushes check valve (4) and
8. Pump merge-divider valve flows into end cover (5) and then is shut off by
9. Travel control valve regulator valve (2).
10. Brake valve The hydraulic oil in control chamber (a) flows
through passage (b) of regulator valve (2) into
the motor case.
As a result, swash plate (7) is pushed toward the
maximum swash plate angle by the main hydrau-
lic oil in chamber (P) of the cylinder and the
motor capacity is increased to the maximum and
the travel speed lowers.
PC78MR-6 10-25
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
1. 2-stage travel speed selector solenoid valve If 2-stage travel speed selector solenoid valve
2. Regulator valve (1) is energized, the pilot pressure from the con-
3. Spring trol pump flows into port Pi and pushes regulator
4. Check valve valve (2) to the right.
5. End cover Accordingly, the main hydraulic oil from the con-
6. Regulator piston trol valve flows through passage (c) of regulator
7. Swash plate valve (2) into control chamber (a) and pushes
8. Pump merge-divider valve regulator piston (6) to the left.
9. Travel control valve As a result, swash plate (7) is pushed toward the
10. Brake valve minimum swash plate angle and the motor
capacity is decreased to the minimum and the
travel speed rises.
10-26 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
Function
When the machine travels downhill, its speed
may become higher than the motor speed
because of its momentum. If the engine speed is
low at this time, the motor runs idle and the
machine runs away, and this situation is very
dangerous. The brake valve prevents this phe-
nomenon and limits the travel speed according
to the engine speed (pump discharge).
PC78MR-6 10-27
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
Operation when oil is shut off Operation of brake during downhill travel
If the control lever is returned to neutral, the If the machine starts running away while travel-
hydraulic oil from the control valve is shut off and ing downhill, the motor revolves idle and the
spool (2) is returned to the right by the reaction pressure on the motor inlets side lowers, then
force of spring (3). the pressure in chamber D also lowers through
At this time, the oil flows through orifice (c) of orifice (c).
chamber D into port PA and back pressure is If the pressure in chamber D lowers below the
generated by the throttle effect of orifice (c). This pressure of spring (3), spool (2) is pushed back
back pressure controls the speed of spool (2) to the right.
returning to the right. At this time, the oil in chamber G flows through
Even after the hydraulic oil in port PA is shut off, orifice (f) into port PB. The throttle effect of ori-
the motor continues revolution by inertia. fice (f) generates back pressure, and spool (2)
At this time, the returning oil is reduced gradually returns to the right to control the returning speed
according to the changing speed and shape of of spool (2). Port MB on the outlet side is nar-
spool (2) to stop the motor smoothly. rowed.
The motor continues revolution by inertia and As a result, the pressure on the outlet side rises
can cause cavitation. Since valve (1a) is oper- and revolving resistance is generated in the
ated by very slight negative pressure, however, it motor to prevent the machine from running away.
opens ports PA and MA to prevent cavitation. To put it concretely, spool (2) moves to a position
at which the machine weight and the pressure on
the inlet side are balanced with the pressure at
port MB on the outlet side to narrow the outlet
circuit. Consequently, the speed is controlled
according to the pump discharge.
10-28 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL MOTOR
When travel lever is operated When travel lever is set to neutral position
If the travel lever is operated, the hydraulic oil If the travel lever is set to the neutral position, the
from the pump moves spool (1) to the left and hydraulic oil from the pump is shut off.
flows through port E into chamber A of brake pis- The hydraulic oil in chamber (a) of brake piston
ton (2), then pushes brake piston (2) to the left. (2) is drained into the case and piston (2) is
As a result, the pressing force of spring (5) given pushed to the right by spring (5).
to plate (3) and disc (4) is lost, then plate (3) and As a result, plate (3) and disc (4) are pressed
disc (4) are separated and the brake force is and the braking force is applied.
released.
PC78MR-6 10-29
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Arm cylinder
Bucket cylinder
10-30 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Blade cylinder
PC78MR-6 10-31
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Unit: mm
No. Item Criteria Remedy
Cylinder Basic Allowance Standard Allowable
name dimension Shaft Hole clearance clearance
-0.030 +0.250 0.085
Boom 65 0.654
-0.104 +0.055 0.354
-0.030 +0.163 0.036
Arm 60 0.567
Clearance between -0.104 +0.006 0.267 Replace
1
piston rod and bushing -0.030 +0.163 0.036 bushing
Bucket 55 0.567
-0.104 +0.006 0.267
Boom -0.030 +0.163 0.036
60 0.567
swing -0.104 +0.006 0.267
-0.030 +0.250 0.085
Blade 65 0.654
-0.104 +0.055 0.354
-0.030 +0.174 0.130
Boom 60 1.0
-0.100 +0.100 0.274
-0.030 +0.174 0.130
Arm 60 1.0
-0.100 +0.100 0.274
Clearance between
-0.030 +0.174 0.130
2 piston rod support Bucket 60 1.0
-0.100 +0.100 0.274
shaft and bushing
Boom -0.030 +0.174 0.130
65 1.0
swing -0.100 +0.100 0.274
-0.030 +0.174 0.130
Blade 70 1.0 Replace pin
-0.104 +0.100 0.278
and
-0.030 +0.174 0.130 bushing
Boom 65 1.0
-0.100 +0.100 0.274
-0.030 +0.174 0.130
Arm 55 1.0
-0.100 +0.100 0.274
Clearance between
-0.030 +0.142 0.110
3 cylinder bottom support Bucket 50 1.0
-0.100 +0.080 0.242
shaft and bushing
Boom -0.030 +0.174 0.130
65 1.0
swing -0.076 +0.100 0.250
-0.030 +0.174 0.130
Blade 70 1.0
-0.104 +0.100 0.278
Boom 961 96.1 Nm {98 9.8 kgm}
Arm 785 78.5 Nm {80 8.0 kgm}
Procedure 1) Tighten to 1.18 1.37 kNm {120 140 kgm}.
2) Loosen to 0 Nm {0 kgm}.
Tightening torque Bucket 3) Tighten to 0.39 kNm {40 kgm}.
4
of cylinder head 4) Control tightening of cylinder head by
turning angle (Turning distance: 3.5 4.5 mm).
Boom
981 98.1 Nm {100 10.0 kgm}
swing Retighten
Blade 1.030 103.0 Nm {105 10.5 kgm}
Boom 3.33 0.33 kNm {340 34.0 kgm} (2 Width across flats: 70 mm)
Arm 2.65 0.26 kNm {270 27.0 kgm} (2 Width across flats: 65 mm)
Tightening torque of Bucket 2.16 0.22 kNm {220 22.0 kgm} (2 Width across flats: 60 mm)
5
cylinder piston Boom
2.6 0.26 kNm {265 26.0 kgm} (2 Width across flats: 70 mm)
swing
Blade 3.14 0.31 kNm {320 32.0 kgm} (2 Width across flats: 75 mm)
10-32 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
Serial No.: 1001 1094
10-34 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
Solenoid valve
7. Coil (ON-OFF type)
8. Push pin
9. Valve spool
10. Return spring
11. Valve body
EPC valve
12. Return spring
13. Guide
14. Valve spool
15. Push pin
16. Coil (Proportional)
Check valve
17. Plug
18. Spring
19. Ball
PC78MR-6 10-35
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
10-35-1 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
Solenoid valve
6. Coil (ON-OFF type)
7. Push pin
8. Valve spool
9. Return spring
10. Valve body
EPC valve
11. Return spring
12. Guide
13. Valve spool
14. Push pin
15. Coil (Proportional)
Check valve
16. Plug
17. Spring
18. Ball
PC78MR-6 10-35-2
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
When solenoid is de-energized (circuit is broken) When solenoid is energized (circuit is made)
While a signal current does not flow from the If a signal current flows from the PPC hydraulic
PPC hydraulic lock switch or travel speed boost lock switch or travel speed boost pedal to sole-
pedal, solenoid (1) is de-energized. noid (1), solenoid (1) is energized.
Accordingly, spool (2) is pressed up by spring Accordingly, spool (2) is pushed down by push
(3). pin (4).
Under this condition, port A is closed and the Under this condition, the pilot hydraulic oil flows
pilot hydraulic oil does not flow into the actuator. through port A, spool (2), and port B into the
At the same time, the oil from the actuator is actuator.
drained through ports B and T into the tank. At the same time, port T is closed and the oil
does not flow into the tank.
10-36 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
When signal current is maximum (When coil is When signal current is reduced (When coil is
energized and circuit pressure is maximum) energized and circuit pressure is low)
If the signal current flows from the controller into If the signal current flowing from the controller
coil (1), coil (1) is energized. into coil (1) is reduced, coil (1) is still energized
At this time, the thrust of coil (1) is maximum. but its thrust is lowered in proportion to the signal
As a result, spool (2) is pushed down by push pin current.
(3). As a result, push pin (3) pushes down spool (2)
Accordingly, all the pressurized oil from the PPC and the pressurized oil from port A flows to port
valve flows through port A, spool (2), and port B B.
to the control valve. If the pressure in port B rises and the force
At this time, port T is closed and any oil does not applied to face "a" of spool (2) becomes larger
flow in the tank. than the thrust of coil (1), spool (2) is pushed up
and port A is disconnected from port B and con-
nected to port T.
Accordingly, spool (2) moves up and down so
that the thrust of coil (1) will be balanced with the
pressure in port B.
As a result, the circuit pressure between the
PPC valve and control valve is controlled in pro-
portion to the signal current.
PC78MR-6 10-37
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
10-38 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
PC78MR-6 10-39
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MULTI-CONTROL VALVE
MULTI-CONTROL VALVE
(OPTIONAL)
10-40 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ACCUMULATOR FOR BRAKE
1. Cap Specification
2. Core Type of gas Nitrogen Gas
3. Guard rubber
Gas volume ( ) 0.48
4. Lid
5. Plug Sealed gas pressure
6. Shell (MPa {kg/cm}) 0.1 {1} (at 80 C)
Max. actuating pressure
(MPa {kg/cm}) 6.86 {70}
PC78MR-6 10-41
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
Model: LPD45 + 45
10-42 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
PC78MR-6 10-43
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
10-44 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
With blade
Model: LPD45 + 45
PC78MR-6 10-45
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
10-46 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
PC78MR-6 10-47
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
PC valve LS valve
T: Drain 4. Retainer PE: Control piston pressure 14. Seat
P3: Gear pump pressure input 5. Seat PH: Pump shuttle pressure 15. Spring
PH: Pump shuttle pressure 6. Spool PLS: LS pressure input 16. Seat
PAV: Pump average pressure 7. Sleeve PPL: PC valve output pressure 17. O-ring
PPL: PC valve output pressure 8. Piston PPLS: LS pump pressure input 18. Backup ring
PEPCOUT: EPC output pressure 9. Seal 19. Nut
10. Piston 12. Spool 20. Plug
2. Lever 11. Plug 13. Plug
3. Spring
10-48 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
Function
This pump converts the revolution and torque of The oil in each cylinder of cylinder block (7) can
the engine transmitted to its shaft into hydraulic be drawn and discharged through valve plate (8).
energy and discharges hydraulic oil according to
the load.
The discharge can be changed by changing the
swash plate angle.
Structure
Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported on the
front and rear bearings.
The end of piston (6) is a concave sphere, which
holds shoe (5) as a spherical bearing.
Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) is supported on flange (2) and
ball (12) fixed to the case and slides on the
formed static pressure bearing and high-pres-
sure oil.
Piston (6) moves axially and relatively in each
cylinder of cylinder block (7).
Cylinder block (7) revolves relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic pressure on the revolving surface of
the cylinder block is balanced properly.
PC78MR-6 10-49
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
Operation
1. Operation of pump
Shaft (1) and cylinder block (7) revolve together If center line X of rocker cam (4) is in the direc-
and shoe (5) slides on plane A. As rocker cam tion of the axis of cylinder block (7) (Swash plate
(4) slants around ball (12) at this time, angle ( ) angle = 0), the difference between volumes E
between the center line X of rocker cam (4) and and F in cylinder block (7) is 0 and oil is not
axis of cylinder block (7) changes. Angle ( ) is sucked or discharged (The swash plate angle is
called the swash plate angle. not reduced to 0 actually, however).
In short, swash plate angle ( ) is in proportion to
the discharge of the pump.
The number of holes on cylinder block (7) is
even 10 and every second one of them is fitted
to 2 grooves of valve plate (8). The quantity of
the oil equivalent to 5 pistons is discharged to
each of P1 and P2.
10-50 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
PC78MR-6 10-51
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
10-52 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
PC78MR-6 10-53
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD 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
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
When balanced
PC78MR-6 10-55
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline
(1) Outside view
10-56 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
PC78MR-6 10-57
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
10-58 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Item Criteria Remedy
Basic dimensions Allowable limit
Free length x
Installed Installed Installed
Cooler bypass valve Outside diam- Free length
35 length load load
spring eter
73.5 N 58.8 N
34.5 X 17.7 25
{7.5 kg} {6.0 kg}
Spool return spring 34.3 N 27.4 N
36 41.1 X 19.3 40.5
(Work equipment) {3.5 kg} {2.8 kg}
Spool return spring 103.9 N 83.2 N
37 42.3 X 19.2 38.9
(Arm out) {10.6 kg} {8.48 kg}
Spool return spring 180.5 N 14.5 N
38 29.0 X 17.5 25.0
(Trave) {18.02 kg} {14.74 kg}
129 N 103 N If damaged or
39 Unload valve spring 40.9 X 15.1 33.5
{13.2 kg} {10.6 kg} deformed,
Boom RAISE merge 287.3 N 230 N replace spring.
40 42.4 X 19.0 13
valve spring {29.3 kg} {23.44 kg}
Spool return spring 89.5 N 71.6 N
41 29.01 X 18.3 27.5
(Blade) {9.1 kg} {7.28 kg}
Spool return spring 136.4 N 109 N
42 41.13 X 19.3 38.5
(Boom raise) {13.91 kg} {11.13 kg}
Spool return spring
135.53 N 108 N
43 (Bucket curl, 41.47 X 19.3 38.5
{13.82 kg} {11.06 kg}
Boom lower)
Spool return spring 162.54 N 130 N
44 29.20 X 17.5 25.0
(Boom swing) {16.57 kg} {13.26 kg}
Spool return spring 173.2 N 139 N
45 29.03 X 18.4 26.0
(Swing) {17.66 kg} {14.13 kg}
PC78MR-6 10-59
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
1. Spool (Pump merge-divider valve) 16. Pump pressure pickup plug (P2)
2. Pressure compensation valve F (Left travel) 17. LS pressure pickup plug (LS3)
3. Pressure compensation valve F (Right travel) 18. LS bypass plug (LS2)
4. Pressure compensation valve F (Boom swing) 19. LS bleed valve
5. Pressure compensation valve F (Boom) 20. Travel junction valve, LS bleed valve
6. Pressure compensation valve F (Arm) 21. Logic valve
7. Pressure compensation valve F (Bucket) 22. Boom hydraulic drift prevention valve
8. Pressure compensation valve F (Attachment) 23. Check valve (Blade)
9. Pressure compensation valve R (Attachment) 24. Check valve (Swing)
10. Pressure compensation valve R (Bucket) 25. Check valve (Boom bottom)
11. Pressure compensation valve R (Arm) 26. Check valve (Arm)
12. Pressure compensation valve R (Boom) 27. Check valve (Bucket)
13. Pressure compensation valve R (Boom swing) 28. Check valve (Attachment)
14. Pressure compensation valve R (Right travel)
15. Pressure compensation valve R (Left travel) F: Flow control valve
R: Pressure reducing valve
10-60 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Item Criteria Remedy
Basic dimensions Allowable limit
Free length x
Installed Installed Installed
Pressure compensation Outside diam- Free length
29 length load load
valve spring eter
13.7 N 11.0 N
28.0 X 14.4 14.5
{1.4 kg} {1.12 kg}
Pressure compensation 55.9 N 44.7 N
30 33.4 X 14.4 21.5
valve spring {5.7 kg} {4.56 kg}
Pressure compensation 9.8 N 7.85 N
31 30.9 X 5.2 27
valve spring {1.0 kg} {0.8 kg}
Pressure compensation 6.86 N 5.49 N
32 20.0 X 8.4 12
valve spring {0.7 kg} {0.56 kg} If damaged or
Pump merge-divider deformed,
49.0 N 39.2 N replace spring.
33 valve spool 33.2 X 14.2 22.5
{5.0 kg} {4.0 kg}
return spring
3.92 N 3.14 N
34 Check valve spring 27.2 X 6.9 22
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
35 Check valve spring 12.3 X 11.4 10.5
{0.4 kg} {0.32 kg}
1.96 N 1.57 N
36 Check valve spring 21.9 X 5.0 15.8
{0.2 kg} {0.16 kg}
1.96 N 1.57 N
37 Check valve spring 13.0 X 6.5 9.5
{0.2 kg} {0.16 kg}
Pressure compensation 13.72 N 11.0 N
38 28.0 X 14.4 14.5
valve spring {1.4 kg} {1.12 kg}
PC78MR-6 10-61
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
10-62 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Item Criteria Remedy
Basic dimensions Allowable limit
Free length x
Installed Installed Installed
Outside diam- Free length
1 Check valve spring length load load If damaged or
eter
deformed,
1.96 N 1.57 N replace spring.
21.9 X 5.0 15.8
{0.2 kg} {0.16 kg}
Travel junction valve 15.7 N 12.6 N
2 19.3 X 7.5 14
spring {1.6 kg} {1.28 kg}
PC78MR-6 10-63
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
10-64 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Item Criteria Remedy
Basic dimensions Allowable limit
Free length x
Installed Installed Installed
Outside diam- Free length
5 Check valve spring length load load
eter
If damaged or
1.96 N 1.57 N
13.0 X 6.5 9.5 deformed,
{0.2 kg} {0.16 kg}
replace spring.
Hydraulic drift preven- 11.2 N 8.96 N
6 16.6 X 13.0 13
tion valve spring {1.14 kg} {0.91 kg}
Hydraulic drift preven- 10.8 N 8.64 N
7 13.0 X 8.8 7.5
tion valve spring {1.1 kg} {0.88 kg}
PC78MR-6 10-65
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
10-66 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Item Criteria Remedy
Basic dimensions Allowable limit
Free length x
Installed Installed Installed If damaged or
Outside diam- Free length
4 Logic valve spring length load load deformed,
eter
replace spring.
5.5 N 4.4 N
11.0 X 6.2 9.5
{0.56 kg} {0.45 kg}
PC78MR-6 10-67
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- The CLSS consists of a variable capacity single
tem, and has the following featues. piston pump, control valve, and actuators.
Fine control not influenced by load The pump body consists of the main pump, PC
Control enabling digging even with fine control valve and LS valve.
Ease of compound operation ensured by flow
divider function using area of opening of spoll
during compund operations
Energy saving using variable pump control
10-68 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
BASIC PRINCIPLE
1. Control of pump swash plate angle
The pump swash plate angle (pump discharge
amount) is controlled so that LS differential pres-
sure EPLS (the difference between pump (dis-
charge) pressure PP and control valve outlet port
LS pressure PLS) load pressure of actuator) is
constant.
(LS pressure EPLS=Pump discharge pressure
PP-LS pressure PLS)
PC78MR-6 10-69
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-70 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-72 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
PC78MR-6 10-73
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Unload valve
10-74 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Function Operation
During fine control of the work equipment valve, When fine control is carried out on the work
when the demand flow for the actuator is within equipment valve, LS pressures PLS1 and PLS2
the amount discharged by the minimum swash are generated and act on the right end of spool
plate angle of the pump, pump discharge pres- (1) (PP1 = PP2, PLS1 = PLS2). When this hap-
sure PP1/PP2 is set to LS pressure PLS1/PLS2 pens, the area of the opening of the work equip-
+ 2.45 MPa {25.0 kg/cm2}. When the difference ment valve spool is small, so LS pressures PLS1
between pump discharge pressure PP1/PP2 and and PLS2 are very different from pump dis-
LS pressure PLS1/PLS2 reaches the load of charge pressures PP1 and PP2.
spring (2) (2.45 MPa {25.0 kg/cm 2 }), unload When the difference between pump discharge
spool (1) opens, so LS differential pressure pressure PP1/PP2 and LS pressure PLS1/PLS2
EPLS becomes 2.45 MPa {25 kg/cm2}. reaches the load of spring (2) (2.45 MPa {25.0
Since the pump merge-divider valve is at the kg/cm2}), spool (1) moves to the right, and pump
merge position, pump discharge pressures PP1 discharge pressures PP1 and PP2 are con-
and PP2 are merged. LS pressures PLS1, PLS2, nected to tank circuit T.
and PLS3 are also merged. In other words, pump discharge pressure PP1/
PP2 is set to the spring force (2.45 MPa {25.0
kg/cm2}) + LS pressure PLS1/PLS2, and LS dif-
ferential pressure DPLS becomes 2.45 MPa
{25.0 kg/cm2}.
PC78MR-6 10-75
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Function Operation
When any work equipment valve is operated if When any work equipment valve is operated for
the demand flow for the actuator becomes a long stroke, LS pressures PLS1 and PLS2 are
greater than the pump discharge from the mini- generated and act on the right end of unload
mum swash plate angle, the oil flow to tank cir- spool (1) (PP1 = PP2, PLS1 = PLS2). When this
cuit T is cut off, and all pump discharge amount happens, the area of the opening of the work
Q flows to the actuator circuit. equipment valve spool is large, so LS pressures
Since the pump merge-divider valve is at the PLS1 and PLS2 are not so different from pump
merge position, pump discharge pressures PP1 discharge pressures PP1 and PP2.
and PP2 are merged. LS pressures PLS1,
PLS2, and PLS3 are also merged. For this reason, the difference between pump
discharge pressure PP1/PP2 and LS pressure
PLS1/PLS2 does not reach the load of spring (2)
(2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
to the left by spring (2).
As a result, pump discharge pressures PP1 and
PP2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
10-76 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Function Operation
During fine control of both travel valves, when When fine control is carried out on both travel
the demand flow is below the maximum pump valves, LS pressures PLS1 and PLS2 are gener-
discharge amount, pump discharge pressure ated and act on the right end of spool (1) (PP1,
PP1/PP2 is set to LS pressure PLS1/PLS2 + PP2, PLS1, and PLS2 are separated).
2.45 MPa {25.0 kg/cm2}. When this happens, the area of the opening of
When the difference between pump discharge both travel valve spools is small, so LS pres-
pressure PP1/PP2 and LS pressure PLS1/PLS2 sures PLS1 and PLS2 are very different from
reaches the load of spring (2) (2.45 MPa {25.0 pump discharge pressures PP1 and PP2.
kg/cm2}), unload spool (1) opens, so excessive When the difference between pump discharge
oil (maximum pump discharge mount - demand pressure PP1/PP2 and LS pressure PLS1/PLS2
flow) flows into the tank circuit. reaches the load of spring (2) (2.45 MPa {25.0
Since the pump merge-divider valve is at the kg/cm2}), spool (1) moves to the right, and pump
separate position, pump discharge pressures discharge pressures PP1 and PP2 are con-
PP1 and PP2 are separated. LS pressures PLS1 nected to tank circuit T and the excessive oil
and PLS2 are also separated. (maximum pump discharge mount demand
The swash plate angle of the pump becomes flow) flows.
maximum, so the pump discharge amount In other words, the excessive oil (maximum
becomes maximum. (For details, see the sec- pump discharge mount demand flow) above
tions on the pump merge-divider valve and logic the strokes of both travel valves flows into tank
valve.) circuit T.
PC78MR-6 10-77
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Function Operation
During operation of both travel valves, when the When both travel valves are operated to the
demand flow becomes maximum, the oil flow to stroke ends, LS pressures PLS1 and PLS2 are
tank circuit T is cut off, and all pump discharge generated and act on the right end of unload
amount Q flows to both travel circuits. spool (1) (PP1, PP2, PLS1, and PLS2 are sepa-
Since the pump merge-divider valve is at the rated).
separate position, pump discharge pressures When this happens, the area of the openings of
PP1 and PP2 are separated. LS pressures PLS1 both travel valve spools is large, so LS pressures
and PLS2 are also separated. PLS1 and PLS2 are not so different from pump
The swash plate angle of the pump becomes discharge pressures PP1 and PP2.
maximum, so the pump discharge amount For this reason, the difference between pump
becomes maximum. (For details, see the sec- discharge pressure PP1/PP2 and LS pressure
tions on the pump merge-divider valve and logic PLS1/PLS2 does not reach the load of spring (2)
valve.) (2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
to the left by spring (2).
As a result, pump discharge pressures PP1 and
PP2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
10-78 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
PC78MR-6 10-79
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Function
Pump merge-divider valve spool (3) merges
pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 respectively.
Operation
When the control valve is at HOLD, changeover
pressure is not generated on logic spool (1), so
spring (2) pushes spool (1) to the left.
Since both travel valves are at HOLD,
changeover pressure is not generated on the
pump merge-divider spool.
When the control valve is at HOLD, changeover
pressure is not generated on the pump merge-
divider spool, so spring (4) pushes spool (3) to
the right.
Pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 are merged
respectively (PP1 = PP2, PLS1 = PLS2 = PLS3).
10-80 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
PC78MR-6 10-81
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-82 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Introduction of LS pressure
1. Work equipment valve: Boom, arm, bucket,
boom swing, or attachment
PC78MR-6 10-83
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD 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 pas-
sage (b) to actuator circuit A.
At the same time, reducing valve (3) is moved to
the right by actuator circuit pressure PA, and
notch (c) and notch (d) are interconnected
respectively with travel junction circuit (e) and LS
circuit PLS.
As a result, actuator circuit pressure PA (= A) is
introduced from notch (c) through the internal
check valve and notch (d) into LS circuit PLS.
10-84 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
LS bypass plug
When work equipment valve is operated
PC78MR-6 10-85
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-86 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
PC78MR-6 10-87
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-88 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Function
This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) to cause
hydraulic drift of the boom while the boom con-
trol lever is not operated.
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
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-90 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
PC78MR-6 10-91
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
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
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Function
While the boom is being lowered under a load, if
head pressure B of cylinder (1) is higher than
bottom pressure A, check valve (3) is closed to
shut off the head side and bottom side from each
other.
Operation
While the boom is being lowered under a load,
pressure B on the head side of boom cylinder (1)
is higher than pressure A on the bottom side.
When this happens, check valve (3) is closed by
pressure B on the head side and spring (4) to
shut off the head side and bottom side from each
other.
PC78MR-6 10-93
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-94 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
PC78MR-6 10-95
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD 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 oper-
ated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are sepa-
rated by the pump merge-divider spool.
(See the section on the LS bypass plug).
When both travel spools (1) are operated,
the oil from the pump flows from pump dis-
charge circuits PP1 and PP2 through actua-
tor circuit PB to B.
When the machine travels in straight line,
both reducing valves (2) are pushed to the
right and notch (a) and travel junction circuit
are opened.
The right end of travel junction spool (3) is
the work equipment PPC pressure circuit.
Since the work equipment valve is not oper-
ated at this time, however, any pressure is
not generated.
In this way, both travel actuator circuits are
interconnected by the travel junction circuit.
If any difference occurs in the flow of oil to
both travel motors, the difference is compen-
sated to reduce travel deviation.
2. When steered during travel
Since only both travel valves are operated
and any work equipment valve is not oper-
ated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are sepa-
rated by the pump merge-divider spool.
(See the section on the LS bypass plug).
The machine is steered by supplying the
demand flow to the actuator circuit according
to the strokes of both travel spools. (See the
section on the unload valve.)
While the machine is traveling in a straight
line, if the right travel spool (right 1) is
returned to the neutral position and the
machine is steered, a difference (left B >
right B) is made between the load pressures
in both travel actuator circuits PB.
10-96 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
PC78MR-6 10-97
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
10-98 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
Operation
1. During normal operation
When boom spool (1) is operated, LS circuit
PLS becomes the same pressure as boom
circuit pressure A.
Since the work equipment valve is operated,
pump discharge pressures PP1 and PP2 are
merged by the pump merge-divider valve
spool. LS pressures PLS1, PLS2, and PLS3
are also merged. (See the sections on the
pump merge-divider valve and logic valve.)
At the same time, LS pressure PLS also
goes to spring chamber PLSS of reducing
valve (2) of the travel valve.
Since the travel valve spool is not operated,
notch (a) of reducing valve (2) is closed, and
check valves (3) and (4) of the bleed circuit
are also closed.
As a result, when the boom is operated sin-
gly, the travel LS bypass circuit is closed.
2. When travel actuator and another actuator are
operated
When boom spool (1) is operated, LS circuit
PLS becomes the same pressure as boom
circuit pressure A.
Since the work equipment valve is operated,
pump discharge pressures PP1 and PP2 are
merged by the pump merge-divider valve
spool. LS pressures PLS1, PLS2, and PLS3
are also merged. (See the sections on the
pump merge-divider valve and logic valve.)
As for the actuator circuit pressure, the boom
RAISE pressure is normally higher than the
travel pressure (A > B), so the pressure in
spring chamber PLSS inside reducing valve
(2) of the travel valve is higher than travel cir-
cuit pressure PB.
As a result, reducing valve (2) moves to the
left and LS pressure PLS flows through
check valves (3) and (4) and notch (a) of
reducing valve (2) to travel circuit PB.
PC78MR-6 10-99
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
Model: LMF30AEL
10-100 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MOTOR
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
A Check valve spring Free length
Outside Installed Installed Free length Installed
diameter length load load If damaged
or deformed,
0.9 N 0.69 N replace spring.
15.5 9.0 11.5 {0.09 kg} {0.07 kg}
B Valve return spring
1.8 N 1.41 N
33 13.8 19.5 {0.18 kg} {0.14 kg}
PC78MR-6 10-101
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MOTOR
BRAKE VALVE
Outline 2. When machine stops swinging
The brake valve consists of a check valve and a If the swing control lever is returned to the
safety valve. neutral position, oil is not supplied from the
pump to port MB any more. Since the return
Function circuit for the oil from the motor outlet to the
When the machine stops swinging, control valve tank is closed by control valve (1), the pres-
(1) closes the outlet circuit of the motor. Since sure in port MA rises and revolution resis-
the motor continues revolving because of the tance is generated in the motor, then the
inertia, the motor output pressure rises abnor- motor is braked.
mally to break the motor. Accordingly, the abnor- The pressure in port MA rises to the set pres-
mally high pressure is released through the sure of the safety valve. As a result, high
outlet (high pressure side) of the motor to protect braking torque is generated in the motor,
the motor. then the motor stops.
While the safety valve is operating, the oil
Operation discharged from the safety valve and the oil
1. When machine starts swinging from port S are supplied through check valve
When the swing control lever is operated to CB to port MB so that cavitation will not
swing to the left, the hydraulic oil from the occur in port MB.
pump flows through control valve (1) into port
MB. As a result, the pressure in port MB
rises and the starting torque is generated in
the motor and the motor starts revolution.
The oil from the motor outlet returns from
port MA through control valve (1) to the tank.
10-102 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MOTOR
Operation
1. When circuit pressure is P0
The relief valve does not operate.
2. When circuit pressure rises sharply
When circuit pressure rises to P1, the
hydraulic pressure acts on the area differ-
ence between D1 and D3 (D1 > D3) and
pushes spring (4) to open valve (3).
At this time, pressure acts on the area differ-
ence between D1 and D2 (D2 > D1), so seat
(1) follows valve (3).
As seat (1) moves, the passage for the pres-
surized oil in chamber (a) to flow into port S
is narrowed by ball (2). Accordingly, seat (1)
does not move so fast as valve (3).
As a result, the relief pressure rises gradually
from P1 to P2 while seat (1) is moving to
sleeve (5).
PC78MR-6 10-103
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MOTOR
SWING BRAKE
1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
When the solenoid valve of the swing brake is When the solenoid valve of the swing brake is
de-energized, the hydraulic oil from the self- energized, the valve is changed and hydraulic oil
pressure reducing valve is shut off and port B is from the self-pressure reducing valve flows
connected to the tank circuit. through port B into brake chamber A.
As a result, brake piston (13) is pushed up by The hydraulic oil in chamber A pushes brake
brake spring (12) to press disc (14) and disc (15) spring (12) and brake piston (13) moves down.
to apply the brake. As a result, disc (14) and plate (15) are sepa-
rated and the brake is released.
10-104 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MOTOR
PC78MR-6 10-105
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SWING MOTOR
10-106 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD 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 sys-
tem, and the compression of the hydraulic oil
when the swing is stopped.
This is effective in preventing spillage of the load
when stopping the swing and reducing the cycle
time (the positioning ability is good and it is pos-
sible to move swiftly to the next job).
PC78MR-6 10-107
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT AND SWING PPC VALVE
10-108 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT AND SWING PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
6. Nut (For connection of lever)
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
10-110 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT AND SWING PPC VALVE
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
Free length
Centering spring Outside Installed Installed Free length Installed
12 (For ports P3 and P4) diameter length load load
PC78MR-6 10-111
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT AND SWING PPC VALVE
OPERATION
1. At neutral
Ports A and B of the control valve and ports P1,
P2, P3 and P4 of the PPC valve are connected
to drain chamber D through fine control hole f in
spool (1). (Fig. 1)
10-112 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT AND SWING PPC VALVE
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
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL PPC VALVE
10-114 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL PPC VALVE
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
Free length Installed Installed Installed
9 Metering spring Outside diam- length load Free length load
eter If damaged
or deformed,
26.53 8.15 24.9 16.7 N 13.3 N replace spring.
{1.70 kg} {1.36 kg}
PC78MR-6 10-115
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD 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)
10-116 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRAVEL PPC VALVE
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
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM SWING PPC VALVE, BLADE PPC VALVE
T : To tank
P : From main pump
P1 : To right boom swing/blade raise valve
P2 : To left boom swing/blade lower valve
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
10-118 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM SWING PPC VALVE, BLADE PPC VALVE
For Blade
Unit: mm
No. Item Criteria Remedy
Basic dimension Allowable limit
Free length
Outside Installed Installed Free length Installed
10 Centering spring diameter length load load If damaged
or deformed,
14.7 N 118 N replace spring.
42.36 15.5 32.5 {15 kg} {12 kg}
16.67 N 13.3 N
11 Metering spring 22.73 8.1 22.0 {1.7 kg} {1.36 kg}
PC78MR-6 10-119
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM SWING PPC VALVE, BLADE PPC VALVE
Operation
1. In the neutral mode
P1 and P2 ports of the operation valves A, B and
PPC valve are connected to drain room D via the
fine control hole f on the spool (1).
10-120 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM SWING PPC VALVE, BLADE PPC VALVE
PC78MR-6 10-121
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM HYDRAULIC ANTI-BURST VALVE
10-121-1 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM HYDRAULIC ANTI-BURST VALVE
1. Pilot spool
2. Spring (1st stage of spool)
3. Spring (2nd stage of spool)
4. Safety valve
5. Check valve
6. Spring
Unit: mm
PC78MR-6 10-121-2
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM HYDRAULIC ANTI-BURST VALVE
Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the oil
from flowing back from the work equipment cylinder
to prevent sudden fall of the work equipment.
Operation
1. When the work equipment is in neutral
[When piping is normal]
Check valve (5) is closed by the work equip-
ment cylinder holding pressure applied
through port CY to chamber b.
When the work equipment is in neutral, no
pilot pressure is applied from the PPC valve
to port PI. Accordingly, pilot spool (1) is
moved to the left end by the force of springs
(2) and (3), then chambers a and b are shut
off from each other.
Accordingly, oil does not flow from the main
valve to the work equipment cylinder, thus
the work equipment cylinder is held.
If the pressure in the work equipment cylin-
der rises high abnormally, work equipment
cylinder holding pressure Pb operates safety
valve (4).
10-121-3 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM HYDRAULIC ANTI-BURST VALVE
PC78MR-6 10-121-4
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BOOM HYDRAULIC ANTI-BURST VALVE
10-121-5 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
Unit : mm
10-122 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
PC78MR-6 10-123
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD DIMENSIONS OF EACH PART OF WORK EQUIPMENT
10-124 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD DIMENSIONS OF EACH PART OF WORK EQUIPMENT
PC78MR-6
No. Allowance
Measuring point Basic dimension
Shaft Hole
-0.030 +0.100
1 60
-0.100 0
+1.0
Arm side 71.5
2 0
Cylinder head side 70 1.2
-0.030 +0.100
3 60
-0.100 0
+0.5
Boom side 220
0
4
-0.5
Arm side 220
-1.0
5 142.4 2.0
6 218.8 1.0
7 458.6 1.0
8 1,650
9 2,093.9 3.0
10 1,661.2 1.3
11 258.7 0.3
12 15.1 1.0
13 395.1 0.1
14 342 0.1
15 312.2
16 1,066.9
-0.225 0
17 50
-0.285 -0.150
-1.0
Link side 200
-2.0
18
+2.0
Bucket side 200
0
-0.225 0
19 50
-0.285 -0.150
-0.50
Arm side 188
-1.0
20
+3.0
Bucket side 211
0
Min. 1,055 1.5
21
Max. 1,765
PC78MR-6 10-125
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD DIMENSIONS OF EACH PART OF WORK EQUIPMENT
2. BUCKET PORTION
10-126 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD DIMENSIONS OF EACH PART OF WORK EQUIPMENT
PC78MR-6
No.
Measuring point Basic dimension Allowance
1 309.8 0.5
2 38.6 0.5
3 97.1
4 312.2
5 1,057.2
6 143.7
7 8
8 5.2
0
9 50
-0.15
10 60
+0.2
11 70
0
+2.0
12 200
0
13 40
14 71
+1.0
15 296
0
16 18
17 100
18 115
19 95
+3.0
20 211
0
21 40
22 24
23 89.3
24 87.9
25 60
26 66
PC78MR-6 10-127
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD AIR CONDITIONER PIPING
10-128 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
(*1)
Electric Overload alarm function
control system
Self-diagnosis function
PC78MR-6 10-129
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
10-130 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency pump drive switch
8. Emergency boom swing operating and swing
holding brake release switch
9. Resistor
(For emergency boom swing operating)
10. Resistor (For emergency pump drive)
11. Safety lock lever
12. PPC lock switch
13. Starting motor cut relay
14. Safety relay
15. One-touch deceleration switch
16. Fuel control motor relay (For accelerator)
17. Fuel control motor relay (For deceleration)
18. Fuel control dial
19. Fuel control motor
20. Monitor panel
21. Travel speed boost pedal
22. Travel alarm (If equipped)
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
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
10-131-1 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency pump drive switch
8. Emergency boom swing operating and swing
holding brake release switch
9. Resistor
(For emergency boom swing operating)
10. Resistor (For emergency pump drive)
11. Safety lock lever
12. PPC lock switch
13. Starting motor cut relay
14. Safety relay
15. One-touch deceleration switch
16. Fuel control motor relay (For accelerator)
17. Fuel control motor relay (For deceleration)
18. Fuel control dial
19. Fuel control motor
20. Monitor panel
21. Travel speed boost pedal
22. Travel alarm (If equipped)
23. PPC lock solenoid valve
24. 2-stage travel speed selector solenoid valve
25. Swing holding brake solenoid valve
26. Left boom swing stop EPC valve
27. Right boom swing stop EPC valve
28. TVC-EPC valve
29. Right work equipment PPC valve
30. Travel PPC valve
31. Left work equipment PPC valve
32. Boom swing PPC valve
33. Blade PPC valve
34. Attachment control PPC valve
35. Boom RAISE PPC oil pressure switch
36. Travel PPC oil pressure switch
37. Arm IN PPC oil pressure switch
38. Swing PPC oil pressure switch
39. Boom swing potentiometer
40. Engine stop solenoid
41. Engine stop solenoid relay
42. Starting motor
43. Engine speed sensor
44. Coolant temperature sensor
45. Hydraulic pump
45a. Servo piston
45b. LS valve
45c. TVC valve
46. Control valve
46a. Pump merge-divider valve
47. Travel motor
48. Swing motor
49. Overload alarm actuation switch
50. Overload alarm pressure switch
PC78MR-6 10-131-2
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Safety lock lever
8. PPC lock switch
9. Starting motor cut relay
10. Safety relay
11. Fuel control dial
12. Fuel control motor
13. Fuel control motor relay (For accelerator)
14. Fuel control motor relay (For deceleration)
15. One-touch deceleration switch
16. Monitor panel
17. Engine stop solenoid
18. Engine stop solenoid relay
19. Starting motor
10-132 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
PC78MR-6 10-133
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
Stopping engine
If starting switch (4) is turned to the OFF posi-
tion, engine stop solenoid (17) moves the gover-
nor stop lever to the STOP side and the engine
stops.
One-touch deceleration
If one-touch deceleration switch (16) is pressed,
the deceleration signal is output to controller (6).
Controller (6) turns on the one-touch decelera-
tion monitor of monitor panel (16) and drives fuel
control motor (12) to lower the engine speed to
low idling.
If one-touch deceleration switch (15) is pressed
while the engine is being started, the engine
speed is set to low idling. If it is pressed again,
the engine speed returns to the speed set with
fuel control dial (11).
a Even if the engine is stopped while the one-
touch deceleration system is turned on, the latter
is turned off when the engine is started next time
(the engine speed is set the speed set with the
fuel control dial).
a Even if the fuel control dial is operated while the
one-touch deceleration system is turned on, the
engine speed is kept at low idling.
a If the fuel control dial is at low idling, the engine
speed does not lower any more even if the one-
touch deceleration switch is pressed
10-134 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
PC78MR-6 10-135
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
Functions
The "active" or "E" mode is selected with the
working mode selection switch on the monitor
panel. In each mode, proper engine torque and
pump absorption torque are selected according
to the contents of work.
The controller detects the engine governor
speed set with the fuel control dial and the actual
engine speed and controls the hydraulic system
so that the pump will absorb the all torque at
each output point of the engine, according to the
pump absorption torque set for each mode.
If the engine speed is lowered, the pump absorp-
tion torque is reduced to prevent the engine from
stopping.
10-136 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
Active mode
Matching point of active mode:
PC78MR-6 10-137
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
E mode
Matching point of E mode: 85% partial output
point
10-138 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
OVERHEAT PREVENTION
FUNCTION
a For the system circuit diagram, see "Engine and
pump compound control function".
PC78MR-6 10-139
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
10-140 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
PC78MR-6 10-141
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
1. Battery Function
2. Battery relay Changing travel speed
3. Fusible link If the travel speed boost selector switch is oper-
4. Starting switch ated or the travel speed boost pedal is pressed,
5. Fuse box the motor capacity changes to change the travel
6. Controller speed.
7. Monitor panel
8. 2-stage travel speed selector solenoid valve a When the engine is started, the travel speed
9. Left travel motor boost selector switch is set to the low speed
10. Right travel motor position automatically.
11. Travel PPC valve a The travel speed boost pedal is effective only
12. Travel PPC oil pressure switch while the "Lo" lamp of the travel speed boost
13. Travel alarm (If equipped) selector switch is lighting. Even if the pedal is
14. Engine pressed while the "Hi" lamp is lighting up, the
15. Hydraulic pump travel speed does not change.
16. Control valve
16a. Pump merge-divider valve Lo lamp Hi lamp
17. Travel speed boost pedal Travel speed boost
lights up lights up
selector switch
(Low speed) (High speed)
Input/Output signals Motor capacity
a. Controller power source 36.3 24.1
(cc/rev)
b. Solenoid power source
Released
Travel speed
c. Monitor panel power source 3.0 4.5
Travel speed boost pedal
(km/h)
d. S-NET drive signal
e. Solenoid valve drive signal Swash plate
angle of travel Max. Min.
f. Travel PPC oil pressure switch signal
motor
g. Travel alarm drive signal
h. 2nd travel speed selection signal Motor capacity
24.1 24.1
(cc/rev)
Travel speed
Pressed
4.5 4.5
(km/h)
Swash plate
angle of travel Min. Min.
motor
10-142 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
PC78MR-6 10-143
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
Function
If the pressure in the boom cylinder bottom cir-
cuit rises above the set value, the caution lamp
lights up and the buzzer sounds to notify the
operator of possibility of tipping over of the
machine by an overload.
10-143-1 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
If the boom swings and enters area (B) from If the potentiometer is replaced or the work
area (A), its swing speed is lowered gradu- equipment is replaced, an input signal error
ally to reduce the shock made at the stop is made because of the error of the installa-
position. tion of the potentiometer.
At this time, the output pressure from the With the correction function, this error can be
boom swing PPC valve to the boom swing corrected easily without measuring the out-
control valve is reduced by controlling the put voltage or adjusting the potentiometer
EPC valve according to the angle sensor sig- finely.
nal. If the boom is swung to each stroke and the
As a result, the shock made at the stroke end set angle (0) is input, the difference between
is reduced. angle (A) calculated from the actual output
voltage of the potentiometer and standard
angle (B) set in the computer (installation
error) is saved as "correction value (C)".
A. Ordinary area
B. Deceleration area
10-144 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
SELF-DIAGNOSTIC FUNCTION
1. Error code display and alarm function 2. Error code memory function
The system of this function consists of the If a problem occurs in the leading system, it
controller and the electronic components is detected by the self-diagnostic function
such as the potentiometers that output input and its error code is stored in memory.
signals and the solenoid valves and EPC a For details of the display and resetting
valves that receive output signals. The con- method, see TESTING AND ADJUSTING.
troller is constantly checking that those elec-
tronic component and itself are functioning
normally.
If a problem occurs in any of these compo-
nents, the controller carries out trouble-
shooting and displays the result as a "user
code" or "service code" on the display unit
(1) of the monitor panel and turns on the
alarm buzzer to warn the operator of the
trouble.
a For details of the display and action to take,
see TESTING AND ADJUSTING.
PC78MR-6 10-145
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
SYSTEM COMPONENTS
Fuel control dial
10-146 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
PC78MR-6 10-147
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
CONTROLLER
Input/output signals
DEUTSCH-24P [CN-M95]
Pin Signal name I/O signal Pin Signal name I/O signal
No. No.
1 NC 13 NC
(*1) NC 14 NC
2
(*2) Boom cylinder bottom presser sensor Input 15 NC
3 NC 16 NC
4 GND (Signal) 17 Attachment 1 Input
5 2-stage travel speed selection switch Input 18 Travel PPC oil pressure switch Input
6 Arm IN PPC oil pressure switch Input 19 NC
7 NC 20 NC
8 Boom swing angle Input 21 GND (Analog)
9 NC 22 Sensor power source (+5 V) Output
10 GND signal 23 NC
11 NC 24 Swing PPC oil pressure switch Input
12 Boom RAISE PPC oil pressure switch Input
*1. Serial No.: 1001 1094
*2. Serial No.: 1095 and up
10-148 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
PC78MR-6 10-149
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
Potentiometer
1. Shaft 4. Brush
2. Housing 5. Resistor
3. Bearing 6. Connector
Functions
A potentiometer is installed on each of the boom
feet, arm foot and second boom top to detect the
angle of the boom, arm and offset work equip-
ment.
Using the resistance value of the variable resis-
tor, potentiometers send angle data to the con-
troller by converting the supply voltage (5V) into
signal voltage according to the angle of the work
equipment.
10-150 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
Register
1. Register
2. Connector
Specifications
Function
When the emergency pump drive switch is
turned ON, this resistor is used to supply a
proper current to EPC valve according to the
condition of the work equipment.
a Current does not flow under the normal condi-
tion.
PC78MR-6 10-151
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
1. Plug
2. Switch
3. Connector
Specifications
Contact composition: N.O. contact
Operation (ON) pressure: 490 98.1 kPa
{5.0 1.0 kg/cm2}
Reset (OFF) pressure: 294 49.0 kPa
{3.0 0.5 kg/cm2}
Function
The control valve has 5 PPC oil pressure
switches, which sense the operating condi-
tion of each actuator from the PPC pressure
and send it to the controller.
10-152 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
1. Plug
2. Sensor
3. Connector
Function
One pressure switch is installed to the boom cyl-
inder bottom circuit to sense the hydraulic pres-
sure on the boom cylinder bottom side.
PC78MR-6 10-152-1
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SYSTEM COMPONENTS
TVC-EPC valve
a See HYDRAULIC PUMP.
Monitor panel
a See MONITOR SYSTEM
PC78MR-6 10-153
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
10-154 PC78MR-6
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD 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 dis-
played machine condition changes. The currently displayed condition is indicated by the LED at the top of
the switches.
If there is any trouble in the monitor panel, controller, or wiring between monitor panel and controller, the
monitor does not display information correctly.
AMP040-20P [CN-P02]
Input and output signals Input/
Pin
AMP070-12P [CN-P01] Signal name Output
No.
Input/ signal
Pin
Signal name Output 1 Engine coolant temperature Input
No.
signal 2 Fuel level Input
1 Starting switch (Battery) Input 3 Radiator water level Input
2 Starting switch (Battery) Input 4 NC Input
3 Windshield washer motor output Output 5 Air cleaner clogged Input
4 Starting switch (Terminal C) Input 6 NC Input
5 Wiper W contact Input 7 Engine oil pressure Input
6 GND 8 Engine oil level Input
7 GND Input/
9 S-NET signal
8 VB+ (24 V) Input Output
9 Wiper motor (+) Output Input/
10 S-NET signal
10 Wiper motor (-) Output Output
11 Alarm buzzer ON signal Input 11 Charge level Input
12 Wiper P contact Input 12 NC
13 GND (Analog signal)
14 NC
15 Pull-up window limit switch Input
16 Alarm buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Lamp switch Input
20 GND (S-NET)
PC78MR-6 10-155
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
No. Display type Display item Display range Display method Display Remarks
color
Time is measured while engine is running
1 Service meter 0-99999.9 h (alternator is generating) (Lamp always lights
up even if starting switch is at OFF position.)
If electric control system has trouble, 3
alphanumerics (user code, service code) is
[*1] 3 alphanumer- displayed. Blue LCD
2 Display ics Voltage of boom swing potentiometer is
0 99.9 V displayed.
10-156 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
Display
No. Display type Display item Display range Display method color Remarks
PC78MR-6 10-156-1
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
PC78MR-6 10-157
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SENSORS
SENSORS
The signals from the sensors are input directly to the panel or controller.
The sensors are classified into 3 of contact type, resistance type, and electromagnetic type.
Either of each sensor of contact type must be connected to the chassis ground.
Type of display Type of sensor Sensing method When normal When abnormal
Function
This sensor is installed to the engine cylinder block to sense oil pressure with diaphragm (4). If the oil pres-
sure lowers below the set level, the switch is turned on and the signal is sent to the monitor panel.
Function
This sensor is installed to the engine cylinder block. It senses changes of temperature by changes of the
resistance of thermistor (3) and sends the change signals to the monitor panel.
10-158 PC78MR-6
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SENSORS
1. Float 3. Connector
2. Arm 4. Variable resistor
Function
This sensor is installed to the fuel tank and
its float (1) moves up and down according to
the fuel level. Float (1) operates variable
resistor (4) through arm (2) and sends the
signals to the monitor panel.
PC78MR-6 10-159
(1)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SENSORS
Wire Housing
Magnet Connector
Terminal
Function
This sensor is installed to the engine flywheel cover. It counts the number of teeth which pass in front of it and
sends the signals to the controller.
10-160 PC78MR-6
(1)
20 TESTING AND ADJUSTING
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the
safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized peo-
ple near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be carught in the fan, fan belt or other rotating parts.
PC78MR-6 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Engine S4D95LE-3
Blow-by pressure (Water temperature operating range) Pa Max. 490 {50} 980 {100}
(SAE30 oil) At rated output {mmH2O} reference value reference value
Oil temperature All revolution range (In oil pan) C 90 110 120
Fuel injection timing Before compression top dead center (Deg.) 5 0.75 5 0.75
Deflection under
finger pressure of
Tension of fan belt 6 10 6 10
approx. 58.8 N {6
kg}
mm
Deflection under
Tension of air compres- finger pressure of
sor belt approx. 58.8 N {6 6 10 6 10
kg}
20-2 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Max. 95
Boom control lever N o RAISE, LOWER 85 10
Min. 75
Max. 95
N o CURL, DUMP
Stroke of control lever, pedal stroke
Forward Max. 39
Attachment control N o FORWARD, Forward 37 Min. 35
pedal REVERSE Reverse 23 Reverse Max. 25
Min. 21
PC78MR-6 20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Standard
Cate- Value for Service Limit
gory Item Measurement Conditions Unit New Value
Machine
Time required
to start swing-
ing
Run engine at full throttle
Hydraulic oil temperature: 45 55 C 3.7 0.3 Max. 4.3
180
Time required to swing 90 and 180 {4.1 0.3} {Max. 4.7}
from starting point
Value in { } is measured under rated
bucket load
20-4 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Standard
Service
Cate- Value for
gory Item Measurement Conditions Unit New Limit
Machine Value
Time required to
finish swinging sec 30 2 Max. 35
Hydraulic drift of mm 0 0
swing (deg) (0) (0)
Low speed 34 3 41
sec
Position of work equipment
26 2 28
Low speed
{25 2} {20}
PC78MR-6 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Standard
Service
Cate- Value for
gory Item Measurement Conditions Unit New Limit
Machine Value
a Measure distance x
Hydraulic drift of mm 0 0
travel
Stop engine
Hydraulic oil temperature: 45 55 C
Stop machine on slope of 30 with sprocket up
Measure hydraulic drift of travel made in 5 minutes
20-6 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Standard
Service
Cate- Value for
gory Item Measurement Conditions Unit New Limit
Machine Value
Boom cylinder
(Retraction of cyl- Max. 8 Max. 12
inder)
Hydraulic drift
Stop engine
Blade Hydraulic oil temperature: 45 55 C
(Hydraulic drift of Max. 20 Max. 30
blade tip Measure hydraulic drift of blade tip from Max. height in
15 minutes
Work equipment
sec
Position for measurement
3.3 0.3 Max. 4.1
Arm IN (To just before (To just before
Max. retraction of cushion) cushion)
cylinder
PC78MR-6 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Standard
Service
Cate- Value for
gory Item Measurement Conditions Unit New Limit
Machine Value
20-8 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
sec
Bucket 0 Max. 1.0
Work equipment
PC78MR-6 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
a Avoid measuring near a bend of the graph since the error is large there.
a When measuring without removing the pump from the machine, if the engine speed cannot be set to the specified level
with the fuel control dial, calculate the pump discharge pressure at the specified speed from the actual engine speed
and measured pump discharge.
20-10 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRIC PARTS
Measurement
1) Turn starting
switch OFF.
voltage
Source Since power is constantly supplied, volt-
M97 2) Insert T-adapter.
voltage age is detected even if starting switch is 3) Turn starting
turned OFF.
switch ON.
Between (2), (12) , (22) chassis ground 20 30 V
1) Turn starting
PPC main switch OFF.
voltage
pressure M97
When safety 2) Insert T-adapter.
lock sole- M13
noid lock lever is at 20 30 V 3) Turn starting
FREE M13 switch ON.
When safety Between (1) (2)
lock lever is at Max. 0 V
LOCK
2) Insert T-adapter.
of current
3) Turn starting
switch ON.
Controller
switch OFF.
Model M95 2) Insert T-adapter.
selection M96 Between M96 (27) M95 (10) Min. 7 V
3) Turn starting
switch ON.
Between M96 (7) M95 (10) Max. 1 V
PC78MR-6 20-11
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRIC PARTS
Inspec-
Sys- Component Connector tion Criteria
Measurement
tem Name No. Conditions
Method
If the condition is within the range shown in the table
below, it is normalTurn starting switch OFF.
Measurement
When arm is moved IN (24) - chas- Max. 1 V
Swing, arm switch OFF.
of voltage
When machine travels sis ground
IN, travel Between 2) Insert T-
pressure M95
(6) - chassis adapter.
switch ground 3) Turn starting
Between switch ON.
When in neutral (18) - chas- Max. 1 V
sis ground
adapter.
angle poten-
M95 3) Turn starting
tiometer
signal switch ON.
4) Move right
swing to stroke
end.
Swing connector.
(When normal) Between
holding 3) Insert T-
M97
Controller
switch OFF.
Swing 2) Disconnect
angle poten- M101 Between (B) (A) 0.2 7 kz
(Male) connector.
tiometer
Between (C) (A) 4 6 kz 3) Insert T-
adapter.
20-12 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRIC PARTS
Measurement of
Between M13 (Male) switch OFF.
resistance
35 80 z
PPC main pres- M13 (1) (2) 2) Disconnect
sure lock solenoid (Male) adapter.
Between M13 (Male) Min. 1 Mz 3) Connect T-
(1), (2) chassis ground
adapter.
Measurement of
Machine control
resistance
Swing holding 35 80 z
M14 (1) (2) 2) Disconnect
brake reset sole-
noid (Male) adapter.
Between M14 (Male) Min. 1 Mz 3) Connect T-
(1), (2) chassis ground
adapter.
35 80 z
2nd travel speed M15 (1) (2) 2) Disconnect
selection solenoid (Male) adapter.
Between M15 (Male) 3) Connect T-
Min. 1 Mz
(1), (2) chassis ground
adapter.
Sensor
Monitored Item Measurement
(Input connector) Conditions Display Input
Signal
Light is
Machine monitor system
ON. Max. 1 V
Engine oil pressure Start engine.
P02 (7)
Light is
OFF. 20 30 V
Check and caution 1) Connect T-
section adapter
Light is Max. 5 V
ON.
Charge level
P02 (11) Start engine.
Light is 20 30 V
OFF.
Light is
20 30 V
ON.
Preheater
P02 (18) Stop Engine.
Light is Max. 1 V
OFF.
PC78MR-6 20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRIC PARTS
Com-
Sys-
ponent Connector No. Inspection Method Criteria Measurement Conditions
tem
Name
Table 2 (Gauge)
Min. Max.
8 3.13 3.75
I 7 3.39 3.94
Measurement of resis- 6 3.56 4.39
tance of coolant tem-
perature gauge P02 (1)
(13) Position of indication 5 3.97 5.18
4 4.68 6.89
O 3 6.23 10.88
Machine monitor system
2 10.34 36.86
Min. Max.
8 6.2 13.7
I 7 12.4 22.1
4 37.1 54.6
O 3 49.4 77.7
2 70.3 101.9
a Level 1 blinks.
20-14 PC78MR-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRIC PARTS
Inspec-
Sys- Component Connector Measurement
tion Criteria
tem Name No. Conditions
Method
Check of continuity
Normal
engine oil No continuity 1) Start engine
Engine oil pres- Between termi- pressure
T6 nal chassis 2) Disconnect
sure sensor
ground terminal
Low engine Normal conti-
oil pressure nuity
Approx. 3.3
105 C kz connector
below, it is normal.
PC78MR-6 20-15
TESTING AND ADJUSTING
PC78MR-6 20-101
TESTING AND ADJUSTING LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING
790-261-1203 Digital hydraulic tester Pressure gauge 58.8 MPa {600 kg/cm2}
2 795-502-1370 Adapter
799-601-7370 Relay 6P
20-102 PC78MR-6
TESTING AND ADJUSTING MEASURING ENGINE SPEED
PC78MR-6 20-103
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
20-104 PC78MR-6
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
PC78MR-6 20-105
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
20-106 PC78MR-6
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
PC78MR-6 20-107
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
20-108 PC78MR-6
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
Adjustment by delivery valve method 4. Using spring pusher O2, compress the valve
(When installing a repaired or replaced fuel injection spring and remove valve cotter (5).
pump, when checking after disassembling or replac- 5. Loosen spring pusher O2 and remove spring
ing the gear train) seat (6) and valve spring (7).
6. Turn the stem of air intake valve (8) with the fin-
gers while it is in contact with the top of piston (9)
to fit it securely.
PC78MR-6 20-109
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
20-110 PC78MR-6
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
Sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}
Sleeve nut:
7.84 9.8 Nm {0.8 1.0 kgm}
PC78MR-6 20-111
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
20-112 PC78MR-6
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
2. Install rod (4) and rod end (5) to ball joint (2) tem-
porarily.
a Screwing depth b of rod in ball joint:
Approx. 12.5 mm
a Screwing depth c of rod end in rod: 4. Check that solenoid (1) is turned on, then con-
Approx. 10.0 mm nect rod end (5) to stop lever (6) and adjust the
length of rod (4) so that the stop lever will touch
the lever end on the service side.
a If solenoid (1) is connected to the power
source without using the machine wiring, do
not keep the PULL terminal cable connected.
(If the PULL terminal cable is kept con-
nected, the operating current flows continu-
ously and the coil will burn.)
PC78MR-6 20-113
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
a Stop lever (6) touches the lever end on the 5. Tighten nut (7) of the joint of stop lever (6) and
service side (inside the fuel injection pump). rod end (5) and insert the cotter pin.
a Play: 0 mm a Install the rod end with grease hole (8) up.
20-114 PC78MR-6
ADJUSTING ENGINE STOP SOLENOID,
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
PC78MR-6 20-115
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
20-116 PC78MR-6
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
PC78MR-6 20-117
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
1. Measuring
1) Installing pressure gauge
i) Open the top cover of the valve and
remove the side cover.
ii) Remove pressure pickup plug (1) or (2)
(10 mm, P = 1.25) and install nipple C3,
then connect oil pressure gauge C1
(58.8 MPa {600 kg/cm}
a Use plug (1) to measure the hydraulic
pressure in boom, arm, and bucket cir-
cuits and use plug (2) to measure the
hydraulic pressure in the swing and
travel circuits.
2) Measuring unload pressure
Measure the hydraulic pressure while the
engine is running at full throttle and the con-
trol lever is in neutral.
3) Measuring pump relief pressure
Measure the hydraulic pressure when each
actuator is relieved while the engine is run-
ning at full throttle.
20-118 PC78MR-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
2. Adjusting
Adjusting main relief valve for boom, arm,
bucket, swing, and travel circuits.
Remove cap (2) of main relief valve (1) and
loosen locknut (3), then adjust with adjust-
ment screw (4).
a As the adjustment screw is
rotated to the right, the pressure is
heightened, and it is
rotated to the left, the pressure is low-
ered.
a Quantity of adjustment per turn of adjustment
screw: 12.5 MPa {128 kg/cm}
Locknut: 39 49 Nm {4 5 kgm}
Cap: 39 49 Nm {4 5 kgm}
PC78MR-6 20-119
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
20-120 PC78MR-6
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
PC78MR-6 20-121
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
Adjusting
1. Adjusting LS valve
a If the differential pressure is abnormal, adjust
the LS valve according to the following pro-
cedure.
a Before loosening the locknut, be sure to
make match marks.
1) Loosen locknut (3) and adjust with adjust-
ment screw (4).
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 adjust-
ment screw: 1.27 MPa {13 kg/cm}.
2) After adjusting, tighten locknut (3).
20-122 PC78MR-6
TESTING AND ADJUSTING ADJUSTING PC VALVE
PC78MR-6 20-123
TESTING AND ADJUSTING MEASURING CONTROL CIRCUIT PRESSURE
Locknut: 20 29 Nm {2 3 kgm}
20-124 PC78MR-6
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
PC78MR-6 20-125
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
Table 1
Oil pressure
Solenoid Name Measurement Condition Remarks
MPa {kg/cm}
3.14 0.49
While boom is swinging to right
{32 5}
1 Swing right stop EPC
1.13 0.29
Stroke end
{11.5 3}
3.14 0.49
While boom is swinging to left
Boom swing stop {32 5}
2
EPC 1.13 0.29
Stroke end
{11.5 3}
20-126 PC78MR-6
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
Table 2
Operation of Oil pressure
Solenoid Name Measurement Condition Operating Condition Remarks
solenoid MPa {kg/cm}
Oil pressure is
Set safety lock lever in 3.14 0.29
applied to PPC valve ON
PPC FREE position. {32 3}
circuit.
1 oil pressure-
ssure lock Oil pressure is not
Set safety lock lever in
applied to PPC valve OFF 0
LOCK position.
circuit.
Operate swing or boom 3.14 0.49
Brake is released. ON
swing or arm-in lever. {32 5}
Swing hold-
2 Set swing or arm-in lever
ing brake
in neutral (5 sec after Brake is applied. OFF 0
setting in neutral)
Set travel speed selector Travel speed is 3.14 0.49
ON
Travel speed switch in Hi. increased. {32 5}
3
selector Set travel speed selector Travel speed is
OFF 0
switch in Lo. decreased.
Note: Operation of solenoid valve is as follows;
When ON: Power is applied (Hydraulic oil is generated).
When OFF: Power is not applied (Hydraulic oil is 0).
PC78MR-6 20-127
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE
20-128 PC78MR-6
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
PC78MR-6 20-129
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
20-130 PC78MR-6
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT
TESTING AND ADJUSTING OF WORK EQUIPMENT
PC78MR-6 20-131
TESTING AND ADJUSTING MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS
20-132 PC78MR-6
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
PC78MR-6 20-133
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
20-134 PC78MR-6
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
PC78MR-6 20-135
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
1 2 3 4 5 6 7 8
Bleeding
air from cir- Bleeding Bleeding Bleeding
Bleeding Starting
cuit Bleeding Bleeding air from air from air from Starting
air from between air from LS air from
engine swing travel swing PPC operation
pump pump and circuit cylinders
motor motor
hydraulic circuit
Contents of work
tank
Replacing hydraulic oil
Cleaning strainer
Q Q Q Q Q Q Note) Q Note) Q
1. Bleeding air from pump 2. Bleeding air between pump and hydraulic tanks.
a If the pump is operated without filling pump a If the pump is operated without bleeding air
case with hydraulic oil, it is heated abnor- from the circuit between the pump and
mally and may be broken soon. Accordingly, hydraulic tank, it is heated abnormally and
bleed all air from the pump before operating may be broken soon. Accordingly, bleed all
the pump. air.
1) Loosen air bleeder (1) installed to the drain 1) Run the engine at medium speed (approx.
port and check that oil oozes out. 1,650 rpm)
2) After bleeding air, tighten the air bleeder. 2) Operate the work equipment slowly for about
5 minutes to bleed air.
Bleeder: 7.8 9.8 Nm {0.8 1.0 kgm}
3. Bleeding air from LS circuit
a Bleed air only after the hoses of the pump,
valve, and LS circuit are replaced.
a If air is not bled from the LS circuit, the work
equipment may malfunction.
1) Loosen air bleeder (2) installed to the LS port
of the pump.
2) Run the engine at low idling for 2 minutes.
3) Operate the bucket (dump and curl bucket to
the stroke ends) for about 2 minutes.
4) After bleeding air, tighten air bleeder (2).
20-136 PC78MR-6
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
PC78MR-6 20-137
TESTING AND ADJUSTING REPLACEMENT PROCEDURE OF POTENTIOMETERS
20-138 PC78MR-6
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODE
PC78MR-6 20-139
TROUBLESHOOTING
PC78MR-6 20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait
for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some
idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. If components 5) Other maintenance items can be checked
are disassembled immediately after a failure externally, so check any item that is consid-
occurs: ered to be necessary.
Parts that have no connection with the failure
or other unnecessary parts will be disassem- 4. Confirming the failure.
bled. Confirm the extent of the failure yourself, and
It will become impossible to find the cause of judge whether to handle it as a real failure or as a
the failure. problem with the method of operation, etc.
It will also cause a waste of man hours, parts, or a When operating the machine to re-enact the
oil and grease. At the same time, it will also lose troubleshooting symptoms, do not carry out
the confidence of the user or operator. For this any investigation or measurement that may
reason, when carrying out troubleshooting, it is make the problem worse.
necessary to carry out thorough prior investiga-
tion and to carry out troubleshooting in accor- 5. Troubleshooting
dance with the fixed procedure. Use the results of the investigation and inspec-
tion in Steps 2 4 to narrow down the causes of
2. Points to ask the user or operator. the failure, then use the troubleshooting flow-
1) Have any other problems occurred apart chart to locate the position of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1) Start from the simple points.
3) Did the failure occur suddenly, or were there 2) Start from the most likely points.
problems with the machine condition before 3) Investigate other related parts or informa-
this? tion.
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure.
failure? When were these repairs carried Even if the failure is repaired, if the root cause of
out? the failure is not repaired, the same failure will
6) Has the same kind of failure occurred occur again.
before? To prevent this, always investigate why the prob-
lem occurred. Then, remove the root cause.
3. Check before troubleshooting.
1) Check the oil level.
2) Check for any external leakage of oil from the
piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202 PC78MR-6
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
Step 2
Determining probable location of cause
Step 3
Preparation of troubleshooting tools
Step 6
Re-enacting failure
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
PC78MR-6 20-203
TROUBLESHOOTING POINT 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).
20-204 PC78MR-6
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring
If the wiring is held and the connectors are pulled apart,
or components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be
damaged, or the wiring may be broken.
PC78MR-6 20-205
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the con-
nectors and not the wires. For connectors held by a
screw, loosen the screw fully, then hold the male and
female connectors in each hand and pull apart. For
connectors which have a lock stopper, press down
the stopper with your thumb and pull the connectors
apart.
a Never pull with one hand.
20-206 PC78MR-6
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water stuck to
the connector pins (mating portion).
2) Check that there is no deformation, defective
contact, corrosion, or damage to the connector
pins.
3) Check that there is no damage or breakage to
the outside of the connector.
a If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth. If any
water has got inside the connector, warm the
inside of the wiring with a dryer, but be care-
ful not to make it too hot as this will cause
short circuits.
a If there is any damage or breakage, replace
the connector.
PC78MR-6 20-207
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-208 PC78MR-6
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
PC78MR-6 20-209
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Sealing openings
After any piping or equipment is removed, the openings
should be sealed with caps, tapes, or vinyl bags to pre-
vent any dirt or dust from entering. If the opening is left
open or is blocked with a rag, there is danger of dirt
entering or of the surrounding area being made dirty by
leaking oil so never do this.
Do not simply drain oil out on to the ground, collect it and
ask the customer to dispose of it, or take it back with you
for disposal.
20-210 PC78MR-6
TROUBLESHOOTING POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equipment, or
changing the oil, use flushing oil to remove the contami-
nants, sludge, and old oil from the hydraulic circuit.
Normally, flushing is carried out twice: primary flushing is
carried out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump, control
valve, etc.) or when running the machine, carry out oil
cleaning to remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3) particles that the filter built into the
hydraulic equipment cannot remove, so it is an
extremely effective device.
PC78MR-6 20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
20-212 PC78MR-6
TROUBLESHOOTING TYPE AND LOCATION OF CONNECTORS
D5 SWP 2 Diode (Battery relay BR) G1 K23 5 Starting motor cut-out relay R8
D11 SWP 2 Diode (TVC solenoid) R7 K27 SWP 6 Fuel governor control motor N7
D12 SWP 2 Diode (TVC solenoid) R8 K28 M 3 PPC hydraulic lock switch P2
D30 SWP 2 Diode (PPC basic pressure R7 K51 090 20 Intermediate connector M7
lock solenoid) (Starting, light switch)
D32 SWP 2 Diode (Swing RIGHT stop R6 K53 M 2 Buzzer cancel switch O8
circuit)
Revolving warning lamp
D33 SWP 2 Diode (Swing LEFT stop circuit) Q8 K54 M 3 P8
(Optional)
K17 X 2 Optional power supply unit P2 M13 DT 2 PPC hydraulic lock solenoid M2
20-214 PC78MR-6
(1)
TROUBLESHOOTING TYPE AND LOCATION OF CONNECTORS
M15 DT 2 Travel speed shifting sole- M2 P15 040 2 Sunlight sensor (Optional) M6
noid
Pressure switch
M21 X 2 (Boom RAISE) G9 T4 Terminal 1 Alternator (Terminal R) L6
M25 X 2 Pressure switch (Travel) I9 T10 Terminal 1 Battery relay (Terminal BR) A3
Intermediate connector
M28 DT 2 (Working lamp) J9 T16 Terminal 1 Engine stop solenoid relay K3
M30 X 2 Safety relay (S, R) J3 T17 Terminal 1 Engine stop solenoid relay K3
PC78MR-6 20-215
(1)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
20-216 PC78MR-6
(1)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
PC78MR-6 20-217
(1)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
20-218 PC78MR-6
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04702
2 799-601-7020
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040
PC78MR-6 20-219
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
20-220 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04715
16 BWP04716 799-601-7320
PC78MR-6 20-221
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04718
2 BWP04717 799-601-7090
8 799-601-7340
BWP04725 BWP04726
20-222 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04728
8 BWP04727 799-601-7140
10 BWP04729 BWP04730
(White) 799-601-7150
PC78MR-6 20-223
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04736
10 BWP04735
(Blue)
12 BWP04737 BWP04738
(Blue) 799-601-7160
20-224 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04742
BWP04741
5 799-601-2710
BWP04743 BWP04744
9 799-601-2950
BWP04745 BWP04746
13 799-601-2720
PC78MR-6 20-225
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04748
BWP04747
17 799-601-2730
BWP04749 BWP04750
21 799-601-2740
20-226 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04752
8 BWP04751 799-601-7180
PC78MR-6 20-227
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP070-Type Connector
Num-
ber of
Pins Male (Female Housing) Female (Male Housing) T-adapter Part
Number
BWP04760
10 BWP04759 799-601-7510
20-228 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04770
2 BWP04769
BWP04772
9 BWP04771
BWP04774
10 BWP04773 799-601-3460
PC78MR-6 20-229
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04776
BWP04775
2
Part Number: 08027-10210 (Natural color) Part Number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778
BWP04779 BWP04780
4
Part Number: 08027-10410 (Natural color) Part Number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6
Part Number: 08027-10610 (Natural color) Part Number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
20-230 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04784
BWP04783
8
Part Number: 08027-10810 (Natural color) Part Number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
PC78MR-6 20-231
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04786
5 BWP04785 799-601-7360
BWP04788
6 BWP04787 799-601-7370
20-232 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04786
BWP04785
4
PC78MR-6 20-233
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The pin number is also marked on the connector (Electric wire insertion end).
20-234 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The pin number is also marked on the connector (Electric wire insertion end).
PC78MR-6 20-235
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The pin number is also marked on the connector (Electric wire insertion end).
20-236 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The pin number is also marked on the connector (Electric wire insertion end).
Part Number: 08191-81201, 08191-81202, 08191- Part Number: 08191-84101, 08191-84102, 08191-
24-22 81203, 08191-81204, 08191-81205, 08191-81206 84103, 08191-84104, 08191-84105, 08191-84106
799-601-9280
(8) Pin (Female Terminal) Pin (Male Terminal)
Part Number: 08191-82201, 08191-82202, 08191- Part Number: 08191-83101, 08191-83102, 08191-
82203, 08191-82204, 08191-82205, 08191-82206 83103, 08191-83104, 08191-83105, 08191-83106
PC78MR-6 20-237
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The pin number is also marked on the connector (Electric wire insertion end).
20-238 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The pin number is also marked on the connector (Electric wire insertion end).
2 799-601-9020
Part Number: 08192-12200 (Normal type) Part Number: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
Part Number: 08192-13200 (Normal type) Part Number: 08192-13100 (Normal type)
08192-23200 (Fine wire type) 08192-23100 (Fine wire type)
4 799-601-9040
Part Number: 08192-14200 (Normal type) Part Number: 08192-14100 (Normal type)
08192-24200 (Fine wire type) 08192-24100 (Fine wire type)
6 799-601-9050
Part Number: 08192-16200 (Normal type) Part Number: 08192-16100 (Normal type)
08192-26200 (Fine wire type) 08192-26100 (Fine wire type)
PC78MR-6 20-239
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8GR:799-601-9060
8B:799-601-9070
8
8G:799-601-9080
8BR:799-601-9080
Part Number: 08192-1820T (Normal type) Part Number: 08192-1810T (Normal type)
08192-2820T (Fine wire type) 08192-2810T (Fine wire type)
12GR:799-601-9110
12B:799-601-9120
12 12G:799-601-9130
12BR:799-601-9140
Part Number: 08192-1920T (Normal type) Part Number: 08192-1910T (Normal type)
08192-2920T (Fine wire type) 08192-2910T (Fine wire type)
20-240 PC78MR-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
The pin number is also marked on the connector (Electric wire insertion end).
2 799-601-9000
The pin number is also marked on the connector (Electric wire insertion end).
Part Number: 08192-31200 (Contact size #12) Part Number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC78MR-6 20-241
(1)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM
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
20-242 PC78MR-6
(1)
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
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).
All trouble information items of the controller are sent to the monitor panel. An emergent information item
among them is displayed as a "user code" automatically on the display (1) of the monitor panel to urge the
operator to take proper actions.
a The lamps other than display (1), service meter unit (2), and lighting parts (solid parts in the following illus-
tration) are turned OFF.
PC78MR-6 20-243
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
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.
20-244 PC78MR-6
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Example 3) If any service code is not iv) To stop display of the service code, push
saved, "-" is displayed in the "Buzzer c ancel switch (8)" and
every column of display (1) "Working mode selector switch (7)".
and service meter unit (2). v) To delete the saved service codes, press
ii) To see the next displayed service code, the "Buzzer cancel switch (8)" and turn
push the "Buzzer cancel switch (8)" and OFF the "starting switch" simultaneously,
"Mode selector switch (UP)" (3). then turn ON the "starting switch" again
iii) To see the previous displayed service and push and hold the "Buzzer cancel
code, push the "Buzzer cancel switch (8)" switch (8)" for 5 seconds.
and "Mode selector switch (DOWN) (4)". a If the number of service codes
exceeds 20, they are deleted one by
one from the oldest one.
PC78MR-6 20-245
(1)
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
The input signals from the sensors to each component and the output signals to drive the solenoids can be
checked in real time with the monitoring codes.
If the following operation is executed, the monitoring code No. is displayed in the 3rd column through the 5th
column from the left on service meter unit (2) of the monitor panel and the monitoring information is dis-
played on display (1).
20-246 PC78MR-6
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
PC78MR-6 20-247
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Code No. Item Bit Details (State When Bit Lights Up)
(1) ID2 is connected.
(2) ID3 is connected.
(3) ID4 is connected.
0008 S-NET connection state
(4) ID5 is connected.
(5) ID6 is connected.
(6) ID7 is connected.
(1) Starting switch is at "ON"
(2) Starting switch is at "START"
0045 Sensor input 1
(3) Starting switch is at "PREHEAT"
(4) Light switch is at "ON"
(2) Constant bit
0046 Sensor input 2 (3) Engine oil pressure (When low)
(6) Charge level is low (Engine is stopped)
0047 State of output (1) Buzzer output
(2) Washer output (Washer switch is turned ON)
(3) Wiper output 1
0048 State of wiper (4) Wiper output 2
(5) Wiper output 3
(6) Wiper output 4
(2) Buzzer cancel switch
(3) Window limit switch (ON)
0049 Spare
(4) W contact (Wiper is operated)
(5) P contact (Wiper is operated)
(1) ATT selection 2 (GND is connected)
ON/OFF input 1 (2) ATT selection 1 (GND is connected)
For detail of model (3) Model selection 1 (GND is connected)
1020 selection, see Table 1.
For detail of ATT selec- (4) ATT selection 3 (GND is connected)
tion, see Table 2. (5) UU/US selection (GND is connected)
(6) Model selection 2 (GND is connected)
(1) MR selection (GND in connected)
(3) Compressor signal
1021 ON/OFF input 2
(4)
(5) (a) Tier 2 selection signal (When power source is connected)
20-248 PC78MR-6
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Code No. Item Bit Details (State When Bit Lights Up)
(1) 2nd travel speed selection switch (Panel)
(2) Working mode selector switch
(3) Backup light
1022 ON/OFF input 3
(4) SET/CLEAR switch
(5) Mode selector (E) switch
(6) Mode selector (R) switch
(3) Travel pressure switch
(4) Swing pressure switch
1023 ON/OFF input 4
(5) Arm IN pressure switch
(6) Boom RAISE pressure switch
(1) Deceleration signal
(2) Acceleration signal
(3) Motor drive power supply
1024 ON/OFF input/output
(4) Auto deceleration signal
(5) Motor relay (-)
(6) Motor relay (+)
(1)
(2) Display selector switch (Monitor)
1025 ON/OFF input/output
(3) Arm ground angle alarm cancel switch
(6) Bucket dump prohibition solenoid + Rotary lamp
(1) Deceleration switch
(2) Alarm cancel
1026 ON/OFF input/output (3) Emergency work equipment operation switch
(4) 2nd travel speed selection switch (Pedal)
(5) Slide arm limit switch
(1) Swing holding brake switch (Brake is released)
(2) PPC main pressure lock (Main pressure lock is reset)
1060 ON/OFF input/output 2nd travel speed is selected (Machine travels at 2nd gear
(4)
speed)
(5) Travel/Swing alarm (Alarm is output)
PC78MR-6 20-249
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
Table 1
Model selection table
Model Selection 1 Model Selection 2
Table 2
1:Connection of the attachment selection wires is shown.
(The bits of GND are displayed during normal operation.)
20-250 PC78MR-6
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
PC78MR-6 20-251
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
If the system is not reset normally, " " flashes. When abnormal
Set the machine in "position 2" and press switch (c). After switch (c) is pressed, "ooo" is displayed, and
(Position 2) then " " is displayed on the display section.
Boom swing LEFT end When normal
(Completion of setting)
3
20-252 PC78MR-6
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
PC78MR-6 20-253
TROUBLESHOOTING TVC VALVE CURRENT ADJUSTMENT TABLE
20 4 Q Initial value
20-254 PC78MR-6
TROUBLESHOOTING ADJUSTING SERVICE METER
PC78MR-6 20-255
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the controller
(decelerator control) system "E3:OO".
2) When a service code is not displayed on the monitor panel and "Engine does not start":
When the starting motor rotates:
Check the rotation .... Advance to mechanical system troubleshooting "S-2".
of a starting motor. When the starting motor does not rotate:
.... Advance to electrical system troubleshooting "E-8".
20-256 PC78MR-6
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
[Decision]
1) When a service code is displayed on the monitor panel: ....... Run a diagnostic check using the controller
(pump control) system "C:OO".
2) When a service code is not displayed on the monitor panel and "Swing is not performed":
Check controller input When the signal is provided:
signal. .... Advance to mechanical system troubleshooting "H-34" and "C-38".
(Check it in the monitor- When the signal is not provided:
ing mode.) .... Advance to the CR700 controller input signal system troubleshooting
"F-OO". (See section F mode)
PC78MR-6 20-257
(1)
TROUBLESHOOTING HOW TO READ FLOW OF TROUBLESHOOTING
20-258 PC78MR-6
TROUBLESHOOTING HOW TO READ FLOW OF TROUBLESHOOTING
<Example>
(1) M-1[E101](Error history data are abnormal) is displayed
(2) a This error is displayed when the connector P01, connector K1, fuse 18, connector M6, connector M2,
battery relay terminal B, or battery terminal in the monitor panel power supply system is disconnected or
connected for troubleshooting. This phenomenon does not indicate an error.
(When the power supply circuit of the monitor panel is cut out while the starting switch is at the OFF posi-
tion.)
a If the service code is displayed again after the resetting operation is performed, carry out the trouble-
shooting according to the following procedure.
Cause Remedy
1
After resetting operation,
operate machine normally After "resetting operation", is NO
Normal
and observe its condition for service code displayed again?
a while. (See Note 1.)
YES
2
Disconnection, defective contact,
Turn starting switch OFF Is voltage between P01 (8) NO or short circuit with chassis Repair or
ground in wiring harness
20 30 V chassis ground normal? between battery battery relay B replace
M27 (1), (2) P01 (Female) (8)
YES
Defective monitor panel Replace
PC78MR-6 20-259
TROUBLESHOOTING CONTENTS AND PROCEDURE OF TROUBLESHOOTING
Before starting the troubleshooting, ask the operator about the trouble as long as possible and check the follow-
ing items in advance. (1) Connecting condition of the controller (Check with monitoring code 0001), (2) Break-
age of the fuses, (3) Battery voltage, (4) Generating (charge input) voltage (Monitoring code 0043 "H-34").
(Swing holding
brake and 2nd
YES E03 travel speed
selection sole- o Go to No. 2
noid systems)
1 (Governor motor
E05 system)
Is user E200 group: Troubleshooting for pump controller (Pump control system) (C-mode)
code dis- Carry out trouble-
played on shooting in corre-
YES sponding mode.
monitor
panel? E300 group: Troubleshooting for pump controller (Governor control system) (E-mode)
5
Engine system Is electric system
of engine with no
failure code nor-
4 mal?
Is trouble in engine sys- Flow of part of
YES tem or hydraulic judgment table
(Mechanical) system?
where no trou-
3 bles are indi-
Adjust hydraulic pres-
Is input/output sure, then judge by cated.
Carry out troubleshooting
signal of con- engine speed.
NO NO by electric system of
troller normal? Is work equipment engine (in E-mode).
Check by always heavy and (Flow of part where there
monitoring does engine speed is no indication) (E-6 E-
lower under heavy 8)
code.
load?
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)
PC78MR-6 20-301
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
[Questions]
Sections (A) + (B) in the chart on the right cor-
responds to the items where answers can be
obtained from the user. The items in (B) are Causes
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection
to narrow down the causes. The items under
(C) in the chart on the right correspond to this.
The serviceman narrows down the causes
from information (A) that he has obtained from (1) (2) (3)
the user and the results of (C) that he has
obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
(a)
[Check items].
Questions
A (b)
(c)
(d)
(e)
Check items
B
C
i
shooting
Trouble-
ii
iii
20-302 PC78MR-6
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
on)
down the causes.
jecti
2. Use the E in the Cause column as ref-
ve in
erence for [Degree of use (Operated
si
for long period)] in the [Questions] sec-
zle
renc
xces
noz
tion as reference. As a rule, do not use
ent
erfe
p (e
r
tion
it when calculating the points for locat-
lem
inde
ing
, int
pum
n tim
er e
injec
ing the cause, but it can be included if
, cyl
rger
tion
lean
necessary to determine the order for
ectio
ring
cha
ized
injec
troubleshooting. air c
urbo
ston
, se
r inj
ctive
ged
ged
rope
ed t
n pi
Defe
Clog
Clog
Seiz
Wor
Imp
1 Confirm recent repair history
2 Degree of use Operatred for long period
PC78MR-6 20-303
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
d)
d
hea
)
eize
ction
er s
e, va rger and
e inje
lung
eat
ssiv
lve s
leme nce
ck, p
ocha
le
exce
nozz
re
p (ra
nt
turb
terfe
(
er
ance
r
tion
ing
ump
le
valv
pum
n
d
er, in
ff
e
n
m
er e
injec
u
etwe
, cyli
lear
p
dm
t of
ti
ction
harg
tion
ction
lean
lve c
c
ring
gge
ized
air b
onta
injec
Legend
e inje
rboc
air c
r inje
, clo
ton
e
r va
: Possible causes (judging from Questions and check items)
f
c
s
o
ed tu
ctive
ctive
,
n pis
ectiv
kage
hed
ged
ged
rope
rope
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Crus
Defe
Clog
Clog
Seiz
Wor
Deff
Imp
Imp
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Adjust
Adjust
Adjust
Remedy
20-304 PC78MR-6
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
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
eat
ASTM D975 No.1
)
ircuit
lve s
a Battery charging rate
ing c
d va
aer
heat
Charging rate
e an
ent
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
r
train
e
elem
der
pre-
in
f valv
20C 1.28 1.26 1.24 1.23 1.22
, stra
cylin
mp s
0C 1.29 1.27 1.25 1.24 1.23
ding
aner
act o
10C 1.30 1.28 1.26 1.25 1.24
filter
ing,
d pu
(inclu
ir cle
cont
ton r
A battery can be used if the specific gravity shows 70% or
l
e
e
e
u
a
plug
f
f
higher charging rate shown in the above table.
ctive
n pis
ging
gibg
ging
In cold weather, 75% or higher charging rate is required.
Glow
Defe
Clog
Clog
Clog
Wor
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Replace
Correct
: Most probable causes (judging from Questions and check items) Remedy
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
20-306 PC78MR-6
Replace Defe
ctive
Replace Defe alter
nato
ctive r (ex
Replace Defe a ltern terna
ctive ator l reg
Replace o (buil ulato
PC78MR-6
Defe r deg t-in r r typ
rade egula e)
ctive d b a
Adjust Injec injec
tion t t e ry
tor ty
pe)
tion nozz
Replace Defe
timin
g fail le
tive u re
Correct Leak
injec
tion
age, pum
Clean clog p (ra
TROUBLESHOOTING
Clog ging ck a
ged , or a nd p
Replace Defe
air b
reath ir in
fuel
lung
er st
ctive er ho pipin uck)
Replace Defe f e ed p le in g
Causes
20-307
TROUBLESHOOTING S-2
ch
operations".
ction
swit
Defective electrical system
it
nne
ttery
circu
fety
a l co
d ba
r sa
id
ting
eno
ch
n
otor
e
lay o
star
i
lay
t
term
swit
iora
t sol
ng m
ry re
ty re
g of
eter
ting
ttery
el cu
ear
atte
tarti
wirin
safe
or d
star
in g g
Legend
a
u
b
b
s
f
: Possible causes (judging from Questions and check items)
ctive
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
: Items to confirm the cause.
Remedy
20-308 PC78MR-6
TROUBLESHOOTING S-2
General causes why engine turns but no exhaust smoke comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Causes
a Standards for use of fuel
AMBIENT TEMPERATURE
KIND OF
d)
FLUID -4 14 32 50 68 86 F
eize
-20 -10 0 10 20 30
er s
ASTM D975 No. 2
y
ASTM D975 No.2
nk
lung
t, ke
el ta
n
ck, p
shaf
Diesel fuel
pisto
n fu
ASTM D975 No.1
p (ra
er
g
drive
o le i
pipin
l use e n o i d
r
mp
train
n e
pum
u
i
h
stra
tank
ump
fuel
ol
her
eed
cut s
d
pum
tion
ilter,
on p
reat
el in
king
en f
injec
uel f
fuel
air b
jecti
feed
nt fu
r f ue
, lea
Legend
brok
: Possible causes (judging from Questions and check items)
ctive
ctive
en in
fficie
g ed
ged
ged
g ed
rope
: Most probable causes (judging from Questions and check items)
ed,
: Possible causes due to length of use (used for a long period)
Defe
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Exhaust smoke suddenly stops coming out (when starting again)
Questions
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
PC78MR-6 20-309
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
.)
Insufficient intake of air
r, etc
ck)
Improper selection of fuel and oil
r leve
r stu
ap
y
spra
it )
rocke
nk c
nge
circu
em
tive
el ta
, plu
syst
alve,
ating
ery
efec
n fu
k
r
r line
m (v
batt
c
fuel
t
a
e
n
aine
le, d
r
ole i
r e -h
leme
er
(
syste
te d
mp
inde
ir in
rain
p str
nozz
er h
ing p
riora
u
er e
g, a
r, st
, cyl
alve
p
d
h
pum
tion
l use
lean
tion
reat
ggin
e
l filte
ken v
rin g
u
e t
(incl
injec
or d
injec
feed
air b
air c
, clo
r f ue
Legend
e
, bro
ton
u
plug
: Possible causes (judging from Questions and check items)
ctive
ctive
n pis
kage
g ed
ged
ged
ged
ged
rope
ctive
: Most probable causes (judging from Questions and check items)
Glow
: Possible causes due to length of use (used for a long period)
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Lea
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly failed to start
Questions
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
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-310 PC78MR-6
TROUBLESHOOTING S-3
ap
pray
seat
nk c
ve s
alve
el ta
nce
fecti
nd v
r
n fu
r
fe re
nge
r line
nt
, de
g
iner
ve a
pipin
ole i
leme
iner
inter
lu
ance
inde
e
p
stra
f val
l
nozz
stra
er h
mp
er e
fuel
ger,
lear
, cyl
ump
act o
n pu
h
ilter,
lean
tion
char
reat
king
lve c
ring
ed p
jectio
cont
uel f
injec
air c
air b
, lea
urbo
Legend
r va
n
e
o
: Possible causes (judging from Questions and check items)
f
f
ed in
ctive
n pis
ged
ged
rope
ged
ged
ged
ed t
ged
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
C lo g
Defe
C lo g
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Noise of interference is heard from around turbocharger
Engine pick-up suddenly became poor
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Mud is stuck to fuel tank cap
Check items
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
PC78MR-6 20-311
TROUBLESHOOTING S-4
etc.)
Overheating
)
ver,
a If there is overheating and the engine stops,
tuck
ker le
carry out troubleshooting for overheating.
er s
od
, roc
nk
lung
in g r
el ta
g
y
nt
alve
ton
arin
ck, p
t, ke
e
nect
in fu
m
p pis
m (v
t be
p
shaf
p (ra
r
g
i
aine
u
pipin
r
, con
aine
hole
q
shaf
pum
e
train
ry e
t
pum
drive
s
p str
tank
y
iston
, str
lve s
fuel
rank
her
xilia
eed
ear
pum
tion
mp
filter
el in
reat
ic va
king
ed c
ed g
ed p
ed f
a
injec
u
air b
feed
uel p
ump
nt fu
ynam
, lea
Legend
fuel
seiz
seiz
z
seiz
e i
: Possible causes (judging from Questions and check items)
ctive
s
en p
fficie
en f
ged
ged
ged
ged
en,
en d
en,
: Most probable causes (judging from Questions and check items)
en,
en,
: Possible causes due to length of use (used for a long period)
Defe
Brok
Brok
Clog
Clog
C l og
Clog
Brok
Brok
Brok
Brok
Insu
Brok
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Questions
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
20-312 PC78MR-6
TROUBLESHOOTING S-5
p
zzle
Defective electric governor mechanism
pum
d no
(engine with electric governor)
feed
a If hunting stops when electric governor rod is
p an
an d
disconnected, carry out troubleshooting for
pum
nk
t a nk
el ta
ack
the chassis.
feed
erno
rnor
fuel
ro l r
in fu
r
een
v
gove
een
aine
f go
low
t
ner
n
hole
of co
betw
betw
i
p str
nt o
too
stra
tank
n of
her
it
tion
stme
cuit
e d is
pum
circu
lter,
ratio
el in
reat
ir
pera
c
i
adju
f
ope
air b
air in
nt fu
air in
g sp
fuel
Legend
e
o
e
: Possible causes (judging from Questions and check items)
f
ctive
ctive
ctive
fficie
idlin
g ed
ged
ged
ged,
ged,
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Clog
Defe
Clog
Clog
Defe
Defe
Clog
Insu
Clog
Low
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Occurs at low idling
Condition of hunting
Questions
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
PC78MR-6 20-313
TROUBLESHOOTING S-6
nt
stme
(if non-specified fuel is used, output drops)
eat
ragm
spra
lve s
adju
Lack of output due to overtaking
nk
iaph
tive
el ta
a If there is overheating and lack of output,
ce
d va
tive
efec
or d
eren
in fu
er
carry out troubleshooting for overheating.
c
e an
g
nt
e
ng
r
nsat
le, d
aine
f
f
iner
leme
, de
inter
p pl u
hole
e
i
r
p
inde
valv
c
p i
mpe
n
nozz
p str
stra
kage
a
er e
fuel
ger,
pum
her
lear
, cyl
ct of
st co
pum
lter,
er lin
tion
reat
le a n
char
king
lve c
r in g
onta
o
i
boo
njec
f
b
feed
i
air c
t
Legend
, lea
urbo
l lev
fuel
c
r va
ton
r
c
e
a i
: Possible causes (judging from Questions and check items)
j
i
ctive
ctive
ed in
n pis
t fue
ged
ged
ged
ged
rope
ged
ged
ed t
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Defe
Clog
Clog
Clog
Clog
Clog
C log
Seiz
Seiz
Ben
Wor
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly
Power was lost
Gradually
Questions
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-314 PC78MR-6
TROUBLESHOOTING S-7
d)
ead
on)
eize
nd h
jecti
at
er s
e se
er a
ve in
lung
v
harg
l
essi
nce
a
ck, p
timin ozzle
nd v
rboc
fere
(exc
nt
p (ra
ve a
nn
leme
n tu
inter
ance
er
fler
u mp
g
r i n je i n j e c t i o
f val
p um
ylind
twee
u f
er e
ger,
lear
on p
dm
act o
c
tion
ction
lean
ir be
char
lve c
gge
r in g
zed
jecti
injec
cont
air c
of a
Legend
, clo
u rbo
, sei
r va
n
ton
i
: Possible causes (judging from Questions and check items)
ctive
ctive
ctive
n pis
kage
hed
ged
rope
ge d
rope
ed t
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Crus
Clog
Clog
Seiz
Wor
Lea
Imp
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
is stopped
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 color returns to normal
When control rack is pushed, it is found to be heavy, or
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
PC78MR-6 20-315
TROUBLESHOOTING S-8
rger
General causes why oil consumption is excessive
ocha
Abnormal combustion of oil
Turb
External leakage of oil
seal
d
Wear of lubrication system
hea
ce
stem
se
a
er
ken
r f
der
r ho
cool
al su
r
, bro
r line
e sy
cylin
e
p lug
r oil
h
l, se
t
intak
ide)
brea
nde
d
nd
r
n
er o
ipin g
an o
a
rain
ine e
er e
, gu
e
, cyli
ar s
om
r or
i l f ilt
oil d
oil p
oil p
blow
ring
stem
turb
in fr
oler
e
ring
n re
o
t h
from
rom
from
m
iston
brea
i l co
al at
Legend
lve (
a l at
ked
roke
ton
r o
: Possible causes (judging from Questions and check items)
f
f
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
L ea
L ea
Lea
L ea
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-316 PC78MR-6
TROUBLESHOOTING S-9
nd
Operation under excessive load
ee
r b in
se
er tu
e
n pip
r ho
r
r line
harg
drai
athe
inde
ide
k
rboc
blac
ger
, bre
e gu
, cyl
at tu
char
r
ke is
ther
oo le
valv
r ing
lter
urbo
seal
brea
smo
oil c
oil fi
Legend
ton
lve,
: Possible causes (judging from Questions and check items)
t
ctive
n pis
ged
g ed
ged
n va
g ed
aust
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Clog
Clog
Clog
Clog
Wor
Wor
Exh
: Items to confirm the cause.
Confirm recent repair history
Questions
None
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
PC78MR-6 20-317
TROUBLESHOOTING S-10
n)
jectio
ton)
e
er
nkag
el filt
p (pis
ive in
rol li
g, fu
pum
cess
nger
cont
pipin
y
feed
spra
p (ex
lu
timin
fuel
p
fuel
ump
side
nt of
lder
pum
tion
from
p
le ho
al in
stme
injec
tion
tion
age
oil se
Legend
nozz
injec
injec
adju
fuel
leak
: Possible causes (judging from Questions and check items)
ctive
ctive
ctive
ctive
ctive
ctive
: Most probable causes (judging from Questions and check items)
rnal
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Defe
Defe
Defe
Exte
: Items to confirm the cause.
Confirm recent repair history
Questions
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-318 PC78MR-6
TROUBLESHOOTING S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
Causes
Internal leakage in lubrication system
Internal leakage in cooling system
t
aske
lock
g
g
O-rin
ea d
der b
ad, h
ting
ore,
cylin
y pit
er he
ler c
s in
b
Legend
il coo
used
ylind
rack
: Possible causes (judging from Questions and check items)
nal c
: Most probable causes (judging from Questions and check items)
en o
en c
s ca
: Possible causes due to length of use (used for a long period)
Brok
Hole
Brok
Inter
: Items to confirm the cause.
Confirm recent repair history
Questions
Remedy
PC78MR-6 20-319
TROUBLESHOOTING S-12
Causes
n
i l pa
i de o
g
pipin
pan
e ins
r
enso
g
aulic
azin
e oil
r
uctio n oil pip
enso
s
valv
hydr
e br
e
insid
l
urna
ve
r
essu
pan
vel s
lator
ump
n pip
f val
shed
roke
g, jo
iner
n oil
lter
n oil
r
oil le
regu
relie
oil p
oil p
oil fi
Legend
or b
stra
, cru
arin
uel i
i
: Possible causes (judging from Questions and check items)
i l
ctive
ctive
ctive
ctive
ctive
of o
en s
n be
ged
ged
ged
king
er, f
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Defe
Defe
Lack
Brok
C lo g
Clog
Clog
Wor
Wat
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
20-320 PC78MR-6
TROUBLESHOOTING S-13
ber)
General causes why oil level rises
cham
Water in oil (milky white)
stion
Fuel in oil (diluted, and smells of diesel fuel)
seal
ombu
Entry of oil from other component
t
mp
e n
e
uipm
n pu
(prec
rfac
ve
ring
u
slee
ectio
sket
k
q
s
bloc
e
, O-
seal
y
ad ga
lder
r
e inj
a
der
core
ting
l i
ear
t
auxi
d, he
osta
le ho
nsid
cylin
y pit
r
oler
r hea
ged
herm
p
art i
nozz
pum
de b
side
i l co
Legend
ama
linde
p
t
: Possible causes (judging from Questions and check items)
s ma
ctive
ctive
ctive
ks in
ctive
en o
en cy
n, d
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Hole
Defe
Crac
Brok
Wor
Brok
: Items to confirm the cause.
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
PC78MR-6 20-321
TROUBLESHOOTING S-14
)
pen
ge
t
aske
y
ot o
gau
pulle
ins
ad g
es n
ure
tor f
fan
ler
, he
erat
e
t (do
o
valv
radia
worn
o
core
ting
ead
r
oil c
p
wate
osta
r te m
p
ure
p um
y pit
shed
er h
ing,
ator
ken
erm
ress
o ling
wate
de b
ylind
ater
slipp
, bro
Legend
radi
, cru
p
t
: Possible causes (judging from Questions and check items)
of co
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
: Most probable causes (judging from Questions and check items)
: Possible causes due to length of use (used for a long period)
Lack
Defe
Brok
Brok
Defe
Clog
Hole
Defe
Clog
Clog
Fan
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-322 PC78MR-6
TROUBLESHOOTING S-15
.)
Abnormality due to defective parts
, etc
ead
d)
n)
tion)
Abnormal combustion
eize
ositio
lever
nd h
r
r line
njec
Air sucked in from intake system
er s
t of p
ce
cker
er a
aran
inde
ive i
l ung
e, ro
d ou
harg
e
renc
nce
s
, cyl
e cle
ck, p
le
xces
(valv
boar
rboc
nozz
fere
erfe
ring
ash
valv
p (ra
p (e
ystem
iding
n tu
inter
lt int
ackl
tion
iston
ng
t of
pum
p um
r (div
twee
lve s
injec
ushi
ain b
n be
ger,
n
of p
e
tion
tion
uffle
justm
ir be
ic va
ed b
char
n, fa
ar tr
Defe , seized
ear
injec
injec
ide m
ynam
of a
Legend
seiz
urbo
d
d fa
r ge
ve w
a
: Possible causes (judging from Questions and check items)
ctive
ctive
ctive
ct ins
kage
rme
rope
ged
en d
ed t
ing,
: Most probable causes (judging from Questions and check items)
essi
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defo
Clog
Miss
Defe
Seiz
Brok
Imp
Lea
Exc
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Remedy
PC78MR-6 20-323
TROUBLESHOOTING S-16
uck)
tc. st
tion)
on
General causes why vibration is excessive
ver, e
ushi
injec
Defective parts (abnormal wear, breakage)
r)
ker le
mpe
en c
Improper alignment
sive
ring
brok
e, roc
t (da
Abnormal combustion
xces
bea
(valv
shaf
olts,
ash
in g
p (e
main
bush
ystem
ing b
ackl
tput
pu m
rod,
e ou
ain b
lve s
t
am
oun
tion
a
er, c
cting
nsid
ar tr
mic v
em
injec
art i
Legend
lanc
r ge
ngin
nne
dyna
: Possible causes (judging from Questions and check items)
ctive
en p
n ba
rope
n co
se e
: Most probable causes (judging from Questions and check items)
ctive
: Possible causes due to length of use (used for a long period)
Defe
Brok
Wor
Wor
Imp
Defe
Loo
: Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Replace
Correct
Adjust
Remedy
20-324 PC78MR-6
TROUBLESHOOTING OF COMMUNICATION
SYSTEM
(N MODE)
a When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-adapter is
removed and the connector is returned, if the service code "E" is not displayed, the condition has returned to
normal.
a If the starting switch was turned OFF after the trouble occurred, turn the starting switch ON and check that
the service code displays "E" at the head. (If "E" is not displayed, the condition has returned to normal.)
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect and disconnected connectors before going on to the next step.
PC78MR-6 20-401
TROUBLESHOOTING N-1
YES
Condition is normal
2
Turn starting switch ON
Min. 0.75 V Is voltage between M96 (Female) (21) NO
Disconnect M96 and measure chassis ground normal?
voltage on wiring harness side
YES
Defective controller Replace
3
NO Disconnection or defective contact in
Is resistance between P02 (Female) (9), Repair or
wiring harness between P02 (Female)
(10) M96 (Female) (21) normal? replace
(9), (10) M96 (Female) (21)
YES
Defective monitor panel Replace
20-402 PC78MR-6
TROUBLESHOOTING FOR CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
PC78MR-6 20-501
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM)
When displaying a saved service code for troubleshooting, "take the notes of the all displayed items and delete
those items", then reproduce the trouble and start the troubleshooting according to the service code displayed
at this time.
(Troubles caused by wrong operation, disconnection of a connector, etc. may be saved in the memory. In this
case, you can avoid unnecessary work by performing the above operation.)
20-502 PC78MR-6
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND
TROUBLESHOOTING PROBLEMS ON MACHINE
When fuel control dial is operated (Slow o Full) Displayed code [1024] : (2), (3), (4), (6), light up and motor operates, then (2),
(3), (4), (6) go off and motor stops (Only (4) keeps
lighting up).
When fuel control dial is operated (Full o Slow) Displayed code [1024] : While only (4) is lighting up, (1), (3), (5) light up and
motor operates, then all lamps go off and motor
stops.
In E-mode (When fuel control dial is at FULL Displayed code [1024] : While only (4) is lighting up, (3), (5) light up and
position) motor operates, then (2) lights up and (3), (5) go off
and motor stops (Only (2) and (4) keep lighting up).
When E-mode is changed to standard motor Displayed code [1024] : While only (2), (4) are lighting up, (3), (6) light up and
(When fuel control dial is at FULL position) motor operates, then (2), (3), (6) go off and motor
stops (Only (4) keeps lighting up).
When one-touch slow-down mechanism is Displayed code [1024] : While only (4) is lighting up, (3), (5) light up and
turned on (When fuel control dial is at FULL motor operates, then (2) lights up and (3), (4), (5) go
position) off and motor stops (Only (2) keeps lighting up).
Displayed code [1026] : When one-touch slow-down switch is turned on, (1)
lights up (This is same as in resetting operation).
When one-touch slow-down mechanism is Displayed code [1024] : While only (2) is lighting up, (3), (6) light up and
turned off (When fuel control dial is at FULL motor operates, then (4) lights up and (2), (3), (6) go
position) off and motor stops (Only (4) keeps lighting up).
20-504 PC78MR-6
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND
TROUBLESHOOTING PROBLEMS ON MACHINE
PC78MR-6 20-505
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)
TROUBLESHOOTING AND ENGINE
relay
relay
User
Code E05 Monitoring Code
20-506 PC78MR-6
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)
TROUBLESHOOTING AND ENGINE
Items
Items checked/ inspected
inspected by with machine
monitoring
monitor Is value in red range?
95 Series
Engine speed
Min. 105 C
Acceleration
Signal
(S-1)
E-8 (S-2)
(S-3)
(S-4)
(S-5)
(S-6)
(S-7)
(S-8)
(S-9)
(S-10)
(S-11)
(S-12)
(S-13)
Q (S-14)
(S-15)
(S-16)
E-4
E-6
E-4, E-5
E-8
M-2
PC78MR-6 20-507
TROUBLESHOOTING E-1
Cause Remedy
1
Is voltage between M96 (Female) (1), (11) NO
Turn starting switch ON
(21), (31), (32), (33), chassis ground
20 30 V
normal?
YES
Defective controller Replace
2
Turn starting switch ON Is voltage between fuse 20 and chassis NO Disconnection or defective Repair or
contact in wiring harness between
20 30 V ground normal? fuse 20 battery relay terminal B replace
YES Disconnection or defective Repair or
contact in wiring harness between
fuse 20 M97 (Female) (1), (11) replace
20-508 PC78MR-6
TROUBLESHOOTING E-2
YES
Defective controller Replace
2
Short circuit with chassis ground
Disconnect M97 and K32 Is resistance between M97 (Female) (25) NO or negative (-) wire in wiring Repair or
Min. 1 Mz and chassis ground normal? harness between M97 (Female) replace
(25) K32 (Female) (1)
YES Repair or
Defective Relay
replace
If the wiring harness between M97 (25) K34 (1) is shorted to the coil actually, the controller output is cut
out. Accordingly, if [E323] is displayed, the controller is defective.
PC78MR-6 20-509
TROUBLESHOOTING E-3
YES
Defective controller Replace
2
Short circuit with chassis ground
Disconnect M97 and K33 Is resistance between M97 (Female) (35) NO or negative (-) wire in wiring Repair or
Min. 1 Mz chassis ground normal? harness between M97 (Female) replace
(35) K33 (Female) (1)
YES
Repair or
Defective Relay
replace
If the wiring harness between M97 (35) K33 (1) is shorted to the coil actually, the controller output is cut
out. Accordingly, if [E325] is displayed, the controller is defective.
20-510 PC78MR-6
TROUBLESHOOTING E-4
Cause Remedy
1
For state of bit, see Action
taken by controller when NO
Is monitored value normal?
trouble occurs and problems
on machine.
YES
Defective motor
Replace motor
(Drive system)
4
Is resistance between M97
Disconnect M97 and K27. (Female) (19) K27 (Female) (5),
Resistance between pins: between M97 (29) K27 Disconnection or defective
Max. 1 z (Female) (6), between M97 NO contact in wiring harness between Repair or
Resistance between pin and (Female) (39) K27 (Female) (3) M97 (Female) (19), (29), (39) replace
chassis and ground: normal? Is resistance between K27 (Female) (5), (6), (3)
Min. 1 Mz each wiring harness and chassis
ground normal?
YES
Turn starting switch ON
When dial is raised
5
Between K97 (19), (39) (23):
24 V When dial is operated, is each input NO
Defective motor (Signal system) Replace
When dial is lowered signal normal?
(slowed)
Between M97 (29) (23):
24 V YES
Defective controller Replace
PC78MR-6 20-511
TROUBLESHOOTING E-4
20-512 PC78MR-6
TROUBLESHOOTING E-5
2
Disconnect M16 Is resistance between M16 (Male) (1) (2) NO Defective engine speed Repair or
500 1,000 z normal? sensor replace
YES 3
Disconnection or defective
Disconnect M16 Is resistance between M96 (Female) (39) NO contact in wiring harness between Repair or
500 1,000 z (40) normal? M96 (Female) (39) M16 replace
(Female) (1), (2)
YES Defective installation of engine
Test/Adjust
speed sensor
PC78MR-6 20-513
TROUBLESHOOTING E-6
YES
See troubleshooting in E-5
2
Disconnect K18
When switch is ON: Max. 1z Is resistance between K18 (Male) (1) (2) NO Defective one-touch decelerator Replace lever
When switch is OFF: normal? switch assembly
Min. 1 Mz
YES 3
Disconnect K18 Disconnection or defective
Is voltage between K18 (Male) (1) NO contact in wiring harness between Repair or
Turn starting switch ON
chassis ground normal? K18 (Female) (1) fuse (11) or replace
20 30 V breakage of fuse (11)
YES Disconnection or defective
contact in wiring harness between Repair or
K18 (Female) (2) M97 (Female) replace
(9)
20-514 PC78MR-6
TROUBLESHOOTING E-7
Cause Remedy
1
Disconnect M97.
Resistance between M97 Is resistance between M97 (female) (4) NO
(female) (4) chassis chassis ground normal?
ground: 68 z 10%
YES
Defective controller Replace
Disconnect M36. 2
Resistance between M36 Is resistance between stop solenoid relay NO
(male) (1) (2): 68 z 10%
M36 (male) (1) (2) and between each Defective stop solenoid relay Replace
Resistance between M36
(male) (1), (2) chassis pin and chassis ground normal?
ground: Min. 1 Mz YES
3
Disconnect D26
(with M36 disconnected). Is resistance between M97 (female) (4) NO Defective wiring harness Repair or
Resistance between M97
(female) (4) chassis chassis ground normal? (Grounding fault) replace
ground: Min. 1 Mz
YES
Defective diode D26 Replace
PC78MR-6 20-515
TROUBLESHOOTING E-7
Cause Remedy
1
See TESTING AND When engine stop solenoid linkage is NO
ADJUSTING adjusted, does engine start?
2
20 29 V Is voltage between engine stop solenoid NO
Turn starting switch ON terminal chassis ground normal?
YES 3
Max. 1 z Is resistance between engine stop Disconnection or defective
NO contact in wiring harness between Repair or
Turn starting switch OFF solenoid terminal GND chassis ground
engine stop solenoid terminal replace
Disconnect T8 normal? GND chassis ground
YES 4
20 29 V Disconnection or defective
Is voltage between engine stop solenoid NO contact in wiring harness between Repair or
Disconnect PULL terminal.
PULL terminal and chassis ground engine stop solenoid PULL
For only 3 seconds after terminal fusible link M26 (male) replace
normal?
starting switch is turned ON. (2)
YES
Defective engine stop solenoid Replace
5
20 29 V Is voltage between outlet of fuse (15) NO
Turn starting switch ON chassis ground normal?
6
20 29 V Is voltage between starting switch terminal NO Defective starting switch
Replace
Turn starting switch ON ACC chassis ground normal? (Between B ACC)
20-516 PC78MR-6
TROUBLESHOOTING E-7
PC78MR-6 20-517
TROUBLESHOOTING E-7
d) Starting System
Cause Remedy
1
Min. 24 V Are battery voltage and specific gravity of NO Insufficient battery Charge or
Specific gravity: Min. 1.26 battery fluid normal? capacity replace
YES 2
When starting switch is turned OFF, does NO
Turn starting switch OFF
battery relay make sound?
YES
3
Is engaging sound of starting motor pinion NO
heard?
YES
5
Turn starting switch to Defective starting switch
Is voltage between starting switch terminal NO
START position. (Between terminals B and Replace
C and chassis ground normal?
20 29 V C)
YES
6
Is voltage between safety relay terminal S NO
Conditions are same as 5
chassis ground normal?
YES
7
Is voltage between starting motor terminal NO
Conditions are same as 5
C chassis ground normal?
8
Is voltage between safety relay terminal C NO
Conditions are same as 5
chassis ground normal?
Disconnection or defective
YES contact in wiring harness Repair or
between starting motor
safety relay terminal C replace
starting motor terminal C
9
Turn starting switch ON Is voltage between safety relay terminal R NO Repair or
Defective alternator
Max. 13 V chassis ground normal? replace
YES
Defective starting motor
Replace
To page 20-520 safety relay
To page 20-519
20-518 PC78MR-6
TROUBLESHOOTING E-7
Cause Remedy
10
20 29 V NO
Is voltage between V2 (8) chassis
Turn starting switch to
ground normal?
START.
Disconnection or defective
YES contact in wiring harness
Repair or
between safety relay terminal S
M30 (1) M5 (4) V2 replace
(Female) (8)
11
20 29 V NO
Is voltage between V2 (7) chassis
Turn starting switch to
ground normal?
START
YES Disconnection or defective
contact in wiring harness
between V2 (Male) (7) (8)
12
20 29 V NO
Is voltage between K23 (3) chassis
Turn starting switch to
ground normal?
START
Disconnection or defective
YES contact in wiring harness Repair or
between K23 (Female) (3) V3
replace
(Female) (3)
13
Disconnection or defective
20 29 V NO contact in wiring harness
Is voltage between K23 (5) chassis Repair or
Turn starting switch to between K23 (Female) (5)
ground normal? K51 (6) starting switch replace
START
terminal C
YES 14
20 29 V NO
Is voltage between K23 (1) chassis
Turn starting switch ON
ground normal?
Lock PPC lock switch
YES 15
Max. 1 z Disconnection or defective
Is resistance between K23 (Female) (2) NO contact in wiring harness Repair or
Turn starting switch ON
chassis ground normal? between K23 (Female) (2) M1 replace
Disconnect K23 (2) chassis ground
YES
Defective K23 relay Replace
16
20 29 V NO
Is voltage between k28 (3) chassis
Turn starting switch ON
ground normal?
Lock PPC lock lever
Disconnection or defective
YES contact in wiring harness Repair or
between K28 (Male) (3) K23 replace
(Female) (1) chassis ground
To page 20-520
PC78MR-6 20-519
TROUBLESHOOTING E-7
Cause Remedy
18 Disconnection or defective
Connect (-) pin of tester to (-) contact in wiring harness between
Is voltage at starting switch terminal B NO battery (+) terminal M27 (1), (2)
terminal of battery Replace
normal? M2 (1) fuse (20) K51 (1)
20 29 V starting switch terminal B
YES (including fusible link)
19
Disconnect terminal B
Is there continuity between starting switch NO Defective starting switch
Turn starting switch to Replace
terminals B BR? (between terminal B BR)
START
YES 20
Set tester in diode range and Disconnection or defective
apply (+) to starting switch Is there continuity between starting switch NO contact in wiring harness between
and (-) to battery relay starting switch terminal BR K51 Replace
Disconnect both starting terminal BR battery relay terminal BR? (3) D51 (2), (1) battery relay
switch and battery relay terminal BR (including diode)
YES 21
Defective contact in wiring
Is there continuity between chassis NO harness between battery relay Repair or
Turn starting switch OFF
ground and battery relay terminal B? terminal E - revolving frame replace
ground terminal
YES
Defective battery relay Replace
20-520 PC78MR-6
TROUBLESHOOTING E-7
PC78MR-6 20-521
TROUBLESHOOTING E-8
2
Is voltage between engine stop solenoid Contact of (+) wiring harness with
Max. 1 V NO wiring harness between starting Replace or
terminal HOLD and chassis ground
Turn starting switch OFF switch terminal ACC fuse (15) repair
normal? M3 (3) solenoid terminal HOLD
YES
Defective engine stop solenoid Replace
20-522 PC78MR-6
TROUBLESHOOTING FOR CONTROLLER
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)
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER
TROUBLESHOOTING (PUMP CONTROL SYSTEM)
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
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS
TROUBLESHOOTING AND PROBLEMS ON MACHINE
1. Disconnection in wiring harness between
M97 pin 27 M15 pin 2
Disconnection in 2nd travel speed selection
E216 2. Disconnection in solenoid
solenoid system
3. Disconnection in wiring harness between
M15 pin 1 M97 pin 3
Short circuit in 5 V system of sensor power 1. Short circuit in wiring harness between M95
E258
supply pin 22 M29 pin C, M71 pin C, M72 pin A
20-604 PC78MR-6
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS
TROUBLESHOOTING AND PROBLEMS ON MACHINE
PC78MR-6 20-605
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS
TROUBLESHOOTING AND PROBLEMS ON MACHINE
20-606 PC78MR-6
(1)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS
TROUBLESHOOTING AND PROBLEMS ON MACHINE
Resistance between M97 pin 5 M11 pin 2: Boom swing LEFT EPC solenoid out- Boom cannot be swing to LEFT.
Max. 1 z put is stopped.
Resistance of M11 EPC solenoid: 3 15 z
Resistance between M11 pin 1 M97 pin 23:
Max. 1 z
Resistance between M97 pin 15 M12 pin 2: Boom swing RIGHT EPC solenoid Boom cannot be swing RIGHT.
Max. 1 z output is stopped.
Resistance of M11 EPC solenoid: 3 15 z
Resistance between M12 pin 1 M97 pin 23:
Max. 1 z
PC78MR-6 20-607
(1)
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM)
TROUBLESHOOTING AND HYDRAULIC EQUIPMENT
(*2)
User Code E02 E03 E40
Failure Mode
Service Code 232 233 203 213 206 216 227 414 251 258 412 413
Boom
Boom swing
Work equip-
ment
Boom
Boom swing
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
20-608 PC78MR-6
(1)
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM)
TROUBLESHOOTING AND HYDRAULIC EQUIPMENT
State of
Disconnection in boom swing LEFT EPC solenoid system
Hydraulic Switch
Short circuit in boom swing RIGHT EPC solenoid system
Solenoid
Short circuit in boom swing LEFT EPC solenoid system
detected
ATT selection
Swing (4)
Travel (3)
(*2)
(*2)
E41 Monitoring Code
451 452 453 454 1023 1021 1026 1060 1020 1010 1031 1026 1040 1050 1052 1053
(*1) H-7
q q q q (*1) H-10
H-11
(*1) H-12
q q q q (*1) H-14
(*1) H-26
H-33
q q (*1) C-15
(*1) (*1)
(*1) (*1)
C-17
PC78MR-6 20-609
(1)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
20-610 PC78MR-6
(1)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
PC78MR-6 20-611
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
20-611-1 PC78MR-6
(1)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
PC78MR-6 20-611-2
(1)
TROUBLESHOOTING C-1, C-2
Cause Remedy
1
Disconnect M20 Is resistance of EPC solenoid normal Defective TVC-EPC solenoid
3 15 z
NO
and is EPC solenoid insulated from (Internal short circuit, Replace
Resistance between solenoid chassis? disconnection)
and chassis ground: Min. 1 Mz
YES
2
Disconnection or defective
Disconnect M97 Is resistance between M97 (Female) NO contact in wiring harness Repair or
Resistance: 3 15 z (16) (23) normal? between M97 (Female) (16), replace
(23) M20 (Female) (1), (2)
YES
3
Short circuit with chassis ground
Disconnect M97 Is resistance between M97 (Female) NO or negative (-) wire in wiring Repair or
Resistance: Min. 1 Mz (16) chassis ground normal? harness between M97 (Female) replace
(16) M20 (Female) (1)
YES
Defective controller Replace
20-612 PC78MR-6
TROUBLESHOOTING C-3, C-4
C-3 [E203], C-4 [E213] Trouble in swing holding brake solenoid system
a Since this error is displayed when the emergency swing holding brake release switch is turned ON (RAISE),
check that this switch is turned OFF (LOWER).
Cause Remedy
1
Disconnect M14 Defective swing holding brake
Is resistance of solenoid normal and is NO
35 80 z solenoid (Internal short circuit, Replace
Resistance between solenoid solenoid insulated from chassis?
disconnection)
and chassis ground: Min. 1 Mz
YES
2
Disconnection or defective
Disconnect M97 Is resistance between M97 (Female) NO contact in wiring harness Repair or
Resistance: 35 80z (7) (3) normal? between M97 (Female) (7), (3) replace
M14 (Female) (2), (1)
YES
3
Short circuit with chassis ground
Disconnect M97 Is resistance between M97 (Female) NO or negative (-) wire in wiring Repair or
Resistance: Min. 1 Mz (7) chassis ground normal? harness between M97 (Female) replace
(7) M14 (Female) (2)
YES
Defective controller Replace
PC78MR-6 20-613
TROUBLESHOOTING C-5, C-6
C-5 [E206], C-6 [E216] Trouble in 2nd travel speed selection solenoid
system
Cause Remedy
1
Disconnect M14 Defective 2nd travel speed
Is resistance of solenoid normal and is
NO
35 80 z selection solenoid (Internal Replace
Resistance between solenoid solenoid insulated from chassis?
short circuit, disconnection)
chassis ground: Min. 1 Mz
YES
2
Disconnection or defective
Disconnect M97 Is resistance between M97 (Female) NO contact in wiring harness Repair or
Resistance: 35 80 z (27) (3) normal? between M97 (Female) (27), (3) replace
M15 (Female) (2), (1)
YES
3
Short circuit with chassis ground
Disconnect M97 Is resistance between M97 (Female) NO or negative (-) wire in wiring Repair or
Resistance: Min. 1 Mz (27) chassis ground normal? harness between M97 (Female) replace
(27) M15 (Female) (2)
YES
Defective controller Replace
20-614 PC78MR-6
TROUBLESHOOTING C-7
Cause Remedy
1
Reset data again according to Is error turned off after data are reset NO Defective correction (Wrong
potentiometer correction
again resetting)
procedure in back mode
YES
2
Is monitored voltage of angle sensor at NO
See Table 1 Defective controller Replace
each cylinder end normal?
YES
3
M101
Between (A) (C): 3 7 kz NO
Is resistance of each angle sensor Defective angle sensor having
Between (A), (C) (B): 0 7 kz Replace
normal? abnormal resistance
(Resistance changes as shaft is
turned)
PC78MR-6 20-615
TROUBLESHOOTING C-8, C-9
Cause Remedy
1
When normal: There is a bit. Is signal input of overload alarm reset NO Disconnection in wiring harness Repair or
When reset: There is not a bit. switch normal? between M97 (20) fuse box replace
(Monitoring code 1026 (2)) (10) or defective switch
YES
2
0 26.5 MPa
(If boom circuit is relieved at Is boom cylinder bottom pressure NO
RAISE end, pressure changes.) sensor signal normal?
(Monitoring code 1040)
YES
Defective controller Replace
3
Is resistance between M95 (2) and
M92 (C), between M95 (21) and M92 Disconnection or short circuit in
(A), and between M95 (22) and M92 wiring harness between M95 (2) Repair or
NO
Disconnect M95 and M92. (B) below 1 z? M92 (C), M95 (21) M92 (A), replace
Is resistance between M95 (2), or M95 (22) M92 (B)
(22), M92 (C), (B) and chassis ground
above 1 Mz?
YES
Defective pressure sensor Replace
20-615-1 PC78MR-6
(1)
TROUBLESHOOTING C-9
C-9 [E258] Short circuit in 5V system of sensor power supply (For STD
spec.)
a If E258 is displayed, E40 is also displayed.
Carry out the following troubleshooting and the troubleshooting for E40 system (C-10 C-11).
Cause Remedy
1
Short circuit with chassis ground in
Is resistance between M95 NO wiring harness between M95 (Female)
Disconnect M95 Repair or
(Female) (22) (21) chassis (22) M101 (Female) (C) (Short circuit
Min. 1Mz Replace
ground normal? of sensor power supply with chassis
ground.)
YES
2
Short circuit with chassis ground or
disconnect M95, M101 and NO
Is resistance between M95 negative (-) wire in wiring harness Repair or
M29.
(Female) (22) (21)normal? between M101 (Female) (A), M72 Replace
Min. 1Mz
(Female) (C)
YES
3
Between (A) (C): 3 7 kz
Between (A), (C) (B): 0 7 kz Is resistance of each angle NO Defective angle sensor having abnormal
Replace
(Resistance changes as shaft is sensor normal? resistance (Internal short circuit)
turned)
YES
Defective controller Replace
20-616 PC78MR-6
(1)
TROUBLESHOOTING C-10, C-11
C-10 [E412], C-11 [E413] Trouble in boom swing angle sensor system
Cause Remedy
1
0.3 4.7 V Is monitored voltage of boom NO
(Monitoring code 1033) angle sensor normal?
2
Between (A) (C): 3 7 kz
NO Defective boom angle sensor
Between (A), (C) (B): 0 7 kz Is resistance of M101 angle
(Disconnection, short circuit with chassis Replace
(Resistance changes as shaft is sensor normal?
ground)
turned.)
If the wiring harness between M95(3) M101 (B) is shorted actually, the controller output is cut out. Accord-
ingly, if [E402] is displayed, the controller is defective.
PC78MR-6 20-617
(1)
TROUBLESHOOTING C-12
C-12 [E451] Short circuit in boom swing LEFT stop EPC solenoid system
is displayed
Cause Remedy
1
Is resistance between M11 (male) (1) NO Defective boom swing LEFT
Turn starting switch OFF. and (2) and between (2) and chassis stop EPC solenoid Replace
Disconnect M11. ground as shown in Table 1? (Internal disconnection)
YES
2
Is resistance between D33 (female) (1) Disconnection in wiring harness
Turn starting switch OFF. and chassis ground and between D33 NO between D33 (female) (1) M11 Repair or
Disconnect D33 and M97. (female) (1) and M97 (female) (23) as (female) (2), M97 (female) (23) Replace
shown in Table 2? M11 (female) (1)
YES
3
Grounding fault or internal short
Is resistance between M97 (female) NO
Turn starting switch OFF. circuit in wiring harness Repair or
(5) and M97 (female) (23) between
Disconnect D33 and M97. between D33 (female) (2) M97 Replace
M97 (female) (5) as shown table 3?
(female) (5)
YES
Defective controller Replace
20-618 PC78MR-6
(1)
TROUBLESHOOTING C-13
C-13 [E452] Disconnection in boom swing LEFT stop EPC solenoid sys-
tem is displayed
Cause Remedy
1
Turn starting switch OFF. NO Defective boom swing LEFT stop
Is resistance between M11
Disconnect M11. EPC solenoid Replace
(male) (1) and (2) normal?
Resistance: 5 25z (Internal disconnection)
YES
2
Is resistance between D33 Disconnection in wiring harness
(female) (1) and M97 (female) NO between D33 (female) (1) M11
Turn starting switch OFF. Repair or
(23) and between D33 (female) (female) (2), D15 (female) (2) M97
Disconnect D33 and M97. Replace
(2) and M97 (female) (5) as (female) (5), or M97 (female) (23)
shown in Table 1? M11 (female) (1)
YES
3
Turn starting switch OFF. NO
Disconnect D33. Is diode D15 normal? Defective diode (Disconnection) Replace
* See TESTING AND ADJUSTING.
YES
Defective controller Replace
Table 1
Between D33 (1) M97 (23) 5 25 z
Between D33 (2) M97 (26) Min. 1 z
PC78MR-6 20-619
(1)
TROUBLESHOOTING C-14
C-14 [E453] Short circuit in boom swing RIGHT stop EPC solenoid sys-
tem is displayed
Cause Remedy
1
Is resistance between M12 (male) (1) Defective boom swing RIGHT
Turn starting switch OFF. NO stop EPC solenoid
and (2) and between (2) and chassis Replace
Disconnect M12. ground as shown in Table 1? (Internal short circuit or
grounding fault)
YES
2
Grounding fault or internal short
Is resistance between D31 (female) (1)
NO circuit in wiring harness
Turn starting switch OFF. and chassis ground and between D31 Repair or
between D31 (female) (1) M12
Disconnect D31 and M97. (female) (1) and M97 (female) (23) as Replace
(2) or between M97 (23) M12
shown in Table 2?
(1)
YES
3
Is resistance between M97 (female) Grounding fault or internal short
Turn starting switch OFF. (15) and chassis ground and between NO circuit in wiring harness Repair or
Disconnect D31 and M97. M97 (female) (15) and M97 (female) between D31 (female) (2) M97 Replace
(23) as shown in Table 3? (female) (15)
YES
Defective controller Replace
20-620 PC78MR-6
(1)
TROUBLESHOOTING C-15
C-15 [E454] Disconnection in boom swing RIGHT stop EPC solenoid sys-
tem is displayed
Cause Remedy
1
Turn starting switch OFF. NO Defective boom swing RIGHT stop
Is resistance between M12
Disconnect M12. EPC solenoid Replace
(male) (1) and (2) normal?
Resistance: 5 25z (Internal disconnection)
YES
2
Is resistance between D31
NO Disconnection in wiring harness
(female) (1) and M97 (female)
Turn starting switch OFF. between D31 (female) (1) M12 (2), Repair or
(23) and between D31 (female)
Disconnect D31 and M97. D31 (female) (2) M97 (15), or M97 Replace
(2) and M97 (female) (15) as
(23) M12 (1))
shown in Table 1?
YES
3
Turn starting switch OFF. NO
Disconnect D31. Is diode D31 normal? Defective diode (Disconnection) Replace
* See TESTING AND ADJUSTING.
YES
Defective controller Replace
Table 1
Between D31 (1) M97 (23) 5 25 z
Between D31 (2) M97 (15) Min. 1 z
PC78MR-6 20-621
(1)
TROUBLESHOOTING C-16
C-16 Boom swing LEFT end cushion does not work at all or normally
a Check that the boom swing angle sensor voltage input is normal by monitoring code 1033.
a (Standard value: 0.9 V when boom swing is at left end)
a Check that the boom swing EPC current output is normal by monitoring code 1052.)
a Check installation of the boom swing angle sensor for abnormality.
Cause Remedy
1
When boom swing angle sensor is
NO
corrected again, does condition
become normal?
YES
Defective correction
2
Between (A) and (C): 3 7 kz
Between (A), (C) and (B): 0 7 Is resistance of boom swing angle NO Defective boom swing angle
Replace
kz (If shaft is rotated, resistance sensor normal? sensor
changes.)
YES
3
Is resistance between M101 (A) and Disconnection or defective
M95 (21), between M101 (B) and M95 NO contact in wiring harness of Repair or
Normal value: Max. 1 z
(8), and between M101 (C) and M95 circuit having abnormal replace
(22) normal? resistance (See circuit diagram)
YES
Defective controller
20-622 PC78MR-6
(1)
TROUBLESHOOTING C-16
PC78MR-6 20-623
(1)
TROUBLESHOOTING C-17
C-17 Boom swing RIGHT end cushion does not work at all or normally
a Check that the boom swing angle sensor voltage input is normal by monitoring code 1033.
(Standard value:At 4.3 V)
a Check that the boom swing RIGHT EPC current output is normal by monitoring code 1053.
a Check installation of the boom swing angle sensor for abnormality.
Cause Remedy
1
When boom swing angle sensor is NO
corrected again, does condition
become normal?
YES
Defective correction
2
Between (A) and (C): 3 7 kz
Between (A), (C) and (B): 0 7 Is resistance of boom swing angle NO Defective boom swing angle
Replace
kz (If shaft is rotated, resistance sensor normal? sensor
changes.)
YES
3
Is resistance between M101 (A) and Disconnection or defective
M95 (21), between M101 (B) and M95 NO contact in wiring harness of Repair or
Normal value: Max. 1 z
(8), and between M101 (C) and M95 circuit having abnormal replace
(22) normal? resistance
YES
Defective controller Replace
20-624 PC78MR-6
(1)
TROUBLESHOOTING C-17
PC78MR-6 20-625
(1)
TROUBLESHOOTING C-18
C-18 Work equipment still moves after work equipment lock lever is set to
LOCK
Cause Remedy
1
When pushed, (1) (3) are
connected to each other. Is PPC hydraulic lock switch
NO
When released, (1) (2) are Defective hydraulic lock switch Replace
normal?
connected to each other
(Test on switch unit)
YES
2
NO Short circuit with positive (+) wire in Repair or
When locked: 0 V Is voltage between M13 (2)
wiring harness between K28 (2) replace wiring
When released: 20 29 V chassis ground normal?
M13 (2) harness
YES
Defective PPC lock solenoid valve Replace
20-626 PC78MR-6
(1)
TROUBLESHOOTING C-19
Cause Remedy
YES
Go to H-34
PC78MR-6 20-627
(1)
TROUBLESHOOTING C-20, C-21
Cause Remedy
1
20 29 V Is voltage between K3 (Female) (2) NO
Turn starting switch ON chassis ground normal?
Disconnect K3
YES
2
In 1-spool mode: Max. 1Mz
In 2-spool mode: Max. 1Mz Is resistance between K3 (Male) (2) NO Defective 2nd travel speed
Replace
Turn starting switch OFF (1) normal? selection switch
Disconnect K3
YES
Disconnection or defective
contact in wiring harness Repair or
between K3 (Female) (1) replace
chassis ground
3
20 29 V NO
Is voltage between M95 (5)
Turn starting switch ON Defective controller Replace
chassis ground normal?
Disconnect K3
20-628 PC78MR-6
(1)
TROUBLESHOOTING FOR CONTROLLER
(INPUT SIGNAL SYSTEM)
(F MODE)
F-1 Bit pattern 1023-(4) Swing pressure switch does not light up........................................................... 20-702
F-2 Bit pattern 1023-(3) Travel pressure switch does not light up........................................................... 20-703
F-3 Bit pattern 1023-(6) Boom RAISE pressure switch does not light up ............................................... 20-704
F-4 Bit pattern 1023-(5) Arm IN pressure switch does not light up ......................................................... 20-705
F-5 Bit pattern 1026-(1) Deceleration switch of left knob does not light up............................................. 20-706
F-6 Bit pattern 1026-(4) 2nd travel speed selection switch (pedal) does not light up.............................. 20-707
F-7 Bit pattern 1021-(3) Compressor signal does not light up................................................................. 20-708
a When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-adapter is
removed and the connector is returned, if the monitoring code is displayed normally, the condition has
returned to normal.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
PC78MR-6 20-701
TROUBLESHOOTING F-1
2 F-1 Bit pattern 1023-(4) Swing pressure switch does not light up
Before operating the swing control lever (even a little distance), stick the bucket into the ground to lock the
swing mechanism.
Cause Remedy
Disconnect M22. 1
Start engine.
Set swing control lever in Is resistance between M22 (Male) (1) NO Defective left swing pressure
neutral: Min. 1Mz (2) normal and are they insulated from Replace
switch
Move swing control lever to chassis ground?
swing to left: Max. 1z
See note. YES
Disconnect M23.
2
Start engine.
Set swing control lever in Is resistance between M23 (Male) (1)
NO Defective right swing pressure
neutral: Min. 1 Mz (2) normal and are they insulated from Replace
switch
Move swing control lever to chassis ground?
swing to right: Max. 1 z
See note. YES
3
Turn starting switch OFF. Disconnection, defective
Disconnect M95, M22, and M23. Is resistance between M95 (Female) contact, or short circuit with
Between M95 M22, M23: Max. (24) M22, M23 (Female) (2) normal NO chassis ground in wiring Repair or
1z and are they insulated from chassis harness between M95 (Female) replace
Between wiring harness ground? (24) M22 (Female) (2), M23
chassis ground: Min. 1 z (Female) (2)
YES
4
Start engine.
Set swing control lever in Disconnection or defective
neutral: 20 30 V Is voltage between M95 (24) chassis NO contact in wiring harness Repair or
Move swing control lever: Max. ground normal? between M22 (Female) (1), M23 replace
1V (Female) (1) chassis ground
YES
Defective controller Replace
Note: This item may be judged by fitting a short connector. In this case, judge by the voltage between M95
(24) chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
20-702 PC78MR-6
TROUBLESHOOTING F-2
2 F-2 Bit pattern 1023-(3) Travel pressure switch does not light up
Before operating the travel lever (even a little distance), check the condition and safety around the
machine.
Before operating the travel lever, put a block in the grouser of the track shoe or between the sprocket and
frame to lock the track shoe.
Cause Remedy
Disconnect M25. 1
Start engine. Is resistance between M25 (Male) (1)
Set swing control lever in NO
(2) normal and are they insulated from Defective travel pressure switch Replace
neutral: Min. 1 Mz chassis ground?
Move travel lever: Max. 1 z
See note. YES
2
Turn starting switch OFF. Disconnection, defective
Is resistance between M95 (Female)
Disconnect M95 and M25. contact, or short circuit with
(18) M25 (Female) (2) normal and NO Repair or
Between M95 M25: Max. 1 z chassis ground in wiring
are they insulated from chassis replace
Between wiring harness harness between M95 (Female)
ground?
chassis ground: Min. 1 Mz (18) M25 (Female) (2)
YES
3
Start engine. Disconnection or defective
Set travel lever in neutral: Is voltage between M95 (18) chassis NO contact in wiring harness Repair or
20 30 V ground normal? between M25 (Female) (1) replace
Move travel lever: Max. 1 V chassis ground
YES
Defective controller Replace
Note: This item may be judged by fitting a short connector. In this case, judge by the voltage between M95
(18) chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
PC78MR-6 20-703
TROUBLESHOOTING F-3
F-3 Bit pattern 1023-(6) Boom RAISE pressure switch does not light up
When measuring while the engine is running, move each lever to the degree that the work equipment will
not move.
Cause Remedy
Start engine. 1
Set boom control lever in Is voltage between M95 (12) chassis NO
neutral: 20 30 V ground normal?
Move boom control lever to
lower boom: Max. 1 V
YES Defective governor or pump
Replace
controller
Disconnect M21.
2
Start engine.
Set boom control lever in Is resistance between M21 (Male) (1) NO Defective boom RAISE
neutral: Min. 1 Mz (2) normal and are they insulated from Replace
pressure switch
Move boom control lever to chassis ground?
lower boom: Max. 1 z
See note. YES
3
Turn starting switch OFF. Disconnection, defective
Is resistance between M95 (Female)
Disconnect M95 M21. contact, or short circuit with
(12) M21 (Female) (2) normal and NO Repair or
Between M95 M21: Max. 1 z chassis ground in wiring
are they insulated from chassis replace
Between wiring harness harness between M95 (Female)
ground?
chassis ground: Min. 1 Mz (12) M21 (Female) (2)
Note: This item may be judged by fitting a short connector. In this case, judge by the voltage between M95
(12) chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
20-704 PC78MR-6
TROUBLESHOOTING F-4
F-4 Bit pattern 1023-(5) Arm IN pressure switch does not light up
When measuring while the engine is running, move each lever to the degree that the work equipment will
not move.
Cause Remedy
Start engine. 1
Set arm control lever in neutral: Is voltage between M95 (6) chassis NO
20 30 V ground normal?
Move arm control lever to move
arm in: Max. 1 V
YES Defective governor or pump
Replace
controller
Disconnect M24.
2
Start engine.
Set arm control lever in neutral: Is resistance between M24 (Male) (1) NO Defective arm IN pressure
Min. 1 Mz (2) normal and are they insulated from Replace
switch
Move arm control lever to move chassis ground?
arm in: Max. 1 z
See note. YES
3
Turn starting switch OFF.
Disconnection, defective
Disconnect M95 M24.
Is resistance between M95 (Female) NO contact, or short circuit with
Between M95 and M24: Max. Repair or
(6) M24 (Female) (2) normal and are chassis ground in wiring
1z replace
they insulated from chassis ground? harness between M95 (Female)
Between wiring harness
(6) M24 (Female) (2)
chassis ground: Min. 1 Mz
YES Disconnection or defective
contact in wiring harness Repair or
between M24 (Female) (1) replace
chassis ground
Note: This item may be judged by fitting a short connector. In this case, judge by the voltage between M95 (6)
chassis ground.
If 20 30 V: Go to YES.
If below 1 V: Go to NO.
PC78MR-6 20-705
TROUBLESHOOTING F-5
F-5 Bit pattern 1026-(1) Deceleration switch of left knob does not light up
a Check that fuse 1! is normal.
Cause Remedy
1
Turn starting switch ON. Is voltage between M97 (9) chassis NO
Turn knob switch ON: 20 30 V ground normal?
Turn knob switch OFF: Max. 1 V
2
Disconnection or defective
Turn starting switch ON. Is voltage between K18 (Male) (2) NO contact in wiring harness Repair or
20 30 V chassis ground normal? between fuse (11) K18 (1) replace
knob switch inlet
YES
20-706 PC78MR-6
TROUBLESHOOTING F-6
2 F-6 Bit pattern 1026-(4) 2nd travel speed selection switch (pedal) does not
light up
Cause Remedy
Turn starting switch OFF. 1
Disconnect 2nd travel speed
selection switch terminal K3. Is resistance between K3 (Male) (1) NO Defective 2nd travel speed
Replace
Turn 2nd travel speed selection (2) normal? selection switch (pedal)
switch ON: Max. 1z
Turn 2nd travel speed selection YES
switch OFF: Min. 1 Mz
2
Turn starting switch OFF. Disconnection, defective
Disconnect M95 and K3. Is resistance between K3 (Female) (2) NO contact, or short circuit with
Repair or
Between M95 K3: Max. 1z M95 (Female) (5) normal and are chassis ground in wiring
replace
Between wiring harness they insulated from chassis ground? harness between M95 (Female)
chassis ground: Min. 1 Mz (5) K3 (Female) (2)
YES
3
Turn starting switch ON. Disconnection or defective
Turn 2nd travel speed selection Is voltage between M95 (Female) (5) NO contact in wiring harness Repair or
switch ON: Max. 1 V chassis ground normal? between K3 (Female) (1) replace
chassis ground
YES
Defective controller Replace
PC78MR-6 20-707
TROUBLESHOOTING F-7
Cause Remedy
20-708 PC78MR-6
TROUBLESHOOTING FOR HYDRAULIC AND
MECHANICAL SYSTEMS
(H MODE)
PC78MR-6 20-801
H-18 Hydraulic drift of swing is large ......................................................................................................... 20-834
a) Hydraulic drift of swing to left is large ............................................................................................ 20-834
b) Hydraulic drift of swing to right is large .......................................................................................... 20-834
H-19 Time lage is large (when engine speed is low) .................................................................................. 20-835
H-20 Part loaded more moves slower in compound operation of work equipment .................................... 20-835
H-21 Boom RAISE speed is low in compound operation of swing and boom RAISE ................................ 20-836
H-22 Travel speed lowers extremely in compound operation of travel and boom RAISE .......................... 20-836
H-23 Speed is low in compound operation of work equipment relief and swing,
work equipment relief and work equipment ....................................................................................... 20-836
H-24 Travel deviation is large ..................................................................................................................... 20-837
a) Travel deviation is large during ordinary travel .............................................................................. 20-837
b) Travel deviation is large when machine starts (but during normal ordinary travel) ........................ 20-838
H-25 Travel deviation is large in compound operation of travel and swing, travel and work
equipment .......................................................................................................................................... 20-839
H-26 Travel speed or power is low (work equipment, swing, and blade operations are normal)................ 20-840
H-27 Machine cannot be steered sharply or steering force is insufficient................................................... 20-842
H-28 Travel speed does not change at all or does not change quickly ...................................................... 20-843
H-29 Machine does not travel..................................................................................................................... 20-844
H-29 Supplement........................................................................................................................................ 20-845
H-30 Overrun of travel is large.................................................................................................................... 20-846
H-31 Travel hydraulic drift is large .............................................................................................................. 20-846
H-32 Fine controllability or response is low ................................................................................................ 20-847
H-33 Swing speed or power is low (work equipment, travel, and blade operations are normal) ................ 20-848
H-34 Machine does not swing (work equipment, travel, and blade operations are normal) ....................... 20-850
a) Swing speed or power is low in both directions ............................................................................. 20-850
b) Swing speed or power is low in either direction ............................................................................. 20-851
H-35 Swing acceleration is low................................................................................................................... 20-852
a) Swing acceleration is low in both directions................................................................................... 20-852
b) Swing acceleration is low in either direction .................................................................................. 20-852
H-36 Overrun of swing is large ................................................................................................................... 20-853
a) Overrun of swing is large in both directions ................................................................................... 20-853
b) Overrun of swing is large in either direction................................................................................... 20-853
H-37 Large shock is made when machine stops swinging ......................................................................... 20-854
H-38 Large abnormal sound is made when machine stops swinging......................................................... 20-854
H-39 Swing hydraulic drift is large .............................................................................................................. 20-855
H-40 Fine controllability more response of swing is low ............................................................................. 20-856
H-41 Blade speed or power is low (work equipment, travel, and swing operations are normal) ................ 20-857
H-42 Blade does not move (work equipment, travel, and swing operations are normal) ........................... 20-858
a) Blade does not rise ........................................................................................................................ 20-858
b) Blade does not lower ..................................................................................................................... 20-859
H-43 Hydraulic drift of blade is large........................................................................................................... 20-860
H-44 Fine controllability or response of blade is low .................................................................................. 20-861
20-802 PC78MR-6
TROUBLESHOOTING TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
Control pump
LS line choke
Unload valve
Piston pump
Hydraulic oil
Merge valve
Servo valve
Logic valve
Gear pump
PTO spline
EPC valve
PC valve
LS valve
Strainer
Orifice
Spool
Failure mode
Cap
Machine model PC78MR-6 Standard specification q
Failure mode
Speed or power of 2 or more systems or work equipment, travel, and
blade is low q q q q q q q q q q
Boom q q
Speed or
power of work Arm q q
equipment is
low Bucket q q
Boom swing q q
Boom q q
Work equip- Arm q q
Work equip- ment does not
ment move Bucket q q
Boom swing q q
Boom q
Hydraulic drift Arm q
of work equip-
ment is large Bucket q
Boom swing q
Time lag is large (When engine speed is low) q
Part loaded more moves slower in compound operation of work
equipment
Boom RAISE speed is low in compound operation of swing and boom
RAISE q
Compound
operation Travel speed lowers extremely in compound operation of travel and
boom RAISE
Speed is low in compound operation of work equipment relief and
swing, work equipment relief and other work equipment q q
20-804 PC78MR-6
q
q
PPC circuit check valve
Travel junction variable throttle
q
q
q
valve
q
Travel LS bleed valve
q
Centralized safety valve
PC78MR-6
q
q
q
q
q
q
q
q
q
q
q
q
q
Suction valve
q q
q
Boom lock valve
Control Valve
q
q
q q q
Boom assist valve
q
q
q q
Gear pump circuit relief valve
q
q
q
q
q q q
Blade safety valve
TROUBLESHOOTING
q
q
Pressure release valve
q
q
Swing PPC slow return valve
q q
q q
q q
q q
q q
Swing PPC line choke
q q
q
2nd travel speed selection choke
q
q
q
q
PPC valve (Right lever) 1 0
q
q
q
q
q
q
q
q
PPC valve (Left lever) 1 0
q
q
q
q
q
q
PPC valve (Travel lever)
PPC valve (Blade bar)
PPC Valve
q q
q
q
PPC valve (Offset pedal)
q
noid
2nd travel speed selection
q
solenoid valve
Swing holding brake solenoid
q
q
valve
Solenoid Valve
q
q
Boom RAISE EPC valve
q
q Arm IN EPC valve
q
q
Left offset EPC valve
Piston motor
q
Safety valve
Check valve
q q q
q q q q
Suction valve
Swing Motor
q q q q q
q q q q q
Parking brake
q q
q
q q q q q q
q q q q q q
Reaction prevention valve
q
q
Swing machinery
q
q
q
q
q
q
q
q q
Piston motor
q q
q
Counterbalance valve
q q q
q q q
q q q q
q q q q
Check valve
2nd speed select valve and
q
piston
Parking brake
Travel Motor
q q
q q
Parking brake valve
q q q
q q q
q q q
Final drive
q
q
q
q
q
q
q
q
q
q
Hydraulic cylinder
q
q
q
q
q
PPC pressure switch
q q
q
q
q q q
q q q
q
H-44
H-43
H-42
H-41
H-40
H-39
H-38
H-37
H-36
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-11
H-10
H- 9
H- 8
H- 7
H- 6
H- 5
H- 4
H- 3
H- 2
H- 1
mode
Failure
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
20-805
TROUBLESHOOTING H-1
Q : Normal
Table 1
x : Speed or power is low
Work Equipment Travel Swing Blade Diagnosis Item
x x x x Go to a
x x Q Q Go to b
Q Q x x Go to c
Q x Q x Go to d
x Q Q Q Go to e
Q x x Q Go to f
a) Speed or power of work equipment (including blade), travel, and swing systems is low
Cause Remedy
1
NO
Is suction strainer clogged?
2
3.14 0.3 MPa
Is output pressure of PPC main pressure lock NO
{32 3 kg/cm2}
solenoid valve normal?
Run engine at full throttle
YES
Go to H-1, b)
3
When control relief valve is adjusted, is NO
trouble repaired?
YES
Defective adjustment of control valve Adjust
4
When PPC lock solenoid valve is replaced, is NO
Defective pump control Replace
trouble repaired?
20-806 PC78MR-6
TROUBLESHOOTING H-1
b) Speed or power of all work equipment (excluding blade) and travel is low
Cause Remedy
1
Curl bucket
NO
26.5 1.47 MPa {270 15 kg/cm2} Is work equipment relief pressure normal?
Run engine at full throttle
YES
2
Curl bucket
NO Go to corresponding section
26.5 1.47 MPa {270 15 kg/cm2} Is travel relief pressure normal?
in H-7 10, 26
Run engine at full throttle
YES
3
When blade is relieved in RAISE mode, NO Defective main pump Repair or
(Lowering of volumetric
does the travel speed rise? efficiency) replace
YES Repair or
Defective boom assist valve
replace
4
Curl bucket
NO
26.5 1.47 MPa {270 15 kg/cm2} Is travel relief pressure normal?
Run engine at full throttle
YES Go to corresponding section
in H-7 10, 26
5
When travel relief valve is adjusted or NO
replaced, is trouble repaired?
YES Repair or
Defective main relief valve
replace
6
NO Repair or
Does unload valve move smoothly? Defective unload valve
replace
YES Repair or
Go to diagnosis No. 3
replace
Cause Remedy
1
Lower blade
21.08 1.47 MPa NO
Is gear pump relief pressure normal?
{215 15 kg/cm2}
Run engine at full throttle
YES Go to corresponding section
in H-26, 33
2
When gear pump relief valve is adjusted or NO Repair or
Defective gear pump
replaced, is trouble repaired? replace
PC78MR-6 20-807
TROUBLESHOOTING H-1
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is travel relief pressure normal?
Run engine at full throttle
YES Go to corresponding section
H-26, 41
2
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is blade LOWER relief pressure normal?
Run engine at full throttle
YES Go to corresponding section
H-26, 41
3
When hose is disconnected from valve outlet NO Go to corresponding section
and plugged, is relief pressure normal? H-26, 41
YES Repair or
Defective swivel joint
replace
Cause Remedy
1
Is all PPC pressure normal (At PPC pressure NO
inlet of control valve?
YES
2
2.11 0.1 MPa
{21.5 1 kg/cm2} NO Defective adjustment of pump
Is LS differential pressure normal? Adjust
Run engine at full throttle and LS valve
curl bucket
YES
3
When compound operation of travel, work NO Go to corresponding section
equipment, and swing is performed, is trouble
in H-7 10
repaired?
YES Defective travel pressure
compensation valve
4
Is PPC pressure normal at only 1 place NO
(When single operation is performed)?
YES Defective check valve in PPC
circuit having normal PPC Replace
pressure
5
NO Leakage of PPC pressure
Is check valve at swing holding brake
caused by defective ball
pressure inlet of logic valve normal?
check valve
YES Go to corresponding section
in H-7 10
a If the PPC main pressure is judged low by troubleshooting in b) above, this trouble can occur.
20-808 PC78MR-6
TROUBLESHOOTING H-2
3
26.5 1.45 MPa
NO
{270 15 kg/cm2} Is bucket CURL relief pressure normal?
Run engine at full throttle
YES
4
12.74 1.47 MPa
NO
{130 15 kg/cm2} Is blade RAISE relief pressure normal?
Run engine at full throttle
YES
5
When gear pump circuit relief valve is NO
adjusted, repaired, or replaced, is
trouble repaired?
YES Defective gear pump circuit Adjust or
relief valve replace
6
When main relief valve is replaced, is NO
trouble repaired?
YES Repair or
Defective main relief valve
replace
7
Does monitor display error code "E02" NO
of TVC trouble?
YES
8
NO
Is TVC connector connected? Defective connection Repair
9
When engine speed changes, does NO Repair or
Defective controller
TVC current change? replace
YES
To next page
PC78MR-6 20-809
TROUBLESHOOTING H-2
Cause Remedy
From previous page
10
0.54 ~ 0.83 MPa
Is output voltage of TVC-EPC solenoid NO
{5.5 ~ 8.5 kg/cm2}
normal?
Run engine at full throttle
YES
11
When PC valve is adjusted, is trouble NO
repaired?
YES Adjust or
Defective PC valve
replace
12
When orifice of servo is cleaned, is NO
trouble repaired?
YES
Clogged orifice
13
When EPC valve of TVC is replaced, is NO
Execute diagnosis No. 11
trouble repaired?
YES Repair or
Defective EPC valve
replace
14
When pump assembly is replaced, is NO
Defective engine system
trouble repaired?
YES Repair or
Defective pump or servo
replace
20-810 PC78MR-6
TROUBLESHOOTING H-3
Q : Normal
Table 1
x : Speed or power is low
Work Equipment Travel Swing Blade Diagnosis Item
x x x x Go to a
x x Q Q Go to b
Q Q x x Go to c
Q x Q x Go to d
x Q Q Q Go to e
Q x x Q Go to f
a) All work equipment (including blade), travel, and swing systems do not move
Cause Remedy
1
When engine is cranked, does oil flow NO
out of pump?
YES
2
When oil does not flow out of any of
following pumps
Main pump
Gear pump
Control pump
YES
3
NO
Is suction strainer clogged?
YES
Clogged suction strainer Clean or adjust
4
NO
Is damper or spline damaged? Defective main pump shaft Replace
YES
Defective damper or spline Replace
5
When oil flows out of main pump but NO
does not flow out of gear pump and
control pump.
YES
6
Is coupling or spline between main NO
Defective gear pump Replace
pump and gear pump damaged?
YES
Defective coupling or spline Replace
PC78MR-6 20-811
TROUBLESHOOTING H-3
Cause Remedy
From item 3 on previous page
5
When engine is cranked, does oil flow out of NO Repair or
Defective control pump
control pump? replace
YES
6
Defective PPC main pressure
3.14 0.3 MPa {32 3 kg/cm2} Is output pressure of PPC main pressure lock NO Repair or
lock solenoid valve or
Run engine at full throttle solenoid valve normal? replace
defective electric system
YES Go to corresponding section
in H-11 ~ 14, 29, 34, 42
b) All work equipment (excluding blade) and travel systems do not move
Cause Remedy
1
When engine is cranked, does oil flow out of NO Repair or
Defective control
control? replace
YES
2
3.14 0.3 MPa Defective PPC main pressure Repair or
Is output pressure of PPC main pressure lock NO
{32 3 kg/cm2} lock solenoid valve or
solenoid valve normal? defective electric system replace
Run engine at full throttle
YES
3
Is only 1 part of each of work equipment and NO Go to corresponding section Repair or
travel normal? in H-11 14, 29 replace
YES Defective check valve in PPC Repair or
circuit having normal
pressure replace
Cause Remedy
1
When engine is cranked, does oil flow out of NO Repair or
Defective control pump
pump? replace
YES
2
When gear pump circuit relief valve is NO Go to corresponding section
adjusted or replaced, is trouble repaired? in H-34, 42
YES Defective gear pump circuit Adjust or
relief valve replace
20-812 PC78MR-6
TROUBLESHOOTING H-3
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is travel relief pressure normal?
Run engine at full throttle
YES Go to corresponding section
H-29
2
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is blade relief pressure normal?
Run engine at full throttle
YES Go to corresponding section
H-42
3
When hose is disconnected from valve outlet NO Go to corresponding section
and plugged, is relief pressure normal? H-29, 42
YES Repair or
Defective swivel joint
replace
Cause Remedy
1
3.14 0.5 MPa
Are all PPC pressures normal NO
{32 5 kg/cm2}
(At connected PPC pressure inlets)?
Run engine at full throttle
YES Go to corresponding section
in H-11 14
2
NO Go to corresponding section
Is only 1 place normal?
in H-11 14
YES Defective check valve in PPC
circuit having normal Replace
pressure
Note: If machine is equipped with an attach-
ment, check that attachment.
PC78MR-6 20-813
TROUBLESHOOTING H-4
YES
3
When engine is stopped, do bubbles in tank NO
Low hydraulic oil level
disappear?
YES
Go to diagnosis No. 4
4
NO
Foreign matter: Cloth, etc. Is suction strainer clogged with foreign matter?
5
Is suction strainer clotted with metallic foreign NO
matter or metal chips?
YES Repair or
Defective inside pump
replace
6
Re-inspect
NO Operate machine and (according to
Is hydraulic tank cap clogged?
observe condition for a while change of
condition)
YES Negative pressure caused by Clean or
clogging of cap replace cap
20-814 PC78MR-6
TROUBLESHOOTING H-5
a The following troubleshooting is not applicable to travel, swing, and blade systems.
Cause Remedy
1
See TESTING AND NO
Is LS differential pressure normal?
ADJUSTING
YES
2
NO
Is LS line choke clogged?
YES Clean or
Clogging of LS line choke
replace
3
NO
Is orifice of unload valve clogged?
4
NO Defective PC valve or servo Repair or
Is orifice of piston pump clogged?
piston replace
YES Clogging of orifice or piston
Clean
pump
5
NO Repair or
When LS valve is adjusted, is trouble repaired? Defective LS valve
replace
YES Defective adjustment of LS
Adjust
valve
PC78MR-6 20-815
TROUBLESHOOTING H-6
Cause Remedy
1
Is pressure release plug of control valve NO Leakage through pressure
Retighten
tightened? release circuit
YES
2
NO
Is seal of pressure release plug broken?
3
When centralized safety valve is replaced, is NO Go to corresponding section
trouble repaired? in H-15 H-18
YES Defective concentrated
Clean
safety valve
20-816 PC78MR-6
TROUBLESHOOTING H-7
Cause Remedy
1
Run engine at full throttle and
set boom in neutral: 410 mA When boom is raised in monitoring mode NO
Diagnose by F-3
Run engine at full throttle and 1050, does current lower?
raise boom: 100 mA
YES
2
0.54 ~ 0.83 MPa
Is output pressure of pump TVC-EPC NO Defective pump TVC-
{5.5 8.5 kg/cm2} Replace
solenoid normal? EPC solenoid
Run engine at full throttle
YES
3
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is boom relief pressure normal?
Run engine at full throttle
YES
4
3.14 0.49 MPa
Is PPC valve output pressure normal?
{32 5 kg/cm2}
(PPC pressure inlet of control valve)
Run engine at full throttle
YES
5
NO Defective operation of Repair or
Does control valve spool move smoothly?
control valve spool replace
YES
6
NO Defective operation of
Does pressure compensation valve move
pressure compensation
smoothly?
valve
YES
7
26.5 1.47 MPa
NO Defective centralized
{270 15 kg/cm2} Is boom LOWER relief pressure normal? Replace
safety valve
Run engine at full throttle
YES Defective suction valve Repair or
(Boom LOWER side) replace
8
When pilot hose of boom assist valve is NO Defective boom cylinder Repair or
disconnected, does speed rise? packing replace
YES Defective seat of check
Repair or
valve of boom assist
replace
valve
9
(Move boom RAISE with arm IN When PPC hose is replaced with arm IN hose NO
Go to diagnosis No. 3
oil.) on control valve side, is trouble repaired?
YES Defective boom RAISE Repair or
PPC valve replace
PC78MR-6 20-817
TROUBLESHOOTING H-7
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is boom LOWER relief pressure normal?
Run engine at full throttle
YES
2
3.14 0.49 MPa
Is PPC valve output pressure normal? (At NO
{32 5 kg/cm2}
control valve PPC pressure inlet)
Run engine at full throttle
YES
3
NO Defective operation of Repair or
Does control valve spool move smoothly?
control valve spool replace
YES
4
Does poppet of pilot piston of boom lock NO Repair,
valve move smoothly and its orifice free Malfunction of lock valve clean, or
from clogging? replace
YES Check 3
Malfunction of spool
again
5
26.5 1.47 MPa
NO Defective concentrated
{270 15 kg/cm2} Is boom RAISE relief pressure normal? Replace
safety valve
Run engine at full throttle
YES Defective suction valve Repair or
(Boom LOWER side) replace
6
When PPC hose of control valve is replaced NO
(Move boom LOWER with arm
with arm DUMP, is trouble repaired? (Return Go to diagnosis No. 3
OUT oil.)
it immediately after testing.)
YES Defective boom LOWER Repair or
PPC valve replace
20-818 PC78MR-6
TROUBLESHOOTING H-8
Cause Remedy
7
26.5 1.47 MPa
NO Defective centralized safety
{270 15 kg/cm2} Is arm OUT relief pressure normal? Replace
valve
Run engine at full throttle.
YES Defective suction valve (Boom Repair or
LOWER side) replace
8
When PPC hose is replaced with boom
(Move arm IN with boom RAISE hose on control valve side, is NO
RAISE) trouble repaired? (Return it immediately
after testing.)
YES Repair or
Defective arm IN PPC valve
replace
9
When swing operation and arm IN NO
operation are executed simultaneously, is Go to diagnosis No. 3
trouble repaired?
YES Defective seats of swing
Repair or
brake circuit check valve and
replace
swing PPC slow-return valve
PC78MR-6 20-819
TROUBLESHOOTING H-8
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is arm OUT relief pressure normal?
Run engine at full throttle
YES
2
3.14 0.49 MPa
Is PPC valve output pressure normal? NO
{32 5 kg/cm2}
(At control valve PPC pressure inlet)
Run engine at full throttle
YES
3
NO Malfunction of control valve Repair or
Does control valve spool move smoothly?
spool replace
YES
4
Does pressure compensation valve move NO Malfunction of pressure Repair or
smoothly? compensation valve replace
YES Defective arm cylinder Repair or
packing replace
5
26.5 1.47 MPa
NO Defective concentrated
{270 15 kg/cm2} Is arm OUT relief pressure normal? Replace
safety valve
Run engine at full throttle
YES Defective suction valve Repair or
(Arm IN side) replace
6
When PPC hose of control valve is
(Move arm OUT with boom replaced with boom LOWER, is trouble NO
Go to diagnosis No. 3
LOWER oil) repaired? (Return it immediately after
testing.)
YES Defective arm OUT PPC Repair or
valve replace
20-820 PC78MR-6
TROUBLESHOOTING H-9
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is bucket CURL relief pressure normal?
Run engine at full throttle
YES
2
3.14 0.49 MPa
Is PPC valve output pressure normal? NO
{32 5 kg/cm2}
(At control valve PPC pressure inlet)
Run engine at full throttle
YES
3
NO Malfunction of control valve Repair or
Does control valve spool move smoothly?
spool replace
YES
4
Does pressure compensation valve move NO Malfunction of pressure Repair or
smoothly? compensation valve replace
YES Defective arm cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective concentrated
{270 15 kg/cm2} Is bucket DUMP relief pressure normal? Replace
safety valve
Run engine at full throttle
YES Defective suction valve Repair or
(Bucket CURL side) replace
6
When PPC hose of control valve is NO
(Move bucket CURL with
replaced with arm IN, is trouble repaired? Go to diagnosis No. 3
arm IN oil)
(Return it immediately after testing.)
YES Defective bucket CURL PPC Repair or
valve replace
PC78MR-6 20-821
TROUBLESHOOTING H-9
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is bucket DUMP relief pressure normal?
Run engine at full throttle
YES
2
3.14 0.49 MPa
Is PPC valve output pressure normal? NO
{32 5 kg/cm2}
(At control valve PPC pressure inlet)
Run engine at full throttle
YES
3
NO Malfunction of control valve Repair or
Does control valve spool move smoothly?
spool replace
YES
4
Does pressure compensation valve move NO Malfunction of pressure Repair or
smoothly? compensation valve replace
YES Defective bucket cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective concentrated
{270 15 kg/cm2} Is bucket CURL relief pressure normal? Replace
safety valve
Run engine at full throttle
YES Defective suction valve Repair or
(Bucket DUMP side) replace
6
When PPC hose of control valve is replaced NO
(Move bucket DUMP with
with arm OUT, is trouble repaired? (Return it Go to diagnosis No. 3
arm OUT oil)
immediately after testing.)
YES Defective bucket DUMP PPC Repair or
valve replace
20-822 PC78MR-6
TROUBLESHOOTING H-10
H-10 Boom swing speed or power is low (other work equipment is normal)
a) Swing left speed or power is low
a Relieve the swing LEFT actuator in a position at which the swing end cushion system does not detect the
work equipment.
a When the offset speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
pressure and carry out troubleshooting No. 2.
a Check that the emergency pump drive switch is turned OFF.
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is swing left relief pressure normal?
Run engine at full throttle
YES
2
3.14 0.49 MPa
Is solenoid valve output pressure normal? NO
{32 5 kg/cm2}
(PPC pressure inlet of control valve)
Run engine at full throttle
YES
3
NO Defective operation of control Repair or
Does control valve spool move smoothly?
valve spool replace
YES
4
Does pressure compensation valve move NO Defective operation of Repair or
smoothly? pressure compensation valve replace
YES Defective swing cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective pressure Repair or
{270 15 kg/cm2} Is swing right relief pressure normal?
compensation valve replace
Run engine at full throttle
YES Defective packing seal near
Repair or
extraction end of swing
replace
cylinder
6
When PPC hose and bucket CURL hose
(Move swing left by curling are exchanged at control valve, does NO
Go to troubleshooting No. 3
bucket) condition become normal?
(Return hoses immediately after testing.)
YES
7
NO Defective swing left PPC Repair or
Is PPC valve output pressure normal?
valve replace
PC78MR-6 20-823
TROUBLESHOOTING H-10
Cause Remedy
1
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is swing right relief pressure normal?
Run engine at full throttle
YES
2
3.14 0.49 MPa
Is PPC valve output pressure normal? NO
{32 5 kg/cm2}
(PPC pressure inlet of control valve)
Run engine at full throttle
YES
3
NO Defective operation of control Repair or
Does control valve spool move smoothly?
valve spool replace
YES
4
Does pressure compensation valve move NO Defective operation of Repair or
smoothly? pressure compensation valve replace
YES Defective swing cylinder Repair or
packing replace
5
26.5 1.47 MPa NO Defective pressure Repair or
{270 15 kg/cm2} Is swing right relief pressure normal?
compensation valve replace
Run engine at full throttle
YES Defective suction valve Repair or
(Right swing side) replace
6
When PPC hose and bucket DUMP hose
(Move swing right by dumping are exchanged at control valve, does NO
Go to troubleshooting No. 3
bucket) condition become normal?
(Return hoses immediately after testing.)
YES Repair or
Defective swing right PPC
replace
valve
20-824 PC78MR-6
TROUBLESHOOTING H-11
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is PPC valve output pressure normal? NO
Run engine at full throttle. (At control valve PPC pressure inlet)
YES
2
NO Malfunction of control valve Repair or
Does boom lower?
spool replace
YES
3
26.5 1.47 MPa
When boom is raised, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle. Deformation of cylinder or
YES work equipment (Boom does Repair or
not rise above the deformed replace
part
4
NO Malfunction of spool in raising Repair or
Does spool move smoothly?
mode replace
YES Malfunction of pressure Repair or
compensation valve replace
5
When PPC hose of control valve is
replaced with arm IN, is trouble NO
(Move boom lower with arm IN oil) Go to diagnosis No. 2
repaired? (Return it immediately after
testing.)
YES Defective boom RAISE PPC Repair or
valve replace
PC78MR-6 20-825
TROUBLESHOOTING H-11
Cause Remedy
1
2.94 0.49 MPa
Is PPC valve output pressure normal? NO
{30 5 kg/cm2}
(At control valve PPC pressure inlet)
Run engine at full throttle.
YES
2
NO Malfunction of control valve
Repair or
Does boom rise? spool or seizure of lock valve
replace
poppet
YES
3
26.5 1.47 MPa
When boom is lowered, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle.
YES
4
NO Malfunction of spool in Repair or
Does spool move smoothly?
lowering mode replace
YES Malfunction of pressure Repair or
compensation valve replace
5
When PPC hose of control valve is
(Move boom lower with arm replaced with arm OUT, is trouble NO
Go to diagnosis No. 2
OUT oil) repaired? (Return it immediately after
testing.)
YES Defective boom LOWER PPC Repair or
valve replace
6
Is seal drain line of control valve NO Repair or
Defective lock valve
clogged? replace
YES Defective lock valve caused Repair or
by clogging replace
20-826 PC78MR-6
TROUBLESHOOTING H-12
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is PPC valve output pressure normal? NO
Run engine at full throttle (At control valve PPC pressure inlet.)
YES
2
NO Malfunction of control valve Repair or
Does arm move out?
spool replace
YES
3
26.5 1.47 MPa
When arm is moved in, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle Deformation of cylinder or
YES work equipment (Arm does Repair or
not move more than replace
deformed part)
4
NO Malfunction of spool in IN Repair or
Does spool move smoothly?
mode replace
YES Malfunction of pressure Repair or
compensation valve replace
5
When PPC hose of control valve is
(Move arm out with boom RAISE replaced with boom RAISE, is trouble NO Repair or
Defective arm IN PPC valve
oil) repaired? (Return it immediately after replace
testing.)
YES
6
When swing operation and arm IN NO
operation are executed simultaneously, Go to diagnosis No. 2
is trouble repaired?
YES Defective seats of swing
Repair or
brake circuit check valve and
replace
swing PPC slow-return valve
PC78MR-6 20-827
TROUBLESHOOTING H-12
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is PPC valve output pressure normal? NO
Run engine at full throttle (At control valve PPC pressure inlet)
YES
2
NO Malfunction of control valve Repair or
Does arm move in?
spool replace
YES
3
26.5 1.47 MPa
When arm is moved out, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle Deformation of cylinder or
YES work equipment (Arm does Repair or
not move more than replace
deformed part)
4
NO Malfunction of spool in OUT Repair or
Does spool move smoothly?
mode replace
YES Malfunction of pressure Repair or
compensation valve replace
5
When PPC hose of control valve is
(Move arm out with boom LOWER replaced with boom LOWER, is trouble NO Defective arm OUT PPC Repair or
oil.) repaired? (Return it immediately after valve replace
testing.)
YES
Go to diagnosis No. 2
20-828 PC78MR-6
TROUBLESHOOTING H-13
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is PPC valve output pressure normal? NO
Run engine at full throttle (At control valve PPC pressure inlet.)
YES
2
NO Malfunction of control valve Repair or
Is bucket dumped?
spool replace
YES
3
26.5 1.47 MPa
When bucket is curled, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle Deformation of cylinder or
YES work equipment Repair or
(Bucket does not move more replace
than deformed part)
4
NO Malfunction of spool in CURL Repair or
Does spool move smoothly?
mode replace
YES Malfunction of pressure Repair or
compensation valve replace
5
When PPC hose of control valve is
replaced with arm IN, is trouble NO
(Move bucket curl with arm IN oil) Go to diagnosis No. 2
repaired? (Return it immediately after
testing.)
YES Defective bucket CURL PPC Repair or
valve replace
PC78MR-6 20-829
TROUBLESHOOTING H-13
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is PPC valve output pressure normal? NO
Run engine at full throttle (At control valve PPC pressure inlet)
YES
2
NO Malfunction of control valve Repair or
Is bucket curled?
spool replace
YES
3
26.5 1.47 MPa
When bucket is dumped, is pump relief NO
{270 15 kg/cm2}
pressure normal?
Run engine at full throttle Deformation of cylinder or
YES work equipment Repair or
(Bucket does not move more replace
than deformed part)
4
NO Malfunction of spool in DUMP Repair or
Does spool move smoothly?
mode replace
YES Malfunction of pressure Repair or
compensation valve replace
5
When PPC hose of control valve is
replaced with arm OUT, is trouble NO
(Move bucket dump with arm OUT) Go to diagnosis No. 2
repaired? (Return it immediately after
testing.)
YES Defective bucket DUMP PPC Repair or
valve replace
20-830 PC78MR-6
TROUBLESHOOTING H-14
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is solenoid valve output pressure normal? NO
Run engine at full throttle. (PPC pressure inlet of control valve)
YES
2
NO Defective operation of control Repair or
Does boom swing right move?
valve spool replace
YES
3
26.5 1.47 MPa
When swing left is operated, is pump NO
{270 15 kg/cm2}
relief pressure normal?
Run engine at full throttle. Deformed cylinder or work
YES equipment Repair or
(Work equipment does not replace
move over deformed part)
4
NO Repair or
Does spool move smoothly? Defective operation of spool
replace
YES Defective operation of Repair or
pressure compensation valve replace
5
When PPC hose and bucket CURL hose
are exchanged at control valve, does NO
(Move swing left by curling bucket) Go to troubleshooting No. 2
condition become normal?
(Return hoses immediately after testing.)
YES
6
NO Defective swing left PPC Repair or
Is PPC valve output pressure normal?
valve replace
YES Defective swing left EPC Repair or
valve replace
PC78MR-6 20-831
TROUBLESHOOTING H-14
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} Is PPC valve output pressure normal? NO
Run engine at full throttle. (PPC pressure inlet of control valve)
YES
2
NO Defective operation of control Repair or
Does boom swing left move?
valve spool replace
YES
3
26.5 1.47 MPa
When swing right is operated, is pump NO
{270 15 kg/cm2} relief pressure normal?
Run engine at full throttle. Deformed cylinder or work
YES equipment Repair or
(Work equipment does not replace
move over deformed part)
4
NO Repair or
Does spool move smoothly? Defective operation of spool
replace
YES Defective operation of Repair or
pressure compensation valve replace
5
When PPC hose and bucket DUMP hose
(Move swing right by dumping are exchanged at control valve, does NO
Go to troubleshooting No. 2
bucket) condition become normal?
(Return hoses immediately after testing.)
YES
6
NO Defective swing RIGHT PPC Repair or
Is PPC valve output pressure normal?
valve replace
YES Defective swing RIGHT EPC Repair or
valve replace
20-832 PC78MR-6
TROUBLESHOOTING H-15, H-16
3
When suction valve is replaced with NO Defective oil-tightness of control Repair or
blind plug, is trouble repaired? valve spool replace
YES Repair or
Defective centralized safety valve
replace
PC78MR-6 20-833
TROUBLESHOOTING H-17, H-18
3
When suction valve is replaced with NO Defective oil-tightness of control Repair or
blind plug, is trouble repaired? valve spool replace
YES Repair or
Defective suction valve
replace
Cause Remedy
1
Is leakage from hydraulic cylinder NO Repair or
Defective cylinder piston packing
normal? replace
YES
2
When suction valve is replaced with NO
Defective oil-tightness of control Repair or
blind plug, does condition become
valve spool replace
normal?
YES Repair or
Defective suction valve
replace
Cause Remedy
1
Is leakage from hydraulic cylinder NO Repair or
Defective cylinder piston packing
normal? replace
YES Defective oil-tightness of control Repair or
valve spool replace
20-834 PC78MR-6
TROUBLESHOOTING H-19, H-20
YES
2
When poppet and spring of back NO
pressure valve are replaced, is trouble
repaired?
YES
Defective back pressure valve Replace
3
When LS valve is replaced, is trouble NO Replace
Defective pump servo piston pump
repaired? assembly
YES
Defective LS valve Replace
PC78MR-6 20-835
TROUBLESHOOTING H-21, H-22, H-23
Cause Remedy
Defective boom assist valve or LS Clean or
select valve replace
Cause Remedy
Malfunction of LS bleed valve Repair or
(Clogged choke, etc.) replace
20-836 PC78MR-6
TROUBLESHOOTING H-24
2
Above 3.14 0.49 MPa
{Above 32 5 kg/cm2} Are PPC output pressures on both NO
Run engine at full throttle sides normal?
Move lever to stroke end
YES
3
When both hoses are exchanged NO
at pump outlet, does deviating
direction change?
YES Wrong adjustment or breakage of Adjust, repair
pump or replace
4
When both hoses between control NO
valve and swivel joint are exchanged,
does deviating direction change?
YES
5
Is pressure at top PP pressure NO
When only travel operation is
pickup port of control valve same
executed
as pump pressure?
YES
6
Does spool of travel junction NO Defective travel junction variable Clean or
variable choke valve move smoothly
and is hole free from clogging? choke valve replace
YES
7
Does spool of pump merge valve NO Repair or
move smoothly and is hole free Defective pump merge valve
from clogging? replace
9
Does unload valve move smoothly NO Malfunction of unload valve Repair or
and is hole free from clogging? (Clogging of hole, etc.) replace
YES
To 12 on next page To 10 on next page To 13 on next page
PC78MR-6 20-837
TROUBLESHOOTING H-24
From 4 on previous page From 9 on previous page From 2 on previous page Cause Remedy
10
Does pressure compensation NO Defective pressure compensation Repair or
valve move smoothly? valve replace
YES
11
NO Repair or
Does travel spool move smoothly? Malfunction of spool
replace
YES
Go to diagnosis No. 11
12
When both hoses between
swivel joint and travel motor are NO Defective travel motor (Motor, Check, repair
exchanged, does deviating counterbalance valve, final drive) or replace
direction change?
YES Repair or
Defective swivel joint
replace
13
When both PPC hose are NO Defective PPC circuit check valve Repair or
exchanged, does deviating
direction change? of control valve replace
YES
14
NO Repair or
Does lever interfere with floor? Defective PPC valve
replace
b) Travel deviation is large when machine starts (but normal during ordinary travel)
1 Cause Remedy
When machine starts, is dragging NO
sound of brake heard from travel
motor on deviating side?
YES Delay of release of parking brake Repair or
(Malfunction of brake, brake valve replace
2
Does counterbalance valve of NO
Go to diagnosis No. 5 in (a) above
travel motor move smoothly?
20-838 PC78MR-6
TROUBLESHOOTING H-25
Cause Remedy
1
3.14 0.49 MPa
Is output pressure of swing holding NO Defective swing holding brake
{32 5 kg/cm2} brake solenoid normal? solenoid
Replace
Run engine at full throttle
YES Seizure of filter and check valve at
output pressure inlet port of swing
Replace
holding brake solenoid of rotary
valve
PC78MR-6 20-839
TROUBLESHOOTING H-26
H-26 Travel speed or power is low (Work equipment, swing, and blade
operations are normal)
a If another part of the work equipment has a trouble, see H-1.
a Check that the emergency pump drive switch is turned OFF.
Cause Remedy
3
Is travel pressure switch NO
Omission of connection Connect
connected?
4
26.5 1.47 MPa
NO
{270 15 kg/cm2} Is travel relief pressure normal?
Run engine at full throttle
YES
5
Is pressure at top PP pressure NO
pickup port of control valve same
as port pressure?
YES
6
Does pump merge-divider spool NO Malfunction pump merge-divider Repair or
move smoothly and is hole free
from clogging? valve replace
YES Repair or
Malfunction logic valve
replace
7
When driven on flat
concrete with engine at full Is pump pressure normal during NO Large resistance to travel motor Repair or
throttle, if pressure is below travel? and undercarriage replace
11.7 MPa {120 kg/cm2}
YES Large leakage through travel Repair or
motor or swivel joint replace
8
Above 3.14 0.49 MPa Is PPC pressure normal? (At PPC NO
{32 5 kg/cm2} pressure inlet of control valve)
YES
9
NO Repair or
Does spool move smoothly? Malfunction of spool
replace
YES
To 12 on next page To 10 on next page
20-840 PC78MR-6
TROUBLESHOOTING H-26
YES
11
Does unload valve move NO Repair or
Defective unload valve
smoothly? replace
12
When PPC circuit check valve is NO Repair or
Defective PPC valve
replaced, is trouble repaired? replace
YES
Defective PPC circuit check valve Replace
PC78MR-6 20-841
TROUBLESHOOTING H-27
Cause Remedy
1
Does engine speed lower NO
(extremely only when machine is
steered during travel)?
YES Repair or
Defective pump servo
replace
2
Is pressure at top PP pressure NO
pickup port of control valve same
as port pressure?
YES
3
Does spool of travel junction NO Defective travel junction variable Repair or
variable choke valve move smoothly
and is hole free from clogging? choke valve replace
YES
4
Does pump merge-divider spool NO Malfunction pump merge-divider Repair or
move smoothly and is hole free
from clogging? valve replace
YES Repair or
Malfunction of logic valve
replace
5
Is drive pump pressure of inside
motor normal? (Inside pump
pressure must be below above 10 NO
MPa {100 kg/cm2} while machine is
turning on flat concrete with turning
radius of about 5 m.)
YES
6
NO Repair or
Is inside PPC pressure low? Defective PPC
replace
YES
7
Does spool move smoothly? NO Repair or
Malfunction of spool
replace
YES Repair or
Defective unload valve
replace
8
When main relief circuit check NO Defective counterbalance valve of Repair or
valve is replaced, is trouble
repaired? travel motor or swivel joint replace
20-842 PC78MR-6
TROUBLESHOOTING H-28
H-28 Travel speed does not change at all or does not change quickly
Cause Remedy
1
31.4 0.49 MPa Electric trouble in defective 2nd
Is output of 2nd travel speed NO travel speed selection solenoid Repair or
{32 5 kg/cm2} valve, 2nd travel speed selection
selection solenoid valve normal? replace
Run engine at full throttle switch, etc.
YES
2
Is outlet choke of 2nd travel speed NO Repair or
selection solenoid valve free from Malfunction caused by clogging
clogging? replace
YES
3
Is output pressure of 2nd travel NO Repair or
speed selection solenoid valve at Defective swivel joint
travel motor inlet normal? replace
PC78MR-6 20-843
TROUBLESHOOTING H-29
YES Repair or
Defective final drive
replace
3
Does counterbalance valve of NO Repair or
Defective counterbalance valve
travel motor operate smoothly? replace
YES
4
When driven on flat
concrete with engine at full Is undercarriage deformed or NO Repair or
Defective undercarriage
throttle, if pressure is below damaged? replace
11.7 MPa {120 kg/cm2}
YES Defective travel motor (Motor, Repair or
parking brake system) replace
See 1 5
Above 3.14 0.49 MPa
{Above 32 5 kg/cm2} Is PPC pressure normal?(At PPC NO
Run engine at full throttle pressure inlet of control valve)
Move lever to stroke end
YES
1 6
If machine does not travel on
flat concrete with engine at full
throttle and pump pressure NO
above about 10 MPa Does travel spool move smoothly? Malfunction of spool
{100 kg/cm2}, perform
diagnosis 2.
YES
7
Does pressure compensation valve NO Defective pressure compensation
move smoothly? valve
YES
8
Does unload valve move NO Repair or
Defective unload valve
smoothly? replace
9
Drive machine with boom
PPC pressure When PPC hose is replaced with NO
boom hose on control valve side, Defective PPC circuit check valve
(Return piping immediately does PPC pressure rise?
after testing)
YES
Defective PPC valve
20-844 PC78MR-6
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.
PC78MR-6 20-845
TROUBLESHOOTING H-30, H-31
YES
2
NO Repair or
Does spool move smoothly? Malfunction of spool
replace
YES
3
When suction valve is replaced, is NO
trouble repaired?
YES Repair or
Defective suction valve
replace
4
Does travel motor counterbalance NO Repair or
Defective counterbalance valve
valve move smoothly? replace
YES
5
Does travel motor check valve move NO Repair or
Defective check valve
smoothly? replace
YES Repair or
Defective travel motor
replace
20-846 PC78MR-6
TROUBLESHOOTING H-32
YES
Air in PPC Bleed PPC
2
Is pressure at top PP pressure pickup NO
port of control valve same as port
pressure?
YES
3
Does spool of pump merge-divider NO Malfunction of pump merge-divider Repair or
valve move smoothly and is hole free
from clogging? valve replace
YES Repair or
Defective logic valve
replace
4
Does unload valve move smoothly NO Repair or
Malfunction of unload valve
and is hole free from clogging? replace
YES
5
Does pressure compensation valve NO Malfunction of pressure Repair or
move smoothly? compensation valve replace
YES
6
NO Repair or
Does spool move smoothly? Malfunction of spool
replace
YES
7
When PPC valve is replaced, is NO Repair or
Defective travel motor
trouble repaired? replace
YES Repair or
Defective PPC
replace
PC78MR-6 20-847
TROUBLESHOOTING H-33
H-33 Swing speed or power is low (Work equipment, travel, and blade
operations are normal)
a If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
Cause Remedy
1
When work equipment is relieved, NO
does speed rise?
YES Repair or
Defective boom assist valve
replace
2
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is swing relief pressure normal?
Run engine at full throttle
YES
3
Does pressure rise to near relief NO
pressure during stable swing?
YES
4
NO Defective motor unit, brake, or Repair or
Is swing dragging sound heard?
swing machinery circle replace
YES
5
Is swing brake release pressure NO Defective swing brake release
Replace
output? solenoid
YES
6
When controller is replaced, is trouble NO Repair or
Malfunction of swing holding brake
repaired? replace
YES
Malfunction of controller Replace
7
3.14 0.49 MPa {32 5 kg/cm2} Is PPC pressure at PPC control valve NO
Run engine at full throttle. normal?
YES
8
When fixed choke of swing PPC slow- NO
return valve is cleaned, is trouble
repaired?
YES Clean
Clogging of choke
repair or
Malfunction of slow return valve
replace
9
NO Repair or
Does spool move smoothly? Malfunction of spool
replace
YES Repair or
Defective swing motor
replace
10
When choke of swing PPC line is NO Repair or
Defective PPC valve
cleaned, is trouble repaired? replace
YES Clean
Clogging of choke repair or
replace
To 11 on next page
20-848 PC78MR-6
TROUBLESHOOTING H-33
12
When check valve and suction valve NO
of swing motor are replaced, is trouble
repaired?
YES Defective check valve or suction Repair or
valve replace
13
When reverse prevention valve is NO
replaced, is trouble repaired?
PC78MR-6 20-849
TROUBLESHOOTING H-34
H-34 Machine does not swing (Work equipment, travel, and blade opera-
tions are normal)
a If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
a Carry out the following troubleshooting, if the electric system is normal. (If the electric system is defective,
carry out E first.)
Cause Remedy
1
When swing operation and operation NO
other than boom RAISE operation are
executed, does machine move?
YES
Defective LS select valve Replace
2
Does pressure compensation valve NO Defective pressure compensation
move smoothly and is hole free from Replace
clogging? valve
YES
3
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is swing relief pressure normal?
Run engine at full throttle.
YES
4
3.14 0.49 MPa {32 5 kg/cm2} Is swing holding brake relief pressure NO Malfunction of swing holding brake
Run engine at full throttle normal? (At motor inlet) solenoid valve
5
Is swing motor turning? (Judge by NO
sound)
6
When safety valve of swing motor is NO
adjusted or replaced, is trouble
repaired?
YES Repair or
Defective safety valve
replace
7
When check valve and suction valve NO
of swing motor are adjusted or Go to diagnosis No. 6
replaced, is trouble repaired?
YES Clean
Defective check valve or suction
repair or
valve
replace
20-850 PC78MR-6
TROUBLESHOOTING H-34
Cause Remedy
1
26.5 1.47 MPa NO
{270 15 kg/cm2} Is swing relief pressure normal?
Run engine at full throttle
YES
2
3.14 0.49 MPa Are swing brake release pressures on NO
{32 5 kg/cm2} both sides normal? (At solenoid
Run engine at full throttle outlet)
Note that swing timer is set to YES Defective swing motor or swing
Replace
5 seconds machinery circle
3
Since motor may be broken, When lever is moved to right and left, NO Repair or
does work equipment move for 5 Malfunction of spool
operate in fine control mode seconds? replace
YES Repair or
Disconnection of wiring harness
replace
4
When check valve and suction valve NO Repair or
of swing motor are replaced, is trouble Malfunction of spool
repaired? replace
PC78MR-6 20-851
TROUBLESHOOTING H-35
Cause Remedy
1
When swing motor safety valve is NO
Execute diagnosis in H-33, H-40
replaced, is trouble repaired?
YES
Defective swing motor safety valve Replace
Cause Remedy
20-852 PC78MR-6
TROUBLESHOOTING H-36
Cause Remedy
1
21.08 1.47 MPa
NO
{215 15 kg/cm2} Is swing relief pressure normal? Defective swing motor safety valve Replace
Run engine at full throttle
YES Repair or
Go to b)
replace
Cause Remedy
1
Does control valve spool move NO Repair or
Malfunction of control valve spool
smoothly? replace
YES
2
When swing motor suction valve is NO
replaced, is trouble repaired?
3
When reverse prevention valve is NO
replaced, is trouble repaired?
YES Repair or
Defective reverse prevention valve
replace
4
When swing motor check valve is NO
replaced, is trouble repaired?
YES Repair or
Defective swing motor check valve
replace
5
When swing PPC slow-return valve,
swing PPC line, and swing PPC NO Repair or
Defective PPC valve
circuit choke are cleaned, is trouble replace
repaired?
YES Clogging of swing PPC slow-return Repair or
valve, swing PPC line choke, or
swing PPC circuit choke replace
PC78MR-6 20-853
TROUBLESHOOTING H-37, H-38
YES
2
When swing motor safety valve is NO
Go to H-36 Replace
replaced, is trouble repaired?
YES Repair or
Defective swing motor safety valve
replace
YES
2
When suction valve is replaced, is NO
trouble repaired?
3
When reverse prevention valve is NO
replaced, is trouble repaired?
YES Repair or
Defective reverse prevention valve
replace
4
Is foreign matter drained from final NO Defective swing motor, swing Repair or
drive? machinery, or swing circle replace
YES Repair or
Defective swing machinery
replace
20-854 PC78MR-6
TROUBLESHOOTING H-39
Cause Remedy
1
When connector of swing pressure NO
switch is disconnected, is trouble
repaired?
YES
Defective swing pressure switch Replace
2
When connector of swing brake NO
release solenoid is disconnected, is
trouble repaired?
YES
Defective controller or wiring Replace
3
When hose of swing brake release NO Repair or
line is disconnected, is trouble Defective swing motor brake
repaired? replace
YES Replace
Malfunction of solenoid valve
assembly
PC78MR-6 20-855
TROUBLESHOOTING H-40
YES
Air in PPC Bleed Air
2
Is pressure at top PP pressure pickup NO
port of control valve same as port
pressure?
YES
3
Does spool of pump merge-divider NO Malfunction of pump merge-divider Repair or
valve move smoothly and is hole free
from clogging? valve replace
YES Repair or
Malfunction of logic valve
replace
4
Does unload valve move smoothly NO Repair or
Malfunction of unload valve
and is hole free from clogging? replace
YES
5
Does pressure compensation valve NO Malfunction of pressure Repair or
move smoothly and is hole free from
clogging? compensation valve replace
YES
6
NO Repair or
Does spool move smoothly? Malfunction of spool
replace
YES
7
When PPC valve is replaced, is NO Repair or
Defective travel motor
trouble repaired? replace
YES Repair or
Defective PPC valve
replace
20-856 PC78MR-6
TROUBLESHOOTING H-41
H-41 Blade speed or power is low (Work equipment, travel, and swing
operations are normal)
a If there is any other trouble in the work equipment, travel system, or swing system, see H-1.
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} NO Repair or
Is blade PPC pressure normal? Defective PPC valve
Run engine at full throttle replace
YES
2
21.08 1.47 MPa
Is blade LOWER relief pressure NO
{215 15 kg/cm2} Go to diagnosis 5
normal?
Run engine at full throttle
YES
3
Does pump pressure reach relief NO
pressure during operation?
YES
4
Is hose between control valve and NO Malfunction of check valve in spool Repair or
cylinder flattened or deformed? or clogging of hole of spool replace
YES
Flattened or deformed hose Replace
5
NO Execute diagnosis in H-43
Is hydraulic drift normal?
(Hydraulic drift of blade is large)
PC78MR-6 20-857
TROUBLESHOOTING H-42
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.
Cause Remedy
1
3.14 0.49 MPa {32 5 kg/cm2} NO Repair or
Is blade PPC pressure normal? Defective PPC valve
Run engine at full throttle replace
YES
2
21.08 1.47 MPa
Is blade LOWER relief pressure NO
{215 15 kg/cm2}
normal?
Run engine at full throttle
YES
3
Is cylinder or work equipment NO
deformed?
4
NO Repair or
Is hose flattened or deformed? Malfunction of control valve spool
replace
YES
Flattened or deformed hose Replace
YES
If trouble is not repaired by H-41 Leakage in control valve (Large Repair or
leakage from line between swing replace
valve and blade valve)
20-858 PC78MR-6
TROUBLESHOOTING H-42
Cause Remedy
1
NO
Is blade held in air?
YES
2
NO Repair or
Is blade PPC normal? Defective blade PPC valve
replace
YES
3
Is cylinder or work equipment NO
deformed?
4
NO Repair or
Is hose flattened or deformed? Malfunction of spool
replace
YES
Flattened or deformed hose Replace
5
Is it impossible to raise machine by
bracing blade on ground?
PC78MR-6 20-859
TROUBLESHOOTING H-43
YES
2
When hose is disconnected from NO
valve outlet and plugged, is hydraulic
drift large?
YES Large leakage through swivel Repair or
joint replace
3
If blade is held in air and hydraulic When centralized safety valve is NO
drift is large replaced, is trouble repaired?
YES
Defective centralized safety valve Replace
4
When suction valve is replaced with NO Repair or
Low oil-tightness of spool
plug, is trouble repaired? replace
YES Repair or
Defective suction safety valve
replace
5
If hydraulic drift is large when When blade safety valve is replaced, NO Repair or
Low oil-tightness of spool
machine body is raised with blade is trouble repaired? replace
YES
Defective blade safety valve Replace
20-860 PC78MR-6
TROUBLESHOOTING H-44
YES
Air in PPC Bleed Air
2
Is pressure at top PP pressure pickup NO
port of control valve same as port
pressure?
YES
3
Does spool of pump merge-divider NO Malfunction of pump merge-divider Repair or
valve move smoothly and is hole free
from clogging? valve replace
YES Repair or
Malfunction of logic valve
replace
4
Does unload valve move smoothly NO Repair or
Malfunction of unload valve
and is hole free from clogging? replace
YES
5
Does pressure compensation valve NO Malfunction of pressure Repair or
move smoothly and is hole free from
clogging? compensation valve replace
YES
6
NO Repair or
Does spool move smoothly? Malfunction of spool
replace
YES
7
When PPC valve is replaced, is NO Repair or
Defective travel motor
trouble repaired? replace
YES Repair or
Defective PPC
replace
PC78MR-6 20-861
TROUBLESHOOTING FOR MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by controller when trouble occurs and problems on machine ............................................... 20-902
Electric circuit diagram of M mode system ................................................................................................ 20-904
M- 1 [E101] (Error history data are abnormal) is displayed ..................................................................... 20-906
M- 2 [E108] (Engine coolant temperature is 105 C) is displayed ........................................................... 20-907
M- 3 [E112] (Wiper forward output is shorted) is displayed ..................................................................... 20-907
M- 4 [E113] (Wiper reverse output is shorted) is displayed ..................................................................... 20-907
M- 5 [E114] (Contact with washer output of 24 V) is displayed ............................................................... 20-907
M- 6 [E115] (Wiper does not start wiping in 10 seconds) is displayed ..................................................... 20-907
M- 7 [E116] (Wiper is not retracted in 10 seconds) is displayed .............................................................. 20-907
M- 8 Monitor panel segments do not light up at all for 3 seconds after starting switch is turned ON ...... 20-908
a) Monitor panel segments do not light up at all .............................................................................. 20-908
b) Some monitor panel segments do not light up ............................................................................ 20-908
M- 9 When starting switch is set to ON position, all monitor panel segments light up but do not go off ..... 20-910
M-10 While preheating is not executed, "Preheater monitor" lights up ................................................... 20-910
M-11 When starting switch is set to ON position and engine is started, basic check items flash ............. 20-911
a) Alternator system ........................................................................................................................ 20-911
b) Engine oil system ........................................................................................................................ 20-912
M-12 When starting switch is set to ON position (but engine is stopped), caution items and
emergency stop items (excluding battery and engine oil) flash ....................................................... 20-913
a) Alternator system ........................................................................................................................ 20-913
b) Engine oil pressure sensor system ............................................................................................. 20-914
M-13 When starting switch is set to ON position and engine is started, caution items and
emergency stop items flash (When there is not abnormality in inspection items and
engine before troubleshooting, however) ........................................................................................ 20-915
a) "Engine oil" flashes ..................................................................................................................... 20-915
b) "Charge level" flashes ................................................................................................................. 20-915
c) "Coolant temperature" flashes ..................................................................................................... 20-916
d) "Fuel level" flashes ...................................................................................................................... 20-917
M-14 When starting switch is set to ON position (but engine is stopped), buzzer does not sound
for 1 second
While caution item is flashing, buzzer does not sound .................................................................... 20-918
M-15 Monitor plane lamp for nighttime is not turned on (LC display is normal) ....................................... 20-919
M-16 Coolant temperature gauge does not rise ....................................................................................... 20-920
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to 1st line during operation) ..... 20-920
M-18 Fuel level gauge always displays full .............................................................................................. 20-921
M-19 Fuel level gauge is not displayed .................................................................................................... 20-921
M-20 While engine is running, service meter does not advance .............................................................. 20-922
M-21 Trouble in fuel level sensor .............................................................................................................. 20-923
M-22 Trouble in coolant temperature sensor ............................................................................................ 20-924
M-23 Wiper does not operate or operates while wiper switch is turned off .............................................. 20-925
a) Wiper does not operate ............................................................................................................... 20-925
b) Wiper operates while wiper switch is turned off .......................................................................... 20-925
M-24 Washer motor does not operate or operates while washer switch is turned off .............................. 20-928
a) Washer motor does not operate .................................................................................................. 20-928
b) Washer operates while wiper switch is turned off ....................................................................... 20-928
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 the troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
PC78MR-6 20-901
ACTION TAKEN BY CONTROLLER WHEN TROUBLE
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Service
User Code Code Troubled System Contents of Trouble
20-902 PC78MR-6
ACTION TAKEN BY CONTROLLER WHEN TROUBLE
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
1. If abnormality is detected
continuously, coolant tem-
Resistance between M18 (Male) (1) (2): perature caution lamp
Min. 3.70 kz flashes and buzzer sounds.
(With engine started) 2. If abnormality is detected
continuously, engine
speed is set to low idling.
PC78MR-6 20-903
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM
20-904 PC78MR-6
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM
(2/2)
PC78MR-6 20-905
TROUBLESHOOTING M-1
Cause Remedy
1
After resetting operation,
operate machine normally After "resetting operation", is NO
Normal
and observe its condition for service code displayed again?
a while. (See Note 1.)
YES
2
Disconnection, defective contact,
Turn starting switch OFF Is voltage between P01 (8) NO or short circuit with chassis Repair or
ground in wiring harness
20 30 V chassis ground normal? between battery battery relay B replace
M27 (1), (2) P01 (Female) (8)
YES
Defective monitor panel Replace
Note: Resetting operation: Turn the starting switch to OFF position, then turn it to the ON position again, with
the buzzer cancel switch pushed, and keep pressing the buzzer cancel switch for 5 seconds. (All the ser-
vice codes saved in the memory are deleted by this operation.)
20-906 PC78MR-6
TROUBLESHOOTING M-2, M-3, M-4, M-5, M-6, M-7
YES
See M-13, c)
2
NO
Turn starting switch ON Is "E" attached to head of service code? Trouble in engine unit
(See Note 1)
YES
Note: The display of the monitor panel has been reset normally. Since the coolant temperature sensor
detected coolant temperature above 105C, remove the cause of that temperature rise by troublshooting
the engine unit.
PC78MR-6 20-907
TROUBLESHOOTING M-8
M-8 Monitor panel segments do not light up at all for 3 seconds after start-
ing switch is turned ON
a Check that fuses 13 and 18 are normal.
Cause Remedy
1
Turn starting switch ON. Is voltage between P01 (8) and NO
20 30 V (6), (7) normal?
YES
2
Turn starting switch ON Is voltage between P01 (1), (2) NO
20 30 V and (6), (7) normal?
YES
3
Turn starting switch OFF. Is resistance between P01 NO Disconnection or defective contact
Max. 1 z (female) (6), (7) and chassis in wiring harness between P01 Repair or replace
Disconnect P01. ground normal? (female) (6), (7) chassis ground
YES
Defective monitor panel Replace
4
Turn starting switch ON. Is voltage between fuse 13 and NO Disconnection or defective contact
in wiring harness between fuse 13 Repair or replace
20 30 V chassis ground normal? P01 (female) (1), (2)
YES Disconnection or defective contact
in wiring harness between fuse box Repair or replace
battery relay terminal M
5
Turn starting switch ON. Is voltage between fuse 18 and NO Disconnection or defective contact
in wiring harness between fuse 18 Repair or replace
20 30 V chassis ground normal? P01 (female) (8)
YES Disconnection or defective contact
in wiring harness between fuse box Repair or replace
battery relay terminal B
Cause Remedy
20-908 PC78MR-6
TROUBLESHOOTING M-8
PC78MR-6 20-909
TROUBLESHOOTING M-9,10
M-9 When starting switch is set to ON position, all monitor panel seg-
ments light up but do not go off
Cause Remedy
Defective monitor
Replace
panel
2
Short circuit with power
Turn starting switch ON Is voltage between P02 (18) chassis NO source in wiring
harness between Repair or replace
Max. 1 V ground normal? starting switch R1
P02 (Female) (18)
YES
Defective monitor
Replace
panel
20-910 PC78MR-6
TROUBLESHOOTING M-11
a) Alternator system
a Check monitoring code "43". If it is 100 or larger while the engine speed is above the medium level, the
monitor panel is defective.
Cause Remedy
1
Run engine above medium Is voltage between alternator
NO
speed level terminal R chassis ground Defective alternator Replace
20 30 V normal?
YES
2
Run engine above medium Disconnection or defective
Is voltage between P02 (11) NO contact in wiring harness Repair or
speed level
chassis ground normal? between alternator terminal R replace
20 30 V P02 (Female) (11)
YES
Defective monitor panel Replace
PC78MR-6 20-911
TROUBLESHOOTING M-11
Cause Remedy
1
When engine speed is low, if oil NO
Run engine at low speed pressure sensor terminal T6 is
disconnected, does error disappear?
2
Turn starting switch OFF NO Short circuit with chassis ground
Is there continuity between P02 (7) Repair or
Disconnect sensor wiring in wiring harness between P02
chassis ground normal? (Female) (7) sensor terminal T6 replace
harness and P02
YES
Defective monitor panel Replace
20-912 PC78MR-6
TROUBLESHOOTING M-12
a) Alternator system
a Check monitoring code "43". If it is 100 or larger while the engine speed is above the medium level, the
monitor panel is defective.
Cause Remedy
1
Disconnect terminal R NO
Is voltage between alternator terminal
Turn starting switch ON Defective alternator Replace
R chassis ground normal?
Max. 1 V
YES
2
Disconnect P02 Short circuit with power source in
Is voltage between P02 (Female) (11) NO wiring harness between P02 Repair or
Turn starting switch ON
chassis ground normal? (Female) (11) alternator replace
Max. 1 V terminal R
YES
Defective monitor panel Replace
PC78MR-6 20-913
TROUBLESHOOTING M-12
Cause Remedy
1
Turn starting switch OFF NO
Is there continuity between sensor
Disconnect sensor Defective oil pressure sensor Replace
terminal T6 chassis ground?
terminal T6
YES
2
Disconnection or defective
Turn starting switch OFF NO
Is there continuity between P02 contact in wiring harness Repair or
Disconnect P02 sensor
(Female) (11) sensor terminal T6? between P02 (Female) (7) replace
terminal T6
sensor terminal T6
YES
20-914 PC78MR-6
TROUBLESHOOTING M-13
See M-11-b)
See M-11-a)
PC78MR-6 20-915
TROUBLESHOOTING M-13
Cause Remedy
1
Start engine NO
Is coolant temperature gauge in red
Set engine speed to Defective monitor panel Replace
range?
medium or higher
YES
2
When M18 is disconnected, does gauge NO
Start engine
indicate only level 1 (Lowest line)?
3
Turn starting switch OFF Disconnection or defective contact
Is resistance between P02 (Female) (1) NO Repair or
Disconnect P02 and M18 in wiring harness between P02
M18 (Female) (1) normal? (Female) (1) M18 (Female) (1) replace
Max. 1 z
20-916 PC78MR-6
TROUBLESHOOTING M-13
Cause Remedy
1
NO
Start engine Is fuel level gauge in red range? Defective monitor panel Replace
YES
2
Start engine When M9 (Female) (1) is
Wait for 2 minutes. (Since connected to chassis ground, do NO
fuel level fluctuates, its gauge segments light up to level 9
display is delayed.) (Right end)?
YES Defective fuel level sensor
system (See M-21)
3
Connect M9 (Female) (1) to Disconnection or defective
chassis ground Is voltage between P02 (2) NO contact in wiring harness Repair or
Turn starting switch ON chassis ground normal? between P02 (Female) (2) M9 replace
Max. 0.3 V (Female) (1)
YES Repair or
Defective monitor panel
replace
PC78MR-6 20-917
TROUBLESHOOTING M-14
Cause Remedy
Turn starting switch OFF 1
Disconnect K53
When buzzer cancel switch Is resistance between K53 (Female) (1) NO Defective buzzer cancel
is ON: Max. 1 z Replace
(2) normal? switch
When buzzer cancel switch
is OFF: Min. 1 Mz YES
2
Disconnection, defective
Disconnect K53 contact, or short circuit with
Is voltage between P02 (16) chassis NO Repair or
Turn starting switch ON chassis ground in wiring
ground normal? harness between P02 replace
20 30 V
(Female) (16) K53 (Male) (2)
YES
Defective monitor panel Replace
20-918 PC78MR-6
TROUBLESHOOTING M-15
M-15 Monitor plane lamp for nighttime is not turned on (LC display is nor-
mal)
a Carry out the following troubleshooting when the headlamp and working lamp light up normally.
Cause Remedy
1
Turn starting switch ON Is bit (4) of monitoring code "45" NO
Set monitoring code to "45" turned off?
YES
Defective monitor panel Replace
2
Turn starting switch ON NO Disconnection, defective contact
Is voltage between P02 (19) Repair or
Turn light switch ON in wiring harness between P02
chassis ground normal? (Female) (19) K52 (Male) (1) replace
20 30 V
YES
PC78MR-6 20-919
TROUBLESHOOTING M-16, M-17
2
Disconnection or defective
Turn starting switch OFF Is there continuity between P02 NO contact in wiring harness Repair or
Disconnect P02 and M18 (Female) (1) M18 (Female) (1)? between P02 (Female) (1) replace
M18 (Female) (1)
YES
3
Disconnection or defective
Turn starting switch OFF Is resistance between M18 (Female) (2) NO contact in wiring harness Repair or
Disconnect M18 chassis ground normal? between M18 (Female) (2) replace
chassis ground
YES
Defective monitor panel Replace
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to
1st line during operation)
Cause Remedy
1
Disconnect M18 When M18 is disconnected, is gauge NO
Turn starting switch ON displayed?
2
Turn starting switch ON Is there continuity between P02 (Female) NO
Disconnect P02 and Defective monitor panel Replace
M18 (1) chassis ground?
YES Short circuit with chassis ground Repair or
in wiring harness between P02
(Female) (1) M18 (Female) (1) replace
20-920 PC78MR-6
TROUBLESHOOTING M-18, M-19
Cause Remedy
1
Turn starting switch ON
Wait for 2 minutes. (Since When M9 is disconnected, does gauge NO
fuel level fluctuates, its rise 1 level by 1 and go off at last?
display is delayed.)
YES Defective fuel level sensor
system (See M-21)
2
Turn starting switch OFF Is there continuity between P02 NO
Defective monitor panel Replace
Disconnect P02 and M9 (Female) (2) chassis ground?
Cause Remedy
1
Disconnect M9 When M9 (Female) (1) is connected to NO
Turn starting switch ON chassis ground, does gauge display?
2
Disconnection or defective
Turn starting switch OFF Is there continuity between M9 (Female) NO contact in wiring harness Repair or
Disconnect M9 (2) chassis ground? between M9 (Female) (2) replace
chassis ground
YES
PC78MR-6 20-921
TROUBLESHOOTING M-20
1
Start engine NO
Set engine speed to Does charge level caution lamp flash? Defective monitor panel Replace
medium or higher
YES
See M-13 c)
20-922 PC78MR-6
TROUBLESHOOTING M-21
Cause Remedy
1
When float is moved up and down, does NO
resistance between connector (1)
flange change as shown in Table 1?
YES
2
NO Defective sensor
Does arm move smoothly? Replace
(See Note 2)
YES
3
Is float cracked, broken off, or scratched NO Clean or replace
Bad contact of connector
badly? connector
4
Is breakage of wiring harness detected NO
Defective sensor Replace
by visual inspection?
YES
Breakage of wiring harness
(See Note 3)
Replace sensor
(Defective clamp)
(Application of external force)
Table
At upper (FULL)
Approx. 12 or below
stopper
At lower (EMPTY)
Approx. 85 110z
stopper
Note 1. Difference between actual fuel level and level indicated by gauge
When the gauge indicates 14 (F), the fuel level is 78 100%. When the former indicates 1 (E), the lat-
ter is below 14.5%. If the machine body is slanted, the displayed fuel level is different from the actual
fuel level. Accordingly, stop the machine on a level place and check the fuel level gauge after waiting
for at least 2 minutes. (Since fuel level fluctuates, its display is delayed.)
Note 2. Since the sensor may be interfering in the tank or it may be installed wrongly, install it very carefully.
Note 3. Check the installation position of the connector for vibration. If it vibrates remarkably, take proper mea-
sures to suppress the vibration.
PC78MR-6 20-923
TROUBLESHOOTING M-22
2
Is breakage of wiring harness detected by NO
Defective sensor Replace
visual inspection?
YES
Breakage of wiring harness
(See Note 2)
Replace sensor
(Defective clamp)
(Application of external force)
Table
Normal
Approx. 37 50 kz
Temperature (25 C)
100 C Approx. 3.5 4.0 kz
Note 1. If this error is displayed repeatedly, the connector (Female) on the machine side may be defective.
Accordingly, inspect the connector and wiring harness on the machine side.
Note 2. Check the installation position of the connector for vibration. If it vibrates remarkably, take proper mea-
sures to suppress the vibration.
20-924 PC78MR-6
TROUBLESHOOTING M-23
M-23 Wiper does not operate or operates while wiper switch is turned off
a) Wiper does not operate
a Check that fuse 14 is normal.
a If service code "E112", "E113", "E115", or "E116" is displayed, carry out the following troubleshooting.
Cause Remedy
1
Close front window NO
Does bit (3) of monitoring code "49"
Turn starting switch ON
light up?
Set monitoring code to "49"
YES
2
Turn starting switch ON
Set wiper switch to "ON" or When wiper switch is set to "ON" or NO
"INT" position, do bits (4), (5) of Defective monitor panel Replace
"INT" position monitoring code "49" go off?
Set monitoring code to "49"
YES
3
Is voltage between pins of W04 as NO
Turn starting switch ON
shown in Table 1?
YES
Defective wiper motor Replace
4
Is voltage between pins of P01 Disconnection, defective con-
Turn starting switch OFF NO tact, short circuit, or short circuit Repair or
(Female) W04 (Male) as shown in
Disconnect P02 and W04 with chassis ground in wiring replace
Table 2? having improper resistance
YES
5
Max. 1 z
Is resistance between rear limit NO
Turn starting switch OFF Defective rear limit switch or Inspection or
switch terminals W03 (1) (2)
Disconnect terminals (1), (2) opening of front window replace
normal?
of W03.
YES
6
Max. 1 z Is resistance between rear limit Disconnection or defective
Turn starting switch OFF switch terminal W03 (1) P02 NO contact in wiring harness Repair or
Disconnect terminals (1), (2) (Female) (15), between W03 (2) having improper resistance replace
of P02 and W03 chassis ground normal?
YES
Cause Remedy
1
Close front window NO
Does bit (3) of monitoring code
Turn starting switch ON Defective monitor panel Replace
"49" light up?
Set monitoring code to "49"
YES
2
When wiper switch is set to "ON" NO
Turn starting switch ON or "INT" position, do bits (4), (5) of Defective monitor panel Replace
monitoring code "49" go off?
PC78MR-6 20-925
TROUBLESHOOTING M-23
Table 1
Timing chart of ON-OFF operation of wiper
Table 2
Diagnosis 4 Resistance
Between P01 (Female) (10) W04 (Female) (1)
Between P01 (Female) (9) W04 (Female) (3)
Between P01 (Female) (12) W04 (Female) (4) Max. 1 z
Between P01 (Female) (6), (7) W04 (Female) (5)
Between P01 (Female) (5) W04 (Female) (6)
Between W04 (Female) (1), (3), (4), (5), (6) GND Min. 1 Mz
20-926 PC78MR-6
TROUBLESHOOTING M-23
PC78MR-6 20-927
TROUBLESHOOTING M-24
M-24 Washer motor does not operate or operates while washer switch is
turned off
a) Washer motor does not operate
a Check that fuse 4 is normal.
a)-1 When [E114] is displayed
Cause Remedy
1
Max. 1 V Is voltage between P01 (Female) (3) NO Short circuit with power source in Repair or
Turn starting switch ON M31 (Female) (1) chassis ground wiring harness between P01
normal? replace
Disconnect P02 and M31 (Female) (3) M31 (Female) (1)
YES
1 Cause Remedy
20 30 V Is voltage between fuse 4 M31 NO Disconnection or defective Repair or
Turn starting switch ON (Female) (2) chassis ground contact in wiring harness between
fuse 4 M31 (Female) (2) replace
Disconnect M31 normal?
YES
2
Max. 1 z Disconnection or defective
Is resistance between P01 (Female) NO contact in wiring harness Repair or
Turn starting switch OFF
(3) M31 (Female) (1) normal? between P01 (Female) (3) M31 replace
Disconnect P01 and M31 (Female) (1)
YES
3
Max. 1 V NO
Is voltage between P01 (Female) (3)
Turn starting switch ON Defective washer motor Replace
chassis ground normal?
Turn washer switch ON
YES
Defective monitor panel Replace
Cause Remedy
1
Min. 1 Mz NO Short circuit with chassis ground
Is resistance between M31 (Female) Repair or
Turn starting switch OFF in wiring harness between P01
(1) chassis ground normal? (Female) (3) M31 (Female) (1) replace
Disconnect P02 and M31
YES
20-928 PC78MR-6
TROUBLESHOOTING M-24
PC78MR-6 20-929
30 DISASSEMBLY AND ASSEMBLY
PC78MR-6 30-1
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
(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)
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.
30-2 PC78MR-6
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PC78MR-6 30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
4) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 PC78MR-6
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
4. Other precautions
To maintain the performance of the machine and to prevent failures, it is particularly important to pay atten-
tion to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or
when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are
clean.
To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points
when disassembling or assembling.
Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to
be disassembled.
Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits
of parts that have failed.
When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment
completely.
Do not use the seal tape for the thread of the plug mounts or connectors.
If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment
and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassem-
bled and assembled, also carry out thorough flushing of the hydraulic circuits.
When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping,
always bleed the air before starting the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.
PC78MR-6 30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
a After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5
times without going to the end of this strike. (Stop approx. 100 mm before the end of the stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the
engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more air
comes out from the plugs.
4. After completing bleeding the air, tighten the plugs
3 Plug: 11.3 1.5 Nm {1.15 0.15 kgm}
a If the engine is run at high speed from the start, or the cylinders are operated to the end of their
stroke, the air inside the cylinder will cause damage to the piston packing.
a After repair or long storage, follow the same procedure.
30-6 PC78MR-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
New/
Qty
Component Symbol Part No. Part Name Nature of work, remarks
790-101-5281 Plate 1
3 Installation of oil seal
790-101-5221 Grip 1
01010-51225 Bolt 1
790-101-5331 Plate 1
Press fitting of sub bearing outer
4
race
790-101-5221 Grip 1
Disassembly, assembly of F
swing machinery assembly
01010-51225 Bolt 1
790-101-5431 Plate 1
Press fitting of main bearing
5 outer race
790-101-5421 Grip 1
01010-51240 Bolt 1
PC78MR-6 30-7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
New/
Qty
Component Symbol Part No. Part Name Nature of work, remarks
790-101-5141 Plate 1
1 Press fitting of bushing
Disassembly, assembly of
idler assembly 790-101-5021 Grip 1
01010-50816 Bolt 1
790-101-5111 Plate 1
3 Press fitting of bushing
Disassembly, assembly of
790-101-5021 Grip 1
track roller assembly
01010-50816 Bolt 1
790-201-2860 Spacer t 1
Disassembly, assembly of
recoil spring assembly
M 791-635-3160 Extension assembly t 1 Compression of spring
790-101-1600 Cylinder t 1
(686kN{70ton})
790-101-1102 Pump t 1
Remover and
791-616-1030
installer
t 1
Expansion, installation of Cylinder Pulling out and press fitting of
track shoe assembly R 790-105-1100
(294kN{30ton})
t 1
master pin
790-101-1102 Pump t 1
790-101-2510 Block 1
790-101-2520 Screw 1
791-112-1180 Nut 1
Disassembly, assembly of
T 790-101-2540 Washer 1 Separation of rotor and shaft
center swivel joint assembly
790-101-2630 Leg 2
790-101-2570 Washer 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
Disassembly, assembly of
790-502-1003 Cylinder repair stand t 1
Disassembly, assembly of
U 1
hydraulic cylinder assembly hydraulic cylinder
790-101-1102 Pump t 1
30-8 PC78MR-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
New/
Qty
Component Symbol Part No. Part Name Nature of work, remarks
796-720-1670 Band q 1
Boom
07280-01279 Clamp q 1
796-720-1660 Band q 1
Arm and boom
swing
07281-01159 Clamp q 1
Installation of
5
piston ring
796-720-1650 Band q 1
Bucket
07281-01029 Clamp q 1
796-720-1670 Band q 1
Blade
07281-01279 Clamp q 1
790-101-5021 Grip 1
Disassembly, assembly of Boom and blade
U
hydraulic cylinder assembly
01010-50816 Bolt 1
790-101-5021 Grip 1
Bucket
01010-50816 Bolt 1
790-201-1620 Plate 1
Boom and blade
790-101-5021 Grip 1 Press fitting of
7 cylinder head
01010-50816 Bolt 1 dust seal
PC78MR-6 30-9
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
New/
Qty
Component Symbol Part No. Part Name Nature of work, remarks
790-101-5021 Grip 1
Arm and boom
swing
01010-50816 Bolt 1
01010-50816 Bolt 1
790-441-1802 Remover t 1
790-441-1810 Sleeve 1
792-900-1530 Screw 1
790-270-1110 Adapter 1
Removal of work equip-
ment and boom assembly 1 Pulling out of boom foot pin
01803-13034 Nut 1
01643-33080 Washer 1
790-101-1102 Pump t 1
790-201-2850 Spacer t 1
791-535-1170 Plug t 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
Removal of arm cylinder Pulling out of arm cylinder trun-
assembly 3
nion pin
790-101-2540 Washer t 1
791-112-1180 Nut t 1
790-101-1102 Pump t 1
30-10 PC78MR-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
PC78MR-6 30-11
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
30-12 PC78MR-6
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT ASSEMBLY 8. Remove fuel filler mounting cover (9) of the fuel
tank.
REMOVAL 9. Remove clamp (11) and float gauge hose (10).
Loosen the clamp of the hose connected to the
a Stop the machine on a level place and set the fuel filler tube on the back side of the fuel filler
upper structure in parallel with the track, then mounting cover, then remove the tube and cover
swing to the right about 20 degrees (since the together.
mounting bolts are above the track) and lower a When removing the float gauge hose, check
the work equipment to the ground and stop the that the fuel level is below the connecting
engine. position of the hose.
INSTALLATION
[*1]
4 Weight mounting bolt:
1,150 1,1440 Nm {118 147 kgm}
PC78MR-6 30-13
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
INJECTION PUMP ASSEMBLY 4. Remove the engine stop solenoid (8) and
bracket together.
REMOVAL
5. Remove the injection pipe clamp, and loosen the
4 sleeve nuts each on the pump side and nozzle
a Disconnect the wiring harness from the negative
side of the injection pipe (9), then remove the
terminal of the battery.
injection pipe (9). [*1]
a Remove the counterweight. (See REMOVAL OF
COUNTERWEIGHT.)
6. Disconnect the inlet and outlet hoses (10) of the
feed pump and lubrication tube (11).
1. Remove the nut (1) of the engine stop solenoid
rod and the nut of the accelerator cable (2) from
7. Remove the rear bracket (12) of the pump. [*2]
the lever side of the pump, then remove the rod
and cable assembly.
30-14 PC78MR-6
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
INSTALLATION
3 Sleeve nut:
[*1]
[*3]
1. When installing holder (13) to pump (16), match
the engraved lines (17) on them to each other.
When installing the pump to the front cover,
match the match marks made on the gear and
pump when the pump was removed. Further-
more, match the engraved lines (18) of holder
(13) and plate to each other and tighten the
mounting bolts temporarily.
PC78MR-6 30-15
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD ASSEMBLY 8. Remove the air intake connector (6) between the
turbocharger and the air intake manifold.
REMOVAL
6 Coolant: 10.5 l
30-16 PC78MR-6
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
12. Loosen the 2 mounting bolts of the air compres- 17. Disconnect the blow-by hose (19).
sor and adjustment bolt, and remove the air
compressor belt (12). 18. Remove the fuel injection pipe clamp (20) and
then remove the fuel injection pipes (21). [*3]
13. Disconnect the 3 hoses (13) from the fuel filter.
19. Disconnect the spill pipe (22).
14. Remove the air conditioner compressor (14), the
bracket and the fuel filter together.
16. Remove the engine stop solenoid (15) and the 22. Remove the turbocharger and exhaust manifold
bracket (18) together. assembly (25). [*5]
PC78MR-6 30-17
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
23. Remove the cylinder head cover (26). [*6] 29. Remove the 8 mounting bolts and the rocker arm
(35), then remove the push rod. [*7]
25. Remove the fan (29). 31. Remove the 17 mounting bolts of the cylinder
head (37), and lift off the cylinder head assembly.
26. Disconnect the heater hoses (30) and (31). [*8]
27. Disconnect the radiator upper hose (32) and 32. Remove the air intake manifold (38) from the cyl-
lower hose (33). inder head assembly.
30-18 PC78MR-6
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
3 U-clamp nut:
[*1]
: 39.2 49 Nm {4 5 kgm}
[*8]
1. Tighten the cylinder head mounting bolts in the
following order.
1) Apply molybdenum disulphide LM-P all over
the threads and seating face of each bolt and
the seats of the cylinder head holes.
2) Turn the bolts in the order of [1] [17] shown
in figure with the fingers until they are
screwed in the holes of the cylinder head to 2
3 threads.
3) Tighten the bolts in the order of [1] [17]
shown in figure to the torque of 68.6}9.8 Nm
{7}1 kgm}.
4) Tighten the bolts in the order of [1] [17]
shown in figure to the torque of 107.8}4.9 Nm
{11}0.5 kgm}.
PC78MR-6 30-19
DISASSEMBLY AND ASSEMBLY MAIN PUMP
MAIN PUMPASSEMBLY
REMOVAL
6 PTO: 0.5 l
30-20 PC78MR-6
DISASSEMBLY AND ASSEMBLY CONTROL PUMP
7. Lift pump (5) temporarily and remove suction CONTROL PUMP ASSEMBLY
tube (15) and pump mounting bolts, then remove
pump (5). [*3]
REMOVAL
4 Main pump assembly: 75 kg
a Remove the counter weight (See REMOVAL OF
COUNTER WEIGHT).
INSTALLATION
[*1]
1. Tighten the mounting bolts of clamp (10) of the
joint between exhaust muffler (8) and exhaust
pipe to 39.2 49 Nm {4 5 kgm} first, then
tighten to 68.6 122.5 Nm {7 12.5 kgm}.
INSTALLATION
2. Tighten the nuts of mounting U-bolts (11) of
exhaust muffler (8) to 7.8 9.8 Nm {0.8 1.0 Carry out installation in the reverse order to
kgm}. removal.
[*2]
When installing the rubber hoses, be careful not
to twist them.
[*3]
After supplying hydraulic oil and before starting
the engine, bleed air from the main pump.
PC78MR-6 30-21
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
ENGINE AND MAIN PUMP 6. Remove the 2 bolts from the bottom of the
engine to remove centralized wiring harness
ASSEMBLY bracket (8) from the engine block.
REMOVAL
6 Hydraulic oil: 80 l
6 Cooling water: 8 l
30-22 PC78MR-6
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
11. Remove guard (13) of air conditioner compres- 20. Remove protector (25) of exhaust muffler (24).
sor (10) from the fan guard. Remove the clamp of the muffler and exhaust
pipe to remove the muffler. Remove the exhaust
12. Remove the mounting bolt of the adjustment bolt pipe from the exhaust manifold. [*2]
and air conditioner compressor (10).
13. Remove return hose (15) for the tank from fuel
filter (14).
PC78MR-6 30-23
DISASSEMBLY AND ASSEMBLY ENGINE AND MAIN PUMP
[*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}.
[*3]
After installing the engine mount to the revolving
frame, apply clear lacquer to the unpainted
engine mount fitting face.
3 Mounting bolt:
249 309 Nm {25 31.5 kgm}
2 Mounting bolt:
Apply liquid adhesive LT-2
30-24 PC78MR-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR
INSTALLATION
PC78MR-6 30-25
DISASSEMBLY AND ASSEMBLY RADIATOR
[*1]
When installing the radiator and oil cooler, check
that the sealing material (sponge) between them
is not deformed or broken but normal.
[*2]
1. When inserting each hose, apply LG-6 to the
adapter of the mating part. When tightening
each clamp, check that it is not over the tube
lock part.
3 Hose clamp: 8.8 Nm {0.9 kgm}
4. Remove the 2 bolts and bracket (8) installed to
the partition under the operator's cab. Remove 2
mounting bolts (9) on the underside and radiator
(1).
30-26 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
SWING MOTOR AND SWING 4. Remove the (9) swing machinery mounting bolts.
MACHINERY ASSEMBLY 5. Pull the plugs out of the forcing screw holes of
the swing machinery and hang the body of the
REMOVAL swing machinery with 2 slings wound onto it.
a Extend the work equipment to the maximum 6. Using 2 forcing screws, disconnect the swing
reach and lower it to the ground and stop the motor and swing machinery assembly (6) from
engine. the frame.
k Loosen the oil filler cap of the hydraulic tank 7. Lift off swing motor and swing machinery assem-
gradually to release the residual pressure from bly (6). [*1]
INSTALLATION
PC78MR-6 30-27
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
30-28 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
PC78MR-6 30-29
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
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)
30-30 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
4. Shaft assembly 6) Using tool (8) and the press, press fit shaft
1) Install collar (30) to shaft (31). (31) until 2-piece collar (26) is secured.
2) Using tool F6 and the press, press fit main 7) Using tool F8, measure the running torque of
bearing (29). the shaft.
a Press fitting force: Max. 65.7 ~ 178.4 kN a Running torque: Max. 19.6 Nm {Max. 2.0
{Max. 6.7 ~18.2 tons} kgm}
PC78MR-6 30-31
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
7. Ring gear
Install ring gear (14).
2 Fitting face of ring gear:
Gasket sealant (LG-6)
3 Ring gear mounting bolt:
58.5 73.5 Nm {6 7.5 kgm}
30-32 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
PC78MR-6 30-33
DISASSEMBLY AND ASSEMBLY SWING MOTOR, CENTER SWIVEL JOINT
INSTALLATION
30-34 PC78MR-6
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
PC78MR-6 30-35
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY ASSEMBLY
1. Remove cover (1). 1. Install slipper seal (7) and O-ring (6) to swivel
shaft (5).
2. Remove snap ring (2).
2. Set swivel shaft (5) to the block. Using the push
3. Using tool T, pull swivel rotor (4) and ring (3) out tool, hit swivel rotor (4) with a plastic hammer
of swivel shaft (5). lightly to install it.
a Apply grease (G2-LI) to the contact surfaces
4. Remove O-ring (6) and slipper seal (7). of swivel shaft (5) and swivel rotor (4).
a When installing the rotor, take care fully not
to damage the lips of the slipper seal and oil
seal.
30-36 PC78MR-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE ASSEMBLY 7. Remove hoses (8) on the operator's cab side of
the control valve in order from the top one. [*1]
a Fit male or female plugs to the removed
REMOVAL
hoses and nipples.
k Lower the work equipment to the ground and
stop the engine, then loosen the oil filler cap
gradually to release the residual pressure from
the hydraulic tank.
4. Remove 5 connectors (1) of the hydraulic 8. Remove the 4 control valve mounting bolts from
switches and the wiring harness bracket. the underside of control valve stand (9) and lift
off control valve assembly (10), using sling (1).
INSTALLATION
[*1]
1. When assembling, take care fully so that dirt,
rust, flaw, etc. will not cause a trouble.
PC78MR-6 30-37
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
ASSEMBLY
30-38 PC78MR-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
6. Tighten the combination bolts (1) and (2) in the WORK EQUIPMENT PPC
order of (1) (4) gradually in 3 times.
1) Combination bolt (1) tightening torque. VALVE ASSEMBLY
1st tightening torque:
19.6 29.4 Nm {2 3 kgm} ASSEMBLY
2nd tightening torque:
39.2 49.0 Nm {4 5 kgm} a When assembling, clean and inspect the parts
3rd tightening torque: closely and take care fully so that dirt, rust, flaw,
58.8 73.5 Nm {6 7.5 kgm} etc. will not cause a trouble.
2) Combination bolt (2) tightening torque
29.4 34.3 Nm {3 3.5 kgm} 1. When installing piston (1), apply grease (G2-LI)
to its outside and the inside of the body hole.
PC78MR-6 30-39
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
6. Apply grease (G2-LI) to the rocking part of joint TRAVEL PPC VALVE
(3) and the contact surfaces of disc (2) and pis-
ton (1). ASSEMBLY
Quantity of grease
1) Rocking part of joint: 2 4 cc/periphery ASSEMBLY
2) Contact surfaces of disc and piston:
0.3 0.8 cc/place a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust, flaw,
7. Seal the ports (P1 - P4, T, P) with nylon caps, etc. will not cause a trouble.
etc.
1. When installing piston (1), apply grease (G2-LI)
8. Tighten each part to the following torque. to its outside and the inside of the body hole.
Joint (3): 39 49 Nm {4 5 kgm}
Bolt (8): 11.8 14.7 Nm {1.2 1.5 kgm} 2. Install spring (2) with its small diameter side on
Nut (9): 98 127 Nm {10 13 kgm} the shim (3) side.
Plug (10): 6 11 Nm {0.6 1.1 kgm} Diameter of spring (Inside diameter)
Small diameter side: 4.9,
Large diameter side: 5.55
30-40 PC78MR-6
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
PC78MR-6 30-41
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION
30-42 PC78MR-6
DISASSEMBLY AND ASSEMBLY FUEL TANK
6. Remove the fuel sensor top cover of the floor 10. Remove the nut and fuel tank band (11) on the
and disconnect sensor connector (6). deeper side from the tank. [*1]
PC78MR-6 30-43
DISASSEMBLY AND ASSEMBLY CONTROLLER
11. Pull out fuel tank (4) and remove the clamp and CONTROLLER ASSEMBLY
tank air bleed hose (12), then remove the fuel
tank.
REMOVAL
INSTALLATION
Carry out installation in the reverse order to 3. Loosen the mounting bolts and remove connec-
removal. tors (4), (5), and (6) of controller (3).
INSTALLATION
30-44 PC78MR-6
DISASSEMBLY AND ASSEMBLY MONITOR PANEL, AIR CONDITIONER UNIT
INSTALLATION
PC78MR-6 30-45
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
7. Loosen the clamp and remove heater hose (8) 11. Remove the 3 front mounting bolts and 3 rear
under the rear part of the operator's seat. ones and air conditioner unit assembly (12).
INSTALLATION
[*2]
1. When fitting the pipes, apply compressor oil
(SNISO 5GS) to the flared parts and threaded
parts.
30-46 PC78MR-6
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
INSTALLATION
PC78MR-6 30-47
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
30-48 PC78MR-6
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
13. Install 4 eyebolts (1) to floor frame (13) and lift off
the floor frame assembly.
INSTALLATION
[*1]
a See INSTALLATION OF AIR CONDITIONER
UNIT.
PC78MR-6 30-49
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL
30-50 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
PC78MR-6 30-51
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
ASSEMBLY
REMOVAL
k Since an accumulator is not installed, 7. Remove the lock plate (9) of the boom foot pin
loosen the sleeve nut of each hose gradu- and handrail (10).
ally and check that oil will not spout out,
then remove the hose. 8. Lift the work equipment assembly (5) tempo-
rarily.
30-52 PC78MR-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
[*1]
1. Check that the O-rings are fitted to the sealing
parts of each hose.
[*2]
1. When assembling, apply GT2-T to the sliding
surfaces of the pins.
[*3]
1. When assembling, apply GT2-T to the sliding
surfaces of the pins.
PC78MR-6 30-53
DISASSEMBLY AND ASSEMBLY SWING BRACKET
4 Boom cylinder assembly: 112kg 7. Remove the bolt of the upper and lower brack-
ets, then remove the potentiometer assembly
(8). [*5]
a After removing the potentiometer assembly,
do not swing it around the lever or turn the
lever unnecessarily.
30-54 PC78MR-6
DISASSEMBLY AND ASSEMBLY SWING BRACKET
10. Pull out the pins (12) and (13) toward upper or [*1]
lower. 1. When installing, check that the O-ring is fitted to
a If the pins are difficult to pull out, use puller the sealing part of the hose.
V2.
2. When installing the rubber hoses, be careful not
11. Pull out the work equipment hoses and the boom to twist them.
cylinder hose, and remove the swing bracket
assembly (10). [*6] [*2] [*3]
a Check the quantity of the shims installed to 1) When assembling, apply G2-T to the sliding
the top of pin (13). surface of the pins.
4 Swing bracket assembly: 234kg
2) Use G2-T HYPER WHITE GREASE.
3) Adjust the shims so that the clearance
between the cylinder and bracket will be 1
mm or less.
[*4]
a When installing the hoses, be careful not to
twist them.
[*5]
a Referring to TROUBLESHOOTING, Proce-
dure for correcting angle sensor, correct the
sensor.
[*6]
1) When assembling, apply G2-T to the sliding
surface of the pins.
2) Use G2-T HYPER WHITE GREASE.
3) Adjust the shims so that the clearance
between the swing bracket and the bracket
on the chassis side (the clearance on the
upper side of the lower pin) will be 0.5 mm or
less.
a Shims of 3 thicknesses of 0.5, 1.0, and
2.0 mm are prepared.
PC78MR-6 30-55
DISASSEMBLY AND ASSEMBLY STEEL SHOE, RUBBER PAD SHOE, ROAD LINER
STEEL SHOE, RUBBER PAD 4. Remove tool R and move the machine forward
so that the temporary pin will be in front of the
SHOE, ROAD LINER idler and set block [1].
ASSEMBLY
5. Pull out the temporary pin and move the
machine in reverse to expand track shoe (2).
EXPANSION
INSTALLATION
[*1]
a Adjust the tension of the steel shoe and road
liner. For details, see TESTING AND ADJUST-
ING, Testing and adjusting track shoe tension.
30-56 PC78MR-6
DISASSEMBLY AND ASSEMBLY RUBBER SHOE, FINAL DRIVE
1. Lower the work equipment to the ground and 1. Expand the track shoe assembly. (See EXPAN-
loosen lubricator (1) to lower the track shoe ten- SION OF TRACK SHOE.)
sion. [*1]
2. Swing the work equipment by 90 degrees and k Lower the work equipment to the ground
raise the machine body a little. and stop the engine. Loosen the oil filler
cap of the hydraulic tank to release the
3. Put steel pipes in rubber shoe (2) and turn the residual pressure from the hydraulic tank.
sprocket in the reverse direction. If the rubber
shoe is floated from the idler by the steel pipes, 3. Remove travel motor side cover (2).
slide off the rubber shoe sideways.
INSTALLATION
[*1]
a Adjust the rubber shoe tension. For details, see
TESTING AND ADJUSTING, Testing and adjust-
ing track shoe tension.
PC78MR-6 30-57
DISASSEMBLY AND ASSEMBLY IDLER
[*1]
2 Final drive assembly mounting bolt:
Liquid adhesive (LT-2)
a Bleed air from the travel motor. For details,
see TESTING AND ADJUSTING, Bleeding
air from each part.
a Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
30-58 PC78MR-6
DISASSEMBLY AND ASSEMBLY IDLER
a When installing the floating seal, thoroughly 4. Install the assembly of shaft (5) and support (7)
clean, degrease, and dry the parts marked to idler (4).
with the thick lines (the load ring and faces in
contact with the load ring).
PC78MR-6 30-59
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
6. Using tool L2, install floating seal (3) to idler (4) RECOIL SPRING ASSEMBLY
and support (2).
a Apply oil to the sliding surfaces of the floating
DISASSEMBLY
seal and take care that dirt will not stick to
the floating seal.
1. Remove lubricator (1).
a Degrease the contact faces of the floating
seal and O-ring.
2. Remove yoke piston assembly (3) from recoil
spring assembly (2).
30-60 PC78MR-6
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
3) Apply hydraulic pressure slowly. After the 3) Set recoil spring (2) to tool M.
spring is compressed, remove nut (5).
a Compress the spring until the nut is loos-
ened.
a Release the hydraulic pressure slowly to
eliminate the spring force.
4) Remove pilot (7) and cylinder (8) from spring
(6).
a Remove O-ring (13) from the cylinder.
ASSEMBLY
PC78MR-6 30-61
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
5) Remove recoil spring assembly (2) from tool TRACK ROLLER ASSEMBLY
M.
6) Install set bolt (4).
DISASSEMBLY
3 : 58.8 73.5 Nm {6 7.5 kgm}
1. Remove pin (2) from track roller assembly (1),
7) Fill cylinder (8) with grease (G2-LI).
then remove collar (3).
a Quantity of grease (G2-LI):
Approx. 232 cc (Rubber shoe)
Approx. 96 cc (Steel shoe)
8) Loosen lubricator (1) and insert yoke piston
assembly (3) in recoil spring assembly (4)
until grease comes out through part B.
3 Sliding parts of yoke piston and wear
ring: Grease (G2-LI)
9) Tighten lubricator (1).
3: 58.8 88.2 Nm {6.0 9.0 kgm}
a Install the valve so that the fitting will be
on the outside.
30-62 PC78MR-6
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
6. Pull out pin (8) and remove collar (10) from shaft
(9).
PC78MR-6 30-63
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
a The metallic faces of the floating seal which are 3. Using tool L4, press fit floating seal (7b) to shaft
in contact with each other must be free from dirt. (9).
a Supply GO140 oil.
Quantity of oil: 210 230 cc 4. Using tool L4, press fit floating seal (7a) to roller
a Thoroughly clean the parts to be in contact with (5).
the supplied oil. After cleaning them, the dirt a Press fit floating seal (4b) similarly.
remaining on these parts of 1 roller assembly
must be below 25 mg and the size of the dirt
must be below 0.3.
a Set plug (2) on the outside of the machine body.
30-64 PC78MR-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
8. Install collar (3) to shaft (9), then install pin (2). HYDRAULIC CYLINDER
9. Fill the roller with oil and tighten plug (13). ASSEMBLY
5 Track roller: 210 230 cc (GO-140) DISASSEMBLY
1. Cylinder assembly
1) Set cylinder assembly (1) to tool U1.
2) Using a hydraulic pump or a power wrench
and tool U2, loosen head assembly (2).
PC78MR-6 30-65
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
30-66 PC78MR-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
PC78MR-6 30-67
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
6. Cylinder assembly
1) Set the cylinder to tool U1.
2) Install piston rod assembly (3).
a Push in the piston rod to the end.
2) Install head assembly (2) to piston rod (5).
3) Install piston assembly (6) to piston rod (5).
30-68 PC78MR-6
90 OTHERS
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)