SM Pc78uu-6 Sebm025118 PDF

SEBM025118
MACHINE MODEL SERIAL NUMBER
PC78UU-6 22832 and up

PC78US-6 4001 and up
PC78US-6 4809 and up (For Norway & EU)
• 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.
• PC78UU-6, PC78US-6 mounts the 4D95LE-2 and S4D95LE-3-A engine.
For details of the engine, see the 95-2 Series and 95-3 Series Engine Shop Manual.
• For the PC78US-6 for Norway (Serial No. 4809 and up), the parts which different from the standard
model have been put together and added as Section 50. For the common parts, see this manual.
© 2010
All Rights Reserved
Printed in Japan 04-10(02) 00-1
(18)
CONTENTS
No. of page
01 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . 10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
50 OTHER SPECIFICATIONS (PC78US-6 For Norway) . . . . . . . . . . . . 50-1
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 PC78US-6
(16)
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
q 00-1 (18) 01-15 (13) 10-34 (10) 10-75 (10) 10-120 (10)
00-2 (16) 01-16 (6) 10-35 (10) 10-76 (10) 10-121 (10)
q 00-2-1 (18) 01-17 (6) 10-36 (10) 10-77 (10) 10-122 (10)
q 00-2-2 (18) 01-18 (13) 10-37 (10) 10-78 (10) 10-124 (10)
q 00-2-3 (18) 01-19 (13) 10-38 (10) 10-80 (10) 10-125 (10)
q 00-2-4 (18) 01-20 (6) 10-39 (10) 10-81 (10) 10-126 (10)
q 00-2-5 (18) 01-21 (10) 10-40 (10) 10-82 (10) 10-127 (10)
00-3 01-22 (10) 10-41 (10) 10-83 (10) 10-128 (10)
00-4 10-42 (10) 10-84 (10) 10-129 (10)
00-5 10-1 (14) 10-43 (10) 10-85 (10) 10-130 (10)
00-6 10-2 (10) 10-44 (10) 10-86 (10) 10-131 (10)
00-7 10-3 (10) 10-45 (10) 10-87 (10) 10-132 (10)
00-8 10-4 (10) 10-46 (10) 10-88 (10) 10-133 (10)
00-9 10-5 (10) 10-47 (14) 10-90 (10) 10-134 (10)
00-10 10-6 (10) 10-48 (10) 10-91 (10) 10-135 (10)
00-11 10-7 (10) 10-49 (14) 10-92 (10) 10-136 (10)
00-12 10-8 (10) 10-50 (10) 10-93 (10) 10-137 (10)
00-13 10-10 (10) 10-51 (10) 10-94 (10) 10-138 (10)
00-14 10-11 (10) 10-52 (10) 10-95 (10) 10-139 (10)
00-15 10-12 (10) 10-53 (10) 10-96 (10) 10-140 (10)
00-16 10-13 (10) 10-54 (14) 10-97 (10) 10-141 (10)
00-17 10-14 (10) 10-55 (10) 10-98 (10) 10-142 (10)
00-18 10-15 (10) 10-56 (10) 10-99 (10) 10-143 (10)
00-19 10-16 (10) 10-57 (10) 10-100 (10) 10-144 (10)
00-20 10-17 (13) 10-58 (10) 10-101 (10) 10-145 (10)
00-21 10-18 (13) 10-59 (10) 10-102 (10) 10-146 (10)
00-22 10-19 (10) 10-60 (10) 10-104 (10) 10-147 (10)
10-20 (10) 10-61 (10) 10-105 (10) 10-148 (10)
01-1 (6) 10-21 (10) 10-62 (10) 10-106 (10) 10-149 (10)
01-2 (6) 10-22 (10) 10-63 (10) 10-107 (10) 10-150 (10)
01-3 (6) 10-23 (10) 10-64 (10) 10-108 (10) 10-151 (10)
01-4 (5) 10-24 (10) 10-65 (10) 10-109 (10) 10-152 (10)
01-6 (6) 10-25 (10) 10-66 (10) 10-110 (10) 10-153 (10)
01-7 (6) 10-26 (10) 10-67 (10) 10-111 (10) 10-154 (10)
01-8 (13) 10-27 (10) 10-68 (10) 10-112 (10) 10-155 (10)
01-9 (13) 10-28 (10) 10-69 (10) 10-114 (10) 10-156 (10)
01-10 (6) 10-29 (10) 10-70 (10) 10-115 (10) 10-157 (10)
01-11 (6) 10-30 (10) 10-71 (10) 10-116 (10) 10-158 (10)
01-12 (6) 10-31 (10) 10-72 (10) 10-117 (10) 10-159 (10)
01-13 (6) 10-32 (10) 10-73 (10) 10-118 (10) 10-160 (10)
01-14 (13) 10-33 (10) 10-74 (10) 10-119 (10) 10-161 (10)
PC78US-6 00-2-1
(18)
10-162 (10) 10-215 (10) 10-268 (10) q 20-117 (18) 20-218-5 (12)
10-163 (10) 10-216 (10) 10-269 (10) q 20-118 (18) 20-218-6 (12)
10-164 (10) 10-217 (10) 10-270 (10) 20-119 (12) 20-218-8 (17)
10-165 (10) 10-218 (10) 10-271 (10) 20-120 (12) 20-218-9 (12)
10-166 (10) 10-219 (10) 10-272 (10) 20-121 (13) 20-218-10 (12)
10-167 (10) 10-220 (10) 10-273 (10) 20-121-1 (13) 20-219 (12)
10-168 (10) 10-221 (10) 10-274 (10) 20-122 (5) 20-219-1 (12)
10-169 (10) 10-222 (10) 20-123 (12) 20-219-3 (12)
10-170 (13) 10-223 (10) 20-1 (1) 20-124 (12) 20-219-4 (12)
10-171 (13) 10-224 (10) 20-2 (7) 20-125 (5) 20-219-5 (12)
10-172 (10) 10-225 (10) 20-2-1 (7) 20-126 (12) 20-219-6 (12)
10-173 (10) 10-226 (10) 20-3 (5) 20-127 (1) 20-219-7 (12)
10-174 (13) 10-227 (10) 20-4 (12) 20-128 (1) 20-219-9 (12)
10-175 (13) 10-228 (10) 20-5 (5) 20-129 (12) 20-219-10 (12)
10-176 (10) 10-229 (10) 20-6 (5) 20-130 (12) 20-219-11 (12)
10-177 (10) 10-230 (10) 20-7 (12) 20-131 (1) 20-220 (1)
10-178 (13) 10-231 (10) 20-8 (12) 20-132 (1) 20-221 (1)
10-179 (13) 10-232 (10) 20-9 (12) 20-133 (12) 20-222 (1)
10-180 (10) 10-233 (10) 20-10 (5) 20-134 (12) 20-223 (12)
10-181 (10) 10-234 (10) 20-11 (7) 20-135 (12) 20-224 (1)
10-183 (10) 10-236 (10) 20-12 (12) 20-136 (12) 20-225 (1)
10-184 (10) 10-237 (10) 20-13 (7) Q 20-136-1 (18) 20-226 (12)
10-185 (10) 10-238 (10) 20-14 (7) Q 20-136-2 (18) 20-227 (1)
10-186 (13) 10-239 (10) 20-15 (7) 20-137 (13) 20-228 (12)
10-187 (13) 10-240 (10) 20-16 (7) 20-138 (12) 20-229 (1)
10-188 (13) 10-241 (10) 20-17 (5) 20-139 (15) 20-230 (1)
10-189 (13) 10-242 (10) 20-18 (12) 20-140 (15) 20-231 (1)
10-190 (13) 10-243 (10) 20-19 (12) 20-141 (15) 20-232 (1)
10-191 (10) 10-244 (10) 20-20 (12) 20-142 (15) 20-233 (1)
10-192 (10) 10-245 (10) 20-21 (12) 20-201 (13) 20-234 (1)
10-193 (10) 10-246 (10) 20-22 (12) 20-202 (12) 20-235 (1)
10-195 (10) 10-247 (10) q 20-101 (18) 20-203 (2) 20-236 (1)
10-196 (10) 10-248 (10) 20-102 (13) 20-204 (12) 20-237 (1)
10-197 (10) 10-249 (10) 20-103 (12) 20-205 (12) 20-238 (1)
10-198 (10) 10-250 (10) 20-104 (12) 20-206 (12) 20-239 (1)
10-199 (10) 10-252 (10) 20-105 (13) 20-207 (12) 20-240 (1)
10-200 (10) 10-253 (10) 20-106 (12) 20-208 (12) 20-241 (12)
10-201 (10) 10-254 (10) 20-106-1 (7) 20-209 (12) 20-242 (12)
10-202 (10) 10-255 (10) 20-106-2 (12) 20-210 (2) 20-244 (12)
10-203 (10) 10-256 (10) 20-107 (7) 20-211 (2) 20-245 (12)
10-204 (10) 10-257 (10) 20-108 (13) 20-212 (1) 20-245-1 (5)
10-205 (10) 10-258 (10) 20-109 (13) 20-214 (12) 20-245-2 (5)
10-206 (10) 10-259 (10) 20-110 (13) 20-215 (7) 20-246 (5)
10-207 (10) 10-260 (10) 20-111 (13) 20-215-1 (7) 20-247 (1)
10-208 (10) 10-261 (10) 20-111-1 (12) 20-215-2 (7) 20-248 (12)
10-209 (10) 10-262 (10) 20-112 (7) 20-216 (7) 20-248-1 (12)
10-210 (10) 10-263 (10) 20-113 (12) 20-217 (12) 20-249 (1)
10-211 (10) 10-264 (10) 20-114 (12) 20-218 (12) 20-250 (7)
10-212 (10) 10-265 (10) 20-115 (12) 20-218-2 (12) 20-251 (12)
10-213 (10) 10-266 (10) 20-115-1 (7) 20-218-3 (7) 20-252 (12)
10-214 (10) 10-267 (10) 20-116 (12) 20-218-4 (7) 20-252-1 (13)
00-2-2 PC78US-6
(18)
20-253 (12) 20-342 (12) 20-368 (12) 20-432 (1) 20-478 (5)
20-253-1 (13) 20-343 (12) 20-369 (12) 20-433 (1) 20-479 (5)
20-253-2 (13) 20-343-1 (12) 20-370 (12) 20-434 (1) 20-480 (5)
20-254 (5) 20-343-2 (12) 20-371 (12) 20-435 (1) 20-481 (5)
20-255 (5) 20-344 (12) 20-372 (12) 20-436 (5) 20-482 (5)
20-255-1 (13) 20-345 (12) 20-373 (12) 20-437 (5) 20-483 (5)
20-255-2 (12) 20-346 (12) 20-374 (12) 20-438 (4) 20-484 (5)
20-255-3 (12) 20-347 (12) 20-375 (12) 20-439 (1) 20-485 (5)
20-255-4 (12) 20-348 (12) 20-376 (12) 20-440 (1) 20-501 (12)
20-255-6 (12) 20-349 (12) 20-376-1 (12) 20-441 (1) 20-502 (1)
20-255-7 (12) 20-349-1 (12) 20-376-2 (12) 20-442 (5) 20-503 (6)
20-256 (12) 20-349-2 (12) 20-377 (12) 20-443 (4) 20-504 (12)
20-259 (12) 20-349-3 (12) 20-378 (12) 20-444 (5) 20-505 (12)
20-260 (12) 20-349-4 (12) 20-379 (12) 20-444-1 (5) 20-506 (12)
20-301 (1) 20-351 (12) 20-380 (12) 20-445 (4) 20-507 (12)
20-302 (12) 20-352 (1) 20-381 (12) 20-446 (1) 20-508 (12)
20-303 (12) 20-354 (12) 20-381-1 (12) 20-447 (1) 20-509 (12)
20-325 (12) 20-355 (12) 20-382 (12) 20-447-1 (5) 20-510 (12)
20-326 (12) 20-355-1 (5) 20-383 (12) 20-447-2 (5) 20-511 (12)
20-328 (16) 20-355-2 (5) 20-384 (12) 20-448 (5) 20-512 (12)
20-329 (12) 20-355-3 (12) 20-385 (12) 20-449 (5) 20-513 (12)
20-329-1 (12) 20-355-4 (12) 20-386 (12) 20-450 (5) 20-514 (12)
20-329-2 (12) 20-356 (12) 20-387 (12) 20-451 (4) 20-515 (12)
20-329-3 (13) 20-357 (12) 20-387-1 (12) 20-452 (5) 20-516 (12)
20-330 (13) 20-357-1 (12) 20-387-2 (12) 20-453 (5) 20-517 (12)
20-331 (13) 20-357-2 (12) 20-387-3 (12) 20-453-1 (5) 20-518 (12)
20-331-1 (13) 20-358 (7) 20-388 (12) 20-453-2 (5) 20-519 (12)
20-331-2 (12) 20-358-1 (5) 20-388-1 (12) 20-454 (5) 20-520 (12)
20-332 (12) 20-358-2 (7) 20-389 (12) 20-455 (5) 20-521 (12)
20-332-1 (12) 20-358-3 (7) 20-389-1 (12) 20-456 (5) 20-522 (12)
20-333 (7) 20-358-4 (7) 20-401 (12) 20-457 (5) 20-523 (12)
20-334 (12) 20-358-5 (7) 20-402 (12) 20-458 (5) 20-524 (12)
20-334-1 (12) 20-358-6 (12) 20-403 (12) 20-459 (5) 20-525 (12)
20-334-2 (12) 20-358-7 (7) 20-404 (12) 20-460 (5) 20-526 (12)
20-334-3 (12) 20-358-8 (12) 20-405 (12) 20-461 (5) 20-527 (12)
20-335 (12) 20-358-9 (12) 20-406 (12) 20-462 (5) 20-528 (12)
20-335-1 (12) 20-359 (12) 20-407 (12) 20-463 (5) 20-529 (12)
20-336 (7) 20-359-1 (12) 20-408 (12) 20-464 (5) 20-530 (12)
20-336-1 (7) 20-360 (12) 20-409 (12) 20-465 (5) 20-531 (12)
20-336-2 (12) 20-360-1 (12) 20-410 (12) 20-466 (5) 20-532 (12)
20-337 (7) 20-361 (12) 20-411 (12) 20-467 (5) 20-533 (12)
20-337-1 (12) 20-361-1 (12) 20-412 (12) 20-468 (5) 20-534 (12)
20-338 (12) 20-362 (5) 20-413 (12) 20-469 (5) 20-535 (12)
20-338-1 (12) 20-363 (5) 20-414 (12) 20-470 (5) 20-536 (12)
20-338-2 (12) 20-364 (5) 20-415 (12) 20-471 (5) 20-537 (12)
20-338-3 (12) 20-365 (5) 20-425 (5) 20-472 (5) 20-538 (12)
20-339 (12) 20-366 (12) 20-426 (5) 20-473 (5) 20-539 (12)
20-339-1 (12) 20-366-1 (12) 20-428 (5) 20-474 (5) 20-540 (12)
20-340 (12) 20-366-2 (12) 20-429 (5) 20-475 (5) 20-541 (12)
20-340-1 (12) 20-366-3 (12) 20-430 (5) 20-476 (5) 20-542 (12)
20-341 (12) 20-367 (12) 20-431 (1) 20-477 (5) 20-543 (12)
PC78US-6 00-2-3
(18)
20-544 (12) 30-38 (11) 30-89 (11) 30-141 (16) 50-19 (13)
20-545 (12) 30-39 (11) 30-90 (11) 30-142 (16) 50-20 (13)
20-546 (12) 30-40 (11) 30-91 (11) 30-143 (16) 50-21 (10)
20-547 (7) 30-41 (11) 30-92 (11) 30-144 (16) 50-22 (10)
20-548 (12) 30-42 (11) 30-93 (11) 30-145 (16) 50-23 (10)
20-549 (12) 30-43 (11) 30-94 (11) 30-146 (16) 50-23-1 (10)
20-550 (12) 30-44 (11) 30-95 (11) 30-147 (16) 50-23-2 (10)
20-551 (12) 30-45 (11) 30-96 (11) 30-148 (16) 50-23-3 (10)
20-552 (12) 30-46 (11) 30-97 (11) 30-149 (16) 50-23-4 (10)
20-553 (12) 30-47 (11) 30-98 (11) 30-150 (16) 50-24 (10)
30-48 (11) 30-99 (11) 30-151 (16) 50-25 (10)
q 30-1 (18) 30-49 (11) 30-100 (11) 30-152 (16) 50-26 (10)
30-2 (11) 30-50 (11) 30-101 (16) 30-153 (16) 50-101 (7)
30-3 (11) 30-51 (11) 30-102 (16) 30-154 (16) 50-102 (12)
30-4 (11) 30-52 (11) 30-103 (16) 30-155 (16) 50-104 (7)
30-5 (11) 30-53 (11) 30-105 (16) 30-156 (16) 50-105 (7)
30-6 (11) 30-54 (11) 30-106 (16) 30-157 (16) 50-106 (4)
30-7 (11) 30-55 (11) 30-107 (16) 30-158 (16) 50-107 (12)
30-8 (11) 30-56 (11) 30-108 (16) 30-159 (16) 50-107-1 (12)
30-9 (11) 30-57 (11) 30-109 (16) 30-160 (16) 50-107-3 (12)
30-10 (11) 30-58 (11) 30-110 (16) 30-161 (16) 50-107-4 (7)
30-11 (11) 30-59 (11) 30-111 (16) 30-162 (16) 50-107-5 (7)
30-12 (11) 30-60 (11) 30-112 (16) 30-163 (16) 50-107-6 (12)
30-13 (11) 30-61 (11) 30-113 (16) 30-164 (16) 50-107-7 (12)
30-14 (11) 30-62 (11) 30-114 (16) 50-107-9 (12)
30-15 (11) 30-63 (11) 30-115 (16) 50-1 (10) 50-107-10 (12)
30-16 (11) 30-64 (11) 30-116 (16) 50-3 (10) 50-107-11 (12)
30-17 (11) 30-65 (11) 30-117 (16) 50-4 (14) 50-108 (12)
30-18 (15) 30-66 (11) 30-118 (16) 50-5 (10) 50-108-1 (12)
30-18-1 (15) 30-67 (11) 30-119 (16) 50-6 (10) 50-109 (4)
30-19 (11) 30-68 (11) 30-120 (16) 50-6-2 (10) 50-110 (4)
30-20 (15) 30-69 (11) 30-121 (16) 50-6-3 (6) 50-111 (12)
30-20-1 (15) 30-70 (11) 30-122 (16) 50-6-4 (13) 50-112 (4)
30-21 (11) 30-71 (11) 30-123 (16) 50-7 (13) 50-113 (12)
30-22 (11) 30-72 (11) 30-124 (16) 50-8 (6) 50-114 (7)
30-23 (11) 30-73 (11) 30-125 (16) 50-9 (6) 50-115 (12)
30-24 (11) 30-74 (11) 30-126 (16) 50-10 (13) 50-116 (4)
30-25 (11) 30-75 (11) 30-127 (16) 50-11 (10) 50-117 (12)
30-26 (11) 30-76 (11) 30-128 (16) 50-12 (14) 50-118 (4)
30-27 (11) 30-77 (11) 30-129 (16) 50-13 (14) 50-120 (12)
30-28 (11) 30-78 (11) 30-130 (16) 50-13-1 (14) 50-121 (12)
30-29 (11) 30-79 (11) 30-131 (16) 50-13-2 (14) 50-121-1 (12)
30-30 (11) 30-80 (11) 30-132 (16) 50-13-3 (14) 50-121-2 (12)
30-31 (11) 30-81 (11) 30-133 (16) 50-13-4 (14) 50-122 (12)
30-32 (11) 30-82 (11) 30-134 (16) 50-13-5 (14) 50-123 (12)
30-33 (11) 30-83 (11) 30-135 (16) 50-14 (6) 50-123-1 (12)
30-34 (11) 30-84 (11) 30-136 (16) 50-15 (3) 50-123-2 (12)
Q 30-34-1 (18) 30-85 (11) 30-137 (16) 50-16 (3) 50-124 (7)
30-35 (11) 30-86 (11) 30-138 (16) 50-17 (13) 50-124-1 (12)
30-36 (11) 30-87 (11) 30-139 (16) 50-17-1 (13) 50-124-2 (12)
30-37 (11) 30-88 (11) 30-140 (16) 50-18 (13) 50-125 (12)
00-2-4 PC78US-6
(18)
50-126 (12) 90-23 (10)
50-127 (12) 90-23-2 (10)
50-128 (12) 90-23-4 (10)
50-129 (12) 90-25 (6)
50-130 (12) 90-27 (6)
50-131 (12) 90-29 (6)
50-132 (12) 90-31 (6)
50-132-1 (12)
50-132-2 (12)
50-132-3 (12)
50-132-4 (12)
50-132-5 (12)
50-132-6 (12)
50-132-7 (12)
50-132-8 (12)
50-132-9 (12)
50-132-10 (12)
50-133 (7)
50-134 (7)
50-135 (4)
50-135-1 (12)
50-135-2 (7)
50-135-3 (12)
50-135-4 (12)
50-136 (12)
50-137 (12)
50-137-1 (12)
50-137-2 (12)
50-138 (12)
50-139 (12)
50-140 (12)
50-141 (12)
90-1 (10)
90-3 (10)
90-3-2 (10)
90-5 (6)
90-7 (10)
90-7-2 (10)
90-7-4 (14)
90-7-6 (14)
90-7-8 (10)
90-9 (6)
90-11 (6)
90-13 (10)
90-15 (10)
90-15-2 (10)
90-15-4 (10)
90-17 (10)
90-19 (10)
90-21 (10)
PC78US-6 00-2-5
(18)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

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

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

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

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

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
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 4
• If a part cannot be smoothly removed from the

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

wound onto the load.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(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.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
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
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
! The allowable load value is estimated to be one-

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

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

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

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

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

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

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

! In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
! Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

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

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

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

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

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

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

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

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

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

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

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
Specifiaction dimensions drawing ............... 01- 2

Working range drawing ................................. 01- 4
Specifications ................................................. 01- 6
Weight table ................................................... 01-18
List of lubricants and coolant ........................ 01-22
PC78US-6 01-1
GENERAL SPECIFICATION DIMENSIONS DRAWING
12
SPECIFICATION DIMENSIONS DRAWING
PC78US-6
PC78US-6
Item Unit
Steel shoe spec. Road liner spec. Rubber shoe spec.
Standard spec. 6,850 6,880 6,780
Machine weight kg
Blade sped. 7,190 7,220 7,120
Bucket capacity m³ 0.28
*1 KOMATSU 4D95LE-2 Diesel engine
Engine model —
*2 KOMATSU S4D95LE-3-A Diesel engine
Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850
A Overall length mm 5,770
B Overall height mm 2,730 2,750 2,730
C Overall width mm 2,330
D Shoe width mm 450
E Tail swing radius mm 1,240
F Overall length of track mm 2,840 2,900 2,880
Distance between tumbler
G mm 2,235 2,235 2,265
centers
Minimum ground clearance mm 360 400 380
Travel speed (Low/High) km/h 3.0/4.5 3.2/4.8
Continuous swing speed rpm 10.0
*1. Serial No.: 4001 – 5500

*2. Serial No.: 5501 and up
01-2 PC78US-6
PC78UU-6
PC78UU-6
Item Unit
Road liner spec. Rubber shoe spec. Steel shoe spec.
Machine weight kg 7,700 7,600 7,670
Bucket capacity m³ 0.28
*1 KOMATSU 4D95LE-2 Diesel engine
Engine model —
*2 KOMATSU S4D95LE-3-A Diesel engine
Rated engine output kW {HP}/rpm 40.5 {54.0}/1,850
B Overall height mm 2,750 2,730 2,730
D Shoe width mm 450
F Overall length of track mm 2,900 2,880 2,840
Distance between tumbler
G mm 2,235 2,265 2,235
centers
Minimum ground clearance mm 400 380 360
Travel speed (Low/High) km/h 3.0/4.5 3.2/4.8 3.0/4.5
*1. Serial No.: 22832 – 23500

PC78US-6 01-3
GENERAL WORKING RANGE DRAWING
WORKING RANGE DRAWING
Working range (mm) PC78US-6 PC78UU-6

A Max. digging reach 6,380 6,400
B Max. digging depth 4,100 4,200
C Max. digging height 7,300 7,360
D Max. vertical wall depth 3,610 3,160
E Max. dumping height 5,180 5,290
Min. swing radius of work
F 1,750 1,200
equipment
G Max. reach at ground level 6,240 6,240
H Max. blade lifting height 380 415
I Max. blade lowering depth 245 210
01-4 PC78US-6
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC78US-6
PC78US-6
Machine model
Blade-less specification Blade specification
Serial Number 4001 – 5500
Bucket capacity m3 0.28 0.28
6,850 (6,880) 7,190 (7,220)
Machine weight kg
[6,780] [7,120]
Max. digging depth mm 4,100 4,100
Max. vertical wall depth mm 3,610 3,610
Working range
Max. digging reach mm 6,380 6,380

Max. reach at ground level mm 6,240 6,240
Max. digging height mm 7,300 7,300
Performance
Max. dumping height mm 5,180 5,180

Max. blade lifting height mm – 380
Max. blade lowering depth mm – 245
Max. digging force (Bucket) kN {kg} 61.29 {6,250} 61.29 {6,250}
Continuous swing speed rpm 10.0 10.0
Max. slope angle for swing deg. 20.0 19.0
Travel speed (Low/High) km/h 3.0/4.5 [3.2/4.8] 3.0/4.5 [3.2/4.8]
Gradeability deg. 35 35
Ground pressure kPa {kg/cm2} 30.4 {0.31} 32.4 {0.33}
Overall length (for transport) mm 5,770 5,770
Overall width mm 2,330 2,330
Overall height (for transport) mm 2,730 (2,750) 2,730 (2,750)
Overall height (for operation) mm 2,710 (2,750 [2,730] 2,710 (2,750) [2,730]
Ground clearance of counterweight mm 735 (780) [760] 735 (780) [760]
Min. ground clearance mm 360 (400) [380] 360 (400) [380]
Tail swing radius mm 1,240 1,240
Dimension
Min. swing radius of work equipment mm 1,750 1,750

Height of work equipment at min. swing
mm 5,570 (5,590) 5,570 (5,590)
radius
Overall width of track mm 2,320 2,320
Overall length track mm 2,840 (2,900) [2,880] 2,840 (2,900) [2,880]
Distance between tumbler centers mm 2,235 [2,265] 2,235 [2,265]
Track gauge mm 1,870 1,870
Machine cab height mm 1,745 (1,795) [1,775] 1,745 (1,795) [1,775]
Blade width × height mm – 2,320 × 470
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
( ) Figures in ( ): Road liner specification
[ ] Figures in [ ]: Rubber shoe specification
01-6 PC78US-6
PC78US-6
5501 and up
0.28 0.28
6,850 (6,880) 7,190 (7,220)
[6,780] [7,120]
4,100 4,100
3,610 3,610
6,380 6,380
6,240 6,240
7,300 7,300
5,180 5,180
– 380
– 245
61.29 {6,250} 61.29 {6,250}
10.0 10.0
20.0 19.0
3.0/4.5 [3.2/4.8] 3.0/4.5 [3.2/4.8]
35 35
30.4 {0.31} 32.4 {0.33}
5,770 5,770
2,330 2,330
2,730 (2,750) 2,730 (2,750)
2,710 (2,750 [2,730] 2,710 (2,750) [2,730]
735 (780) [760] 735 (780) [760]
360 (400) [380] 360 (400) [380]
1,240 1,240
1,750 1,750
5,570 (5,590) 5,570 (5,590)
2,320 2,320
2,840 (2,900) [2,880] 2,840 (2,900) [2,880]
2,235 [2,265] 2,235 [2,265]
1,870 1,870
1,745 (1,795) [1,775] 1,745 (1,795) [1,775]
– 2,320 × 470
PC78US-6 01-7
PC78US-6
Machine model
Model 4D95LE-2
Type 4-cycle, water-cooled, in-line vertical type, direct injection
No. of cylinders - bore × stroke mm 4-95 × 115
Total displacement {cc} 3.26 {3,260}
Rated output kW/rpm 40.5/1,850

{HP/rpm} {54.0/1,850}
Performance
Nm/rpm 226/1,500
Max. torque {kgm/rpm} {23.0/1,500}
Engine
Max. speed at no load rpm 2,020

Min. speed at no load rpm 1,130
g/kWh
Min. fuel consumption {g/HPh} 231 {172}
Starting motor 24 V, 3.0 kw

Alternator 24 V, 25 A
Battery (*1) 12 V, 48 Ah × 2
Type of radiator core CF29-3
Carrier roller 1 on each side
Undercarriage
Track roller 5 on each side
Track shoe (Steel shoe) Assembly-type triple grouser, 39 on each side

(Road liner) Assembly-type road liner, 39 on each side
(Rubber shoe) Unit-type rubber crawler
Type × No. Variable-capacity piston pump Variable-capacity piston pump
×1 ×1
Hydraulic pump
Discharge Gear pump × 1 Gear pump × 2

{cc} 80× 2+12.7 80× 2+60+12.7
Set pressures
*2 (Work equipment, swing, travel) MPa 26.5 {270} –
*3 (Work equipment, travel) {kg/cm2} – 26.5 {270}
*3. (Swing, blade) – 21.1 {215}
(Control) 3.1 {32} 3.1 {32}
Hydraulic system
Hydraulic motor Control
Type × No. 6-spool type × 1 7-spool type × 1

valve
Control method Hydraulically assisted Hydraulically assisted
Travel motor Variable-capacity piston motor

(with brake valve, parking brake) × 2
Swing motor Fixed-capacity piston motor

(with safety valve, pivot shaft brake) × 1
Hydraulic tank Box-shaped, open

Hydraulic oil filter Tank return side
Oil cooler Air-cooled (CF40-1)
*1: Battery capacity (Ah) shows the rate of 5 hours.

*2: Blade-less specification
*3: Blade specification
01-8 PC78US-6
(13)
PC78US-6 PC78US-6
Blade-less specification Blade specification Blade-less specification Blade specification
6501 and up 5501 – 6500
S4D95LE-3-A S4D95LE-3-A
4-cycle, water-cooled, in-line vertical type, 4-cycle, water-cooled, in-line vertical type,
direct injection, with turbocharger direct injection, with turbocharger
4-95 × 115 4-95 × 115
3.26 {3,260} 3.26 {3,260}
40.5/1,850 40.5/1,850
{54.0/1,850} {54.0/1,850}
237/1,500 237/1,500
{24.2/1,500} {24.2/1,500}
2,020 2,020
1,130 1,130
227 {169} 227 {169}
24 V, 3.0 kw 24 V, 3.0 kw
24 V, 25 A 24 V, 25 A
12 V, 48 Ah × 2 12 V, 48 Ah × 2
ALW-4 CF29-3
1 on each side 1 on each side
Assembly-type triple grouser, 39 on each side Assembly-type triple grouser, 39 on each side
Assembly-type road liner, 39 on each side Assembly-type road liner, 39 on each side
Unit-type rubber crawler Unit-type rubber crawler
Variable-capacity piston pump Variable-capacity piston pump Variable-capacity piston pump Variable-capacity piston pump
×1 ×1 ×1 ×1
Gear pump × 1 Gear pump × 2 Gear pump × 1 Gear pump × 2
80× 2+12.7 80× 2+60+12.7 80× 2+12.7 80× 2+60+12.7
26.5 {270} – 26.5 {270} –

– 26.5 {270} – 26.5 {270}
– 21.1 {215} – 21.1 {215}
3.1 {32} 3.1 {32} 3.1 {32} 3.1 {32}
6-spool type × 1 7-spool type × 1 6-spool type × 1 7-spool type × 1
Hydraulically assisted Hydraulically assisted Hydraulically assisted Hydraulically assisted
Variable-capacity piston motor Variable-capacity piston motor

(with brake valve, parking brake) × 2 (with brake valve, parking brake) × 2
Fixed-capacity piston motor Fixed-capacity piston motor

(with safety valve, pivot shaft brake) × 1 (with safety valve, pivot shaft brake) × 1
Box-shaped, open Box-shaped, open

Tank return side Tank return side
Air-cooled (CF42) Air-cooled (CF40-1)
PC78US-6 01-9
(13)
PC78US-6
Machine model
Type Reciprocating piston Reciprocating piston
Boom cylinder
Inside diameter of cylinder mm ø 115 ø 115

Diameter of piston rod mm ø 65 ø 65
Stroke mm 858 858
Max. distance between pins mm 2,143 2,143
Min. distance between pins mm 1,285 1,285
Arm cylinder

Work equipment cylinder
Stroke mm 865 865

Hydraulic system

Bucket cylinder

Stroke mm 710 710
Type – Reciprocating piston
Blade cylinder
Inside diameter of cylinder mm – ø 130

Diameter of piston rod mm – ø 65
Stroke mm – 130
Max. distance between pins mm – 679
Min. distance between pins mm – 549
01-10 PC78US-6
PC78US-6
5501 and up
Reciprocating piston Reciprocating piston
ø 115 ø 115
ø 65 ø 65
858 858
2,143 2,143
1,285 1,285
ø 100 ø 100
ø 60 ø 60
865 865
2,193 2,193
1,328 1,328
ø 90 ø 90
ø 55 ø 55
710 710
1,765 1,765
1,055 1,055
– Reciprocating piston
– ø 130
– ø 65
– 130
– 679
– 549
PC78US-6 01-11
PC78UU-6
PC78UU-6
Machine model
—
Bucket capacity m3 0.28
Machine weight kg 7,700 (7,600) [7,670]
Max. digging depth mm 4,200
Max. vertical wall depth mm 3,160
Max. digging reach mm 6,400
Working range
Max. reach at ground level mm 6,240

Max. digging height mm 7,360
Max. dumping height mm 5,290
Performance
Boom offset mm 1,030/1,065

(left side/right sede)
Max. blade lifting height mm 415
Max. blade lowering depth mm 210
Max. digging force (Bucket) kN {kg} 61.3 {6,250}
Max. slope angle for swing deg. 13.0
Travel speed (Low/High) km/h 3.0/4.5 (3.2/4.8)
Gradeability deg. 35
Ground pressure kPa {kg/cm2} 34.3 {0.35}
Overall length (for transport) mm 6,060
Overall width mm 2,330
Overall height (for transport) mm 2,750 (2,730) [2,730]
Overall height (for operation) mm 2,750 (2,730) [2,710]
Ground clearance of counterweight mm 780 (760) [735]
Min. ground clearance mm 400 (380) [360]
Tail swing radius mm 1,240
Dimension
Min. swing radius of work equipment

mm 1,200
(at boom offset)
Height of work equipment at min. swing
mm 5,490 (5,470) [5,470]
radius
Overall width of track mm 2,320
Overall length track mm 2,900 (2,880) [2,840]
Distance between tumbler centers mm 2,235 (2,265)
Track gauge mm 1,870
Machine cab height mm 1,795 (1,775) [1,745]
Blade width × height mm 2,320 x 470
Figures (Road liner specification) are common to the all specifications unless otherwise specified.
( ) Figures in ( ): Rubber shoe specification
[ ] Figures in [ ]: Steel shoe specification
01-12 PC78US-6
PC78UU-6
—
23501 and up
0.28
7,700 (7,600) [7,670]
4,200
3,160
6,400
6,240
7,360
5,290
1,030/1,065
415
210
61.3 {6,250}
10.0
13.0
3.0/4.5 (3.2/4.8)
35
34.3 {0.35}
6,060
2,330
2,750 (2,730) [2,730]
2,750 (2,730) [2,710]
780 (760) [735]
400 (380) [360]
1,240
1,200
5,490 (5,470) [5,470]
2,320
2,900 (2,880) [2,840]
2,235 (2,265)
1,870
1,795 (1,775) [1,745]
2,320 x 470
PC78US-6 01-13
PC78UU-6
Machine model
—
Model 4D95LE-2
Type 4-cycle, water-cooled, in-line vertical type, direct injection
No. of cylinders - bore × stroke mm 4–95 × 115
Rated output kW/rpm 40.5/1,850

{HP/rpm} {54.0/1,850}
Performance
Nm/rpm 226/1,500
Engine

g/kWh

Battery (*1) 12 V, 48 Ah × 2
Undercarriage

(Road liner) Assembly-type road liner, 39 on each side
(Rubber shoe) Unit-type rubber crawler
Type × No. Variable-capacity piston pump × 1
Hydraulic pump
Discharge Gear pump × 2

{cc} 80× 2+60+12.7
Set pressures MPa 26.5 {270}

(Work equipment, travel)
(Swing, blade) {kg/cm2} 21.1 {215}
3.1 {32}
(Control)
Hydraulic system
Type × No. 8-spool type × 1

valve
Control method Hydraulically assisted
Variable-capacity piston motor

Travel motor (with brake valve, parking brake) × 2
Fixed-capacity piston motor

Swing motor (with safety valve, pivot shaft brake) × 1

01-14 PC78US-6
(13)
PC78UU-6
—
23501 and up
S4D95LE-3-A
4-cycle, water-cooled, in-line vertical type,
direct injection, with turbocharger
4–95 × 115
3.260 {3,260}
40.5/1,850
{54.0/1,850}
237/1,500
{24.2/1,500}
2,020
1,130
227 {169}
24 V, 3.0 kw
24 V, 25 A
12 V, 48 Ah × 2
CF29-3
1 on each side
5 on each side
Assembly-type triple grouser, 39 on each side

Assembly-type road liner, 39 on each side
Unit-type rubber crawler
Variable-capacity piston pump × 1
Gear pump × 2
80× 2+60+12.7
26.5 {270}
21.1 {215}
3.1 {32}
8-spool type × 1
Hydraulically assisted


Box-shaped, open
Tank return side
Air-cooled (CF40-1)
PC78US-6 01-15
(13)
PC78UU-6
Machine model
—
Type Reciprocating piston
Boom cylinder
Inside diameter of cylinder mm ø 120

Diameter of piston rod mm ø 70
Stroke mm 1,015
Max. distance between pins mm 2,436.5
Min. distance between pins mm 1,421.5
Arm cylinder

Stroke mm 715
Max. distance between pins mm 955
Min. distance between pins mm 240

Hydraulic system
Bucket cylinder

Stroke mm 710
Max. distance between pins mm 1,765
Min. distance between pins mm 1,055
Offset cylinder

Stroke mm 350
Blade cylinder

Stroke mm 130
01-16 PC78US-6
PC78UU-6
—
23501 and up
Reciprocating piston
ø 120
ø 70
1,015
2,436.5
1,421.5
ø 110
ø 65
715
955
240
ø 90
ø 55
710
1,765
1,055
ø 110
ø 55
350
1,500
1,150
ø 130
ø 65
130
679
549
PC78US-6 01-17
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This mass list is for reference in handling or transporting these components.
PC78US-6 PC78UU-6
Machine model
Blade-less specification Blade specification —
Serial Number 4001 – 5500 22832 – 23500
Engine assembly (without water and oil) 400 403 403

• Engine (without water and oil) 300 300 300
• Engine mount 30 30 30
• PTO 7 7 7
• Hydraulic pump 63 66 66
Cooling assembly (without coolant and oil) 29 29 29
• Radiator (without coolant) 6.3 6.3 6.3
• Oil cooler (without oil) 5.2 5.2 5.2
Revolving frame 930 930 930
Operator's cab 260 260 260
Operator's seat 18 18 18
Fuel tank (without fuel) 11 11 11
Hydraulic tank (without hydraulic oil) 75 75 75

Control valve 56 58 60
Counterweight 950 800 800
Swing motor (Including brake valve) 22 22 22
Swing circle 104 104 104
Swing machinery 47 47 47
Center swivel joint 16 17 17
1,067 1,142 1,142
Track frame assembly (without track shoe)
[1,048] [1,123] [1,123]
• Track frame 704 779 779
• Idler assembly 54 x 2 54 x 2 54 x 2
• Recoil spring assembly 40 x 2 40 x 2 40 x 2
• Carrier roller 3.4 x 2 3.4 x 2 3.4 x 2
• Track roller 13 x 10 13 x 10 13 x 10
• Travel motor (with reduction gears) 81 x 2 81 x 2 81 x 2

• Sprocket 19 x 2 19 x 2 19 x 2
Figures (steel shoe specification) are common to the all specifications unless otherwise specified.
[ ] Figures in [ ]: Rubber shoe specification
01-18 PC78US-6
(13)
Unit: kg
PC78US-6 PC78US-6 PC78UU-6
Blade-less specification Blade specification Blade-less specification Blade specification —
5501 – 6500 6501 and up 23501 and up
401 404 401 404 404

300 300 300 300 300
30 30 30 30 30
7 7 7 7 7
64 67 64 67 67
29 29 29 29 29
6.3 6.3 5.8 5.8 6.3
5.2 5.2 5.5 5.5 5.2
930 930 984 984 930
260 260 260 260 260
18 18 18 18 18
(*3) 11
11 11 48 48
(*4) 17
75 75 70 70 75
56 58 56 58 60
950 800 885 732 800
22 22 22 22 22
104 104 104 104 104
47 47 46 46 47
16 17 16 17 17
1,067 1,142 1,067 1,142 1,142
[1,048] [1,123] [1,048] [1,123] [1,123]
704 779 704 779 779
54 x 2 54 x 2 54 x 2 54 x 2 54 x 2
39 x 2 39 x 2 39 x 2 39 x 2 39 x 2
3.4 x 2 3.4 x 2 3.4 x 2 3.4 x 2 3.4 x 2
(*1) 13 x 10
13 x 10 13 x 10 12.4 x 10 12.4 x 10
(*2) 12.4 x 10
81 x 2 81 x 2 81 x 2 81 x 2 81 x 2
19 x 2 19 x 2 19 x 2 19 x 2 19 x 2
*1. PC78UU-6 (Serial No.: 23501 – 24066)

*2. PC78UU-6 (Serial No.: 24067 and up)
*3. PC78UU-6 (Serial No.: 23501 – 24085)
*4. PC78UU-6 (Serial No.: 24086 and up)
PC78US-6 01-19
(13)
PC78US-6 PC78UU-6
Machine model
Blade-less specification Blade specification —
Serial Number 4001 – 5500 22832 – 23500
Track shoe assembly

• City pad shoe (450 mm) 410 X 2 410 X 2 410 X 2
• Road liner (450 mm) 450 X 2 450 X 2 450 X 2
• Rubber shoe (450 mm) 385 X 2 385 X 2 385 X 2
• Triple grouser (600 m) 495 X 2 495 X 2 –
Boom assembly 418 418 731
• 1st boom – – 293
• 2nd boom – – 177
• 3rd bracket – – 135
• Sublink – – 27
Arm assembly 147 147 165
Bucket link assembly 56 56 56
Bucket assembly (with side cutter) 210 210 210
Blade assembly – 374 374
Boom cylinder assembly 86 86 107
Arm cylinder assembly 72 72 87
Bucket cylinder assembly 51 51 51
Offset cylinder assembly – – 47
Blade cylinder assembly – 46 46
Figures are common to the all specifications unless otherwise specified.
01-20 PC78US-6
(6)
Unit: kg
PC78US-6 PC78US-6 PC78UU-6
Blade-less specification Blade specification Blade-less specification Blade specification —
5501 – 6500 6501 and up 23501 and up
410 X 2 410 X 2 410 X 2 410 X 2 410 X 2

450 X 2 450 X 2 450 X 2 450 X 2 450 X 2
385 X 2 385 X 2 385 X 2 385 X 2 385 X 2
495 X 2 495 X 2 495 X 2 495 X 2 –
418 418 418 418 731
– – – – 293
– – – – 177
– – – – 135
– – – – 27
147 147 147 147 165
56 56 54 54 56
210 210 204 204 210
– 374 – 358 374
86 86 86 86 107
72 72 72 72 87
51 51 51 51 51
– – – – 47
– 46 – 46 46
PC78US-6 01-21
(10)
GENERAL LIST OF LUBRICANTS AND COOLANT
LIST OF LUBRICANTS AND COOLANT
AMBIENT TEMPERATURE
KIND OF
RESERVOIR FLUID –22 –4 14 32 50 68 86 104 122˚F
–30 –20 –10 0 10 20 30 40 50˚C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Swing machinery case
Final drive case Engine oil
PTO gear case SAE 30
SAE 10
Hydraulic system
SAE 10W-30
SAE 15W-40
ASTM D975 No. 2

Fuel tank Diesel fuel
ASTM D975 No. 1
Greasing system Grease NLGI No. 2
Cooling system Coolant Add antifreeze
Unit: l
PC78US-6 PC78UU-6
Reservoir
Specified capacity Refill capacity Specified capacity Refill capacity
Engine oil pan 7.5 7.0 7.5 7.0
PTO gear case 0.4 0.4 0.4 0.4
Swing machinery case 2.0 2.0 2.0 2.0
Final drive case (each) 1.3 1.3 1.3 1.3
(*1) 110 64
Hydraulic system 120 64
(*2) 102 56
Fuel tank 125 — 125 —
(*1) 10.5 —
Cooling system 10.5 —
(*2) 11.8 —
*1. PC78US-6 (Serial No.: 4001 – 6500)

*2. PC78US-6 (Serial No.: 6501 and up)
01-22 PC78US-6
(10)
10 STRUCTURE, FUNCTION AND
PTO ........................................................................... 10- 2

Cooling system .......................................................... 10- 4
Power train system .................................................... 10- 6
Swing circle ............................................................... 10- 8
Swing machinery ....................................................... 10-10
Track frame and idler cushion ................................... 10-14
Idler ........................................................................... 10-16
Track roller................................................................. 10-17
Carrier roller .............................................................. 10-19
Sprocket .................................................................... 10-20
Track shoe................................................................. 10-21
Arrangement of hydraulic components...................... 10-26
Hydraulic tank and oil filter ........................................ 10-29
Center swivel joint ..................................................... 10-31
Travel motor .............................................................. 10-33
Work equipment cylinder ........................................... 10-41
Solenoid valve ........................................................... 10-46
Multi-control valve ..................................................... 10-53
Accumulator for braker .............................................. 10-54
Hydraulic pump ......................................................... 10-55
Control valve ............................................................. 10-80
CLSS ....................................................................... 10-120
Swing motor ............................................................ 10-158
Work equipment and swing PPC valve ................... 10-166
Travel PPC valve..................................................... 10-172
Offset PPC valve , attachment PPC valve,
blade PPC valve...................................................... 10-176
Work equipment ...................................................... 10-180
Dimensions of each part of work equipment ........... 10-186
Air conditioner piping (OPTIONAL) ......................... 10-192
Electric control system ............................................ 10-195
System components ................................................ 10-252
Monitor system ........................................................ 10-265
Sensors ................................................................... 10-271
PC78US-6 10-1
(14)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PTO
PTO
PC78US-6 Serial No.: 4001 – 6500
PC78UU-6 Serial No.: 22832 and up
1. Drain plug
2. Coupling
3. Flywheel
4. Pump case
5. Cage
6. Level plug
7. Breather/Oil filler plug
10-2 PC78US-6
(10)
MAINTENANCE STANDARD PTO
PC78US-6 Serial No.: 6501 and up
1. Drain plug
2. Coupling
3. Flywheel
4. Pump case
5. Level plug
6. Breather/Oil filler plug
PC78US-6 10-3
(10)
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
PC78US-6 Serial No.: 4001 – 6500
1. Fan guard SPECIFICATIONS

2. Radiator inlet hose Radiator Oil cooler
3. Drain valve
Type of core CF29-3 CF40-1
4. Radiator outlet hose
5. Radiator cap Fin pitch (mm) 4.0/2 4.5/2
6. Oil cooler Total heat dissipation area 16.53 6.15
7. Radiator (m2)
8. Shroud Pressure valve cracking 88.3±14.7 –
9. Oil cooler inlet pressure (kPa {kg/cm2}) (0.9±0.15)
10. Reservoir tank Vacuum valve cracking 4.9 –
11. Oil cooler outlet pressure (kPa {kg/cm2}) (0.05)
10-4 PC78US-6
(10)
MAINTENANCE STANDARD COOLING SYSTEM
1. Fan guard SPECIFICATIONS

2. Radiator inlet hose Radiator Oil cooler
3. Drain valve
Type of core ALW-4 CF42
4. Radiator outlet hose
5. Radiator cap Fin pitch (mm) 3.5/2 3.5/2
6. Oil cooler Total heat dissipation area 16.04 5.96
7. Radiator (m2)
8. Shroud Pressure valve cracking 49 –
9. Oil cooler inlet pressure (kPa {kg/cm2}) (0.5)
10. Reservoir tank Vacuum valve cracking 4.9 –
11. Oil cooler outlet pressure (kPa {kg/cm2}) (0.05)
PC78US-6 10-5
(10)
MAINTENANCE STANDARD POWER TRAIN SYSTEM
POWER TRAIN SYSTEM

PC78US-6
1. Idler 8. Hydraulic pump

2. Control valve (Blade-less specification: For travel, swing,
3. Center swivel joint and work equipment)
4. Swing motor (Blade specification: For travel and work
5. Travel motor equipment)
6. Control pump (for pilot control) 9. Engine
7. Hydraulic pump (for swing and blade) 10. Swing holding brake solenoid valve
[Installed to only blade specification] 11. 2-stage travel speed selector solenoid valve
12. PPC lock solenoid valve
13. Swing machinery
14. Swing circle
10-6 PC78US-6
(10)
MAINTENANCE STANDARD POWER TRAIN SYSTEM
PC78UU-6
1. Idler 10. Boom RAISE stop EPC valve

2. Control valve 11. Arm IN stop EPC valve
3. Center swivel joint 12. Left offset stop EPC vaolve
4. Swing motor 13. Swing holding brake solenoid valve
5. Travel motor 14. 2-stage travel speed selector solenoid valve
6. Control pump (for pilot control) 15. PPC lock solenoid valve
7. Hydraulic pump (for swing and blade) 16. Swing machinery
8. Hydraulic pump 17. Swing circle
(For travel and work equipment)
9. Engine
PC78US-6 10-7
(10)
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance

1 Clearance between bearing and circle Replace
0.3 – 1.2 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 (l) 5.5
10-8 PC78US-6
(10)
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
PC78US-6 Serial No.: 4001 – 6500
1. Swing pinion (Number of teeth: 10) Specification

2. Swing machinery case (14+58)/14X(14+58)/14 =
3. No. 2 planetary carrier Reduction ratio
26.45
4. Ring gear (Number of teeth: 58)
Swing reduction ratio 26.45X8.0 = 211.59
5. No. 2 sun gear (Number of teeth: 14)
6. No. 1 planetary carrier Swing speed (rpm) 10
8. Swing motor
9. Oil filler
10. Level gauge
11. No. 1 planetary gear (Number of teeth: 22)
13. Drain plug
10-10 PC78US-6
(10)
Unit: mm

Backlash between swing motor
1
shaft and No. 1 sun gear 0.03 – 0.11 —
Backlash between No. 1 sun

2 0.10 – 0.27 0.6
gear and No. 1 planetary gear
Backlash between No. 1 plane-
3 0.12 – 0.38 0.6
tary gear and ring gear
4 0.10 – 0.25 —
tary carrier and No. 2 sun gear Replace
5 0.10 – 0.27 0.6
6 0.12 – 0.38 0.6
7 0.07 – 0.21 —
tary carrier and swing pinion
Backlash between swing pinion
8 0.27 – 0.83 2.0
and swing circle
Basic dimension Allowance Allowable Limit Plating with hard
Wear of sliding surface of swing
9 0 chromium or
pinion collar against oil seal 75 74.8
- 0.074 replace
PC78US-6 10-11
(10)
1. Swing pinion (Number of teeth: 10) Specification

2. Swing machinery case (14+58)/14X(14+58)/14 =
3. No. 2 planetary carrier Reduction ratio
26.45
4. Ring gear (Number of teeth: 58)
Swing reduction ratio 26.45X8.0 = 211.59
6. No. 1 planetary carrier Swing speed (rpm) 10
8. Swing motor
9. Oil filler
10. Level gauge
13. Drain plug
10-12 PC78US-6
(10)
Unit: mm

Backlash between swing motor
1
shaft and No. 1 sun gear 0.03 – 0.11 —

2 0.10 – 0.27 0.6
3 0.12 – 0.37 0.6
4 0.10 – 0.25 —
tary carrier and No. 2 sun gear Replace
5 0.10 – 0.27 0.6
6 0.12 – 0.37 0.6
7 0.009 – 0.117 —
tary carrier and swing pinion
Backlash between swing pinion
8 0.27 – 0.83 2.0
and swing circle
Basic dimension Allowance Allowable Limit Plating with hard
Wear of sliding surface of swing
9 0 chromium or
pinion collar against oil seal 75 74.8
- 0.074 replace
PC78US-6 10-13
(10)
MAINTENANCE STANDARD TRACK FRAME AND IDLER CUSHION
TRACK FRAME AND IDLER CUSHION
10-14 PC78US-6
(10)
MAINTENANCE STANDARD TRACK FRAME AND IDLER CUSHION
Unit: mm
Basic dimension Allowable limit

Track Overlay
Vertical width of 74 78
1 frame
idler guide
Overlay or
Idler support 73 69
replace
Track
158 162 Overlay
Lateral width of frame
2
idler guide Overlay or
Idler support 156 152
replace
Installed Installed Installed
Free length Free length
length load load
(*1)
47.4 kN 42.2 kN
Road liner, 410 323 400
{4,837 kg} {4,305 kg}
steel shoe
(*1)
3 Recoil spring 69.2 kN 61.6 kN Replace
Rubber 410 283 400
{7,061 kg} {6,284 kg}
shoe
(*2)
47.4 kN 42.2 kN
Road liner, 412 323 402
{4,837 kg} {4,305 kg}
steel shoe
(*2)
69.2 kN 61.6 kN
Rubber 412 283 402
{7,061 kg} {6,284 kg}
shoe
*1. PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500
*2. PC78US-6 Serial No.: 5501 and up
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)
PC78US-6 10-15
(10)
MAINTENANCE STANDARD IDLER
IDLER
Unit: mm
Outside diameter of Basic dimension Allowable limit

1
projected part 460 —
2 Outside diameter of tread 415 407
Overlay or
3 Depth of tread 22.5 26.5
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 shaft dimension Shaft Hole clearance clearance
7
and bushing
-0.250 +0.062 0.250 –
44 1.5
-0.290 0 0.352
Replace
Interference between idler and dimension Shaft Hole interference interference
8
bushing
+0.117 +0.025 0.062 –
50 —
+0.087 0 0.117
Side clearance of idler (Each Standard clearance Allowable clearance
9
side) 0.190 – 0.395 1.5
Thickness of tread (at center of Basic dimension Allowable limit Overlay or
10
width of tread) 13.8 9.8 replace
— Quantity of oil 60 cc (Engine oil: SAE30CD) —
10-16 PC78US-6
(10)
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
PC78US-6 Serial No.: 4001 – 6500
PC78UU-6 Serial No.: 22832 – 24066
Unit: mm

Outside diameter of
1
Overlay or
2 Outside diameter of tread 120 113 replace
3 Width of flange 43 36.6
4 Overall width 129 — —
Overlay or
5 Width of tread 43 47.3
replace
Clearance between shaft and dimension Shaft Hole clearance clearance
6
bushing -0.250 +0.075 0.225 –
38 1.5
-0.270 - 0.025 0.345
Interference between roller and dimension Shaft Hole interference interference Replace
7
bushing +0.117 +0.030 0.057 –
48 —
+0.087 0 0.117
Side clearance of track roller
8
(Each side) 0.38 – 0.73 1.5

Thickness of tread (at center of Overlay or
9
width of tread) 36 32.5 replace
— Quantity of oil 210 – 230 cc (Gear oil: G0140) —
PC78US-6 10-17
(13)
MAINTENANCE STANDARD TRACK ROLLER

Unit: mm

Outside diameter of
1
Overlay or
2 Outside diameter of tread 110 103 replace
3 Width of flange 43 36.6
4 Overall width 136.6 — —
Overlay or
5 Width of tread 46.8 51.1
replace
Clearance between shaft and dimension Shaft Hole clearance clearance
6
bushing
-0.250 +0.165 0.230 –
40 1.5
-0.270 - 0.020 0.435
Interference between roller and dimension Shaft Hole interference interference Replace
7
bushing
+0.150 +0.025 0.075 –
44 —
+0.100 - 0.020 0.170
Side clearance of track roller
8
(Each side) 0.53 – 1.06 1.5

Thickness of tread (at center of Overlay or
9
width of tread) 33 29.5 replace
— Quantity of oil 160 – 180 cc (Gear oil: G0140) —
10-18 PC78US-6
(13)
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

Outside diameter of Overlay or
1
tread 82 72 replace
2 Width of tread 100 — —

Interference between shaft and dimension Shaft Hole interference interference
3
bearing +0.009 0 -0.004 –
30 — Replace
- 0.004 - 0.010 0.019
Interference between roller and 0 +0.018 -0.031 –
4 62 —
bearing - 0.013 - 0.012 0.012
Overlay or
5 Thickness of tread
10 5 replace
— Quantity of oil 47 – 52 cc (Grease: ALVANIA EP-2) —
PC78US-6 10-19
(10)
MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Basic dimension Allowance Allowable limit

1 Wear of root diameter +1.0
433.004 421
- 2.0
2 Wear of tip diameter 483.7 ±2.0 472

Overlay or
3 Wear of dip width 28 — 23 replace
+0.5
4 Wear of root width 38 33
- 2.5
+0.475
5 Thickness of root 84.002 78
- 1.150
10-20 PC78US-6
(10)
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
CITY PAD SHOE, ROAD LINER, AND TRIPLE SHOE
1. City pad shoe (PC78US: STD, PC78UU: OPT)

Triple shoe (PC78US: OPT)
2. Road liner (PC78US: OPT, PC78UU: STD)
a Part P is the link on the press fitting side of bushing.
PC78US-6 10-21
(10)
Unit: mm

1 Link pitch
154.25 157.25 Reverse or
replace
2 Outside diameter of bushing 41.2 37.2
3 Height of link 74 70
Repair or replace
Thickness of link (Press fitting
4 20 16
part of bushing)
5 89
6 Shoe bolt pitch 73 Replace
7 57
8 Inside width 45
Link Overall Repair or replace

9 30
width
Width of
10 26.3
tread
11 Projection of pin 3
12 Projection of regular bushing 3.15
13 Overall length of pin 131
Overall length of bushing Adjust or replace

14 74.6
(Master bushing)
15 Thickness of bushing
8.4 4.4
16 Thickness of spacer —
17 Bushing 19.6 – 98.1 kN {2 – 10 ton}
Press fitting
18 Regular pin 49.0 – 117.7 kN {5 – 12 ton} —
pressure
(*1)
Master pin 39.2 – 78.5 kN {4 – 8 ton}
19
*1. For dry track.
10-22 PC78US-6
(10)
Unit: mm
Tightening torque
Retightening angle (deg.)
(Nm {kgm})
• City pad 117.7 ± 19.6
90 ± 10
a. Regular link • Triple {12 ± 2}
60 ± 10
117.7 ± 19.6
Shoe bolt • Road liner (Torque after retightening) Retighten
{12 ± 2}
20 Min. 343 Nm {35 kgm}
Tightening Retightening
Lower limit torque
torque angle (deg.)
b. Master link
— — —
Number of shoes
39 —
(Each side)
Basic Allowance Standard
Number of shoes dimension Shaft Hole interference
21
(Each side)
+0.214 +0.062
41 0.112 – 0.214
+0.174 0
Interference between regular pin +0.150 -0.198
22 24 0.198 – 0.400
and link 0 -0.250
Clearance between regular pin dimension Shaft Hole clearance
23
and bushing
+0.150 +0.830
24 0.180 – 0.830 Adjust or replace
0 +0.330
(*1) Interference between master pin dimension Shaft Hole interference
24 and link
+0.020 -0.198
24 0.178 – 0.270
-0.020 -0.250
(*1) Clearance between master pin dimension Shaft Hole clearance
25 and bushing -0.150 +0.630
24 0.380 – 0.880
-0.250 +0.230
26 Height of grouser Replace
Road liner 42 19
*1. For dry track.
PC78US-6 10-23
(10)
TRIPLE SHOE AND CITY PAD SHOE
Unit: mm

1 Height of grouser
20 12
2 Overall height of shoe 26 18
3 Thickness of plate 6 Overlay or

replace
4 14
5 Length of upper side of grouser 10
6 12
10-24 PC78US-6
(10)
RUBBER SHOE (OPTIONAL)
Unit: mm

1 Wear of lug height
30 5
2 Wear of roller guide 42 58 Replace
Basic dimension Allowance Allowable limit

Wear of meshing part of
3
sprocket 22.5 ±0.5 27
PC78US-6 10-25
(10)
MAINTENANCE STANDARD ARRANGEMENT OF HYDRAULIC COMPONENTS
ARRANGEMENT OF HYDRAULIC COMPONENTS

PC78US-6 Serial No.: 4001 – 6500
1. Bucket cylinder 10. Left work equipment PPC valve

2. Arm cylinder 11. Blade PPC valve (Blade specification)
3. Boom cylinder 12. Right work equipment PPC valve
4. Hydraulic tank 13. Center swivel joint
5. Control valve 14. Travel PPC valve
6. Swing motor 15. 3-spool solenoid valve
7. Hydraulic pump 16. Service PPC valve (Machine to which attach-
8. Oil cooler ments can be installed)
9. Travel motor 17. Blade cylinder (Blade specification)
10-26 PC78US-6
(10)

PC78US-6 10-27
(10)
PC78UU-6

2. Arm cylinder 12. Blade PPC valve
3. Offset cylinder 13. Right work equipment PPC valve
4. Boom cylinder 14. Center swivel joint
5. Hydraulic tank 15. Service PPC valve (Machine to which attach-
6. Control valve ments can be installed)
7. Swing motor 16. Travel PPC valve
8. Hydraulic pump 17. 6-spool solenoid valve
9. Oil cooler 18. Offset PPC valve
10. Travel motor 19. Blade cylinder
10-28 PC78US-6
(10)
MAINTENANCE STANDARD HYDRAULIC TANK AND OIL FILTER
HYDRAULIC TANK AND OIL FILTER

PC78US-6 Serial No.: 4001 – 6500
1. Hydraulic tank Specification

2. Sight gauge Tank capacity ( ) 80
3. Strainer
Quantity of oil in tank ( ) 64
4. Drain plug
5. Filter Bypass valve set 0.15 ± 0.03
6. Bypass valve pressure (kPa {kg/cm²}) {1.53 ± 0.3}
7. Oil filler cap Pressure valve cracking 38 ± 15
pressure (kPa {kg/cm²}) {0.39 ± 0.15}
Vacuum valve cracking 0–5
pressure (kPa {kg/cm²}) {0 – 0.05}
PC78US-6 10-29
(10)
MAINTENANCE STANDARD HYDRAULIC TANK AND OIL FILTER
1. Hydraulic tank Specification

2. Sight gauge Tank capacity ( ) 70
3. Strainer
Quantity of oil in tank ( ) 56
4. Drain plug
5. Filter Bypass valve set 0.15 ± 0.03
6. Bypass valve pressure (kPa {kg/cm²}) {1.53 ± 0.3}
7. Oil filler cap Pressure valve cracking 38 ± 15
pressure (kPa {kg/cm²}) {0.39 ± 0.15}
Vacuum valve cracking 0–5
pressure (kPa {kg/cm²}) {0 – 0.05}
10-30 PC78US-6
(10)
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

PC78US-6 (Blade-less specification)
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 2-stage travel speed selector solenoid valve E2: To 2-stage travel speed selector solenoid valve
DR1: To tank DR2: From travel motor drain port
1. Cover 3. Slipper seal

2. Rotor 4. Shaft
Unit: mm
Basic dimension Standard clearance Allowable clearance

Clearance between rotor and
5 Replace
shaft 60 0.056 – 0.105 0.111
PC78US-6 10-31
(10)
MAINTENANCE STANDARD CENTER SWIVEL JOINT
PC78US-6 (Blade specification)

PC78UU-6
A1: From right travel control valve A2: To right travel motor
B1: From right travel control valve B2: To right travel motor
C1: From left travel control valve C2: To left travel motor
D1: From left travel control valve D2: To left travel motor
E1: From blade control valve E2: To blade cylinder bottom
F1: From blade control valve F2: To blade cylinder head
G1: From 2-stage travel speed selector solenoid valve G2: To 2-stage travel speed selector solenoid valve
DR1: To tank DR2: From travel motor drain port
1. Cover 3. Slipper seal

2. Rotor 4. Shaft
Unit: mm
Basic dimension Standard clearance Allowable clearance

Clearance between rotor and
5 Replace
shaft 70 0.056 – 0.105 0.111
10-32 PC78US-6
(10)
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
A. From travel control valve

B. From travel control valve
D. To tank
P. From 2-stage travel speed selector solenoid
valve
PC78US-6 10-33
(10)
1. Check valve 14. Shaft

2. Counterbalance valve 15. Drive gear
3. Valve plate 16. Cover
4. Cylinder 17. Crankshaft
5. Brake piston 18. Drain plug
6. Plate 19. Driven gear
7. Disc 20. Pivot
8. Piston 21. Spindle
9. Swash plate 22. Floating seal
10. Regulator piston 23. End cover
11. RV gear 24. Regulator valve
12. RV gear 25. Check valve
13. Case
10-34 PC78US-6
(10)
Specification
Model GM09VN-E
Theoretical Hi 24.1
displacement (cm³/rev) Lo 36.3
Hi 3,211
Rated speed
Lo 2,154
Brake releasing pressure 0.47
(MPa {kg/cm²}) {4.8}
Speed changeover pressure 2.94
(MPa {kg/cm²}) {30}
Reduction ratio 66.5
Outline
1. Reduction gears 4. 2-stage travel speed changeover mechanism

The reduction gears consists of spur gear unit The 2-stage travel speed changing mechanism
(1a) and differential gear unit (1b) which uses consists of a changeover valve and a piston,
pericycloid gears and converts the high speed which change the displacement of the hydraulic
revolution of the hydraulic motor into low-speed motor to either of 2 stages.
and high-torque revolution.
5. Parking brake
2. Hydraulic motor The parking brake is a friction plate brake, which
The hydraulic motor is a swash plate-type axial is built as a part of the hydraulic motor.
piston motor, which converts the power of the
hydraulic oil sent from the hydraulic pump into
revolution.
3. Brake valve
The brake valve consists of various valves and
has functions of stopping the hydraulic motor
smoothly, preventing the hydraulic motor from
running away, and preventing generation of
abnormally high pressure when the hydraulic
motor is stopped suddenly.
PC78US-6 10-35
(10)
OPERATION
Operation of motor
At low speed (With swash plate angle at maximum)
1. 2-stage travel speed selector solenoid valve • Since 2-stage travel speed selector solenoid
2. Regulator valve valve (1) is de-energized, the hydraulic oil from
3. Spring the control pump does not flow into port Pi.
4. Check valve • Accordingly, regulator valve (2) is pressed to the
5. End cover left by spring (3).
6. Regulator piston • Under this condition, the main hydraulic oil from
7. Swash plate the control valve pushes check valve (4) and
8. Pump merge-divider valve flows into end cover (5) and then is shut off by
9. Travel control valve regulator valve (2).
10. Brake valve • The hydraulic oil in control chamber (a) flows
through passage (b) of regulator valve (2) into
the motor case.
• As a result, swash plate (7) is pushed toward the
maximum swash plate angle by the main hydrau-
lic oil in chamber (P) of the cylinder and the
motor capacity is increased to the maximum and
the travel speed lowers.
10-36 PC78US-6
(10)
At high speed (With swash plate angle at minimum)
1. 2-stage travel speed selector solenoid valve • If 2-stage travel speed selector solenoid valve
2. Regulator valve (1) is energized, the pilot pressure from the con-
3. Spring trol pump flows into port Pi and pushes regulator
4. Check valve valve (2) to the right.
5. End cover • Accordingly, the main hydraulic oil from the con-
6. Regulator piston trol valve flows through passage (c) of regulator
7. Swash plate valve (2) into control chamber (a) and pushes
8. Pump merge-divider valve regulator piston (6) to the left.
9. Travel control valve • As a result, swash plate (7) is pushed toward the
10. Brake valve minimum swash plate angle and the motor capac-
ity is decreased to the minimum and the travel
speed rises.
PC78US-6 10-37
(10)
Operation of brake valve Operation when oil is supplied

• The brake valve consists of check valves (1a) • If the travel lever is operated, the hydraulic oil
and (1b) and counterbalance valve spool (2) as from the control valve flows in port PA, pushes
shown in the following figure. valve (1a) open, and flows through motor input
port MA to motor outlet port MB.
At the same time, the hydraulic oil also flows
through orifice c of spool (2) to chamber D. If its
pressure becomes higher than the pressure of
spring (3), spool (2) is pushed to the left. As a
result, port MB is connected to port PB and the
motor outlet side opens and the motor starts rev-
olution.
Since port PA is connected to port E, too, the
hydraulic oil operates parking brake piston (4) to
release the parking brake force.
Function
• When the machine travels downhill, its speed
may become higher than the motor speed
because of its momentum. If the engine speed is
low at this time, the motor runs idle and the
machine runs away, and this situation is very
dangerous. The brake valve prevents this phe-
nomenon and limits the travel speed according
to the engine speed (pump discharge).
10-38 PC78US-6
(10)
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.
PC78US-6 10-39
(10)
Operation of parking brake When travel lever is set to neutral position

• If the travel lever is set to the neutral position, the
When travel lever is operated
hydraulic oil from the pump is shut off.
• If the travel lever is operated, the hydraulic oil
The hydraulic oil in chamber (a) of brake piston
from the pump moves spool (1) to the left and
(2) is drained into the case and piston (2) is
flows through port E into chamber A of brake pis-
pushed to the right by spring (5).
ton (2), then pushes brake piston (2) to the left.
As a result, plate (3) and disc (4) are pressed
As a result, the pressing force of spring (5) given
and the braking force is applied.
to plate (3) and disc (4) is lost, then plate (3) and
disc (4) are separated and the brake force is
released.
10-40 PC78US-6
(10)
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

PC78US-6
Boom cylinder
Arm cylinder
Bucket cylinder
PC78US-6 10-41
(10)
Blade cylinder
Unit: mm
Cylinder Basic Allowance Standard Allowable

name dimension Shaft Hole clearance clearance
-0.030 +0.250 0.085 –
Boom 65 0.654
-0.104 +0.055 0.354
Clearance between -0.030 +0.163 0.036 – Replace
1 Arm 60 0.567
piston rod and bushing -0.104 +0.006 0.267 bushing
-0.030 +0.163 0.036 –
Bucket 55 0.567
-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 –
Clearance between Arm 60 1.0
-0.100 +0.100 0.274
2 piston rod support
shaft and bushing -0.030 +0.174 0.130 –
Bucket 60 1.0
-0.100 +0.100 0.274
-0.030 +0.174 0.130 –
Blade 70 1.0 Replace
-0.104 +0.100 0.278
pin and
-0.030 +0.174 0.130 – bushing
Boom 65 1.0
-0.100 +0.100 0.274
-0.030 +0.174 0.130 –
Clearance between Arm 55 1.0
-0.100 +0.100 0.274
3 cylinder bottom support
Bucket 50 1.0
-0.100 +0.080 0.242
-0.030 +0.174 0.130 –
Blade 70 1.0
-0.104 +0.100 0.274
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}.
Tightening torque 2) Loosen to 0 Nm {0 kgm}.
4
of cylinder head Bucket 3) Tighten to 0.39 kNm {40 kgm}.
4) Control tightening of cylinder head by
turning angle (Turning distance: 3.5 – 4.5 mm). Retighten
Blade 1.030 ± 103.0 Nm {105 ± 10.5 kgm}
Boom 2.60 ± 0.26 kNm {265 ± 26.5 kgm} (2 Width across flats : 70 mm)
Tightening torque of Arm 2.65 ± 0.26 kNm {270 ± 27.0 kgm} (2 Width across flats : 65 mm)
5
cylinder piston Bucket 2.16 ± 0.22 kNm {220 ± 22.0 kgm} (2 Width across flats : 60 mm)
Blade 3.14 ± 0.31 kNm {320 ± 32.0 kgm} (2 Width across flats : 75 mm)
10-42 PC78US-6
(10)
PC78UU-6
Boom cylinder
Arm cylinder
Bucket cylinder
PC78US-6 10-43
(10)
Offset cylinder
Blade cylinder
10-44 PC78US-6
(10)
Unit: mm
Cylinder Basic Allowance Standard Allowable

name dimension Shaft Hole clearance clearance
-0.030 +0.271 0.105 –
Boom 70 0.675
-0.104 +0.075 0.375
-0.030 +0.262 0.097 –
Arm 65 0.666
Clearance between -0.104 +0.067 0.366 Replace
1
piston rod and bushing -0.030 +0.163 0.036 – bushing
Bucket 55 0.567
-0.104 +0.006 0.267
-0.030 +0.163 0.036 –
Offset 55 0.567
-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 65 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
-0.030 +0.174 0.130 –
Offset 55 1.0
-0.076 +0.100 0.250
Replace
-0.030 +0.174 0.130 –
Blade 70 1.0 pin and
-0.104 +0.100 0.278
bushing
-0.030 +0.174 0.130 –
Boom 65 1.0
-0.100 +0.100 0.274
-0.025 +0.142 0.105 –
Clearance between Bucket 50 1.0
-0.064 +0.080 0.206
cylinder bottom support
Offset 55 1.0
3 -0.076 +0.100 0.250
-0.030 +0.174 0.130 –
Blade 70 1.0
-0.104 +0.100 0.274
Clearance between trun-
-0.080 +0.124 0.130 –
nion support shaft bush- Arm 65 1.0
-0.126 +0.050 0.250
ing
Boom 980 ± 98.0 Nm {100 ± 10.0 kgm}
Arm 1,107 ± 116.7 Nm {113 ± 11.3 kgm}
Procedure 1) Tighten to 1.18 – 1.37 kNm {120 – 140 kgm}.
2) Loosen to 0 Nm {0 kgm}.
Tightening torque
4 Bucket 3) Tighten to 0.39 kNm {40 kgm}.
of cylinder head
4) Control tightening of cylinder head by
turning angle (Turning distance: 3.5 – 4.5 mm).
Offset 931 ± 93.1 Nm {95 ± 9.5 kgm} Retighten
Blade 1.030 ± 103.0 Nm {105 ± 10.5 kgm}
Boom 3.97 ± 0.40 kNm {405 ± 40.5 kgm} (2 Width across flats : 80 mm)
Arm 4.12 ± 0.41 kNm {420 ± 42.0 kgm} (2 Width across flats : 75 mm)
Tightening torque of
5 Bucket 2.16 ± 0.22 kNm {220 ± 22.0 kgm} (2 Width across flats : 60 mm)
cylinder piston
Offset 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (2 Width across flats : 55 mm)
Blade 3.14 ± 0.31 kNm {320 ± 32.0 kgm} (2 Width across flats : 75 mm)
PC78US-6 10-45
(10)
MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PC78US-6
10-46 PC78US-6
(10)
A: From control pump

B1: To PPC valve
B2: To 2nd travel speed selection valve
B3: To swing holding brake
T: To hydraulic tank
1. Swing holding brake solenoid valve

2. 2-stage travel speed selector solenoid valve
Solenoid valve
4. Coil (ON-OFF type)
5. Push pin
6. Valve spool
7. Return spring
8. Valve body
Control relief valve

9. Adjustment screw
10. Locknut
11. Guide
12. Return spring
13. Valve spool
PC78US-6 10-47
(14)
PC78UU-6
10-48 PC78US-6
(10)
A: From control pump

A4: From offset PPC valve "LEFT OFFSET"
A5: From left work equipment PPC valve "ARM IN"
A6: From right work equipment PPC valve "BOOM RAISE"
B1: To PPC valve
B2: To 2-stage travel speed selection valve
B4: To control valve "LEFT OFFSET"
B5: To control valve "ARM IN"
B6: To control valve "BOOM RAISE"
1. Boom raise stop EPC valve

2. Arm in stop EPC valve
3. Left offset stop EPC valve
Solenoid valve
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

20. Adjustment screw
21. Locknut
22. Guide
23. Return spring
24. Valve spool
PC78US-6 10-49
(14)
PPC LOCK SOLENOID VALVE

2-STAGE TRAVEL SPEED SELECTOR SOLENOID VALVE
SWING HOLDING BRAKE SOLENOID VALVE
Operation
When solenoid is de-energized (circuit is broken) When solenoid is energized (circuit is made)
• While a signal current does not flow from the • If a signal current flows from the PPC hydraulic
PPC hydraulic lock switch or travel speed boost lock switch or travel speed boost pedal to sole-
pedal, solenoid (1) is de-energized. noid (1), solenoid (1) is energized.
Accordingly, spool (2) is pressed up by spring • Accordingly, spool (2) is pushed down by push
(3). pin (4).
• Under this condition, port A is closed and the • Under this condition, the pilot hydraulic oil flows
pilot hydraulic oil does not flow into the actuator. through port A, spool (2), and port B into the
At the same time, the oil from the actuator is actuator.
drained through ports B and T into the tank. At the same time, port T is closed and the oil
does not flow into the tank.
10-50 PC78US-6
(10)
BOOM RAISE STOP EPC VALVE

ARM IN STOP EPC VALVE
LEFT OFFSET STOP EPC VALVE
Operation
When signal current is maximum (When coil is When signal current is reduced (When coil is
energized and circuit pressure is maximum) energized and circuit pressure is low)
• If the signal current flows from the controller into • If the signal current flowing from the controller
coil (1), coil (1) is energized. into coil (1) is reduced, coil (1) is still energized
At this time, the thrust of coil (1) is maximum. but its thrust is lowered in proportion to the signal
• As a result, spool (2) is pushed down by push pin current.
(3). • As a result, push pin (3) pushes down spool (2)
• Accordingly, all the pressurized oil from the PPC and the pressurized oil from port A flows to port
valve flows through port A, spool (2), and port B B.
to the control valve. • If the pressure in port B rises and the force
At this time, port T is closed and any oil does not applied to face "a" of spool (2) becomes larger
flow in the tank. than the thrust of coil (1), spool (2) is pushed up
and port A is disconnected from port B and con-
nected to port T.
• Accordingly, spool (2) moves up and down so
that the thrust of coil (1) will be balanced with the
pressure in port B.
• As a result, the circuit pressure between the
PPC valve and control valve is controlled in pro-
portion to the signal current.
PC78US-6 10-51
(10)
When signal current is 0 (When coil is de-ener- Control relief valve

gized and circuit cut out)
• If the signal current flowing from the controller • If the pressure of the hydraulic oil from the con-
into coil (1) becomes 0, coil (1) is deenergized. trol pump rises, the oil in port A pushes spool (1).
• As a result, spool (2) is pressed up by return The reaction force of spool (1) compresses
spring (4). spring (2) and moves spool (1) to the right to
• Accordingly, port A is closed and the pressurized open ports A and T to relieve the circuit.
oil from the PPC valve does not flow into the Set pressure: 3.1 MPa {32 kg/cm²}
control valve.
At this time, the oil from the control valve is
drained through ports B and T into the tank.
Signal current is 0 o increased o maximum

• The valve operates in the order of 3, 2, and 1
explained above.
10-52 PC78US-6
(10)
MAINTENANCE STANDARD MULTI-CONTROL VALVE
MULTI-CONTROL VALVE
(OPTIONAL)
(1) JIS Pattern (2) Backhoe Pattern

a Operation pattern selection drawing (Port names correspond to symbols in drawing)
PC78US-6 10-53
(10)
MAINTENANCE STANDARD ACCUMULATOR FOR BRAKER
ACCUMULATOR FOR BRAKER

(OPTIONAL)
1. Cap Specification
2. Core Type of gas Nitrogen Gas
3. Guard rubber
Gas volume ( ) 0.48
4. Lid
5. Plug Sealed gas pressure
0.1 {1} (at 80 °C)
6. Shell (MPa {kg/cm²})
Max. actuating pressure
6.86 {70}
(MPa {kg/cm²})
10-54 PC78US-6
(14)
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
PC78US-6 (with blade) Serial No.: 4001 – 5500
PC78UU-6 (with blade) Serial No.: 22832 – 23500
Model: LPD45 + 45
P1 : Pump discharge PD2 : Pump drain (plug)

P2 : Pump discharge PDA: Air bleeder
P3 : Gear pump discharge PEN: Control pressure pickup port
P4 : Pilot pump discharge PGS: Gear pump suction
P5 : Gear pump pressure pickup port PLS : LS pressure input (From control valve)
PD : Drain PPT : PTO oil filler
PM : PC mode changeover pressure pickup port PS1 : Main pump suction
P1T : Travel deviation adjustment orifice PEPC: EPC main pressure pickup port
P2T : Travel deviation adjustment orifice PPLS : Pump pressure input (From control valve)
PC78US-6 10-55
(10)
PC78US-6 (without blade) Serial No.: 4001 – 5500

Model: LPD45 + 45

P2 : Pump discharge PEN: Control pressure pickup port
P4 : Pilot pump discharge PLS : LS pressure input (From control valve)
PD2 : Pump drain (plug)
10-56 PC78US-6
(10)
T : Drain PD2 : Drain (Plug)

P1 : Pump discharge PDE: EPC drain
P2 : Pump discharge PEN: Control pressure input
P3 : Gear pump pressure input PPT : PTO oil filler
PD : Drain PS1 : Pump suction
PH : Pump shuttle PEPC: EPC main pressure pickup port
PAV : Pump average pressure
PC78US-6 10-57
(10)
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
10-58 PC78US-6
(10)
PDE: EPC drain

1. EPC valve
PC valve LS valve
T: Drain 4. Retainer PE: Control piston pressure 14. Seat
P3: Gear pump pressure input 5. Seat PH: Pump shuttle pressure 15. Spring
PH: Pump shuttle pressure 6. Spool PLS: LS pressure input 16. Seat
PAV: Pump average pressure 7. Sleeve PPL: PC valve output pressure 17. O-ring
PPL: PC valve output pressure 8. Piston PPLS: LS pump pressure input 18. Backup ring
PEPCOUT: EPC output pressure 9. Seal 19. Nut
10. Piston 12. Spool 20. Plug
2. Lever 11. Plug 13. Plug
3. Spring
PC78US-6 10-59
(10)
PC78US-6 (with blade) Serial No.: 5501 – 6500

PC78UU-6 (with blade) Serial No.: 23501 and up
Model: LPD45 + 45

10-60 PC78US-6
(10)
T : Drain PAV : Pump average pressure

P1 : Pump discharge PD2 : Drain (Plug)
P3 : Gear pump pressure input PEN: Control pressure input
P5 : Gear pump pressure pickup port PPT : PTO oil filler
PC78US-6 10-61
(10)
PC78US-6 (without blade) Serial No.: 5501 – 6500

Model: LPD45 + 45

10-62 PC78US-6
(10)
T : Drain PD3 : Drain

PH : Pump shuttle PS1 : Pump suction
PAV : Pump average pressure PEPC: EPC main pressure pickup port
PD2 : Drain (Plug)
PC78US-6 10-63
(10)
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
10-64 PC78US-6
(10)
PDE: EPC drain

1. EPC valve
PC valve LS valve
3. Spring
PC78US-6 10-65
(10)
PC78US-6 (with blade) Serial No.: 6501 and up

Model: LPD45 + 45

10-66 PC78US-6
(10)
T : Drain PAV : Pump average pressure

P1 : Pump discharge PD2 : Drain (Plug)
P3 : Gear pump pressure input PEN: Control pressure input
P5 : Gear pump pressure pickup port PPT : PTO oil filler
PC78US-6 10-67
(10)
PC78US-6 (without blade) Serial No.: 6501 and up

Model: LPD45 + 45

10-68 PC78US-6
(10)
T : Drain PD3 : Drain

PH : Pump shuttle PS1 : Pump suction
PAV : Pump average pressure PEPC: EPC main pressure pickup port
PD2 : Drain (Plug)
PC78US-6 10-69
(10)
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
10-70 PC78US-6
(10)
PDE: EPC drain

1. EPC valve
PC valve LS valve
3. Spring
PC78US-6 10-71
(10)
Function • The oil in each cylinder of cylinder block (7) can

• This pump converts the revolution and torque of be drawn and discharged through valve plate (8).
the engine transmitted to its shaft into hydraulic
energy and discharges hydraulic oil according to
the load.
• The discharge can be changed by changing the
swash plate angle.
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.
10-72 PC78US-6
(10)
Operation • If center line X of rocker cam (4) is in the direc-

tion of the axis of cylinder block (7) (Swash plate
1. Operation of pump angle = 0), the difference between volumes E
and F in cylinder block (7) is 0 and oil is not
• Shaft (1) and cylinder block (7) revolve together sucked or discharged (The swash plate angle is
and shoe (5) slides on plane A. As rocker cam not reduced to 0 actually, however).
(4) slants around ball (12) at this time, angle ( ) • In short, swash plate angle ( ) is in proportion to
between the center line X of rocker cam (4) and the discharge of the pump.
axis of cylinder block (7) changes. Angle ( ) is • The number of holes on cylinder block (7) is
called the swash plate angle. even 10 and every second one of them is fitted
to 2 grooves of valve plate (8). The quantity of
the oil equivalent to 5 pistons is discharged to
each of P1 and P2.
• If the angle between the center line X of rocker

cam (4) and the axis of cylinder block (7) is a,
plane A works as a cam for shoe (5).
• Accordingly, piston (6) slides inside cylinder
block (7) and makes difference between volumes
E and F in cylinder block (7) and the oil is drawn
and discharged by the difference.
• In short, if cylinder block (7) revolves and volume
of chamber E is reduced, the oil is discharged.
On the other hand, the volume of chamber F is
increased and the oil is sucked. (The figure
shows the end of suction process of chamber F
and the end of discharge process of chamber E.)
PC78US-6 10-73
(10)
2. Control of discharge LS valve

• If swash plate angle ( ) is increased, the differ- Function
ence between volumes E and F, or discharge Q, • The LS valve controls the discharge of the pump
is increased. Swash plate angle ( ) is changed according to the stroke of the control lever, or the
with servo piston (11). demand flow for the actuator.
• Servo piston (11) is reciprocated linearly by the • The LS valve calculates the demand flow for the
signal pressure of PC and LS valves. This linear actuator fr om differential pr essure PLS
motion is transmitted to rocker cam (4) sup- between inlet pressure PPLS and outlet pres-
ported on flange (2) through ball (12). Then, sure PLS of the control valve, and controls dis-
rocker cam (4) slides in the revolutionary direc- charge Q of the main pump.
tion. (PPLS is called the LS pump pressure, PLS
the LS pressure, and PLS the LS differential
pressure.)
• That is, the discharge of the pump is controlled
according to the demand flow for the actuator by
the following method; The pressure loss made
when the oil flows through the opening of the
control valve spool (LS differential pressure
PLS) is sensed and discharge Q of the pump is
so controlled that the pressure loss will be con-
stant.
• The LS valve receives main pump discharge
pressure PP, LS pump pressure (PPLS), and LS
pressure PLS. The relationship between the LS
differential pressure ( PLS) and pump dis-
charge Q changes as shown below.
10-74 PC78US-6
(10)
PC valve • At this time, ports F and G of the LS valve are

connected to each other. As a result, the pres-
Function sure in port J becomes drain pressure PT and
• The PC valve limits the oil flow to a certain level servo piston (6) moves to the left.
(according to the discharge pressure) even if the • Consequently, the pump discharge is increased.
stroke of the control valve is increased so that • As servo piston (6) moves, lever (1) moves to the
the horsepower absorbed by the pump will not left and spring (2) expands and its spring load is
exceed the engine horsepower, as long as pump decreased. Consequently, spool (3) moves to
discharge pressure PP is high. That is, the PC the left to break the connection of ports C and D,
valve performs constant-horsepower control. and then pump discharge ports B and C are con-
• In other words, the PC valve decreases the nected.
pump discharge when the load is increased and • As a result, the pressure in port C rises and the
the pump discharge pressure rises and piston pressure is increased and servo piston (6)
increases it when the pump discharge pressure stops moving to the left.
lowers.
• This pump has 2 discharge openings and the (3) When pump pressure PAVE is high
average of discharge pressures P1 and P2 at • The pressure of spool (4) is increased and spool
those openings is sensed. (3) is a little to the left (Fig. 2 and Fig. 5). At this
The average of P1 and P2 is called the PAVE. time, ports C and B are connected to each other
The relationship between this average and pump and the pressure in the LS valve is pump pres-
discharge (discharge from the 2 discharge open- sure PP.
ings) is shown below. • At this time, ports F and G of the LS valve are
connected to each other. As a result, the pres-
sure in port J becomes pump pressure PP and
servo piston (6) moves to the right.
• Consequently, the pump discharge is decreased.
• As servo piston (6) moves, lever (1) moves to the
right and spring (2) is compressed and its spring
load is increased. Consequently, spool (3)
moves to the right to break the connection of
ports C and B, and then drain pressure ports D
and C are connected.
• As a result, the pressure in port C lowers and the
piston pressure is decreased and servo piston
(6) stops moving to the right.
• Accordingly, the stopping position (= pump dis-
charge) of servo piston (6) is decided by the
Operation position where the pressure caused by pressure
1. PC78UU, 78US-6 (With blade) PP applied to spool (4) is balanced with the force
of spring (2) applied through spool (3) (Fig. 3 and
(1) Function of spring Fig. 6).
• The spring load of spring (2) at the PC valve is
decided by the position of the swash plate. (4) When swing gear pump pressure rises/low-
• If servo piston (6) moves to the right, spring (2) is ers
compressed through lever (1) and its spring load • The pressure of spool (4) changes and the pump
changes. The spring constant of this spring discharge changes similarly to the case where
changes to 2 levels. the PAVE rises/lowers.
• The PC-EPC valve changes the output pressure
(2) When pump pressure PAVE is low according to the input current from the controller,
• The pressure of spool (4) is decreased and spool then the pressure of spool (5) changes and the
(3) is a little to the right (Fig. 1 and Fig. 4). At this pump discharge changes similarly to the case
time, ports C and D are connected to each other where the PAVE rises/lowers.
and the pressure in the LS valve is drain pres-
sure PT.
PC78US-6 10-75
(10)
When load is light
When load is heavy
10-76 PC78US-6
(10)
When balanced
2. PC78US-6 (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
PC78US-6 10-77
(10)
When load is heavy
When balanced
10-78 PC78US-6
(10)
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline
a The control valves of the following types are set.
PC78US-6 • Blade-less, without service valve

• Blade-less, with 1 service valve
• Blade-less, with 2 service valve
• With blade, without service valve
• With blade and 1 service valve
• With blade and 2 service valve
PC78UU-6 • Without service valve

• 1 service valve
• 2 service valve
a Since each service valve is of add-on type, it can

be added or removed later.
1. PC78US-6 blade-less and with 1 service

valve
(1) Outside view
A1: To swing motor PT: To travel pressure switch

A2: To left travel motor TB: To tank
A3: To right travel motor TC: To oil cooler
A4: To boom cylinder bottom TS: To tank
A5: To arm cylinder head PA1: From swing right PPC valve
A6: To bucket cylinder head PA2: From left travel reverse PPC valve
A7: To attachment 1 PA3: From right travel reverse PPC valve
B1: To swing motor PA4: From boom raise PPC valve
B2: To left travel motor PA5: From arm out PPC valve
B3: To right travel motor PA6: From bucket dump PPC valve
B4: To boom cylinder head PA7: From service 1 PPC valve
B5: To arm cylinder bottom PB1: From swing left PPC valve
B6: To bucket cylinder bottom PB2: From left travel forward PPC valve
B7: To attachment 1 PB3: From right travel forward PPC valve
BP: From boom RAISE PPC valve PB4: From boom lower PPC valve
LS: To pump LS valve (LS pressure input) PB5: From arm in PPC valve
P1: From main pump PB6: From bucket curl PPC valve
P2: From main pump PB7: From service 1 PPC valve
PP: To pump LS valve (Pump pressure input) TSW: To swing motor
PS: From swing holding brake reset solenoid valve
10-80 PC78US-6
(10)
(PC78US-6 blade-less and with 1 service valve)
PC78US-6 10-81
(10)
(2) Sectional view

Serial No.: 4001 – 6500
(1/4)
10-82 PC78US-6
(10)
Serial No.: 6501 and up

(1/4)
PC78US-6 10-83
(10)
1. Suction valve (Left travel) 29. Pressure compensation valve F (Swing)

2. Suction valve (Right travel) 30. Pressure compensation valve F (Left travel)
3. Main relief valve 31. Pressure compensation valve F (Right travel)
4. Suction valve (Boom bottom) 32. Pressure compensation valve F (Boom)
5. Suction valve (Arm head) 33. Pressure compensation valve F (Arm)
6. Suction valve (Bucket head) 34. Pressure compensation valve F (Bucket)
7. Suction valve (Attachment) 35. Pressure compensation valve F (Attachment)
8. Safety valve 36. Pump pressure pickup plug (P2)
9. Suction valve (Attachment) 37. LS pressure pickup plug (LS3)
10. Suction valve (Bucket bottom) 38. Pressure compensation valve R (Attachment)
11. Suction valve (Arm bottom) 39. Pressure compensation valve R (Bucket)
12. Suction valve (Boom head) 40. Pressure compensation valve R (Arm)
13. Lift check valve 41. Pressure compensation valve R (Boom)
14. Cooler bypass valve 42. LS bypass plug (LS2)
15. Suction valve (Right travel) 43. Logic valve
16. Suction valve (Left travel) 44. Spool (Pump merge-divider valve)
17. Spool (Swing) 45. Pressure compensation valve R (Right travel)
18. Spool (Left travel) 46. Pressure compensation valve R (Left travel)
19. Spool (Right travel) 47. Pressure compensation valve R (Swing)
20. Unload valve (P1) 48. Check valve (Attachment)
21. Unload valve (P2) 49. Check valve (Bucket)
22. Spool (Boom) 50. Check valve (Arm)
23. Spool (Arm) 51. Boom hydraulic drift prevention valve
24. Spool (Bucket) 52. Check valve (Boom bottom)
25. Spool (Attachment)
26. LS pressure pickup plug (LS2) F: Flow control valve
27. LS pressure pickup plug (LS1) R: Pressure reducing valve
28. Spool (LS selector)
10-84 PC78US-6
(10)
Unit: mm
Basic dimensions Allowable limit

Free length x
Lift check Outside Free length
53 length load load
valve spring diameter
59.6 N 47.7 N
58.1 X 17.0 36 —
{5.8 kg} {4.64 kg}
73.5 N 58.8 N
54 Cooler bypass valve spring 34.5 X 17.7 25 —
{7.5 kg} {6.0 kg}
28.3 N 22.6 N
55 Spool return spring (Swing) 29.2 X 17.5 28.5 —
{2.89 kg} {2.31 kg}
22.6 N 18.1 N
56 Spool return spring (Travel) 29.0 X 17.5 28.5 —
{2.3 kg} {1.84 kg}
43.1 N 34.5 N
57 Spool return spring (Arm in) 41.1 X 19.3 40.5 —
{4.4 kg} {3.52 kg}
Spool return spring 34.3 N 27.4 N
58 41.1 X 19.3 40.5 —
(Work equipment) {3.5 kg} {2.8 kg}
54.9 N 43.9 N
59 Spool return spring (Arm out) 42.3 X 19.2 40.5 —
{5.6 kg} {4.49 kg}
129 N 103 N
60 Unload valve spring 40.9 X 15.1 33.5 — If damaged or
{13.2 kg} {10.6 kg}
deformed,
11.2 N 8.96 N replace spring.
61 LS selector valve spring 16.6 X 13.0 13 —
{1.14 kg} {0.91 kg}
Pressure compensation valve 7.45 N 5.96 N
62 15.4 X 6.0 8 —
spring {0.76 kg} {0.61 kg}
Pump merge-divider valve 49.0 N 39.2 N
63 33.2 X 14.2 22.5 —
spool return spring {5.0 kg} {4.0 kg}
Pressure compensation valve 27.7 N 22.2 M
64 30.9 X 5.2 20 —
spring {2.82 kg} {2.26 kg}
65 28.0 X 14.4 14.5 —
spring {1.4 kg} {1.12 kg}
66 33.4 X 14.4 21.5 —
67 20.0 X 8.4 12 —
68 23.0 X 8.4 15 —
3.92 N 3.14 N
69 Check valve spring 12.3 X 11.4 10.5 —
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
70 Check valve spring 27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
PC78US-6 10-85
(10)
Serial No.: 4001 – 6500

(2/4)
10-86 PC78US-6
(10)

(2/4)
PC78US-6 10-87
(10)
1. Spool (LS selector)

2. Spool (Swing)
3. Pressure compensation valve R (Swing)
4. Pressure compensation valve F (Swing)
5. Pressure compensation valve F (Left travel)
6. Suction valve (Left travel)
7. Spool (Left travel)
9. Pressure compensation valve R (Left travel)
10. LS bleed valve
11. Pressure compensation valve F (Right travel)
12. Suction valve (Right travel)
13. Spool (Right travel)
15. Pressure compensation valve R (Right travel)
16. Travel junction valve, LS bleed valve
17. Pump pressure pickup plug (P1)
18. Spool (Pump merge-divider valve)
19. Unload valve (P1)
20. Check valve (P1)
21. Cooler bypass valve
22. LS pressure pickup plug (LS1)
23. LS bypass plug (LS1)
24. Logic valve
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Free length x
Outside Free length
25 Check valve spring length load load
diameter
If damaged or
1.96 N 1.57 N
21.9 X 5.0 15.8 — deformed,
{0.2 kg} {0.16 kg}
replace spring.
15.7 N 12.6 N
26 Travel junction valve spring 19.3 X 7.5 14 —
{1.6 kg} {1.28 kg}
2.26 N 1.81 N
{0.23 kg} {0.18}
10-88 PC78US-6
(10)
(3/4)
10-90 PC78US-6
(10)

2. Main relief valve
3. Check valve (P2)
4. Lift check valve
7. Pressure compensation valve F (Boom)
8. Suction valve (Boom bottom)
9. Boom hydraulic drift prevention valve
10. Suction valve (Boom head)
11. Spool (Boom)
12. Pressure compensation valve R (Boom)
13. Suction valve (Arm head)
14. Spool (Arm)
15. Suction valve (Arm bottom)
16. Pressure compensation valve R (Arm)
17. Pressure compensation valve F (Arm)
18. Suction valve (Bucket head)
19. Spool (Bucket)
20. Suction valve (Bucket bottom)
21. Pressure compensation valve R (Bucket)
22. Pressure compensation valve F (Bucket)
23. Suction valve (Attachment)
26. Pressure compensation valve R (Attachment)
27. Pressure compensation valve F (Attachment)
29. Safety valve
30. Pressure release plug

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
2.26 N 1.81 N
13.0 X 6.5 9 — deformed,
{0.23 kg} {0.18}
replace spring.
Hydraulic drift prevention valve 11.2 N 8.96 N
33 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
34 13.0 X 8.8 7.7 —
PC78US-6 10-91
(10)
(4/4)
10-92 PC78US-6
(10)

2. LS bleed valve
3. Check valve (Boom head)
4. Logic valve
Unit: mm

Free length x
Outside Free length
5 Check valve spring length load load If damaged or
diameter
deformed,
27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
5.5 N 4.4 N
6 Logic valve spring 11.0 X 6.2 9.5 —
{0.56 kg} {0.45 kg}
PC78US-6 10-93
(10)
2. PC78US-6 with blade and 1 service

valve
(1) Outside view
A1: To blade cylinder head

A2: To swing motor
A3: To left travel motor
A4: To right travel motor
A5: To offset cylinder head
A6: To boom cylinder bottom
A7: To arm cylinder head
A8: To bucket cylinder head
B1: To blade cylinder bottom
B2: To swing motor
B3: To left travel motor
B4: To right travel motor
B5: To offset cylinder bottom
B6: To boom cylinder head
B7: To arm cylinder bottom
B8: To bucket cylinder bottom
BP: From boom RAISE PPC valve
LS: To pump LS valve (LS pressure input)
P1: From main pump
P2: From main pump
P3: From gear pump
PP: To pump LS valve (LS pressure input)
PT: To travel pressure switch
TB: To tank
TC: To oil cooler
TS: To tank
PA1: From blade raise PPC valve
PA2: From swing right PPC valve
PA3: From left travel reverse PPC valve
PA4: From right travel reverse PPC valve
PA5: From offset right PPC valve
PA6: From boom raise PPC valve
PA7: From arm out PPC valve
PA8: From bucket dump PPC valve
PB1: From blade lower PPC valve
PB2: From swing left PPC valve
PB3: From left travel forward PPC valve
PB4: From right travel forward PPC valve
PB5: From offset left PPC valve
PB6: From boom lower PPC valve
PB7: From arm in PPC valve
PB8: From bucket curl PPC valve
TSW: To swing motor
10-94 PC78US-6
(10)
(PC78US-6 with blade and 1 service valve)
PC78US-6 10-95
(10)
(2) Sectional view

Serial No.: 4001 – 6500
(1/4)
10-96 PC78US-6
(10)

(1/4)
PC78US-6 10-97
(10)
1. Safety-suction valve (Blade head) 31. LS pressure pickup plug (LS1)

2. Suction valve (Left travel) 32. Pressure compensation valve F (Left travel)
3. Suction valve (Right travel) 33. Pressure compensation valve F (Right travel)
4. Main relief valve 34. Pressure compensation valve F (Boom)
5. Suction valve (Boom bottom) 35. Pressure compensation valve F (Arm)
6. Suction valve (Arm head) 36. Pressure compensation valve F (Bucket)
7. Suction valve (Bucket head) 37. Pressure compensation valve F (Attachment)
8. Suction valve (Attachment) 38. Pump pressure pickup plug (P2)
9. Safety valve 39. LS pressure pickup plug (LS3)
10. Suction valve (Attachment) 40. Pressure compensation valve R (Attachment)
11. Suction valve (Bucket bottom) 41. Pressure compensation valve R (Bucket)
12. Suction valve (Arm bottom) 42. Pressure compensation valve R (Arm)
13. Suction valve (Boom head) 43. Pressure compensation valve R (Boom)
17. Suction valve (Blade bottom) 47. Pressure compensation valve R (Right travel)
18. Gear pump relief valve 48. Pressure compensation valve R (Left travel)
19. Spool (Boom raise merge) 49. Check valve (Swing)
20. Spool (Blade) 50. LS bleed valve
21. Spool (Swing) 51. Travel junction valve, LS bleed valve
22. Spool (Left travel) 52. Check valve (Attachment)
23. Spool (Right travel) 53. Check valve (Bucket)
24. Unload valve (P1) 54. Check valve (Arm)
25. Unload valve (P2) 55. Boom hydraulic drift prevention valve
26. Spool (Boom) 56. Check valve (Boom bottom)
27. Spool (Arm) 57. Check valve (Blade)
28. Spool (Bucket)
29. Spool (Attachment) F: Flow control valve
30. LS pressure pickup plug (LS2) R: Pressure reducing valve
10-98 PC78US-6
(10)
Unit: mm

Free length x
Cooler bypass Outside Free length
58 length load load
73.5 N 58.8 N
34.5 X 17.7 25 —
{7.5 kg} {6.0 kg}
59 29.0 X 18.3 27.5 —
(Blade, swing) {9.1 kg} {7.28 kg}
22.6 N 18.1 N
60 Spool return spring (Travel) 29.0 X 17.5 28.5 —
{2.3 kg} {1.84 kg}
43.1 N 34.5 N
61 Spool return spring (Arm in) 41.1 X 19.3 40.5 —
{4.4 kg} {3.52 kg}
62 41.1 X 19.3 40.5 —
54.9 N 43.9 N
63 Spool return spring (Arm out) 42.3 X 19.2 40.5 —
{5.6 kg} {4.49 kg}
129 N 103 N
64 Unload valve spring 40.9 X 15.1 33.5 —
{13.2 kg} {10.6 kg}
Boom RAISE merge valve 11.2 N 8.96 N
65 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
If damaged or
Pump merge-divider valve 49.0 N 39.2 N
66 33.2 X 14.2 22.5 — deformed,
replace spring.
67 30.9 X 5.2 20 —
spring {2.82 kg} {2.26 kg}
68 28.0 X 14.4 14.5 —
69 33.4 X 14.4 21.5 —
70 20.0 X 8.4 12 —
2.26 N 1.81 N
{0.23 kg} {0.18}
3.92 N 3.14 N
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
{0.4 kg} {0.32 kg}
1.96 N 1.57 N
{0.2 kg} {0.16 kg}
136.41 N 109 N
75 Spool return spring (Boom) 41.13 X 19.3 38.5 —
{13.91 kg} {11.1 kg}
89.5 N 71.6 N
76 Spool return spring (Blade) 29.01 X 18.3 27.5 —
{9.1 kg} {7.3 kg}
PC78US-6 10-99
(10)
Serial No.: 4001 – 6500

(2/4)
10-100 PC78US-6
(10)

(2/4)
PC78US-6 10-101
(10)
1. Spool (Boom raise merge)

2. Gear pump relief valve
3. Safety-suction valve (Blade head)
4. Suction valve (Blade bottom)
5. Spool (Blade)
6. Check valve (Blade)
7. Spool (Swing)
8. Check valve (Swing)
14. LS bleed valve
27. Logic valve

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
1.96 N 1.57 N
21.9 X 5.0 15.8 — deformed,
{0.2 kg} {0.16 kg}
replace spring.
15.7 N 12.6 N
{1.6 kg} {1.28 kg}
2.26 N 1.81 N
{0.23 kg} {0.18}
10-102 PC78US-6
(10)
(3/4)
10-104 PC78US-6
(10)
1. Logic valve
4. Check valve (P2)
10. Spool (Boom)
14. Spool (Arm)
19. Spool (Bucket)
26. Pressure compensation valve R (Attachment)
27. Pressure compensation valve F (Attachment)

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
2.26 N 1.81 N
13.0 X 6.5 9 — deformed,
{0.23 kg} {0.18}
replace spring.
29 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
30 13.0 X 8.8 7.7 —
PC78US-6 10-105
(10)
(4/4)
10-106 PC78US-6
(10)

2. Safety valve
5. LS bleed valve
9. Logic valve
Unit: mm

Free length x
Outside Free length
diameter
deformed,
27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
5.5 N 4.4 N
{0.56 kg} {0.45 kg}
PC78US-6 10-107
(10)
3. PC78UU-6 without service valve

(1) Outside view
A1: To blade cylinder head

A2: To swing motor
A3: To left travel motor
A4: To right travel motor
A5: To offset cylinder head
A6: To boom cylinder bottom
A7: To arm cylinder head
A8: To bucket cylinder head
B1: To blade cylinder bottom
B2: To swing motor
B3: To left travel motor
B4: To right travel motor
B5: To offset cylinder bottom
B6: To boom cylinder head
B7: To arm cylinder bottom
B8: To bucket cylinder bottom
BP: From boom RAISE PPC valve
LS: To pump LS valve (LS pressure input)
P1: From main pump
P2: From main pump
P3: From gear pump
PP: To pump LS valve (Pump pressure input)
PT: To travel pressure switch
TB: To tank
TC: To oil cooler
TS: To tank
PA1: From blade raise PPC valve
PA2: From swing right PPC valve
PA3: From left travel reverse PPC valve
PA4: From right travel reverse PPC valve
PA5: From offset right PPC valve
PA6: From boom raise PPC valve
PA7: From arm out PPC valve
PA8: From bucket dump PPC valve
PB1: From blade lower PPC valve
PB2: From swing left PPC valve
PB3: From left travel forward PPC valve
PB4: From right travel forward PPC valve
PB5: From offset left PPC valve
PB6: From boom lower PPC valve
PB7: From arm in PPC valve
PB8: From bucket curl PPC valve
TSW: To swing motor
10-108 PC78US-6
(10)
(PC78UU-6 without service valve)
PC78US-6 10-109
(10)
(2) Sectional view

(1/4)
10-110 PC78US-6
(10)
1. Safety-suction valve (Blade head) 30. LS pressure pickup plug (LS1)

2. Suction valve (Left travel) 31. Pressure compensation valve F (Left travel)
3. Suction valve (Right travel) 32. Pressure compensation valve F (Right travel)
4. Suction valve (Offset head) 33. Pressure compensation valve F (Offset)
5. Main relief valve 34. Pressure compensation valve F (Boom)
6. Suction valve (Boom bottom) 35. Pressure compensation valve F (Arm)
7. Suction valve (Arm head) 36. Pressure compensation valve F (Bucket)
8. Suction valve (Bucket head) 37. Pump pressure pickup plug (P2)
9. Safety valve 38. LS pressure pickup plug (LS3)
10. Suction valve (Bucket bottom) 39. Pressure compensation valve R (Bucket)
11. Suction valve (Arm bottom) 40. Pressure compensation valve R (Arm)
12. Suction valve (Boom head) 41. Pressure compensation valve R (Boom)
16. Suction valve (Blade bottom) 45. Pressure compensation valve R (Offset)
17. Gear pump relief valve 46. Pressure compensation valve R (Right travel)
18. Spool (Boom raise merge) 47. Pressure compensation valve R (Left travel)
19. Spool (Blade) 48. Check valve (Blade)
20. Spool (Swing) 49. Check valve (Swing)
21. Spool (Left travel) 50. LS bleed valve
22. Spool (Right travel) 51. Travel junction valve, LS bleed valve
23. Spool (Offset) 52. Check valve (Bucket)
24. Unload valve (P1) 53. Check valve (Arm)
25. Unload valve (P2) 54. Check valve (Boom bottom)
26. Spool (Boom)
27. Spool (Arm) F: Flow control valve
28. Spool (Bucket) R: Pressure reducing valve
PC78US-6 10-111
(10)
Unit: mm

Free length x
Cooler bypass Outside Free length
55 length load load
73.5 N 58.8 N
34.5 X 17.7 25 –
{7.5 kg} {6.0 kg}
56 29.0 X 18.3 27.5 –
(Blade, swing) {9.1 kg} {7.28 kg}
57 29.0 X 17.5 28.5 –
(Travel, offset) {2.3 kg} {1.84 kg}
58 41.1 X 19.3 40.5 –
54.9 N 43.9 N
59 Spool return spring (Arm out) 42.3 X 19.2 40.5 –
{5.6 kg} {4.48 kg}
129 N 103 N
60 Unload valve spring 40.9 X 15.1 33.5 –
{13.2 kg} {10.6 kg}
Boom RAISE merge valve 11.2 N 8.96 N
61 16.6 X 13.0 13 – If damaged or
spring {1.14 kg} {0.91 kg}
deformed,
Pump merge-divider valve 49.0 N 39.2 N replace spring.
62 33.2 X 14.2 22.5 –
63 30.9 X 5.2 20 –
spring {2.82 kg} {2.26 kg}
64 28.0 X 14.4 14.5 –
65 33.4 X 14.4 21.5 –
66 20.0 X 8.4 12 –
2.26 N 1.81 N
67 Check valve spring 13.0 X 6.5 9 –
{0.23 kg} {0.18}
3.92 N 3.14 N
68 Check valve spring 27.2 X 6.9 22 –
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
69 Check valve spring 12.3 X 11.4 10.5 –
{0.4 kg} {0.32 kg}
1.96 N 1.57 N
70 Check valve spring 21.9 X 5.0 15.8 –
{0.2 kg} {0.16 kg}
10-112 PC78US-6
(10)
(2/4)
10-114 PC78US-6
(10)
1. Spool (Boom raise merge)

3. Safety-suction valve (Blade head)
4. Suction valve (Blade bottom)
5. Spool (Blade)
6. Check valve (Blade)
7. Spool (Swing)
8. Check valve (Swing)
13. LS bleed valve
21. Suction valve (Offset head)
22. Spool (Offset)
23. Pressure compensation valve R (Offset)
24. Pressure compensation valve F (Offset)

Unit: mm

Free length x
Outside Free length
diameter
deformed,
21.9 X 5.0 15.8 —
{0.2 kg} {0.16 kg}
15.7 N 12.6 N
{1.6 kg} {1.28 kg}
PC78US-6 10-115
(10)
(3/4)
10-116 PC78US-6
(10)

2. Check valve (P1)
5. Logic valve
17. Spool (Boom)
21. Spool (Arm)
26. Spool (Bucket)

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
2.26 N 1.81 N
13.0 X 6.5 9 — deformed,
{0.23 kg} {0.18}
replace spring.
31 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
32 13.0 X 8.8 7.7 —
PC78US-6 10-117
(10)
(4/4)
10-118 PC78US-6
(10)
1. Safety valve
5. LS bleed valve
9. Logic valve

Unit: mm

Free length x
Outside Free length
diameter
deformed,
27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
5.5 N 4.4 N
{0.56 kg} {0.45 kg}
PC78US-6 10-119
(10)
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
10-120 PC78US-6
(10)
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 PLS (the difference between pump (dis-
charge) pressure PP and control valve outlet port
LS pressure PLS) load pressure of actuator) is
constant.
(LS pressure PLS=Pump discharge pressure
PP–LS pressure PLS)
• If LS differential pressure PLS becomes lower

than the set pressure of the LS valve (when the
actuator load pressure is high), the pump swash
plate moves towards the maximum position; if
the set pressure becomes higher than the set
pressure of the LS valve (when the actuator load
pressure is low), the pump swash plate moves
towards the minimum position.
a For details of the operation, see HYDRAULIC
PUMP.
PC78US-6 10-121
(10)
2. Pressure compensation control between the upstream (inlet port) and down-
• A pressure compensation valve is installed to the stream (outlet port) the same, regardless of the
inlet port side of the control valve spool to bal- size of the load (pressure). In this way, the flow
ance the load. of oil from the pump is divided (compensated) in
When to actuators are operated together, this proportion to the area of openings S1 and S2 of
valve acts to make pressure difference P each valve when it is operated.
10-122 PC78US-6
(10)
OPERATION FOR EACH FUNCTION AND VALVE

Hydraulic circuit diagram and name of valves
(PC78US-6 Blade-less, 1 service valve)
10-124 PC78US-6
(10)

Set pressure: LS pressure + 2.45 MPa
{25 kg/cm2}
{25 kg/cm2}
Set pressure: 26.5 MPa {270 kg/cm2}
4. Lift check valve
6. Suction valve
7. Safety valve
8. Pressure compensation valve
9. LS bypass plug (P1)
11. LS selector valve
12. LS bleed valve
14. Logic valve
PC78US-6 10-125
(10)
10-126 PC78US-6
(10)

{25 kg/cm2}
{25 kg/cm2}
6. Suction valve
7. Safety-suction valve
8. Safety valve
12. Boom raise merge valve
13. LS bleed valve
15. Logic valve
PC78US-6 10-127
(10)
(PC78US-6 without service valve)
10-128 PC78US-6
(10)

{25 kg/cm2}
{25 kg/cm2}
6. Suction valve
7. Safety-suction valve
8. Safety valve
12. Boom raise merge valve
13. LS bleed valve
15. Logic valve
PC78US-6 10-129
(10)
Unload valve
1. When control valve is at HOLD
Function • When the control valve is at HOLD, LS pres-

• When the control valve is at HOLD, pump dis- sures PLS1 and PLS2 are not generated, so
charge amount Q discharged by the minimum only pump discharge pressures PP1 and PP2
swash plate angle is released to the tank circuit. act, and PP1 and PP2 are set by only the load of
At this time, pump discharge pressure PP1/PP2 spring (2).
is set at 2.45 MPa {25.0 kg/cm2} by spring (2) in • As pump discharge pressure PP1/PP2 rises and
the valve. (LS pressure PLS1/PLS2: 0 MPa {0 reaches the load of spring (2) (2.45 MPa {25.0
kg/cm2}) kg/cm2}), spool (1) is moved to the right. Pump
• Since the pump merge-divider valve is at the discharge pressures PP1 and PP2 are con-
merge position, pump discharge pressures PP1 nected to tank circuit T through the cut of spool
and PP2 are merged. LS pressures PLS1, (1)
PLS2, and PLS3 are also merged. • As a result, pump discharge pressure PP1/PP2
is set to 2.45 MPa {25.0 kg/cm2}.
Operation
• Pump discharge pressures PP1 and PP2 are
acting on the left end of unload spool (1) and LS
pressures PLS1 and PLS2 are acting on the
right end. (PP1 = PP2, PLS1 = PLS2)
10-130 PC78US-6
(10)
2. During fine control of work equipment valve

Work equipment valve: Swing (PC78US-6 with-
out blade), boom, arm, bucket, or attachment.
Function Operation
• During fine control of the work equipment valve, • When fine control is carried out on the work
when the demand flow for the actuator is within equipment valve, LS pressures PLS1 and PLS2
the amount discharged by the minimum swash are generated and act on the right end of spool
plate angle of the pump, pump discharge pres- (1) (PP1 = PP2, PLS1 = PLS2). When this hap-
sure PP1/PP2 is set to LS pressure PLS1/PLS2 pens, the area of the opening of the work equip-
+ 2.45 MPa {25.0 kg/cm2}. When the difference ment valve spool is small, so LS pressures PLS1
between pump discharge pressure PP1/PP2 and and PLS2 are very different from pump dis-
LS pressure PLS1/PLS2 reaches the load of charge pressures PP1 and PP2.
spring (2) (2.45 MPa {25.0 kg/cm 2 }), unload • When the difference between pump discharge
spool (1) opens, so LS differential pressure pressure PP1/PP2 and LS pressure PLS1/PLS2
PLS 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, nected to tank circuit T.
PLS2, 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 PLS becomes 2.45 MPa
{25.0 kg/cm2}.
PC78US-6 10-131
(10)
3. When work equipment valve is operated

out blade), boom, arm, bucket, or attachment
Function • For this reason, the difference between pump

• When any work equipment valve is operated if discharge pressure PP1/PP2 and LS pressure
the demand flow for the actuator becomes PLS1/PLS2 does not reach the load of spring (2)
greater than the pump discharge from the mini- (2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
mum swash plate angle, the oil flow to tank cir- to the left by spring (2).
cuit T is cut off, and all pump discharge amount • As a result, pump discharge pressures PP1 and
Q flows to the actuator circuit. PP2 and tank circuit T are shut off, and all pump
• Since the pump merge-divider valve is at the discharge amount Q flows to the actuator circuit.
merge position, pump discharge pressures PP1
and PP2 are merged. LS pressures PLS1,
PLS2, and PLS3 are also merged.
Operation
• When any work equipment valve is operated for
a long stroke, LS pressures PLS1 and PLS2 are
generated and act on the right end of unload
spool (1) (PP1 = PP2, PLS1 = PLS2). When this
happens, the area of the opening of the work
equipment valve spool is large, so LS pressures
PLS1 and PLS2 are not so different from pump
discharge pressures PP1 and PP2.
10-132 PC78US-6
(10)
4. During fine control of both travel valves
Function Operation
• During fine control of both travel valves, when • When fine control is carried out on both travel
the demand flow is below the maximum pump valves, LS pressures PLS1 and PLS2 are gener-
discharge amount, pump discharge pressure ated and act on the right end of spool (1) (PP1,
PP1/PP2 is set to LS pressure PLS1/PLS2 + PP2, PLS1, and PLS2 are separated).
2.45 MPa {25.0 kg/cm2}. • When this happens, the area of the opening of
• When the difference between pump discharge both travel valve spools is small, so LS pres-
pressure PP1/PP2 and LS pressure PLS1/PLS2 sures PLS1 and PLS2 are very different from
reaches the load of spring (2) (2.45 MPa {25.0 pump discharge pressures PP1 and PP2.
kg/cm2}), unload spool (1) opens, so excessive • When the difference between pump discharge
oil (maximum pump discharge mount – demand pressure PP1/PP2 and LS pressure PLS1/PLS2
flow) flows into the tank circuit. reaches the load of spring (2) (2.45 MPa {25.0
• Since the pump merge-divider valve is at the kg/cm2}), spool (1) moves to the right, and pump
separate position, pump discharge pressures discharge pressures PP1 and PP2 are con-
PP1 and PP2 are separated. LS pressures PLS1 nected to tank circuit T and the excessive oil
and PLS2 are also separated. (maximum pump discharge mount – demand
• The swash plate angle of the pump becomes flow) flows.
maximum, so the pump discharge amount • In other words, the excessive oil (maximum
becomes maximum. (For details, see the sec- pump discharge mount – demand flow) above
tions on the pump merge-divider valve and logic the strokes of both travel valves flows into tank
valve.) circuit T.
PC78US-6 10-133
(10)
5. When both travel valves are operated
Function • When this happens, the area of the openings of

• During operation of both travel valves, when the both travel valve spools is large, so LS pressures
demand flow becomes maximum, the oil flow to PLS1 and PLS2 are not so different from pump
tank circuit T is cut off, and all pump discharge discharge pressures PP1 and PP2.
amount Q flows to both travel circuits. • For this reason, the difference between pump
• Since the pump merge-divider valve is at the discharge pressure PP1/PP2 and LS pressure
separate position, pump discharge pressures PLS1/PLS2 does not reach the load of spring (2)
PP1 and PP2 are separated. LS pressures PLS1 (2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
and PLS2 are also separated. to the left by spring (2).
• The swash plate angle of the pump becomes • As a result, pump discharge pressures PP1 and
maximum, so the pump discharge amount PP2 and tank circuit T are shut off, and all pump
becomes maximum. (For details, see the sec- discharge amount Q flows to the actuator circuit.
tions on the pump merge-divider valve and logic
valve.)
Operation
• When both travel valves are operated to the
stroke ends, LS pressures PLS1 and PLS2 are
generated and act on the right end of unload
spool (1) (PP1, PP2, PLS1, and PLS2 are sepa-
rated).
10-134 PC78US-6
(10)
6. When either travel valve is operated
Function • When this happens, the area of the openings of

• The demand flow decided by the valve stroke is both travel valve spools is large, so LS pressures
sent to the travel circuit on the operated travel PLS1 is not so different from pump discharge
valve side and the all pump discharge amount is pressures PP1.
sent to the tank circuit on the non-operated travel • For this reason, the difference between pump
valve side. discharge pressure PP1 and LS pressure PLS1
• Since the pump merge-divider valve is at the does not reach the load of spring (2) (2.45 MPa
separate position, pump discharge pressures {25.0 kg/cm2}), so spool (1) is pushed to the left
PP1 and PP2 are separated. LS pressures by spring (2).
PLS1 and PLS2 are also separated. • As a result, pump discharge pressures PP1 and
• The swash plate angle of the pump becomes tank circuit T are shut off, and all pump dis-
maximum, so the pump discharge amount charge amount QP1 on the P1 side flows to the
becomes maximum. (For details, see the sec- left travel circuit.
tions on the pump merge-divider valve and logic • Since the right travel valve is at HOLD, LS pres-
valve.) sure PLS2 is not generated, so only pump dis-
charge pressure PP2 acts.
Operation • When pump discharge pressure PP2 reaches
When left travel valve is operated to stroke end and the load of spring (4) (2.45 MPa {25.0 kg cm2}),
right one is at HOLD. spool (3) moves to the right, and all pump dis-
• When the left travel valve is operated to the charge amount QP2 on the P2 side flows into
stroke end, LS pressure PLS1 is generated and tank circuit T.
acts on the right end of unload spool (1).
PC78US-6 10-135
(10)
Pump merge-divider valve and logic valve

1. When control valve is at HOLD
Function
• Pump merge-divider valve spool (3) merges
pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 respectively.
Operation
• When the control valve is at HOLD, changeover
pressure is not generated on logic spool (1), so
spring (2) pushes spool (1) to the left.
• Since both travel valves are at HOLD, changeover
pressure is not generated on the pump merge-
divider spool.
• When the control valve is at HOLD, changeover
pressure is not generated on the pump merge-
divider spool, so spring (4) pushes spool (3) to
the right.
• Pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 are merged
respectively (PP1 = PP2, PLS1 = PLS2 = PLS3).
10-136 PC78US-6
(10)
2. When work equipment valve is operated

(including compound operation of work
equipment + travel).
out blade), boom, arm, bucket, or attachment.
Function • When the work equipment valve is operated,

• Pump merge-divider valve spool (3) merges pump changeover pressure for spool (3) is not gener-
discharge pressures PP1 and PP2 and LS pres- ated, so spring (4) pushes spool (3) to the right.
sures PLS1, PLS2, and PLS3 respectively. • Pump discharge pressures PP1 and PP2 are
• As the LS pressure, PLS1, PLS2, and PLS3 are merged. LS pressures PLS1, PLS2, and PLS3
output. are also merged (PP1 = PP2, PLS1 = PLS2 =
PLS3).
Operation
• When any work equipment valve is operated, the
work equipment PPC pressure or the swing hold-
ing brake release pressure is introduced in the
left chamber of logic spool (1) to change over
spool (1).
• When the load of spring (2) reaches 0.6 MPa {6
kg/cm2}, spool (1) moves to the right.
• As a result, the right chamber of spool (3) is con-
nected to tank circuit T and changeover pressure
for spool (3) is not generated.
PC78US-6 10-137
(10)
3. When either or both travel valves are oper-

ated
Function • Furthermore, PP1 and PLS1 are separated for

• Pump merge-divider valve spool (3) separates the left travel circuit and PP2 and PLS2 are sep-
pump discharge pressures PP1 and PP2 and LS arated for the right travel circuit.
pressures PLS1, PLS2, and PLS3 respectively. • The higher pressure of pump discharge pres-
• As the LS pressure, higher pressure of PP1 and sures PP1 and PP2 is output as the LS pressure
PP2 is output. and the swash plate angle of the pump becomes
maximum, so the pump discharge amount
Operation becomes maximum.
• Since the all work equipment valves are at
HOLD, changeover pressure for logic spool (1) is
not generated, spring (2) pushes spool (1) to the
left.
• When both travel valves are operated, travel
PPC pressure is introduced as changeover pres-
sure for spool (3) through spool (1) into the right
chamber of spool (3).
• When the load of spring (4) reaches 0.49 MPa {5
kg/cm2}, spool (3) is pushed to the left.
• As a result, pump discharge pressures PP1 and
PP2 and LS pressures PLS1 and PLS2 are sep-
arated respectively.
10-138 PC78US-6
(10)
Introduction of LS pressure
1. Work equipment valve: Swing (PC78US-6
without blade), boom, arm, bucket, or attach-
ment
Function • When this happens, LS circuit PLS is connected

• The LS pressure is the actuator load pressure at to tank circuit T from LS bypass plug (4) (See the
the outlet port end of the control valve. section on the LS bypass plug).
• Actually, pump discharge pressure PP is reduced • The areas at both ends of reducing valve (3) are
by reducing valve (3) of the pressure compensa- the same (SA = SLS), and actuator circuit pres-
tion valve to the same pressure as actuator circuit sure PA acts on the SA end. The reduced pump
pressure A and sent to LS circuit PLS. discharge pressure PP acts on SLS at the other
• In the travel valve, actuator circuit pressure A is end.
directly introduced to LS circuit PLS. • As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure PA and
Operation the pressure of spring chamber PLSS are the
• When spool (1) is operated, pump discharge same. Pump discharge pressure PP reduced at
pressure PP flows from flow control valve (2) notch (c) becomes actuator pressure A and is
through notch (a) in the spool and bridge pas- introduced into LS circuit PLS.
sage (b) to actuator circuit A.
• At the same time, reducing valve (3) also moves
to the right, so pump discharge pressure PP is
reduced by the pressure loss at notch (c). It goes
to LS circuit PLS, and then goes to spring cham-
ber PLSS.
PC78US-6 10-139
(10)
2. Travel valve
Operation
• When spool (1) is operated, pump discharge
pressure PP flows from flow control valve (2)
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit A.
• At the same time, reducing valve (3) is moved to
the right by actuator circuit pressure PA, and
notch (c) and notch (d) are interconnected
respectively with travel junction circuit (e) and LS
circuit PLS.
• As a result, actuator circuit pressure PA (= A) is
introduced from notch (c) through the internal
check valve and notch (d) into LS circuit PLS.
a The travel circuit is different from the work equip-

ment circuit: actuator circuit pressure PA is
directly introduced into LS circuit PLS.
10-140 PC78US-6
(10)
LS bypass plug
When work equipment valve is operated
When both travel valves are operated
Function PLS1, PLS2, and PLS3 flows from tip filter

• The LS bypass plug releases the residual pres- (a) of LS bypass plug (2) through orifice (b)
sure of LS pressure PLS. to tank circuit T.
• This lowers the rising speed of LS pressure PLS. 2. When either or both travel valves are operated
In addition, the discarded throttled flow causes a • Since pump merge-divider spool (1) is at the
pressure loss in the throttled flow in the reducing separate position, LS circuits PLS1, PLS2,
valve, and that lowers the effective LS differential and PLS3 are separated.
pressure to improve the stability. • The hydraulic oil PLS1 flows from tip filter (a)
of LS bypass plug (3) on the P1 side through
Operation orifice (b) to tank circuit T.
1. When work equipment valve is operated (includ- • The hydraulic oil PLS2 flows from tip filter (a)
ing compound operation of work equipment + of LS bypass plug (2) on the P2 side through
travel) orifice (b) to tank circuit T.
• Since pump merge-divider spool (1) is at the
merge position, the hydraulic oil in LS circuits
PC78US-6 10-141
(10)
LS selector valve (only PC78US-6 without blade)

Function
• When the machine swings and the boom is raised
simultaneously, this valve prevents the high-pres-
sure swing LS pressure from entering LS circuit
PLS and secures sufficient pump discharge
amount to keep the boom raising speed.
Operation
1. During normal operation
• When the boom is not raised, the pilot pressure

is not applied to pilot port BP.
• Under this condition, pump discharge pressure
PP is introduced through the internal passage of
spool (1) into reducing valve (3) of the swing
valve. When the swing lever is operated, LS
pressure PLS is generated according to the load
pressure and sent to the pump LS valve.
10-142 PC78US-6
(10)
2. When machine swings and boom is raised

simultaneously.
• When the machine swings and boom is raised

simultaneously, the signal pressure of the boom
RAISE PPC circuit is applied to pilot port BP.
• When pilot pressure BP acts on spool (1) and
increases above the force of spring (2), spool is
pushed to the right and the internal passage is
closed, then pump discharge pressure PP does
not flow into reducing valve (3) of the swing
valve.
• As a result, swing LS pressure PLS is not gener-
ated and only the boom RAISE LS pressure is
introduced in the pump LS valve to control the
pump discharge amount.
• The level of pilot pressure BP is decided by the
stroke of the control lever (Boom RAISE)
PC78US-6 10-143
(10)
Boom raise merge valve (PC78US-6 with blade, PC78UU-6)

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

• When the machine swings and the boom is taneously
raised simultaneously, this valve merges dis- • When the machine swings and boom is raised
charge amount of the gear pump into that of simultaneously, the signal pressure of the
main pump to heighten the boom raising speed. boom RAISE PPC circuit is applied to pilot
port BP.
Operation • When pilot pressure BP acts on spool (1)
1. During normal operation and increases above the force of spring (2),
• When the boom is not raised, the pilot pres- spool is pushed to the right. Then, check
sure is not applied to pilot port BP. valve (3) in spool (1) is pushed open and oil
• Under this condition, gear pump circuit P3 in gear pump circuit P3 is merged into that in
and main pump circuit PP are shut off by main pump circuit PP to heighten the boom
spool (1), so oil in gear circuit P3 is not raising speed.
merged into that of main pump circuit PP.
10-144 PC78US-6
(10)
Area ratio of pressure compensation valve
Function Area ratio (S1:S2) and compensation character-

• The pressure compensation valve determines istics
the compensation characteristics by carrying out • When ratio is 1.00: [Pump discharge pressure
fine adjustment of the area r atio (S2/S1) PP – spool notch upstream
between (left) area S1 of flow control valve (2) pressure PPB] = [LS circuit
and (right) area S2 of reducing valve (1) to match pressure PLS – actuator cir-
the characteristics of each actuator. cuit pressure PA (= A)] and
oil flow is divided in propor-
S1: Area of flow control valve (2) – area of piston (3) tion to area of opening of
S2: Area of reducing valve (1) – area of piston (3) spool.
• When ratio is more than 1.00:PP – PPB > PLS –
PA ( = A) and oil fl ow i s
divided in a proportion less
tha n ar ea of ope ning of
spool.
• When ratio is less than 1.00:PP – PPB < PLS –
PA ( = A) and oil fl ow i s
divided in a proportion more
tha n ar ea of ope ning of
spool.
PC78US-6 10-145
(10)
Pressure compensation valve
Function • Flow control valve (2) and reducing valve (1) are
• During compound operations, if the load pres- balanced in a position where the difference
sure on either actuator becomes lower than the between PLS and PA acting on both ends of
other actuator and the oil flow is about to reducing valve (1) and the pressure loss made
increase, compensation is made. [When this between PP and PPA on the sides of flow control
happens, the other actuator being used for com- valve (2) will be the same.
pound operation (right side) is at a high load than • In this way, the pressure difference between
the actuator on this side (left side).] upstream pressure PPA and downstream pres-
sure PA of both spools used during compound
Operation operations is the same, so the pump flow is
• When the load pressure on the other actuator divided in proportion to the area of opening of
(right side) becomes higher during compound notch (a) of each spool.
operations, the oil flow in actuator circuit A on
this side (left side) starts increasing.
• When this happens, the LS pressure PLS on the
other actuator acts on spring chamber PLSS,
and reducing valve (1) and flow control valve (2)
are pushed to the left.
• Flow control valve (2) throttles the area of open-
ing between pump circuit PP and spool upstream
PPA to cause a pressure loss between PP and
PPA.
10-146 PC78US-6
(10)
Boom hydraulic drift prevention valve

Function
• This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) to cause
hydraulic drift of the boom while the boom control
lever is not operated.
1. When boom is raised
Operation
• When the boom is "raised", the main pressure
from the control valve pushes up puppet (2). As
a result, the hydraulic oil from the control valve
flows through the valve into the boom cylinder
bottom.
PC78US-6 10-147
(10)
2. When boom is held
• When the boom control lever is returned to the

neutral position after the boom is raised, the
holding pressure on the boom cylinder bottom
side is closed by puppet (2) and the hydraulic oil
that flowed through orifices (a1) and (a2) is
closed by pilot spool (3). Accordingly, the boom
is held.
10-148 PC78US-6
(10)
3. When boom is lowered
• When the boom is lowered, pilot pressure P1

from the PPC valve pushes pilot spool (3) and
the hydraulic oil in chamber (b) in the puppet is
drained.
• The pressure in port (Ab) is heightened by the
hydraulic oil from the boom cylinder bottom, but
the pressure in chamber (b) is lowered by ori-
fices (a1) and (a2).
• When the pressure in chamber b lowers below
that in port (Ab), puppet (2) opens and the
hydraulic oil from port (Ab) flows through port
(Aa) into the control valve.
PC78US-6 10-149
(10)
Boom regeneration circuit

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

• While the boom is being lowered by its weight, if bottom side flows through regeneration pas-
bottom pressure A of cylinder (1) is higher than sages (a) of bottom spool (2), pushes check
head pressure B, this circuit sends the return oil valve (3) open, and flows into the head side.
on the bottom side to the head side to increase • As a result, the boom lowering speed is height-
the cylinder speed by that amount. ened.
Operation
• While the boom is being lowered by its weight,
pressure A on the bottom side of boom cylinder
(1) is higher than pressure B on the head side.
10-150 PC78US-6
(10)
2. When boom is lowered under a load.
Function
• While the boom is being lowered under a load, if
head pressure B of cylinder (1) is higher than
bottom pressure A, check valve (3) is closed to
shut off the head side and bottom side from each
other.
Operation
• While the boom is being lowered under a load,
pressure B on the head side of boom cylinder (1)
is higher than pressure A on the bottom side.
• When this happens, check valve (3) is closed by
pressure B on the head side and spring (4) to
shut off the head side and bottom side from each
other.
PC78US-6 10-151
(10)
Travel junction valve

(L.H., R.H. travel junction circuit)
1. When traveling in a straight line
10-152 PC78US-6
(10)
2. When steered during travel
PC78US-6 10-153
(10)
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.
10-154 PC78US-6
(10)
Travel LS bleed circuit and travel junction valve

PC78US-6 10-155
(10)
2. When travel actuator and another actuator

are operated
10-156 PC78US-6
(10)
Function • As a result, reducing valve (2) moves to the

• When the travel actuator and another actuator left and LS pressure PLS flows through
are operated at the same time, the amount of oil check valves (3) and (4) and notch (a) of
discarded through the throttle in LS circuit PLS reducing valve (2) to travel circuit PB.
increases and the pressure compensation preci- • For this reason, LS circuit pressure PLS,
sion of the travel circuit is lowered to reduce the which is the same pressure as boom circuit
drop of the travel speed. pressure A, flows to travel circuit B to reduce
• When the travel actuator or any other actuator is the pressure.
operated singly, the LS bleed circuit is closed.
• Travel junction valve spool (5) is set to open (b)
(small) or open (c) (large) by the boom PPC
pressure so that the difference between the flow
rates in both travel circuits can be corrected eas-
ily.
Operation
• 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.
PC78US-6 10-157
(10)
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
Model: LMF30AEL
B: From swing brake solenoid valve Specifications

S: From tank Model: LMF30AEL
T: To tank Capacity: 31 cm3/rev
MA: From control valve Set pressure of safety valve: 21 MPa {210 kg/cm2}
MB: From control valve Cracking pressure of check valve: Max. 0.03 MPa
{0.30 kg/cm2}
1. Reverse prevention valve
10-158 PC78US-6
(10)
1. Output shaft 9. Safety valve

2. Housing 10. Check valve
3. Shoe 11. Check valve spring
4. Piston 12. Brake spring
5. Cylinder block 13. Brake piston
6. Valve plate 14. Disc
7. Center spring 15. Plate
8. Swash plate
Unit: mm

A Check valve spring Free length Installed Installed Installed
× Outside length load Free length load
diameter If damaged
or deformed,
15.5 × 9.0 11.5 {0.09 kg} — {0.07 kg}
B Valve return spring
1.8 N 1.41 N
33 × 13.8 19.5 {0.18 kg} — {0.14 kg}
PC78US-6 10-159
(10)
BRAKE VALVE 2. When machine stops swinging

• If the swing control lever is returned to the
Outline neutral position, oil is not supplied from the
• The brake valve consists of a check valve and a pump to port MB any more. Since the return
safety valve. circuit for the oil from the motor outlet to the
tank is closed by control valve (1), the pres-
Function sure in port MA rises and revolution resis-
• When the machine stops swinging, control valve tance is generated in the motor, then the
(1) closes the outlet circuit of the motor. Since motor is braked.
the motor continues revolving because of the • The pressure in port MA rises to the set
inertia, the motor output pressure rises abnor- pressure of the safety valve. As a result,
mally to break the motor. Accordingly, the abnor- high braking torque is generated in the
mally high pressure is released through the motor, then the motor stops.
outlet (high pressure side) of the motor to protect • While the safety valve is operating, the oil
the motor. discharged from the safety valve and the oil
from port S are supplied through check valve
Operation CB to port MB so that cavitation will not
1. When machine starts swinging occur in port MB.
• When the swing control lever is operated to
swing to the left, the hydraulic oil from the
pump flows through control valve (1) into port
MB. As a result, the pressure in port MB
rises and the starting torque is generated in
the motor and the motor starts revolution.
The oil from the motor outlet returns from
port MA through control valve (1) to the tank.
10-160 PC78US-6
(10)
MODULATING RELIEF VALVE
Function
The relief valve for the swing motor prevents the
relief pressure from rising sharply to reduce shocks
when the machine starts and stops swinging.
Operation
1. When circuit pressure is P0
• The relief valve does not operate.
2. When circuit pressure rises sharply
• When circuit pressure rises to P1, the
hydraulic pressure acts on the area differ-
ence between D1 and D3 (D1 > D3) and
pushes spring (4) to open valve (3).
• At this time, pressure acts on the area differ-
ence between D1 and D2 (D2 > D1), so seat
(1) follows valve (3).
• As seat (1) moves, the passage for the pres-
surized oil in chamber (a) to flow into port S
is narrowed by ball (2). Accordingly, seat (1)
does not move so fast as valve (3).
• As a result, the relief pressure rises gradually
from P1 to P2 while seat (1) is moving to
sleeve (5).
PC78US-6 10-161
(10)
SWING BRAKE 2. When solenoid valve is energized
1. When solenoid valve is de-energized Operation

• When the solenoid valve of the swing brake is
Operation energized, the valve is changed and hydraulic oil
• When the solenoid valve of the swing brake is from the self-pressure reducing valve flows
de-energized, the hydraulic oil from the self- through port B into brake chamber A.
pressure reducing valve is shut off and port B is • The hydraulic oil in chamber A pushes brake
connected to the tank circuit. spring (12) and brake piston (13) moves down.
• As a result, brake piston (13) is pushed up by As a result, disc (14) and plate (15) are sepa-
brake spring (12) to press disc (14) and disc (15) rated and the brake is released.
to apply the brake.
10-162 PC78US-6
(10)
REVERSE ROTATION PREVENTION LEVEL
MA : Port 1. Valve Body

MB : Port 2. Spool (MA end)
T1 : Port 3. Spring (MA end)
T2 : Port 4. Plug (MA end)
5. Spool (MB end)
6. Spring (MB end)
7. Plug (MB end)
PC78US-6 10-163
(10)
EFFECT EXPLANATION DRAWING
10-164 PC78US-6
(10)
Function
• This valve reduces the swing back generated in
the swing body by the inertia of the swing body,
the backlash and rigidity of the machinery sys-
tem, and the compression of the hydraulic oil
when the swing is stopped.
• This is effective in preventing spillage of the load
when stopping the swing and reducing the cycle
time (the positioning ability is good and it is pos-
sible to move swiftly to the next job).
1. When brake pressure is being generated at

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

• The motor is reversed by the closing pressure
generated at port MB. (1st reversal)
• When this happens, reversal pressure is gener-
ated at port MA. Pressure MA goes to chamber
a, compresses spring (3), spool (2) moves to the
right, and MA o b is connected.
• At the same time, b o f is connected through the
drill hole in spool (5), so the reversal pressure at
port MA is bypassed to port T to prevent the 2nd
reversal.
PC78US-6 10-165
(10)
MAINTENANCE STANDARD WORK EQUIPMENT AND SWING PPC VALVE
WORK EQUIPMENT AND SWING PPC VALVE

PC78US-6 Serial No.: 4001 – 6500
P : From main pump

T : To tank
P1 : Left - Arm OUT/Right - Boom LOWER
P2 : Left - Arm IN/Right - Boom RAISE
P3 : Left - Swing RIGHT/Right - Bucket CURL
P4 : Left - Swing LEFT/Right - Bucket DUMP
10-166 PC78US-6
(10)
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm

Free length Installed Installed Installed
12 Centering spring × Outside length load Free length load
(For ports P3 and P4) diameter
17.7 N 13.7 N If damaged
42.4 × 15.5 34.0 {1.80 kg} — {1.40 kg} or deformed,
replace spring.
Centering spring 29.4 N 23.5 N
13 (For ports P1 and P2) 44.4 × 15.5 34.0 {3.0 kg} — {2.40 kg}
16.7 N 13.7 N
14 Metering spring 26.5 × 8.15 24.9 {1.70 kg} — {1.40 kg}
PC78US-6 10-167
(10)
P : From main pump

T : To tank
P1 : Left - Arm OUT/Right - Boom LOWER
P2 : Left - Arm IN/Right - Boom RAISE
P3 : Left - Swing RIGHT/Right - Bucket CURL
P4 : Left - Swing LEFT/Right - Bucket DUMP
10-168 PC78US-6
(10)
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm

Free length
Centering spring × Outside Installed Installed Free length Installed
12 (For ports P3 and P4) diameter length load load
21.8 N 15.7 N If damaged

42.5 × 15.5 32.0 {2.22 kg} — {1.6 kg} or deformed,
replace spring.
13 Centering spring 44.5 × 15.5 32.0 35.0 N — 24.5 N
(For ports P1 and P2) {3.57 kg} {2.5 kg}
14 Metering spring 26.5 × 8.15 24.9 16.7 N — 11.8 N

{1.70 kg} {1.2 kg}
PC78US-6 10-169
(10)
OPERATION
1. At neutral
• Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
2. During fine control (neutral o fine control)

• When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
• When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the main pump
passes through fine control hole f and goes from
port P1 to port A.
• When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP. At
almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
• When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P1. The relation-
ship in the position of spool (1) and body (10)
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool
(1).
• Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also
rises in proportion to the travel of the control
lever.
• In this way, the control valve spool moves to a
position where the pressure in chamber A (the
same as the pressure at port P1) and the force of
the control valve spool return spring are bal-
anced. (Fig. 2)
10-170 PC78US-6
(13)
3. During fine control

(when control lever is returned)
• When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
• When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil
at port P1 is released.
• If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
• When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f '
in the valve on the side that is not working. The
oil passes through port P2 and enters chamber B
to fill the chamber with oil. (Fig. 3)
4. At full stroke
• When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
• Therefore, the pilot pressure oil from the main
pump 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)
PC78US-6 10-171
(13)
MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From main pump

T : To tank
P1 : Left travel reverse
P2 : Left travel forward
P3 : Right travel reverse
P4 : Right travel forward
10-172 PC78US-6
(10)
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar 8. Bolt
Unit: mm

Free length
× Outside Installed Installed Free length Installed
A Metering spring diameter length load load If damaged
or deformed,
26.5 × 8.15 24.9 {1.70 kg} — {1.40 kg}
B Centering spring 52.06 × 15.5 32.1 134 N — 107 N

{13.67 kg} {10.94 kg}
PC78US-6 10-173
(10)
OPERATION
1. At neutral
• Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
2. During fine control (neutral o fine control)

• When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
• When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time,
it is connected to pump pressure chamber PP,
and the pilot pressure of the main pump is sent
from port A through fine control hole f to port P1 .
• When the pressure at port P1 rises, spool (1) is
pushed back. Fine control hole f is shut off from
pump pressure chamber PP. At almost the same
time, it is connected to drain chamber D to
release the pressure at port P1.
• As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure of port P1.
• The relationship in the position of spool (1) and
body (10) (fine control hole f is in the middle
between drain hole D and pump pressure cham-
ber PP) does not change until retainer (9) con-
tacts spool (1).
• Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so the
pressure at port P1 also rises in proportion to the
travel of the control lever.
• In this way, the control valve spool moves to a
position where the pressure of chamber A (same
as pressure at port P1) and the force of the
return spring of the control valve spool are bal-
anced. (Fig. 2)
10-174 PC78US-6
(13)
3. Fine control (control lever returned)

• When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
• Because of this, fine control hole f is connected
to drain chamber D, and the pressurized oil at
port P1 is released.
• If the pressure at port P1 drops too much, spool
(1) is pushed up by metering spring (2), so fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, so the pressure at port P1
supplies the pump pressure until the pressure
recovers to a pressure equivalent to the position
of the lever.
• When the control valve returns, oil in drain cham-
ber D flows in from fine control hole f ' of the
valve on the side that is not moving. It passes
through port P2 and enters chamber B to fill the
chamber with oil. (Fig. 3)
4. At full stroke
• Disc (5) pushes down piston (4), and retainer (9)
pushes down spool (1). Fine control hole f is shut
off from drain chamber D, and is connected to
pump pressure chamber PP.
• Therefore, the pilot pressure oil from the main
pump passes through fine control hole f and
flows to chamber A from port P1 to push the con-
trol valve spool.
• The return oil chamber B passes from port P2
through fine control hole f ' and flows to drain
chamber D. (fig. 4)
PC78US-6 10-175
(13)
MAINTENANCE STANDARD OFFSET PPC VALVE, ATTACHMENT PPC VALVE, BLADE PPC VALVE
OFFSET PPC VALVE (PC78UU-6)

ATTACHMENT PPC VALVE (PC78US-6)
BLADE PPC VALVE (PC78UU, PC78US-6)
T : To tank
P : From main pump
P1 : To attachment/blade valve
P2 : To attachment/blade valve
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
Offset/for attachment
10-176 PC78US-6
(10)
MAINTENANCE STANDARD ATTACHMENT AND BLADE PPC VALVA
For Attachment
Unit: mm

Free length
A Centering spring diameter length load load If damaged
or deformed,
125 N 100 N replace spring.
33.9 × 15.3 28.4 {12.7 kg} — {10.2 kg}
16.7 N 13.3 N
B Metering spring 22.7 × 8.10 22.0 {1.70 kg} — {1.36 kg}
For Blade
Unit: mm

Free length
A Centering spring diameter length load load If damaged
or deformed,
42.36 × 15.5 28.4 207.8 N — 166.3 N replace spring.
{21.2 kg} {16.96 kg}
B Metering spring 22.73 × 8.1 22.0 16.67 N — 13.7 N

{1.7 kg} {1.4 kg}
PC78US-6 10-177
(10)
Operation
1. In the neutral mode
• P1 and P2 ports of the operation valves A, B and
PPC valve are connected to drain room D via the
fine control hole f on the spool (1).
2. In the fine control mode

(Neutral o fine control)
• As the piston (4) is pushed by disk (5), the
retainer (7) is pushed too. At the same time, the
spool (1) is also pushed down via the metering
spring (2).
• By this move, connection of the fine control hole
f is switched from the drain room D to the pump
pressure room PP, and pilot pressure oil for the
control pump is conducted from P1 port to A
port.
• As P1 port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure room PP to the drain room D, thereby
relieving P1 port pressure.
• As the result, the spool (1) moves up and down
so that force of the metering spring (2) and P1
port pressure may be balanced.
• Positional relationship between the spool (1) and
body (8) (fine control hole f is situated at mid
point between the drain room D and pump pres-
sure room PP) remains unchanged until the
retainer (7) is contacted against the spool (1).
• The metering spring (2) is, therefore, com-
pressed in proportion to strokes of the operation
lever. Thus, the P1 port pressure too, increases
in proportion to strokes of the operation lever.
• As the result, the operation valve spool moves to
the position where the pressure of A room (the
same as P1 port pressure) is balanced against
force of the operation valve spool return spring.
10-178 PC78US-6
(13)
3. In the fine control mode (when the operation

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

• When the disk (5) pushes down piston (4) and
the retainer (7) pushes down the spool (1), con-
nection of the fine control hole f is switched from
the drain room D, to the pump pressure room PP.
• Thus, pilot pressurized oil from the control pump
passes through fine control hole f and conducted
to A room via P1 port to push the operation valve
spool.
• Return oil from B room is conducted from P2 port
to the drain room D via the fine control hole f '.
PC78US-6 10-179
(13)
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
PC78US-6
Unit: mm

Clearance between mounting dimension Shaft Hole clearance clearance
1 pin and bushing of boom and
revolving frame -0.030 +0.174 0.130–
65 -0.100 1.0
+0.100 0.274
Clearance between -0.030 +0.174 0.130–
2 mounting pin and bushing of 60 -0.100 +0.100 0.274 1.0
boom and arm
Clearance between
3 mounting pin and bushing of 50 -0.225 -0.062 0.105– 1.0
arm and bucket -0.285 -0.120 0.233
Replace pin and
Clearance between bushing
4 mounting pin and bushing of 50 -0.225 -0.062 0.105– 1.0
arm and link -0.285 -0.120 0.233
Clearance between mounting -0.030 +0.173 0.130–

5 pin and bushing of link and link 60 -0.100 +0.100 0.273 1.0
Clearance between mounting

6 pin and bushing of bucket and 50 -0.225 -0.040 0.131– 1.0
link -0.285 -0.094 0.245
Clearance between mounting

7 pin and bushing of blade and -0.025 -0.142 0.105-
track frame (Blade specifica- 50 -0.087 -0.080 0.229 1.0
tion)
10-180 PC78US-6
(10)
PC78US-6 10-181
(10)
PC78UU-6
PC78US-6 10-183
(10)
10-184 PC78US-6
(10)
Unit: mm

Clearance between 1st boom dimension Shaft Hole clearance clearance
1 and revolving frame mounting
pin and bushing - 0.030 +0.174 0.130–
65 - 0.100 +0.100 0.274 1.0
Clearance between 1st boom

2 and 2nd boom mounting pin 100 - 0.036 +0.207 0.156– 1.0
and bushing - 0.090 +0.120 0.297
Clearance between 1st boom - 0.025 +0.142 0.105–
3 and sub-link mounting pin and 50 - 0.087 +0.080 0.229 1.0
bushing
Clearance between 2nd boom - 0.036 +0.207 0.156–
4 and 3rd bracket mounting pin 100 - 0.090 +0.120 0.297 1.0
and bushing
Clearance between 3rd bracket
5 and sub-link mounting pin and 50 - 0.025 +0.142 0.105– 1.0
bushing - 0.087 +0.080 0.229 Replace pin and
bushing
Clearance between 3rd bracket - 0.280 - 0.082 0.130–
6 and arm mounting pin and 65 - 0.350 - 0.150 0.268 1.0
bushing
Clearance between arm and
7 bucket mounting pin and bush- 50 - 0.225 - 0.062 0.105– 1.0
ing - 0.285 - 0.120 0.223
8 Clearance between arm and 50 - 0.225 - 0.062 0.105– 1.0

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

mounting pin and bushing - 0.100 +0.100 0.273
Clearance between link and - 0.225 - 0.040 0.131–
10 bucket mounting pin and bush- 50 - 0.285 - 0.094 0.245 1.0
ing
Clearance between blade and - 0.025 +0.142 0.105–
11 track frame mounting pin and 50 - 0.087 +0.080 0.229 1.0
bushing
PC78US-6 10-185
(10)
MAINTENANCE STANDARD DIMENSIONS OF EACH PART OF WORK EQUIPMENT
DIMENSIONS OF EACH PART OF WORK EQUIPMENT

1. ARM SECTION
PC78US-6
*1. Serial No.: 4001 – 4927
10-186 PC78US-6
(13)
Unit: mm
PC78US-6
No. Allowance
Measuring point Basic dimension
Shaft Hole
- 0.030 +0.100
1 – 60 - 0.100 0
Arm side 71.5 +1.0

2 0
Cylinder head side 70 ±1.2
3 – - 0.030 +0.100
60 - 0.100 0
Boom side 220 +0.5

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
Link side 200 - 1.0

- 2.0
18
+2.0
Bucket side 200 0
19 – - 0.225 0
50 - 0.285 - 0.150
20 Arm as individual part 188 - 0.5

- 1.0
When pressfitting - 0.5
21 bushing 200 - 1.4
Min. 1,055 ±1.5
22
Max. 1,765 –
PC78US-6 10-187
(13)
PC78UU-6
10-188 PC78US-6
(13)
Unit: mm
PC78UU-6
No. Allowance
Shaft Hole
- 0.030 +0.100
1 – 60 - 0.100 0
Arm side 78.5 +2.0

0
2
Cylinder head side 70 0
- 0.5
- 0.280 +0.100
3 – 65 - 0.350 0
Boom side 225 +0.5

0
4
Arm side 220 - 0.5
- 1.0
5 – 192.6 ±2.0
6 – 235 ±1.0
0
±1.0
7 – 335.7 0
8 – 1,720 –
9 – 2,039.6 ±3.0
10 – 1,660.3 ±2.0
11 – 258.8 ±1.0
12 – 11.3 ±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
Link side 200 - 1.0

- 2.0
18
Bucket side 200 +2.0
0
- 0.225 0
19 – 50 - 0.285 - 0.150
20 Arm as individual part 188 - 0.5

- 1.0
When pressfitting - 0.5
21 bushing 200 - 1.4
Min. 1,055 ±1.5
22
Max. 1,765 –
PC78US-6 10-189
(13)
2. BUCKET PORTION
10-190 PC78US-6
(13)
Unit: mm
PC78US-6, PC78UU-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
12 – 200 +2.0
0
13 – 40 –
14 – 71 –
15 – 296 +1.0
0
16 – 18 –
17 – 100 –
18 – 115 –
19 – 95 –
20 – 211 +3.0
0
21 – 40 –
22 – 24 –
23 – 89.3 –
24 – 87.9 –
25 – 60 –
26 – 66 –
PC78US-6 10-191
(10)
MAINTENANCE STANDARD AIR CONDITIONER PIPING (OPTIONAL)
AIR CONDITIONER PIPING (OPTIONAL)

PC78US-6 Serial No.: 4001 – 6500
A: Hot/Cool air outlet 1. Hot water take-out piping

B: Inside air circulation opening 2. Air conditioner compressor
C: Fresh air inlet 3. Hot water return piping
4. Refrigerant piping
5. Condenser
6. Receiver drier
7. Air conditioner unit
8. Duct
10-192 PC78US-6
(10)
MAINTENANCE STANDARD AIR CONDITIONER PIPING (OPTIONAL)
A: Hot/Cool air outlet 1. Hot water take-out piping

B: Inside air circulation opening 2. Air conditioner compressor
C: Fresh air inlet 3. Hot water return piping
D: Refrigerant checking port 4. Refrigerant piping
5. Condenser
6. Receiver drier
7. Air conditioner unit
8. Duct
PC78US-6 10-193
(10)
MAINTENANCE STANDARD ELECTRIC CONTROL SYSTEM
ELECTRIC CONTROL SYSTEM

Engine control function
Engine and pump compound

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

(*1)
Automatic gear shift system
Seed reducing function
Electric (*1)
control system
Turbocharger protection function
Stop/Alarm function
(*2)
Interference prevention system Emergency stop/Alarm function
Cancel function
Reset function
Depth – from – Ground – Level display func-

(*2) tion
Depth measuring system
Depth – from – Datum – Plane display function

(*2)
Automatic height stop system Height setup function
(*2)
Boom end cushion function
(*2)
Arm end cushion function
Error code display and alarm function
Self-diagnosis function
Error code memory function
* 1 For PC78US-6 Serial No. 6501 and up

* 2 For PC78UU-6 machine only.
PC78US-6 10-195
(10)
GENERAL SYSTEM DIAGRAM

PC78US-6 Serial No.: 4001 – 5500
a This drawing shows the PC78US-6 of blade
specification.
10-196 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency pump drive switch
8. Swing holding brake release switch
9. Resistor (For emergency pump drive)
10. Safety lock lever
11. PPC lock switch
12. Starting motor cut relay
13. Safety relay
14. One-touch deceleration switch
15. Fuel control motor relay (For drive)
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 [Blade specification]
22. Travel alarm (If equipped)
26. TVC-EPC valve
27. Right work equipment PPC valve
28. Travel PPC valve
29. Left work equipment PPC valve
30. Blade PPC valve [Blade specification]
31. Boom RAISE PPC oil pressure switch
32. Travel PPC oil pressure switch
33. Arm IN PPC oil pressure switch
34. Swing PPC oil pressure switch
35. Engine stop solenoid
36. Starting motor
37. Engine speed sensor
38. Coolant temperature sensor
39. Hydraulic pump
39a. Servo piston
39b. LS valve
39c. TVC valve
40. Control valve
40a. Pump merge-divider valve
41. Travel motor
42. Swing motor
PC78US-6 10-197
(10)
PC78US-6 Serial No.: 5501 – 6500

specification.
10-198 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
11. PPC lock switch
13. Safety relay
19. Monitor panel
20. Travel speed boost pedal (Blade specification)
25. TVC-EPC valve
29. Blade PPC valve (Blade specification)
35. Engine stop solenoid relay
36. Starting motor
39. Hydraulic pump
39a. Servo piston
39b. LS valve
39c. TVC valve
40. Control valve
41. Travel motor
42. Swing motor
PC78US-6 10-199
(10)

specification.
10-200 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
11. PPC lock switch
13. Safety relay
19. Monitor panel
20. Hydraulic pump pressure sensor
25. TVC-EPC valve
36. Starting motor
39. Hydraulic pump
39a. Servo piston
39b. LS valve
39c. TVC valve
40. Control valve
41. Travel motor
42. Swing motor
43. Travel alarm drive relay
PC78US-6 10-201
(10)
PC78UU-6 Serial No.: 22832 – 23500
10-202 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
7. Emergency work equipment operating switch
10. Resistor
(For emergency work equipment operating)
13. PPC lock switch
14. PPC lock cut relay
16. Safety relay
23. Monitor panel
24. Travel speed boost pedal
29. Boom RAISE stop EPC valve
30. Arm IN stop EPC valve
32. TVC-EPC valve
36. Offset PPC valve
37. Blade PPC valve
42. Boom potentiometer
43. Offset potentiometer
44. Arm potentiometer
46. Starting motor
49. Hydraulic pump
49a. Servo piston
49b. LS valve
49c. TVC valve
50. Control valve
51. Travel motor
52. Swing motor
PC78US-6 10-203
(10)
10-204 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
10. Resistor
(For emergency work equipment operating)
13. PPC lock switch
16. Safety relay
22. Monitor panel
23. Travel speed boost pedal
28. Boom RAISE stop EPC valve
29. Arm IN stop EPC valve
31. TVC-EPC valve
36. Blade PPC valve
41. Boom potentiometer
43. Arm potentiometer
46. Starting motor
49. Hydraulic pump
49a. Servo piston
49b. LS valve
49c. TVC valve
50. Control valve
51. Travel motor
52. Swing motor
PC78US-6 10-205
(10)
ENGINE CONTROL FUNCTION

PC78US-6 Serial No.: 4001 – 5500
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
8. PPC lock switch
10. Safety relay
17. Monitor panel
19. Starting motor
10-206 PC78US-6
(10)
Starting engine One-touch deceleration

• If starting switch (4) is turned to the ON position, • If one-touch deceleration switch (16) is pressed,
engine stop solenoid (18) moves governor stop the deceleration signal is output to controller (6).
lever to the "RUN" side. • Controller (6) turns on the one-touch decelera-
Accordingly, if the electric system has any trou- tion monitor of monitor panel (17) and drives fuel
ble, the engine stops, that is, a fail-safe mecha- control motor (12) to lower the engine speed to
nism is formed. low idling.
• If starting switch (4) is turned to the START posi- • If one-touch deceleration switch (16) is pressed
tion while safety lock lever (7) is at the "LOCK" while the engine is being started, the engine
position, the start signal flows to starting motor speed is set to low idling. If it is pressed again,
(19) and the engine starts. If safety lock lever (7) the engine speed returns to the speed set with
is at the "FREE" position, the start signal to start- fuel control dial (11).
ing motor (19) is cut out by starting motor cut a Even if the engine is stopped while the one-
relay (9) and the engine cannot start. touch deceleration system is turned on, the latter
• At this time, since fuel control motor (12) is linked is turned off when the engine is started next time
with fuel control dial (11), the engine speed is (the engine speed is set the speed set with the
fixed to the speed set with fuel control dial (11). fuel control dial).
a Even if the fuel control dial is operated while the
Controlling engine speed one-touch deceleration system is turned on, the
• Fuel control motor (12) outputs the acceleration engine speed is kept at low idling.
(engine speed raising) signal and deceleration a If the fuel control dial is at low idling, the engine
(engine speed lowering) signal to controller (6) speed does not lower any more even if the one-
according to the position of fuel control dial (11). touch deceleration switch is pressed.
• Upon receiving the signal, controller (6) outputs
the drive signal through fuel control motor relays
(13), (14), and (15) to fuel control motor (12).
• Fuel control motor (12) lengthens or shortens the
cable to control the engine speed according to
the drive signal.
Stopping engine
• If starting switch (4) is turned to the OFF posi-
tion, engine stop solenoid (18) moves the gover-
nor stop lever to the STOP side and the engine
stops.
A: One-touch deceleration switch [ON]

B: One-touch deceleration switch [OFF]
C: Engine speed set with fuel control dial
D: Low idling
E: Max. 1 sec
PC78US-6 10-207
(10)
PC78US-6 Serial No.: 5501 – 6500
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
8. PPC lock switch
10. Safety relay
16. Monitor panel
19. Starting motor
10-208 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
8. PPC lock switch
10. Safety relay
16. Monitor panel
19. Starting motor
PC78US-6 10-209
(10)
Starting engine Function of preventing engine stop solenoid

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

• Fuel control dial (11) outputs the potentiometer
voltage to controller (6) according to its position.
(13) and (14) to fuel control motor (12).
the drive signal.
A: Operation of starting switch
B: Suction coil current
C: Holding coil current
t: 3 seconds
10-210 PC78US-6
(10)
Stopping 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).
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.

D: Low idling
E: Max. 1 sec
PC78US-6 10-211
(10)

• When the engine is started at low temperature, if
the engine speed is increased sharply, the turbo-
charger may be seized. The turbocharger pro-
tection function prevents this trouble.
A: Start of engine
B: Turbocharger protection time (Approx. 0.6 sec)
C: Modulation time (Approx. 1.4 sec)
D: 1,000 rpm
E: 1,200 rpm
F: 2,020 rpm
Operating condition Operation

Coolant temperature: Max. 30° o Protection of turbocharger
Engine speed sensor: Normal (See above figure)
10-212 PC78US-6
(10)
PC78UU-6 Serial No.: 22832 – 23500
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
8. PPC lock switch
10. Safety relay
17. Monitor panel
19. Starting motor
PC78US-6 10-213
(10)
Starting engine One-touch deceleration

• If starting switch (4) is turned to the ON position, • If one-touch deceleration switch (16) is pressed,
engine stop solenoid (18) moves governor stop the deceleration signal is output to controller (6).
lever to the "RUN" side. • Controller (6) turns on the one-touch decelera-
Accordingly, if the electric system has any trou- tion monitor of monitor panel (17) and drives fuel
ble, the engine stops, that is, a fail-safe mecha- control motor (12) to lower the engine speed to
nism is formed. low idling.
• If starting switch (4) is turned to the START posi- • If one-touch deceleration switch (16) is pressed
tion while safety lock lever (7) is at the "LOCK" while the engine is being started, the engine
position, the start signal flows to starting motor speed is set to low idling. If it is pressed again,
(19) and the engine starts. If safety lock lever (7) the engine speed returns to the speed set with
is at the "FREE" position, the start signal to start- fuel control dial (11).
ing motor (19) is cut out by starting motor cut a Even if the engine is stopped while the one-
relay (9) and the engine cannot start. touch deceleration system is turned on, the latter
• At this time, since fuel control motor (12) is linked is turned off when the engine is started next time
with fuel control dial (11), the engine speed is (the engine speed is set the speed set with the
fixed to the speed set with fuel control dial (11). fuel control dial).
Controlling engine speed one-touch deceleration system is turned on, the
• Fuel control motor (12) outputs the acceleration engine speed is kept at low idling.
(engine speed raising) signal and deceleration a If the fuel control dial is at low idling, the engine
(engine speed lowering) signal to controller (6) speed does not lower any more even if the one-
according to the position of fuel control dial (11). touch deceleration switch is pressed.
(13), (14), and (15) to fuel control motor (12).
the drive signal.
Stopping engine
stops.

D: Low idling
E: Max. 1 sec
10-214 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
8. PPC lock switch
10. Safety relay
16. Monitor panel
19. Starting motor
PC78US-6 10-215
(10)
Starting engine Function of preventing engine stop solenoid

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

• Fuel control motor (12) outputs the acceleration
(engine speed raising) signal and deceleration
(engine speed lowering) signal to controller (6)
according to the position of fuel control dial (11).
(13) and (14) to fuel control motor (12).
cable to control the engine speed according to A: Operation of starting switch
the drive signal. B: Suction coil current
C: Holding coil current
t: 3 seconds
10-216 PC78US-6
(10)
Stopping 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).
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.

D: Low idling
E: Max. 1 sec
PC78US-6 10-217
(10)
ENGINE AND PUMP COMPOUND CONTROL FUNCTION

PC78US-6 Serial No. 4001 – 6500 (Blade-less specification)
1. Battery Input/Output signals

2. Battery relay a. Controller power source
3. Fusible link b. Solenoid power source
4. Starting switch c. Monitor panel power source
5. Fuse box d. S-NET signal
6. Controller e. Coolant temperature signal
7. Emergency pump drive switch f. Engine speed signal
8. Resistor (For emergency pump drive) g. EPC valve drive signal
9. Monitor panel
10. TVC-EPC valve
13. Control valve
14. Hydraulic pump
14a. Servo piston
14b. LS valve
14c. TVC valve
10-218 PC78US-6
(10)
PC78US-6 Serial No. 6501 and up (Blade-less specification)

9. Monitor panel
10. TVC-EPC valve
13. Control valve
14. Hydraulic pump
14a. Servo piston
14b. LS valve
14c. TVC valve
PC78US-6 10-219
(10)
PC78US-6 Serial No. 4001 – 6500 (Blade specification)

PC78UU-6 Serial No. 22832 and up

9. Monitor panel
10. TVC-EPC valve
13. Control valve
14. Hydraulic pump
14a. Servo piston
14b. LS valve
14c. TVC valve
10-220 PC78US-6
(10)
PC78US-6 Serial No. 6501 and up (Blade specification)

9. Monitor panel
10. TVC-EPC valve
13. Control valve
14. Hydraulic pump
14a. Servo piston
14b. LS valve
14c. TVC valve
PC78US-6 10-221
(10)
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.
10-222 PC78US-6
(10)
Control method in each mode

Active mode
• Matching point of active mode:
Model PC78US-6, PC78UU-6

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

rises, engine speed lowers.
At this time, the pump discharge is reduced to
heighten the engine speed to near the full output
point. On the other hand, if the pressure lowers,
engine speed is heightened to near the full out-
put point to increase the pump discharge.
The engine is constantly used near the full output
point by repeating this control.
PC78US-6 10-223
(10)
E mode
• Matching point of E mode: 85% partial output
point of active mode
Model PC78US-6, PC78UU-6

37.5 kw / 1.660 rpm
E mode {50.0 HP / 1,660 rpm}
• In this mode, the engine speed is lowered along

the constant horsepower curve of the engine,
keeping the pump absorption torque at a con-
stant level.
The engine is used in the high fuel efficiency
area by this control method.
10-224 PC78US-6
(10)
Driving pump in an emergency

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

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

native type. If it is set to the "CANCEL (2)" posi-
tion while the machine is normal, user code
"E02" is displayed on the display unit.
PC78US-6 Serial No. 4001 – 6500

PC78UU-6
PC78US-6 Serial No. 6501 and up
OVERHEAT PREVENTION FUNCTION

a For the system circuit diagram, see "Engine and
pump compound control function".
• If the coolant temperature rises too high, the

pump load is lowered to prevent the engine from
overheating.
Operating condition Operation Resetting condition
• Pump absorption torque is reduced according to
Coolant temperature is o torque control system to reduce engine load. o Coolant temperature
above 99°C (Matching point: 90% partial output point) is below 95°C
• Engine speed is kept as it is.
PC78US-6 10-225
(10)
SWING CONTROL FUNCTION

PC78US-6 Serial No. 4001 – 6500
a This drawing shows PC78US-6 of the blade-less
specification.

4. Starting switch c. Solenoid valve drive signal
5. Fuse box d. Swing PPC oil pressure switch signal
6. Controller e. Arm IN PPC oil pressure switch signal
9. Swing motor
13. Engine
14. Hydraulic pump
15. Control valve
10-226 PC78US-6
(10)
PC78US-6 Serial No. 6501 and up

a This drawing shows PC78US-6 of the blade-less
specification.

9. Swing motor
13. Engine
14. Hydraulic pump
15. Control valve
PC78US-6 10-227
(10)
PC78UU-6

7. Swing holding brake release switch f. Offset potentiometer signal
9. Swing motor
13. Engine
14. Hydraulic pump
15. Control valve
10-228 PC78US-6
(10)
Function PC78US-6 Serial No. 6501 and up

Swing holding brake
• When the machine stops swinging, the swing
holding brake is applied automatically to prevent
hydraulic drift on a slope, etc.
• When the arm is moved in, the swing holding
brake is released to reduce the load on the swing
unit during digging work.
• If the offset operation is turned ON, the swing
holding brake is released to reduce the shocks
made when the offset operation is started and
stopped.
(PC78UU)
a If the swing holding brake is released, only the
hydraulic brake of the safety valve is used to
stop swinging. Accordingly, if the machine stops Relationship between swing holding brake can-
swinging on a slope, etc. the boom may drift cel switch and swing holding brake
hydraulically. Take care. Swing holding
brake cancel Operation
Releasing swing holding brake switch
• Even if the controller, etc. has a problem and the • If swing control lever or arm IN lever is
swing holding brake does not operate normally set to neutral position, swing holding
Auto brake is applied about 5 seconds later.
and the machine does not swing, the operator
(Normal state) • If swing control lever or arm IN lever is
can swing the machine by releasing the swing operated, swing holding brake is
holding brake with the swing holding brake can- released and machine can swing freely.
cel switch (S). • When swing holding brake system has
trouble, if swing holding brake cancel
(1) Auto: Normal state switch (S) is set to "Cancel (2)", swing
(2) Cancel: Abnormal state Cancel holding brake is released and machine
(Abnormal can swing.
state) • Even if swing control lever or arm IN
a Emergency swing holding brake cancel switch lever is set to neutral position, swing
(S) is of alternative type. If it is set to the "CAN- holding brake does not operate, how-
CEL (2)" position while the machine is normal, ever.
user code "E03" is displayed on the display unit.
Time chart of input and output signals
PC78US-6 Serial No. 4001 – 6500
PC78UU-6
PC78US-6 10-229
(10)
TRAVEL CONTROL FUNCTION

PC78US-6 Serial No. 4001 – 6500 (Blade-less specification)
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, the motor capacity changes to change the
5. Fuse box travel speed.
6. Controller
7. Monitor panel a When the engine is started, the travel speed
8. 2-stage travel speed selector solenoid valve boost selector switch is set to the low speed
9. Left travel motor position automatically.
10. Right travel motor
Travel speed boost Lo lamp lights Hi lamp lights up
11. Travel PPC valve selector switch up (Low speed) (High speed)
Motor capacity
13. Travel alarm (If equipped) (cc/rev)
36.3 24.1
14. Engine
Travel speed (km/h) 3.0 4.5
15. Hydraulic pump
16. Control valve Swash plate angle of
Max. Min.
travel motor
Input/Output signals
a. Controller power source
b. Solenoid power source
c. Monitor panel power source
d. S-NET drive signal
e. Solenoid valve drive signal
f. Travel PPC oil pressure switch signal
g. Travel alarm drive signal
10-230 PC78US-6
(10)
PC78US-6 Serial No. 4001 – 6500 (Blade specification)

PC78UU-6 Serial No. 22832 and up
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 aThe 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
Lo lamp Hi lamp
16a. Pump merge-divider valve Travel speed boost
lights up lights up
17. Travel speed boost pedal selector switch
(Low speed) (High speed)
Motor capacity
36.3 24.1
Input/Output signals (cc/rev)
Released
Travel speed boost pedal
a. Controller power source Travel speed

3.0 4.5
b. Solenoid power source (km/h)
c. Monitor panel power source Swash plate angle
Max. Min.
d. S-NET drive signal of travel motor
e. Solenoid valve drive signal Motor capacity
24.1 24.1
f. Travel PPC oil pressure switch signal (cc/rev)
Pressed
g. Travel alarm drive signal Travel speed

4.5 4.5
h. 2nd travel speed selection signal (km/h)
Swash plate angle
Min. Min.
of travel motor
PC78US-6 10-231
(10)
PC78US-6 Serial No. 6501 and up (Blade-less specification)

5. Fuse box d. S-NET drive signal
6. Controller e. Solenoid valve drive signal
7. Monitor panel f. Travel PPC oil pressure switch signal
8. 2-stage travel speed selector solenoid valve g. Travel alarm drive signal
9. Left travel motor
14. Engine
15. Hydraulic pump
16. Control valve
10-232 PC78US-6
(10)
PC78US-6 Serial No. 6501 and up (Blade specification)

5. Fuse box d. S-NET drive signal
6. Controller e. Solenoid valve drive signal
7. Monitor panel f. Travel PPC oil pressure switch signal
8. 2-stage travel speed selector solenoid valve g. Travel alarm drive signal
9. Left travel motor
14. Engine
15. Hydraulic pump
16. Control valve
PC78US-6 10-233
(10)
Function 2) Automatic selection corresponding to dis-

1. Changing travel speed charge pressure of pump
• If the travel speed boost selector switch is oper- • If travel pressure of 23.0MPa {235 kg/
ated, the motor capacity changes to change the cm 2 } or higher continues for 0.02 sec-
travel speed. onds or more when travel speed selector
switch is in HIGH, travel speed changes
a When the engine is started, the travel speed to LOW automatically.
boost selector switch is set to the low speed • If travel pressure of 13.2MPa {135 kg/
position automatically. cm2} or lower continues for 0.1 seconds
Travel speed boost Lo lamp lights Hi lamp lights up or more when travel speed selector
selector switch up (Low speed) (High speed) switch is in HIGH, travel speed changes
Motor capacity to HIGH automatically.
(cc/rev)
36.3 24.1 a If travel speed selector switch is in LOW,
Travel speed (km/h) 3.0 4.5 travel speed is not changed automati-
cally.
Swash plate angle of
Max. Min.
travel motor
2. "Automatic"change of travel speed

1) Automatic selection corresponding to engine
speed
• If engine speed drops to 1,350 rpm or
less when travel speed selector switch is
in HIGH and travel speed is HIGH, travel
speed changes to LOW automatically.
• If engine speed becomes 1,550 rpm or
less when travel speed selector switch is
in HIGH and travel speed is LOW, travel
speed changes to HIGH automatically.
a If travel speed selector switch is in LOW,
travel speed is not changed automati-
cally.
10-234 PC78US-6
(10)
PPC LOCK FUNCTION

PC78US-6 Serial No.: 4001 – 5500
a This drawing shows PC78US-6 of the blade specification.

5. Fuse box
6. Controller Function
7. Safety lock lever • The PPC lock switch is linked with the safety lock
8. PPC lock switch lever. If the safety lock lever is set to the LOCK
9. PPC lock solenoid valve position, the PPC lock switch is turned OFF.
10. Left work equipment PPC valve • If the PPC lock switch is turned OFF, the current
11. Right work equipment PPC valve to the PPC lock solenoid valve is cut out and the
12. Travel PPC valve work equipment does not move any more even if
13. Blade PPC valve (Blade specification) the work equipment control lever is operated.
14. Engine
15. Hydraulic pump
10-236 PC78US-6
(10)

a This drawing shows PC78US-6 of the blade specification.

5. Fuse box
13. Blade PPC valve (Blade specification) the work equipment control lever is operated.
14. Engine
15. Hydraulic pump
PC78US-6 10-237
(10)
PC78UU-6 Serial No.: 22832 – 23500

5. Fuse box
13. Blade PPC valve the work equipment control lever is operated.
14. Engine
15. Hydraulic pump
10-238 PC78US-6
(10)

5. Fuse box
13. Blade PPC valve the work equipment control lever is operated.
14. Engine
15. Hydraulic pump
PC78US-6 10-239
(10)
INTERFERENCE PREVENTION SYSTEM

PC78UU-6
• Structure of the machine's work equipment can introduce interference of the bucket against the cab when
you turn on the left offset operation or operation of the work equipment.This interference potentially occurs
at the front side and right side of the canopy or the cab.
• The interference prevention system constantly monitors the bucket position in order to automatically stop
movement of the work equipment and sound the alarm buzzer if the bucket approaches any of these inter-
fering zones.
Drawing dimension: A: 230 – 260 mm
B: 150 – 200 mm
• This function ensures work safety and operating performance in the left offset area.
• The potentiometers of boom (1), offset (2), and

arm (3) sense the boom turning angle, offset
turning angle, and arm turning angle. The con-
troller calculates coordinates X, Y, and Z con-
stantly from the signals of the potentiometers.
• If point A enters the zone where it is approaching
the interference zone (speed reducing zone), the
moving speed of the work equipment is lowered.
• If point A moves on and enters the interference
zone, the work equipment is stopped automati-
cally and the alarm buzzer is turned ON to pre-
vent interference.
• If the controller or any potentiometer has abnor-
mality, the controller cuts out the power for each
EPC valve and solenoid valve and stops the
work equipment. If you set the emergency work
equipment operation switch to the "In emer-
gency" position, however, you can do the all
operations temporarily.
10-240 PC78US-6
(10)
Overall operation diagram

a The bucket position in the diagram is somewhat modified from that in actual operations to facilitate descrip-
tions of the system function.
A. Interference
B. Emergency stop/alarm point
B1:50 mm
B2:50 mm
C. Stop/alarm point
C1:200 mm
C2:200 mm
D. Reduction start point
D1:1,500 mm
D2: 700 mm
E. Emergency stop zone
F. Stop zone
G. Reduction zone
H. Safety zone
PC78US-6 10-241
(10)
1. Reduction function
• Speed of the bucket is reduced when it passes
through the safety zone A and enters the reduc-
tion zone B. The system ensures smooth reduc-
tion of the bucket without introducing the "boom
up", "arm retract" and "offset left" speeds.
• In order to reduce the speed, EPC valve reduces
output pressure from PPC valve to the operation
valve.
2. Stop/alarm function
• If the bucket passes through the reduction zone
B and enters the interference zone C its move-
ment is automatically stopped and the alarm A. Safety zone
buzzer is turned on. B. Reduction zone
a The EPC valves cut off output pressure from the C. Interference zone
PPC valve to the operation valve to stop bucket
Boom RAISE
movement. Reduction operation Arm IN
a Resume bucket movement by driving the bucket Offset left
out of the stop zone using the operation not cur-
rently disabled.
Boom RAISE
3. Emergency stop/alarm function Stop operation Arm IN
Offset left
• If the bucket does not stop at the predetermined
Delayed sounding
stop point due to failures of the EPC valves, and Alarm buzzer intervals
enters the emergency stop zone, the system (once every 0.8 seconds)
stops action of all actuator, and sounds the alarm
buzzer.
• Using the solenoid valve, the system cuts off the Stop operation All actuator
source pressure from the control pump to the Quick sounding interval
Alarm buzzer (once every 0.4 seconds)
PPC valve. Thus, every operation using the PPC
circuit will be disabled.
a When this function has been turned on, you
need to resort to the cancel function for the
recovery. See the "Cancel Function" in Section
4.
10-242 PC78US-6
(10)
4. Cancel function
• If the emergency stop function is turned on, or if
the controller or any of the potentiometers fails,
the controller will stop action of the all actuator
by cutting off signal current to the solenoid and
EPC valves.
• This situation requires your immediate checkups.
In case the machine must be moved to a safe
place before starting the checkups, use the
emergency work equipment operation switch S
situated under the operator seat. Turning this
switch on allows you to move the work equip-
ment to any desired location.
(1) Normal position
(2) In emergency
• As soon as the emergency work equipment
operation switch S is turned on, "In emergency
(2)", the alarm buzzer will start sounding will also
start flashing to notify the operator that the can-
cel function has been turned on.
a If the electric circuit of any EPC valve has abnor-
mality (When user code "E41" of "Abnormality in
solenoid system" is displayed on the monitor
panel display), the cancel function is not turned
ON.
a When turning the emergency work equipment
operation switch S to the "emergency (2)" posi-
tion, be careful to operate the work equipment Stop cancel operation All actuator
because the interference prevention function of Alarm buzzer Sounded for 7 seconds
the controller does not work.
a The emergency work equipment operation
switch S is an auto-return type. Namely, if you
move your hand off the switch in the "In emer-
gency (2)" position, it will automatically return to
the "Normal (1)" position.
PC78US-6 10-243
(10)
5. Reset function • For the correction, stop the bucket in the

1) Input signal (potentiometer mount angle) specified position, then enter the automatic
reset function left-and-right stop position reset signal. With
• If a potentiometer is mounted at an inappro- this function, it will reference the actual out-
priate angle in its replacement or replace- put voltage from respective potentiometers,
ment of work equipment, error in input signal will calculate the difference (calculation error)
can result due to an error in the mounting between the computed value A and the stan-
angle. dard value B and stores it in memory as the
This reset function allows you to correct the "compensation value C".
error through a single switch operation with-
out measuring the output voltage level or
resorting to fine adjustment of the potentiom-
eter.
• For the correction, enter the input reset sig-
nal while maintaining the boom up, arm
retract and offset right at the stroke end. The
computer will determine the difference
between the angle A computed based upon
actual output voltage from respective potenti-
ometers and the specified angle B on the
computer (mounting error). The difference
will be stored in memory as the "compensa-
tion value C".
2) Automatic fore-and-aft stop position reset

function
• When an error has resulted in the automatic
cab fore stop position from errors in measur-
ing the work equipment size (used in the
bucket position calculation) or computer cal-
culation error, this function allows you to cor-
rect it in a single switch operation.
• For the correction, stop the bucket in the
specified position, then enter the automatic
fore-and-aft stop position reset signal. With
this function, it will reference the actual out-
put voltage from respective potentiometers,
will calculate the difference (calculation error)
between the computed value A and the stan-
dard value B and stores it in memory as the
"compensation value C".
3) Automatic left-and-right stop position

reset function
• When an error has resulted in the automatic
side stop position of the cab from errors in
measuring the work equipment size (used in
the bucket position calculation) or computer
calculation error, this function allows you to
correct it in a single switch operation.
• This function can also be used for correcting
the stop position when an optional narrower
or wider bucket is used.
10-244 PC78US-6
(10)
4) Depth indication reset function

• When an error has resulted in the depth indi-
cation from errors in measuring the work
equipment size (used in the bucket position
calculation) or computer calculation error,
this function allows you to correct it in a sin-
gle switch operation.
• For the correction, place the bucket on the
ground surface at points a and then b, then
enter the depth indication reset signal when
the bucket is at a as well as at b. This func-
tion will determine the difference (calculation
error) between the actual depth A and the
depth B calculated based upon the output
voltage from respective potentiometers and
stores it in memory as the "compensation
value C".
a A compensation value once stored will
remain undeleted if you turn off the starter
switch.
a If the work equipment positioned significantly
away from the specified position, the com-
pensation value becomes 0 (zero). In this
case, the position control is turned on without
a compensation value.
a For detailed procedures for resetting, refer to
the "TESTING AND ADJUSTING" section.
PC78US-6 10-245
(10)
DEPTH MEASUREMENT SYSTEM

• This system facilitates your operations by dis-
playing a current digging depth or depth of a tar-
get of measurement on the monitor panel.
• Two depth indication approaches are available
from the depth measurement system. One is a
measurement from the ground level (G. L.) and
the other is that from the datum plane.
a When the starter switch is turned on, a measure-
ment from the ground level is automatically
turned on.
1. Depth-from-Ground-Level display function

• The depth C of the measurement level B from 1. Display
the ground level (G.L.) is kept displayed on the 2. Depth set 0 indicator
monitor panel depth indicator during the opera- 3. Height indicator
tion. 4. Setup switch
5. Selector switch
[Setup procedure]
• Turn the starter switch on and this function will
be automatically started.
[Display method]
• Depth under the ground level is displayed in 0.1
mm steps.
a Fractions are rounded off at two decimal places.
• A height above the ground level is preceded by
the indication "UP".
a You must stretch the bucket straight when set-
ting the zero point in this display system. If the
bucket is in any other position, discrepancy E
can result from the displayed and actual depth.
a If you select the Depth-from-Datum-Plane Dis-
play Function, this function will be cancelled.
10-246 PC78US-6
(10)
2. Depth-from-Datum-Plane display function

[Depth 0 set mode]
• This function displays a depth from any datum
plane you set on the monitor panel depth indica-
tor as long as your operation is continued.
a If you select this function, the Depth-from-
Ground-Level display Function is automatically
cancelled.
[Setup procedures]
• Move the bucket to the datum plane A.
• Press the selector switch to flash the depth set 0
indicator (The indicator flashes for 3 seconds).
• While the indicator is flashing, press the setup
switch. Check that the indicator lights up and
"0.0" is displayed.
a Set the bucket in the same position when the
datum plane A is set and when the bucket is
placed on the measurement level B.
a If the bucket is not set in the same position, the
indicated depth may be different from the actual
depth.
[Display method]
• Depth below the datum plane A is indicated in
0.1 mm steps.
a Fractions are rounded off at two decimal places.
• A depth above the datum plane A will be pre-
ceded by the indication "UP".
[Canceling procedures]
• Press the setup switch again.
• The indicator starts flashing and goes off after 3
seconds.
a If you cancel this function, the "Depth-from-
Ground-Level Display Function" will be restored
on the depth indicator.
• Explanatory notes on the depth measurement

C = Yc - Ya
D = Yc - Yb
C : Depth from the ground level (G.L.)
D : Depth from the datum plane.
Ya : Depth from the boom foot to the ground
level (constant)
Yb : Depth from the boom foot to any datum
plane selected
Yc : Depth from the boom foot to the measure-
ment level
PC78US-6 10-247
(10)
AUTOMATIC HEIGHT STOP SYSTEM

• Automatic height stop function is capable of
stopping movement of the boom when it reaches
the predetermined height during operation.
• These functions are helpful in ensuring work
safety and efficiency when working in job sites
where obstacles such as electric wires are
present.
1. Height setup function [height mode]

• You can stop movement of the boom during
operation at any height A you have previously
set.
• You can limit the height of the work equipment by
setting the limit on the boom lift height. 1. Display
• This function reduces speed of the boom prior to 2. Depth set 0 indicator
the forced stop to minimize resulting shocks or 3. Height indicator
impacts. 4. Setup switch
a Note that this function is not usable for limiting 5. Selector switch
the bucket height.
[Setup procedures]
• Lift the boom up to the height where you want to
set the limit.
• Press the selector switch to flash the height indi-
cator (The indicator flashes for 3 seconds).
• While the indicator is flashing, press the setup
switch. Check that the indicator lights up.
[Operation]
• Lower the boom. Then, if you raise the boom
during work, the buzzer always sounds 2 times
at the set position.
• This stop is caused by reducing and then shut-
ting down the output pressure from the PPC
valve to the boom operation valve (UP side) at
the EPC valve.
A: Setup position
B: Setup angle
C: Operation possible zone
D: Operation impossible zone
[Canceling procedures]
• Press the setup switch again.
• The indicator starts flashing and goes off after 3
seconds.
10-248 PC78US-6
(10)
BOOM END CUSHIONING FUNCTION

• In the boom up move, this function reduces
speed of the boom before it reaches the stroke
end to lighten resulting impacts and, thus, to pre-
vent spillage of dirt or dust as well as lighten load
to the machine body and cylinder.
[Operation]
• A cushioning zone is provided before the boom-
up stroke end (approximately 45°).
• This function reduces move speed of the boom
in this zone by reducing output pressure from the
boom PPC valve to the boom operation valve
(UP move) at the EPC valve.
• This arrangement helps reducing undesirable
impacts at the stroke end.
ARM END CUSHIONING FUNCTION

• In the arm retract move, this function reduces
speed of the arm before it reaches the stroke to
lighten resulting impacts and, thus, to prevent
spillage of dirt or dust as well as lighten load to
the machine body and cylinder.
[Operation]
• A cushioning zone is provided before the arm
retract stroke end (approximately 40°).
• This function reduces move speed of the arm in
this zone by reducing output pressure from the
arm PPC valve to the arm operation valve
(RETRACT move) at the EPC valve.
• This arrangement helps reduce undesirable
impacts at the stroke end.
PC78US-6 10-249
(10)
SELF-DIAGNOSTIC FUNCTION 2. Error code memory function

• If a problem occurs in the leading system, it
1. Error code display and alarm function
is detected by the self-diagnostic function
• The system of this function consists of the
and its error code is stored in memory.
controller and the electronic components
a For details of the display and resetting
such as the potentiometers that output input
method, see TESTING AND ADJUSTING.
signals and the solenoid valves and EPC
valves that receive output signals. The con-
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 troubleshoot-
ing 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.
10-250 PC78US-6
(10)
MAINTENANCE STANDARD SYSTEM COMPONENTS
SYSTEM COMPONENTS
Fuel control dial
PC78US-6 Serial No.: 4001 – 6500

10-252 PC78US-6
(10)
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The potentiometer (5) is installed under the knob
(1) below the monitor panel. When the knob is
turned, the shaft of the potentiometer (5) rotates.
• When the shaft rotates, the resistance value of
the variable resistor in the potentiometer (5)
changes and any throttle signal is sent to the
controller.
PC78US-6 10-253
(10)
Fuel control motor

PC78US-6 Serial No.: 4001 – 6500
1. Motor assembly Input and output signals

2. Cable SWP-6P [CN-K27]
3. Connector
Pin No. Signal name Input/Output
signal
1 Motor acceleration signal Input
2 Power source —
3 One-touch deceleration signal Output
4 Motor deceleration signal Input
5 Acceleration signal Output
6 Deceleration signal Output
10-254 PC78US-6
(10)
1. Cable Input and output signals

2. Connector DEUTSCH-6P [CN-M48]
3. Potentiometer
4. Pulley Input/Output
Pin No. Signal name signal
5. Gear unit
6. Motor 1 Potentiometer input Input
2 Potentiometer output Output
3 Potentiometer GND —
4 NC —
5 Motor (+) Input
6 Motor (Ð) Input
PC78US-6 10-255
(10)
Controller
PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
Model selection table

CN-M96, 37P CN-M96, 27P CN-M96, 7P CN-M96, 16P
PC78US-6 Q Q
PC78UU-6 Q
Attachment selection table
CN-M95, 17P CN-M95, 11P CN-M96, 17P

Standard arm Q
Long arm Q
Standard arm with
X-counterweight Q Q
Long arm with X-
counterweight Q Q
Sliding arm Q Q
Multi-changer arm
Q : GND
: OPEN
10-256 PC78US-6
(10)
Input/output signals
DEUTSCH-24P [CN-M95]
Pin Pin
No. Signal name I/O signal No. Signal name I/O signal
1 NC — 13 NC —
2 Boom cylinder bottom pressure sensor Input 14 Offset angle Input
3 Boom angle Input 15 NC —
4 GND (Signal) — 16 NC —
5 2-stage travel speed selection switch Input 17 Attachment 1 Input
6 Arm IN PPC oil pressure switch Input 18 Travel PPC oil pressure switch Input
7 NC — 19 Boom cylinder head pressure sensor Input
8 Slide capacity Input 20 Arm angle Input
9 NC — 21 GND (Analog) —
10 GND signal — 22 Sensor power source (+5 V) Output
11 Attachment 2 Input 23 NC —
12 Boom RAISE oil pressure switch Input 24 Swing PPC oil pressure switch Input
DEUTSCH-40P (1) [CN-M96]

Pin Pin
Signal name I/O signal Signal name I/O signal
No. No.
1 NC — 21 S-NET Input/Output
2 Set Input 22 CAN0-L Input/Output
3 Mode select 2 Input 23 CAN1-L Input/Output
4 232C_RXD Input 24 Prevention signal for writing in flash memory Input
5 NC — 25 NC —
6 NC — 26 Reset 2 Input
7 UU/US selection signal Input 27 Mode selection 2 Input
8 Electrical system Output 28 — —
9 Date Output 29 GND pulse —
10 NC — 30 NC —
11 NC — 31 GND (S-NET) —
12 CAN shield — 32 CAN0-H Input/Output
13 Mode selection 1 Input 33 CAN1-H Input/Output
14 232C_TXD Output 34 GND (232C) —
15 Back-up light signal Input 35 Cancel signal for arm angle alam Input
16 Main monitor selection signal Input 36 Reset 1 Input
17 Attachment 3 Input 37 Model selection 1 Input
18 Strobe Output 38 Clear Input
19 Clock Output 39 GND (Pulse) —
20 Slide arm limit switch Input 40 Engine speed sensor (+) Input

Pin Pin
No. No.
1 Controller power Input 21 GND (Controller) —
2 Solenoid power Input 22 Solenoid power source Input
3 GND (Solenoid) — 23 GND (Solenoid) —
4 NC — 24 Key signal Input
5 Arm IN EPC valve Output 25 Governor motor relay (For acceleration) Output
6 NC — 26 Boom RAISE EPC valve Output
7 Swing holding brake solenoid valve Output 27 2-stage travel speed selector solenoid valve Output
8 One-touch deceleration pilot lamp Output 28 NC —
9 One-touch deceleration switch Input 29 Deceleration signal Input
10 Air conditioner signal Input 30 Emergency work equipment operation switch Input
11 Controller power Input 31 GND controller —
12 Solenoid power Input 32 GND controller —
13 GND (Solenoid) — 33 GND controller —
14 Key signal Input 34 NC —
15 Offset left stop EPC valve Output 35 Governor motor relay (For deceleration) Output
16 TVC-EPC vlave Output 36 NC —
17 Swing and travel alarm Output 37 — —
18 Governor motor relay (For drive) Output 38 PPC lock solenoid valve Output
19 Acceleration signal Input 39 Auto-deceleration signal Input
20 Alarm actuation switch Input 40 NC —
PC78US-6 10-257
(10)
PC78US-6 Serial No.: 5501 – 6500

CN-M96, 37P CN-M96, 27P CN-M96, 7P CN-M96, 16P
PC78US-6 Q Q
PC78UU-6 Q
Attachment selection table
CN-M95, 17P CN-M95, 11P CN-M96, 17P

Standard arm Q
Long arm Q
Standard arm with
X-counterweight Q Q
Long arm with X-
counterweight Q Q
Sliding arm Q Q
Multi-changer arm
Q : GND
: OPEN
10-258 PC78US-6
(10)
Input/output signals
Pin Pin
No. Signal name I/O signal No. Signal name I/O signal
1 NC — 13 NC —
2 Boom cylinder bottom pressure sensor Input 14 Offset angle Input
3 Boom angle Input 15 NC —
4 GND (Signal) — 16 NC —
5 2-stage travel speed selection switch Input 17 Attachment 1 Input
6 Arm IN PPC oil pressure switch Input 18 Travel PPC oil pressure switch Input
7 NC — 19 Boom cylinder head pressure sensor Input
8 Slide capacity Input 20 Arm angle Input
9 NC — 21 GND (Analog) —
10 GND signal — 22 Sensor power source (+5 V) Output
11 Attachment 2 Input 23 NC —
12 Boom RAISE oil pressure switch Input 24 Swing PPC oil pressure switch Input

Pin Pin
No. No.
1 NC — 21 S-NET Input/Output
2 Set Input 22 CAN0-L Input/Output
3 Mode select 2 Input 23 CAN1-L Input/Output
4 232C_RXD Input 24 Prevention signal for writing in flash memory Input
5 NC — 25 Signal for selecting Tire 2 Input
6 NC — 26 Reset 2 Input
7 UU/US selection signal Input 27 Mode selection 2 Input
8 Electrical system Output 28 — —
9 Date Output 29 GND pulse —
10 NC — 30 NC —
11 NC — 31 GND (S-NET) —
12 CAN shield — 32 CAN0-H Input/Output
13 Mode selection 1 Input 33 CAN1-H Input/Output
14 232C_TXD Output 34 GND (232C) —
15 Back-up light signal Input 35 Cancel signal for arm angle alam Input
16 Main monitor selection signal Input 36 Reset 1 Input
17 Attachment 3 Input 37 Model selection 1 Input
18 Strobe Output 38 Clear Input
19 Clock Output 39 GND (Pulse) —
20 Slide arm limit switch Input 40 Engine speed sensor (+) Input

Pin Pin
No. No.
1 Controller power Input 21 GND (Controller) —
2 Solenoid power Input 22 Solenoid power source Input
3 GND (Solenoid) — 23 GND (Solenoid) —
4 NC — 24 Key signal Input
5 Arm IN EPC valve Output 25 Governor motor relay (For acceleration) Output
6 NC — 26 Boom RAISE EPC valve Output
7 Swing holding brake solenoid valve Output 27 2-stage travel speed selector solenoid valve Output
8 One-touch deceleration pilot lamp Output 28 NC —
9 One-touch deceleration switch Input 29 Deceleration signal Input
10 Air conditioner signal Input 30 Emergency work equipment operation switch Input
11 Controller power Input 31 GND controller —
12 Solenoid power Input 32 GND controller —
13 GND (Solenoid) — 33 GND controller —
14 Key signal Input 34 NC —
15 Offset left stop EPC valve Output 35 Governor motor relay (For deceleration) Output
16 TVC-EPC vlave Output 36 NC —
17 Swing and travel alarm Output 37 — —
18 NC — 38 PPC lock solenoid valve Output
19 Acceleration signal Input 39 Auto-deceleration signal Input
20 Alarm actuation switch Input 40 NC —
PC78US-6 10-259
(10)
Pin Signal name I/O signal Pin Signal name I/O signal
No. No.
1 Controller power supply Input 21 GND (Controller) —
2 Key signal Input 22 Potentiometer power supply (+5 V) Output
3 NC — 23 Governor motor FB potentiometer Input
4 Boom angle sensor Input 24 Pump pressure sensor Input
5 Overload alarm ON switch Input 25 Swing PPC oil pressure switch (Right, left) Input
6 Engine speed sensor (+) Input 26 Arm IN PPC oil pressure switch Input
7 Governor motor drive relay (For acceleration) Output 27 Travel/Swing alarm drive relay Output
8 NC — 28 CANO-H Input/Output
9 TVC-EPC valve Output Rotary lamp relay & bucket DUMP prohibi-
29 tion solenoid Output
10 2nd travel speed selection solenoid valve Output
11 Controller power supply Input 30 Solenoid power supply Input
12 Key signal Input 31 GND (Controller) Input
13 Fuel control dial Input 32 GND (Analog) Input
14 Arm angle sensor Input 33 Boom bottom pressure sensor Input
Travel PPC oil pressure switch 34 One-touch deceleration switch Input
15 Input 35 Boom RAISE PPC oil pressure switch
(Right, left, forward, reverse) Input
16 NC — 36 NC —
17 Governor motor drive relay (For deceleration) Output 37 Air conditioner compressor signal Input
18 S-NET Input/Output 38 CANO-L Input/Output
19 Swing holding brake solenoid valve Output 39 CANO-SH —
Engine STOP solenoid seizure prevention 40 GND (Common to solenoids) —
20 relay Output
10-260 PC78US-6
(10)
Potentiometer
PC78UU-6
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.
PC78US-6 10-261
(10)
Register
1. Register
2. Connector
Specifications
Model System Resistance (z)
PC78US-6 For TVC-EPC valve of

hydraulic pump 30
For boom raise stop EPC

PC78UU-6 valve
Arm IN stop EPC valve 5
Left offset stop EPC valve
Function
• When the emergency pump drive switch is
turned ON, this resistor is used to supply a
proper current to EPC valve according to the
condition of the work equipment.
a Current does not flow under the normal condi-
tion.
10-262 PC78US-6
(10)
PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Contact composition: N.O. contact
Operation (ON) pressure:490 ± 98.1 kPa
{5.0 ± 1.0 kg/cm2}
Reset (OFF) pressure: 294 ± 49.0 kPa
{3.0 ± 0.5 kg/cm2}
Function
• The control valve has 5 PPC oil pressure
switches, which sense the operating condition of
each actuator from the PPC pressure and send it
to the controller.
PC78US-6 10-263
(10)
Pump pressure sensor

1. Plug
2. Sensor
3. Connector
Function
• Mounted on the inlet circuit of control valve, this
sensor changes discharging pressure of pump
into voltage, and send it to automatic travel
speed change controller.
Engine speed sensor

a See SENSOR.
TVC-EPC valve
aSee HYDRAULIC PUMP.
PPC lock solenoid valve
2-stage travel speed selector solenoid

valve
Swing holding brake solenoid valve
Boom raise stop solenoid valve

PC78UU-6
Arm IN stop EPC valve

PC78UU-6
Left offset stop solenoid valve

PC78UU-6
a See EPC SOLENOID VALVE.
Monitor panel
a See MONITOR SYSTEM
10-264 PC78US-6
(10)
MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
1. Monitor panel Outline

2. Battery • The monitor system monitors the machine condi-
3. Controller tion by the sensors installed to various parts of
4. Sensors and switches the machine and processes and displays it on
5. Wiper motor, windshield washer motor the panel immediately to notify the operator of
the condition of the machine.
Input and output signals
a. Power source
b. Switch signal
c. Caution signal
d. Sensor, switch signal
e. Sensor, switch signal
f. Drive output
PC78US-6 10-265
(10)
MONITOR PANEL
PC78US-6
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.

AMP070-12P [CN-P01] AMP040-20P [CN-P02]
Pin Input/ Pin Input/
Signal name Output Signal name Output
No. No.
signal signal
1 Starting switch (Battery) Input 1 Engine coolant temperature Input
2 Starting switch (Battery) Input 2 Fuel level Input
3 Windshield washer motor output Output 3 Radiator water level Input
4 Starting switch (Terminal C) Input 4 NC Input
5 Wiper W contact Input 5 Air cleaner clogged Input
6 GND — 6 NC Input
7 GND — 7 Engine oil pressure Input
8 VB+ (24 V) Input 8 Engine oil level Input
9 Wiper motor (+) Output 9 S-NET signal Input/Output
10 Wiper motor (–) Output 10 S-NET signal Input/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) —
10-266 PC78US-6
(10)
PC78UU-6
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.

AMP070-12P [CN-P01] AMP040-20P [CN-P02]
Pin Input/ Pin Input/
Signal name Output Signal name Output
No. No.
signal signal
1 Starting switch (Battery) Input 1 Engine coolant temperature Input
2 Starting switch (Battery) Input 2 Fuel level Input
3 Windshield washer motor output Output 3 Radiator water level Input
4 Starting switch (Terminal C) Input 4 NC Input
5 Wiper W contact Input 5 Air cleaner clogged Input
6 GND — 6 NC Input
7 GND — 7 Engine oil pressure Input
8 VB+ (24 V) Input 8 Engine oil level Input
9 Wiper motor (+) Output 9 S-NET signal Input/Output
10 Wiper motor (–) Output 10 S-NET signal Input/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) —
PC78US-6 10-267
(10)
METER DISPLAY UNIT
Display
No. Display type Display item Display range Display method color Remarks
Time is measured while engine is running
1 Service meter 0-99999.9 h (alternator is generating) (Lamp always lights
up even if starting switch is at OFF position.)
If electric control system has trouble, 3
alphanumerics (user code, service code) is
displayed. In depth 0 set mode, depth from
datum plane is displayed.
3 alphanumerics [*2]
[*1] Display [*2] 0 – 9.9 m Blue LCD
2 0 – 9.9 m • Depth of bucket from ground level is dis-
played.
• If bucket is above ground level, "UP" is dis-
played.
• In depth set 0 mode, depth from datum
plane is displayed.
3a Gauge See above Segment of corresponding level and all seg-

drawing. ments below it light up.
Coolant [Monitor lamp blinks when 8th level lights up
temperature Above set
3b Monitor temperature (above 99°C). Monitor lamp blinks and alarm Red LED
(99°C) buzzer sounds when 9th level lights up.]
4a Gauge See above Segment of corresponding level and all seg- Blue LCD
Fuel level
Below set level [Monitor lamp blinks when 1st level lights up
4b Monitor (below 30 liters).] Red LED
(30 liters)
Lamp lights up for about 30 seconds when
starting switch is turned to HEAT position, then
5 Preheating During preheating blinks (for about 10 seconds) to show that pre-
Pilot heating is finished and then goes off. Green
When one-touch
6 One-touch decelerator Lamp lights up when one-touch decelerator
deceleration operates operates.
Lamp
When charging Lamp lights up when starting switch is turned
7 Charge level is defective to ON position and goes off after engine starts.
(charge voltage Lamp is turned off when normal and on when
Caution < battery voltate) Red
abnormal.
Engine oil Below set pressure (If trouble occurs while engine is running,
8
pressurre (49 kPa {0.5 kg/cm2}) buzzer sounds.)
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
*2: This function is installed to only PC78UU-6.
10-268 PC78US-6
(10)
MONITOR SWITCH UNIT

PC78US-6
No. Name Function Operation

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

denote the position to which each switch is reset
when the starting switch is turned to the "ON"
position.
PC78US-6 10-269
(10)
PC78UU-6
No. Name Function Operation

Switch used to select 1 of 2 travel speeds
Travel speed selector
1 When Lo lamp is ON: Low travel speed Lo io Hi
switch
When Hi lamp is ON: High travel speed
Switch used to set movement and power of work equip-
ment
Working mode Active (OFF) io E
2 When E lamp is OFF: Active mode (For heavy load work)
selector switch (Lamp OFF)
When E lamp is ON: E mode (For work in which fuel con-
sumption is more important)
Switch used to operate front glass wiper
When ON lamp is ON: Wiper operates continuously. OFF (Lamp OFF) o INT (Intermittent) o
3 Wiper switch
When INT lamp is ON: Wiper operates intermittently. ON (Continuous)
When all lamps are OFF: Wiper is stopped.
[When wiper is stopped]
OFF:After switch is released, wiper oper-
ates by 2 cycles continuously and
then stops.
Windshield washer
4 Switch used to spout washing liquid over front glass [When wiper is operating intermittently]
switch
OFF:After switch is released, wiper oper-
ates for 2 cycles continuously and
then starts intermittent operation
again.
Depth set 0 mode and height mode are set/cleared with
Mode selector switch
selector switch and set/clear switch.
5a. Selector
5 Switch used to select depth set 0 mode or height mode OFF (Lamp OFF) o Depth set 0 o Height
switch
5b. Set/Clear • Mode of flashing indicator is set.
Switch used to set and clear mode
switch • Mode of lighting indicator is cleared.
a The boldfaced letters in the operation column

denote the position to which each switch is reset
when the starting switch is turned to the "ON"
position.
10-270 PC78US-6
(10)
MAINTENANCE STANDARD SENSORS
SENSORS
• The signals from the sensors are input directly to the panel or controller.
• The sensors are classified into 3 of contact type, resistance type, and electromagnetic type.
• Either of each sensor of contact type must be connected to the chassis ground.
Type of display Type of sensor Sensing method When normal When abnormal
Caution Engine oil pressure Contact OFF (Open) ON (Closed)
Coolant temperature Resistance — —
Gauge
Fuel level Resistance — —
– Engine speed Electromagnetic — —
ENGINE OIL PRESSURE SENSOR
1. Plug 3. Contact 5. Spring

2. Contact ring 4. Diaphragm 6. Terminal
Function
• This sensor is installed to the engine cylinder block to sense oil pressure with diaphragm (4). If the oil pres-
sure lowers below the set level, the switch is turned on and the signal is sent to the monitor panel.
COOLANT TEMPERATURE SENSOR
1. Connector 2. Plug 3. Thermistor
Function
• This sensor is installed to the engine cylinder block. It senses changes of temperature by changes of the
resistance of thermistor (3) and sends the change signals to the monitor panel.
PC78US-6 10-271
(10)
FUEL LEVEL SENSOR

PC78US-6 Serial No.: 4001 – 6500
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.
10-272 PC78US-6
(10)
1. Float 3. Variable resistor

2. Arm 4. Connector
FUNCTION
• The fuel level sensor is installed to the side of the fuel tank and its float moves up and down according to the
fuel level in the tank. The movement of the float operates the variable resistor through the arm, and then
signals are generated according to the change of the resistance.
PC78US-6 10-273
(10)
ENGINE SPEED SENSOR
1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
• This sensor is installed to the engine flywheel cover. It counts the number of teeth which pass in front of it
and sends the signals to the controller.
Reference: Number of teeth of ring gear: 110
10-274 PC78US-6
(10)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE ..................................... 20- 2

Standard value table for engine ............................. 20- 2
Standard value table for chassis ............................. 20- 3
Standard value table for electrical parts ................. 20-12
TESTING AND ADJUSTING.................................. 20-101
TROUBLESHOOTING ........................................... 20-201
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.
WARNING! 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.
WARNING! When carrying out work together with other workers, always use signals and do not let
unauthorized people near the machine.
WARNING! 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.
WARNING! Be carught in the fan, fan belt or other rotating parts.
PC78US-6 20-1
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
PC78US-6: 4001 – 5500
Machine Model
PC78UU-6: 22832 – 23500
Engine 4D95LE-2
Standard Value for

Item Measurement Conditions Unit New Machine Service Limit Value
High idling (When mounted on machine) 2,020 ± 50 —
Revolving speed Low idling (When mounted on machine) rpm 1,130 +50 —
0
Rated revolving speed 1,850 —
At sudden acceleration Max. 4.0 6.0

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

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

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

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

{Min. 1.8} {1.5}
At low idling
(SAE10W) Min. 0.15 0.13
{Min. 1.5} {1.3}
Oil temperature All revolution range (In oil pan) °C 90 – 110 120
Fuel injection timing Before compression top dead center ° (Deg.) 10 ± 0.75 10 ± 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
6 – 10 6 – 10
sor belt approx. 58.8 N {6
kg}
20-2 PC78US-6
(7)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

PC78US-6: 5501 and up
Machine Model
PC78UU-6: 23501 and up
Engine S4D95LE-3
Item Measurement Conditions Unit Standard Value for Service Limit Value
New Machine
High idling (When mounted on machine) 2,020 ± 50 —
Revolving speed Low idling (When mounted on machine) rpm 1,130 +50 —
0
Rated revolving speed 1,850 —
At sudden acceleration Max. 3.5 6.0

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

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

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

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

{Min. 1.8} {1.5}
At low idling
Min. 0.15 0.13
(SAE10W)
{Min. 1.5} {1.3}
Oil temperature All revolution range (In oil pan) °C 90 – 110 120
Fuel injection timing Before compression top dead center ° (Deg.) 5 ± 0.75 5 ± 0.75
Deflection under
Tension of fan belt finger pressure of 6 – 10 6 – 10
approx. 58.8 N {6
kg}
mm
Deflection under
Tension of air compres- finger pressure of 6 – 10 6 – 10
sor belt approx. 58.8 N {6
kg}
PC78US-6 20-2-1
(7)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

PC78US-6
Machine Model
PC78UU-6
Cate- Standard Value Service Limit

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

• Engine water temperature: Within operat-
At relief of 1 pump rpm Min. 1,800 Min. 1,800
ing range
• Relief of 1 pump....Arm DUMP relief
Boom control lever N → RAISE, LOWER 85 ± 10 Max. 95

Min. 75
Max. 95
Arm control lever N → IN, OUT 85 ± 10
Min. 75
Max. 95
Stroke of control lever
Bucket control lever • Center of N → CURL, DUMP 85 ± 10

Min. 75
lever grip
• End of pedal Max. 95
Swing control lever • Read Max. N → LEFT, RIGHT 85 ± 10
Min. 75
mm
value
Max. 23
Offset control pedal through N → LEFT, RIGHT 21 ± 2 Min. 19
stroke end
• Stop engine
Blade control lever N → RAISE, LOWER 53 ± 6 Max. 59
Min. 47
Max. 127
Travel control lever N → FORWARD, REVERSE 115 ± 12 Min. 103
Play of control lever Max. 10 Max. 15
15.7 ± 3.9 Max. 24.5

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

• Measure operating effort of each control {1.6 ± 0.4} {Max. 2.5}
Operating effort of control lever
lever by installing push-pull scale to center

Bucket control lever of its grip. 12.7 ± 2.9 Max. 21.6
{1.3 ± 0.3} {Max. 2.2}
• Measure operating effort of each control
pedal by installing push-pull scale to its
12.7 ± 2.9 Max. 21.6
Swing control lever end. {1.3 ± 0.3} {Max. 2.2}
• Read Max. value through stroke end. N
{kg}
• Stop engine. 78.4 ± 19.6 Max. 117.7
Offset control pedal
{8.0 ± 2} {Max. 12}
25.5 ± 6.9 Max. 39.2

Blade control lever {2.6 ± 0.7} {Max. 4.0}
24.5 ± 5.9 Max. 39.2

Lever
{2.5 ± 0.6} {Max. 4.0}
Travel control lever
74.5 ± 18.6 Max. 107.6
Pedal
{7.6 ± 1.9} {Max. 11}
PC78US-6 20-3
➄
PC78US-6
Machine Model
PC78UU-6
Standard
Cate- Value for Service Limit
Item Measurement Conditions Unit
gory New Value
Machine
26.5 ± 0.98 26.5 ± 1.47

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

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

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

Offset {270 ± 10} {270 ± 15}
20.5 ± 0.98 20.5 ± 1.47

With blade
• Hydraulic oil temperature: 45 – 55 °C {210 ± 10} {210 ± 15}
Swing • Relief pressure with engine at full throt-
tle (Relieve only circuit to be mea- 23 ± 0.98 23 ± 1.47
Oil pressure
Without blade {235 ± 10} {235 ± 15}

sured) MPa
{kg/cm2} 12.74 + 01.96
RAISE 12.74 ± 1.47
{130 ± 10} {130 ± 15}
Blade
21.08 ± 0.98 21.08 ± 1.47
LOWER {215 ± 10} {215 ± 15}
26.5 ± 0.98 26.5 ± 1.47

Travel
{270 ± 10} {270 ± 15}
3.14 + 0.2
0
3.14 + 0.3
0
Control
{32 + 02 } {32 + 03 }
• Hydraulic oil temperature: 45 – 55 °C

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

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

• Deviation of swing circle made when it stops after swing-
ing 1 turn
• Value in { } is deviation of periphery of swing circle
Swing
90° sec 2.2 ± 0.3 Max. 2.8

{2.6 ± 0.3} {Max. 3.2}
Time required
to start swing-
ing
• Run engine at full throttle
• Time required to swing 90° and 180° 3.7 ± 0.3 Max. 4.3
180°
{4.1 ± 0.3} {Max. 4.7}
from starting point
• Value in { } is measured under rated
bucket load
20-4 PC78US-6
(12)
PC78US-6
Machine Model
PC78UU-6
Standard Service
Cate- Value for
Item Measurement Conditions Unit Limit
gory New
Machine Value
Position of work equipment Max. Reach
Time required to
finish swinging sec 30 ± 2 Max. 35

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

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

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

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

• Hydraulic oil temperature: 45 ~ 55 °C 25 ± 3 30
High speed
• Raise either track and measure time required {23 ± 2} {28}
to move 5 turns after finishing 1 turn.
• { }: Rubber shoe specification
Travel
Position of work equipment sec
24 ± 2 28
Low speed {23 ± 2} {20}
Travel speed (2)
• Run engine at full throttle 16 ± 2 28

• Hydraulic oil temperature: 45 ~ 55 °C High speed
{14.5 ± 2} {18.5}
• Measure time required to travel 20 m after run-
up of at least 10 m on flat surface
• { }: Rubber shoe specification
PC78US-6 20-5
➄
PC78US-6
Machine Model
PC78UU-6
Standard Service
Cate- Value for
gory New
Machine Value
Position for measurement

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

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

Leakage from • Hydraulic oil temperature: 45 ~ 55 °C /min. Max. 4.5 Max. 7.0
travel motor
• Lock shoes and relieve travel circuit
20-6 PC78US-6
➄
PC78US-6
Machine Model
PC78UU-6
Standard Service
Cate- Value for
gory New
Machine Value

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

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

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

US: 3.2 ± 0.3 Max. 4
Boom
Bucket tooth on RAISE UU: 3.5 ± 0.4 Max. 4.3
ground (To just before (To just before
cushion) cushion)
Max. extension of
cylinder LOWER 3.3 ± 0.3 Max. 3.9
Work equipment speed

sec
Arm 3.2 ± 0.3 Max. 4.0
Max. retraction of IN (To just before (To just before
cylinder cushion) cushion)
• Run engine at full throttle 2.7 ± 0.3 Max. 3.3

Max. extension of
cylinder • Hydraulic oil temperature: 45 – 55 °C OUT (To just before (To just before
• Offset to right so that clearance between cushion) cushion)
right end of operator's cab and bucket will be
200 mm or wider (Only PC78UU-6).
PC78US-6 20-7
(12)
PC78US-6
Machine Model
PC78UU-6
Standard Service
Cate- Value for
gory New
Machine Value
Bucket
Max. retraction of CURL 3.1 ± 0.4 Max. 3.9
cylinder
Max. extension of DUMP 2.1 ± 0.3 Max. 2.9

cylinder
Offset
Work equipment speed
Max. retraction of Offset (L.H.) 4.3 ± 0.4 Max. 5.2

cylinder
Max. extension of
cylinder Offset (R.H.) 4.5 ± 0.4 Max. 5.3
Work equipment
Blade sec
Blade on ground RAISE 1.3 ± 0.3 Max. 2.1
Max. height of blade LOWER 1.3 ± 0.3 Max. 2.1


Time lag
Boom Max. 2 Max. 3.9
• Run engine at slow

• Retract arm and bucket cylinder fully and lower boom
from Max. height.
Measure time from when bucket touches ground until
when machine body rises.
20-8 PC78US-6
(12)
PC78US-6
Machine Model
PC78UU-6
Standard
Cate- Item Measurement Conditions Unit Value for New Service Limit
gory Value
Machine
Arm 0 Max. 1.0

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

Time lag
sec
Bucket 0 Max. 1.0
Work equipment

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

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

See following pages /min.
pump pages pages
PC78US-6 20-9
(12)
Cate- PC78US-6 (Without blade)

gory PC78UU-6 Main pump discharge
Performance of hydraulic pump
• Rated pump speed: 1,850 rpm

• Output current of TVC and EPC valves: 200 mA (With boom raised and arm in, in travel mode)
Discharge pressure of
Check- test pump
Average pressure Standard discharge Lower limit of criterion
point (MPa {kg/cm2}) ( /min.) ( /min.)
(MPa {kg/cm2})
Any P1 (P) P1 (P2) See graph See graph
a Avoid measuring near a bend of the graph since the error is large there.
a When measuring without removing the pump from the machine, if the engine speed cannot be set to the specified level
with the fuel control dial, calculate the pump discharge pressure at the specified speed from the actual engine speed
and measured pump discharge.
20-10 PC78US-6
(5)
Cate- PC78US-6 (With blade)

gory PC78UU-6 Main pump discharge
Performance of hydraulic pump
• Rated pump speed: 1,850 rpm
Discharge pressure of test

Check- Average pressure Standard discharge Lower limit of criterion
pump
point (MPa {kg/cm2}) ( /min.) ( /min.)
(MPa {kg/cm2})
Any P1 (P2) P1 (P2) See graph See graph
Avoid measuring near a bend of the graph since the error is large there.
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.
PC78US-6 20-11
(7)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRIC PARTS
STANDARD VALUE TABLE FOR ELECTRIC PARTS

PC78US-6 Serial No.: 4001 – 6500
Compo- Con- Inspec-
Sys Measurement
nent nector tion Criteria
tem Name No. Method Conditions
If the condition is within the range shown in

the table below, it is normal.
Measurement
Between (1), (11) – chassis ground (*1) 20 – 30 V 1) Turn starting

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

Measurement
the table below, it is normal. 1) Turn starting

PPC main switch OFF.
voltage
pressure M97 2) Insert T-adapter.

lock sole- M13 Between M97 (38) – (13) 20 – 28 V
noid 3) Turn starting
switch ON.

1) Turn starting
Between (26) – (23) 940 ± 50 mA switch OFF.
Measurement
2) Insert T-adapter.
of current
Boom
RAISE 3) Turn starting
M97 When safety
EPC sole- 20 – 30 V switch ON.
noid lock lever is at
FREE M13 4) Exclude part near
Between (1) – (2) boom RAISE
When safety stroke end.
lock lever is at Max. 0 V
LOCK
Controller
If the condition is within the range shown in 1) Turn starting

Measurement
the table below, it is normal. switch OFF.

of current
Arm IN 2) Insert T-adapter.

EPC sole- M97 Between (5) – (23) 940 ± 50 mA 3) Turn starting
noid switch ON.
4) Exclude part near
arm IN stroke end.
If the condition is within the range shown in 1) Turn starting

Measurement
the table below, it is normal. switch OFF.

of current
Offset 2) Insert T-adapter.

left stop M97 Between (15) – (23) 940 ± 50 mA 3) Turn starting
solenoid switch ON.
4) Exclude part near
offset stroke end.
Measurement
1) Turn starting
of voltage
Potentio switch OFF.

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

it is normal.
Model PC78US-6 PC78UU-6

Measurement
1) Turn starting
of voltage
Between M96 (37) – M95 (10) Max. 1 V Max. 1 V switch OFF.

Model M95
2) Insert T-adapter.
selection M96
Between M96 (27) – M95 (10) Min. 7 V Min. 7 V 3) Turn starting
switch ON.
Between M96 (7) – M95 (10) Max. 1 V Min. 7 V
Between M96 (16) – M95 (10) — Max. 1 V
20-12 PC78US-6
(12)
Inspec-
Sys- Component Connector Measurement
tion Criteria
If the condition is within the range shown in the table

below, it is normal
Standard
Attachment Long arm
arm
1) Turn starting
Measurement
switch OFF.
of voltage
Between M95 (37) – (10) Max. 1 V Min. 7 V
Attachment M95 2) Insert T-
selection M96 Between M95 (11) – (10) Min. 7 V Max. 1 V adapter.
3) Turn starting
Between M96 (17) – (10) Min. 7 V Min. 7 V switch ON.

below, it is normal
1) Turn starting
Measurement
When normal Between – Max. 1V

switch OFF.
of voltage
System When cleared (Whenelec- (30) – (31), 2) Insert T-

M97
clear signal tric system clear switch is (32), (33) 20 – 30 V adapter.
ON) 3) Turn starting
switch ON.

below, it is normal
1) Turn starting
Measurement
When boom is raised Between Max. 1V switch OFF.

of voltage
Boom M95 (12) –

RAISE 2) Insert T-
M95 chassis
pressure When in neutral ground 5 ± 0.5 V adapter.
switch 3) Turn starting
switch ON.

Controller
below, it is normal
Between
(24) – chas-
When machine swings sis ground 1) Turn starting
Measurement
When arm is moved IN Max. 1 V switch OFF.

of voltage
Swing, arm Between

IN, travel When machine travels (6) – chas- 2) Insert T-
pressure M95 sis ground adapter.
switch Between 3) Turn starting
When in neutral (18) – chas- 5 ± 0.5 V switch ON.
sis ground

below, it is normal
1) Turn starting
PC78US-6 PC78UU-6 switch OFF.
Measurement
2) Insert T-
of voltage
Boom angle Between (3) – (21) 0.30 – 1.25V 0.30 – 1.13V adapter.
potentiome- M95
ter signal 3) Turn starting
switch ON.
4) Raise boom to
stroke end.

below, it is normal
PC78US-6 PC78UU-6 1) Turn starting
switch OFF.
Measurement
Between 2) Insert T-
of voltage
Arm angle STD 0.38 – 1.38V 0.30 – 1.22V

(20) – (21) adapter.
potentiome- M95
ter signal Long 0.48 – 1.48V 0.30 – 1.23V 3) Turn starting
switch ON.
4) Move arm in to
stroke end.
PC78US-6 20-13
(7)
Inspec-
tion Criteria
If the condition is within the range shown in the table 1) Turn starting
below, it is normal switch OFF.
Measurement
2) Insert T-
of voltage
Between (14) – (21) 3.20 – 4.20 V adapter.
Offset angle
potentiome- M95 3) Turn starting
ter signal switch ON.
4) Move right off-
set to stroke
end.
Controller

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

holding (When normal) Between 3) Insert T-
M97
brake clear adapter.
solenoid When swing holding brake (7) ~ (13)
4) Turn starting
clear switch is ON Max. 1 V switch ON.
(When cleared) 5) Swing or move
arm in.

below, it is normal
1) Turn starting
Measurement
of resistance
Between (C) – (B) 0.2 – 7 kz switch OFF.

Boom angle 2) Disconnect
potentiome- M29
(Male) Between (B) – (A) 0.2 – 7 kz connector.
ter
3) Insert T-
Between (C) – (A) 4 – 6 kz adapter.

below, it is normal
1) Turn starting
Measurement
of resistance
Between (A) – (B) 0.2 – 7 kz switch OFF.

Arm angle 2) Disconnect
potentiome- M72
ter (Male) Between (B) – (C) 0.2 – 7 kz connector.
3) Insert T-
Between (A) – (C) 4 – 6 kz adapter.

below, it is normal
1) Turn starting
Measurement
of resistance
Between (C) – (B) 0.2 – 7 kz switch OFF.

Offset angle 2) Disconnect
M71
potentiome-
Four systems
ter (Male) Between (B) – (A) 0.2 – 7 kz connector.

3) Insert T-
Between (C) – (A) 4 – 6 kz adapter.

Measurement
of resistance
switch OFF.
Boom M11 Between M11 (male) (1) – (2) 5 – 25 z 2) Disconnect
RAISE stop (Male)
EPC valve connector.
Between M11 (male) (1), (2) – chassis 3) Insert T-
Min. 1 Mz
ground
adapter.

Measurement
of resistance
switch OFF.
Arm IN stop Between M12 (male) (1) – (2) 5 – 25 z 2) Disconnect
M12
EPC sole-
(Male) connector.
noid Between M12 (male) (1), (2) – chas-
Min. 1 Mz 3) Insert T-
sis ground
adapter.

Measurement
of resistance
switch OFF.
Left offset Between M10 (male) (1) – (2) 5 – 25 z 2) Disconnect
M10
stop EPC
(Male) connector.
solenoid Between M10 (male) (1), (2) – chas- Min. 1 Mz 3) Insert T-
sis ground
adapter.
20-14 PC78US-6
(7)
Sys- Connector Inspection Measurement

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

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

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

1) Turn starting
Measurement of
switch OFF.
resistance

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

Table 1 (Check and caution section).
Sensor
Monitored Item Measurement Display Input
(Input connector) Conditions
Signal
Light is
Machine monitor system
ON. Max. 1 V
Engine oil pressure Start engine.
P02 (7)
Light is
OFF. 20 – 30 V 1) Connect T-
Check and caution
section adapter
Light is
Max. 5 V
ON.
Charge level
Start engine.
P02 (11)
Light is
20 – 30 V
OFF.
Light is
20 – 30 V
ON.
Preheater
P02 (18) Stop Engine.
Light is Max. 1 V
OFF.
PC78US-6 20-15
(7)
Com-
Sys-
ponent Connector No. Inspection Method Criteria Measurement Conditions
tem Name
Table 2 (Gauge)
Display level resis- 1) Turn starting switch

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

Gauge
section Blink at levels 8 and 9.

Item indicated by gauge tance (z) OFF and insert dummy
resistance) resistor or measure
Min. – Max.
Upper side 9 10 – 6.8
8 6.2 – 13.7
I 7 12.4 – 22.1

tance of fuel level
gauge P02 (2) – (13) Position of indication 5 27.6 – 41.0
4 37.1 – 54.6
O 3 49.4 – 77.7
2 70.3 – 101.9
Lower side 1 92.2 – 10
Level 1 blinks.
20-16 PC78US-6
(7)
Inspec-
tion Criteria

below, it is normal.
Check of continuity
Normal
engine oil No continuity 1) Start engine
Engine oil pres- Between ter- pressure
T6 minal ~ chas- 2) Disconnect
sure sensor
sis ground terminal
Low engine Normal conti-
oil pressure nuity
Measurement of resistance
Normal
Approx. 40 1) Turn starting
tempera- kΩ
Coolant temper- Between ture (25 °C) switch OFF
ature sensor M18 (Male) (1) ~ (2) 2) Disconnect
Approx. 3.3
105 °C connector
kΩ

Full 2~5Ω
Between 1) Turn starting
(1) ~ (2) switch OFF
Fuel level sensor M9 (Male) Empty 105 ~ 110 Ω
2) Disconnect
connector
Measurement of voltage
Between T4 While engine is running (at 1/2 or more of full throttle)

(Terminal R) → 27.5 ~ 29.5 V
Alternator ~ chassis If battery is deteriorated or temperature is low, volt- 1) Start engine
ground age may not rise for a while after engine is started.
PC78US-6 20-17
➄

Inspec-
tion Criteria

below, it is normal
Between (1), (11) – chassis ground (*1) 20 – 30 V 1) Turn starting
Measurement
switch OFF.
voltage
*1. Since power is constantly supplied, voltage is 2) Insert T-
Source
M95 detected even if starting switch is turned OFF.
voltage adapter.
3) Turn starting
Between (30) – chassis ground
20 – 30 V switch ON.
or monitoring [1036]
Measurement

of voltage
Potentio 2) Insert T-
M95 Between (22) – (21) 5 ± 0.5 V
powersource adapter.
3) Turn starting
switch ON.

Measurement
switch OFF.
of voltage
Boom
Between 2) Insert T-
RAISE
pressure M95 When boom is raised M95 (35) – Max. 1V
chassis ground adapter.
switch 3) Turn starting
Or monitoring [1023] bit (6) lights up. switch ON.

below, it is normal
Between (25) –
chassis ground
When machine swings
Between (26) –
Controller
When arm is moved IN Max. 1 V

When machine travels chassis ground
Between (15) –
chassis ground 1) Turn starting
Measurement
switch OFF.
of voltage
Swing, arm Or monitoring [1023]

IN, travel 2) Insert T-
M95
pressure adapter.
switch When machine swings Bit (4) Bit lights up. 3) Turn starting
switch ON.
When arm is moved IN Bit (5) Bit lights up.
When machine travels Bit (3) Bit lights up.

Bits (3), (4),
When in neutral Bit goes off.
and (5)
Measurement
2) Insert T-
of voltage
Boom angle PC78US-6

adapter.
potentiome- M95 Between (4) – (32)
ter signal 0.30 – 1.25V 3) Turn starting
or monitoring [1030] switch ON.
4) Raise boom to
stroke end.

switch OFF.
Measurement
PC78US-6
2) Insert T-
of voltage
Arm angle adapter.

Between (14) – (32)
potentiome- M95 STD 0.38 – 1.38V
or monitoring [1032] 3) Turn starting
ter signal
switch ON.
Long 0.48 – 1.48V
4) Move arm in to
stroke end.
20-18 PC78US-6
(12)
Inspec-
tion Criteria

below, it is normal
1) Turn starting
When swing brake clear Between 20 – 30 V switch OFF.
(19) – (40) 2) Disconnect
Measurement
of resistance
When swing brake is applied Max. 1 V connector.
Controller
Swing
holding 3) Insert T-
M95 Or monitoring [1060] bit (1) adapter.
brake clear
solenoid 4) Turn starting
When swing brake is reset Bit lights up
switch ON.
5) Swing or move
When swing brake is applied Bit goes off
arm in.

below, it is normal
1) Turn starting
Measurement
of resistance
Between M13 (Male) 35 – 80 z switch OFF.

PPC main (1) – (2)
M13 2) Disconnect
pressure-
(Male) adapter.
lock solenoi Between M13 (Male)
Min. 1 Mz 3) Connect T-
adapter.

below, it is normal
1) Turn starting
Machine control
Measurement
of resistance
Between M14 (Male) 35 – 80 z switch OFF.

Swing hold- (1) – (2)
ing brake M14 2) Disconnect
reset sole- (Male) adapter.
noid Between M14 (Male) Min. 1 Mz
(1), (2) – chassis ground 3) Connect T-
adapter.

below, it is normal
1) Turn starting
Measurement
of resistance
Between M15 (Male)

35 – 80 z switch OFF.
2nd travel (1) – (2) 2) Disconnect
speed selec- M15
(Male) adapter.
tion solenoid Between M15 (Male) Min. 1 Mz 3) Connect T-
adapter.
PC78US-6 20-19
(12)
Sys- Connector Inspection Measurement

tem Component Name No. Method Criteria Conditions
If the monitor panel displays as shown in Tables 1 and 2, it is normal.

Table 1 (Check and caution section).
Sensor
Monitored Item Measurement
Display Input
(Input connector) Conditions Signal
Light is
Max. 1 V
ON.
Engine oil pressure
P02 (7) Start engine.
Light is
20 – 30 V
Check and caution OFF. 1) Connect T-
section adapter
Light is Max. 5 V
ON.
Charge level
Start engine.
P02 (11)
Light is
20 – 30 V
OFF.
Light is
20 – 30 V
ON.
Preheater
Stop Engine.
P02 (18)
Light is
OFF. Max. 1 V
20-20 PC78US-6
(12)
Com-
Sys-
ponent Connector No. Inspection Method Criteria Measurement Conditions
tem Name
Table 2 (Gauge)

tance (kz) OFF and insert dummy
Item indicated by gauge
resistor or measure
resistance)
Min. – Max.
Upper side 9 4.00 – 3.45
8 3.13 – 3.75
I 7 3.39 – 3.94
tance of coolant tem-
perature gauge P02 (1)
– (13) Position of indication 5 3.97 – 5.18
4 4.68 – 6.89
O 3 6.23 – 10.88
2 10.34 – 36.86
Lower side 1 33.35 – 37.83

Gauge
section Blink at levels 8 and 9.

Item indicated by gauge tance (z) OFF and insert dummy
resistance) resistor or measure
Min. – Max.
Upper side 9 101 – 20.5
8 18.5 – 26.3
I 7 23.8 – 31.5

tance of fuel level
gauge P02 (2) – (13) Position of indication 5 33.3 – 42.5
4 38.5 – 49.4
O 3 44.7 – 58.8
2 53.2 – 72.5
Lower side 1 65.6 – 1111
Level 1 blinks.
PC78US-6 20-21
(12)
Inspec-
tion Criteria

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

Normal
temperature Approx. 40 kz 1) Turn starting
Coolant temper- Between (25 °C) switch OFF
M18 (Male)
ature sensor (1) – (2) 2) Disconnect
Approx. 3.3 connector

105 °C
kz

Full Max. 20.5 z 1) Turn starting

Between
(1) – (2) switch OFF
Fuel level sensor M9 (Male) Empty Min. 65.6 z 2) Disconnect
connector
Measurement of voltage
Between T4 While engine is running (at 1/2 or more of full throttle) o

(Terminal R) 27.5 – 29.5 V
Alternator – chassis * If battery is deteriorated or temperature is low, voltage 1) Start engine
ground may not rise for a while after engine is started.
20-22 PC78US-6
(12)
TESTING AND ADJUSTING
List of devices for testing, adjusting, & troubleshooting .............................................................................. 20-102

Measuring engine speed............................................................................................................................. 20-103
Measuring exhaust gas color ...................................................................................................................... 20-104
Adjusting valve clearance ........................................................................................................................... 20-105
Measuring compression pressure ............................................................................................................... 20-106
Measuring blow-by pressure .................................................................................................................... 20-106-2
Testing and adjusting fuel injection timing................................................................................................... 20-108
Measuring engine oil pressure ..................................................................................................................20-111-1
Adjusting engine stop solenoid ....................................................................................................................20-112
Adjusting fuel control linkage .......................................................................................................................20-114
Adjusting engine speed sensor ................................................................................................................ 20-115-1
Testing and adjusting hydraulic pressure in work equipment, swing, and travel circuits..............................20-116
Measuring LS differential pressure and adjusting LS valve .........................................................................20-119
Adjusting PC valve ...................................................................................................................................... 20-121
Testing TVC-EPC solenoid output pressure ............................................................................................... 20-121
Measuring control circuit pressure .............................................................................................................. 20-122
Measuring PPC valve output pressure ....................................................................................................... 20-123
Testing solenoid valve output pressure ....................................................................................................... 20-124
Adjusting work equipment valve and swing PPC valve .............................................................................. 20-126
Testing travel deviation ............................................................................................................................... 20-127
Testing parts which can cause hydraulic drift of work equipment ............................................................... 20-129
Measuring oil leakage from swing and travel motors .................................................................................. 20-130
Releasing residual pressure from hydraulic circuit ..................................................................................... 20-131
Testing clearance of swing circle bearing ................................................................................................... 20-132
Testing and adjusting track shoe tension .................................................................................................... 20-133
Bleeding air from hydraulic circuit ............................................................................................................... 20-134
Procedure for adjusting installation of long arm .......................................................................................... 20-136
Testing and adjusting hood catch............................................................................................................. 20-136-1
Replacement procedure of potentiometers ................................................................................................. 20-137
Procedure for testing diode ......................................................................................................................... 20-138
Pm-Clinic service ........................................................................................................................................ 20-139
PC78US-6 20-101
(18)
TESTING AND ADJUSTING LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING
LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING

Items to Be Sym-
Tested/Adjusted bol Part No. Part Name Remarks
1 799-205-1100 Tachometer KIT Digital indication: 6.0 – 99999.9 rpm

Engine speed A
2 6210-81-4111 Gear box —
Water temperature and oil

temperature B 799-101-1500 Digital thermometer -50 – 1,200 °C
Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa

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

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

799-401-2910 Nipple
(Female: PT1/8)
4
02896-11008 O-ring —
07043-00108 Plug PT1/8 (Hexagon hole)
Differential pressure
5 799-401-2701 gauge —
1 795-502-1590 Compression gauge 0 – 6.9 MPa {0 – 70 kg/cm2}

Compression pressure D • Kit No.: 795-502-1205
2 795-502-1370 Adapter —
Blow-by pressure E 799-201-1504 Blow-by checker 0 – 4,900 Pa {0 – 500 mmH2O}
Valve clearance F Purchased Filler gauge —
1 799-201-9001 Handy smoke checker

Exhaust gas color G Bosch index: 0 – 9
2 Purchased Smoke meter
Operating effort H Purchased Push-pull scale —
Stroke and hydraulic drift I Purchased Scale —
Work equipment speed J Purchased Stopwatch —
790-601-9320 Box 24-pin

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

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

Fuel injection timing O
Commercialy
3 available Dial guage —
20-102 PC78US-6
(13)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

a Measuring instruments for engine speed
Symbol Part No. Part name
1 799-205-1200 Tachometer KIT
A
2 6210-81-4111 Gear box
a The engine speed can be measured in monitor-

ing mode [1010].
• Unit: 10 rpm
k When installing and removing the measur-

ing instruments, take care not to touch a
hot part of the engine.
4. Measure the engine speed under each condi-
1. Remove the fan guard. tion.
1) Low idling speed
2. Remove injection timing adjustment cover (1) for i) Set the fuel control dial in the low idling
the fuel injection pump from the timing gear case (MIN) position.
and install gear box A2. ii) Set the work equipment, swing, and trav-
el levers in neutral and measure the en-
gine speed.
2) High idling speed
i) Turn the auto-decelerator OFF.
ii) Set the fuel control dial in the high idling
(MAX) position.
iii) Set the work equipment, swing, and trav-
el levers in neutral and measure the en-
gine speed.
3) Engine speed when 1 pump is relieved
i) Set the fuel control dial in the high idling
(MAX) position.
ii) Relieve the arm circuit by moving the
arm IN and measure the engine speed.
3. Install tachometer KIT A1 to gear box A2.
5. After finishing measurement, remove the mea-
suring instruments and return the removed parts.
PC78US-6 20-103
(12)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

a Measuring instruments for exhaust gas color 4) Loosen cap nut [5] of the suction pump and
fit the filter paper.
a Fit the filter paper securely so that the
1 790-201-9000 Handy smoke checker exhaust gas will not leak.
G
2 Commercially available Smoke meter 5) Turn ON the power switch of tool G2.
6) Raise the engine speed sharply and press
• When an air source and a power source are not accelerator pedal [3] of tool G2 simulta-
available in the field, use handy smoke checker neously to have the filter paper absorb the
G1. When recording formal data, etc., use exhaust gas.
smoke meter G2. 7) Place the stained filter paper on the unused
a Before measuring the exhaust gas color, filter paper (at least 10 pieces) in the filter pa-
raise the cooling water temperature to the per holder and read the indicated value.
operating range.
When installing and removing the measuring

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

1) Install a piece of filter paper to tool G1.
2) Insert the exhaust gas suction pipe in the ex-
haust pipe, then raise the engine speed
sharply and operate the handle of tool G1 si-
multaneously to have the filter paper absorb
the exhaust gas.
3) Remove the filter paper and compare it with
the attached scale.
a The firing order of the engine is as follows

2. Measuring with smoke meter G2 • Firing order: 1 – 2 – 4 – 3
1) Insert probe [1] of G2 in the outlet of the ex- a The air intake valves and exhaust valves may be
haust pipe and tighten the clip to secure the adjusted in the firing order by revolving the
probe to the exhaust pipe. crankshaft forward by 180° (4 cylinders).
2) Connect probe hose [2], cable of accelerator a For the valve clearance, see TESTING AND
pedal [3], and air hose [4] to tool G2. ADJUSTING, Failure criteria table.
a Set the supplied air pressure below 1.47
MPa {15 kg/cm2}.
3) Connect the power cable to an outlet of AC
100 V.
a When connecting the power cable,
check that the power switch of tool G2 is
turned OFF.
20-104 PC78US-6
(12)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

a Measuring instruments for valve clearance 1) Insert feeler gauge F in clearance (b) be-
tween rocker arm (2) and valve stem (3) and
adjust the clearance with adjustment screw
F Commercially available Feeler gauge (4).
a With the feeler gauge inserted, turn the
1. Open the engine hood and remove the cylinder adjustment screw to a degree that you
head cover. can move the filler gauge lightly.
2) While securing adjustment screw (4), tighten
2. Rotate the crankshaft forward to bring the locknut (5).
stamped "1.4TOP" line (a) of the crank pulley to Locknut: 39.2 – 49 Nm {4 – 5 kgm}
pointer (2) and set the No. 1 cylinder to the com-
a After tightening the locknut, check the
pression top dead center.
valve clearance again.
a Rotate the crankshaft with the crank pulley
a After adjusting all of the valves marked
mounting bolt.
with q, go to the next procedure.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not at
the compression top dead center. In this
case, rotate the crankshaft one more turn.
4. Rotate the crankshaft forward to bring the

stamped "1.4TOP" line (a) of the crank pulley to
pointer (1) and set the No. 4 cylinder to the com-
pression top dead center.
5. While the No. 4 cylinder is at the compression

top dead center, adjust the valve clearances
3. While the No. 1 cylinder is at the compression
marked with $ in the valve arrangement drawing.
top dead center, adjust the valve clearances
a Adjust the valve clearance according to step
marked with q in the valve arrangement drawing
4 above.
according to the following procedure.
6. After finishing adjustment, return the removed
parts.
Cylinder head cover mounting bolt:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
PC78US-6 20-105
(13)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pres- 5. Set the multi-tachometer to the engine.
sure a See Measuring engine speed.
1 795-502-1590 Compression gauge
D
2 795-502-1370 Adapter
When measuring the compression pressure,

take care not to touch the exhaust manifold,
etc. to burn yourself or the rotary parts such as
the fan, fan belt, etc. to be caught in them.
1. Adjust the valve clearance accurately. For

details, see Adjusting valve clearance.
2. Warm up the engine until the oil temperature is
40 – 60 °C.
3. Remove nozzle holder assembly (1) of the cylin- 6. Disconnect wiring harnesses (2) from the termi-
der to be measured. nals of the engine stop solenoid. Revolve the
4. Install adapter D2 to the fitting part of the nozzle engine with the starting motor and measure the
holder and connect pressure gauge D1. compression pressure and engine speed at this
time.
PC78US-6 Serial No.: 4001 – 5500 a Read the pressure gauge when its pointer is sta-
PC78UU-6 Serial No.: 22832 – 23500 bilized.
a When measuring the compression pressure,
measure the engine speed, too, and check that it
is in the range of the measurement conditions.
a After measuring the compression pressure,
install nozzle holder assembly (1).
Nozzle holder mounting bolt:

39.2 – 49 Nm {4 – 5 kgm}
PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500

20-106 PC78US-6
(12)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

PC78US-6 20-106-1
(7)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instruments for blow-by pressure 3. Install cylinder head cover (1) and install blow-by
pressure gauge E to the oil filler.
E 799-201-1504 Blow-by checker
PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500
1. Remove cylinder head cover (1).
4. Run the engine at the rated output and measure

the blow-by pressure.
Take care not to touch the hot parts or rotating

parts during measurement.
a The regular blow-by pressure is measured

2. Install plug E to breather tube (2).
while the engine is running at the rated out-
put.
• In the field, an approximate value is obtained
by relieving the hydraulic equipment.
• If it is impossible to run the engine at the
rated output or relief the hydraulic equip-
ment, measure while the engine is running
at high idling. The value obtained in this
case is about 80% of the blow-by pressure
at the rated output.
a The blow-by pressure may vary largely with
the engine condition. If the measured value
is judged abnormal, check for increase of oil
consumption, bad exhaust gas color, deteri-
oration of oil, high deterioration speed of oil,
etc. which are related to the abnormal blow-
by pressure.
a After finishing measurement, be sure to remove
plug E from the breather tube.
20-106-2 PC78US-6
(12)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
PC78US-6 Serial No.: 5501 and up a Normally, the blow-by pressure should be
PC78UU-6 Serial No.: 23501 and up measured while the engine is operated at
the rated output. In the field, however, an
a Measure the blow-by pressure under the follow- approximate value can be obtained by
ing condition. relieving the hydraulic circuit.
• Cooling water temperature: a If it is impossible to run the engine at the
Within operating range rated output or relieve the hydraulic circuit,
• Hydraulic oil temperature: 40 – 60°C measure while the engine is running at high
idling.
1. Install the nozzle of blow-by checker E to blow- The value obtained in this case is about 80%
by hose (2). of the blow-by pressure at the rated output.
a The blow-by pressure may vary largely with
the engine condition. If the measured value
is judged abnormal, check for increase of oil
consumption, bad exhaust gas color, deteri-
oration of oil, high deterioration speed of oil,
etc. which are related to the abnormal blow-
by pressure.
2. Connect the nozzle to the gauge by the hose.
3. Set the working mode in the ACTIVE mode, run

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

the blow-by pressure.
Do not touch a hot part or a rotary part dur-
ing measurement.
PC78US-6 20-107
(7)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

a Adjusting instruments for fuel injection timing 2. Remove front cover (3) of the fuel injection
pump.
3. Install the fuel injection pump holder and drive
2 795-102-2102 Spring pusher
O gear as one unit to the engine.
3 Commercially available Dial gauge 4. Insert the timing check pin 4.0 – 4.5 mm in diam-
eter and 80 mm in length on hole a of the front
Adjustment by use of match marks gear cover and match it to the hole of the drive
a Apply this method usually. gear.
(Then installing the fuel injection pump to the a Check that the timing check pin enters
original engine without repairing it, when check- straight and the hole of the fuel injection
ing only the injection timing, etc.) pump holder is aligned with the mounting
hole of the front gear cover (in which the
1. Bring cylinder No. 1 to the compression top dead mounting bolt will be inserted).
center. a If the holes are deviated from each other,
1) Turn the crankshaft forward and match remove the fuel injection pump and check its
1.4Top line (a) on the crank pulley to pointer engagement with the drive gear.
(1).
5. Remove the timing check pin and tighten each

2) Check that cylinder No. 1 is at the compres- bolt.
sion top dead center by the following method.
If the following condition is not obtained, turn
the crankshaft one more turn.
a If the fuel injection pump is removed:
Check that mark C is seen at the tooth
tip of the idler gear (2).
a If the fuel injection pump is installed to
the engine: Remove the head cover and
check that (both air intake valve and
exhaust valve of cylinder No. 1 have the
valve clearance).
20-108 PC78US-6
(13)
Adjustment by delivery valve method 4. Using spring pusher O2, compress the valve
(When installing a repaired or replaced fuel injection spring and remove valve cotter (5).
pump, when checking after disassembling or replac- 5. Loosen spring pusher O2 and remove spring
ing the gear train) seat (6) and valve spring (7).
1. Remove the cylinder head cover.

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

rocker shaft, then remove air intake rocker arm
(4) of cylinder No. 1.
PC78US-6 20-109
(13)
7. Apply dial gauge O3 to the valve stem end and

turn the crankshaft forward or in reverse to set
the dial gauge to 0 when its pointer starts turning
in reverse.
8. Turn the crankshaft about 45 degrees in reverse
from the compression top dead center of cylin-
der No. 1.
9. Turn the crankshaft forward so that the dial
gauge indicates standard dimension b.
a This dimension corresponds to the set angle
of the fuel injection timing.
Fuel injection timing and standard dimension b
Serial No.
PC78US-6 4001 – 5500 5501 and up
PC78UU-6 22832 – 23500 23501 and up
12. Set the fuel injection lever to the FULL position.
BTDC °(Deg) 10 ± 0.75 5 ± 0.75 13. Loosen the nut at the oblong hole of the injection
b mm 1.17 ± 0.17 0.3 ± 0.08 pump mounting flange, then loosen the injection
pump mounting bolts (14).
10. Disconnect fuel injection pipe (10) of cylinder 14. Turning the injection pump outward and operat-
No. 1. ing the priming pump, move the injection pump
11. Remove delivery valve holder (11), and remove toward the cylinder block little by little and stop
delivery valve (12) and spring (13) from its when the fuel stops flowing out of the delivery
inside. Then, install delivery valve holder (11) valve holder.
again. a If the injection pump is slanted out, the injec-
tion timing is delayed. If the former is slanted
toward the cylinder block, the latter is
advanced.
15. Tighten injection pump mounting bolts (14) alter-
nately.
16. Tighten the nut at the oblong hole of the injection
pump mounting flange.
20-110 PC78US-6
(13)
17. Turn the crankshaft forward and check that the

pointer of the dial gauge is in the standard range
shown in the following table when cylinder No. 1
is at the top dead center (when the pointer of the
dial gauge starts moving in reverse).
a If the pointer of the dial gauge is out of this
range, repeat the above steps from 7.
Serial No.
PC78US-6 4001 – 5500 5501 and up
PC78UU-6 22832 – 23500 23501 and up
Dimension
when cylinder
is at top dead 0 ± 0.22 0 ± 0.08
center (mm)
18. Remove the delivery valve holder (11) and install

delivery valve (12) and spring (13) to it, then
install delivery valve holder (14) again.
a Replace the o-ring and copper gasket of the
delivery valve.
Tighten the delivery valve 3 times to secure

it. (If it is not tightened sufficiently, the gas-
ket may be broken.)
Delivery valve holder:

39.2 – 44.1 Nm {4 – 4.5 kgm}
19. Connect fuel injection pipe (3).

Sleeve nut:
19.6 – 24.5 Nm {2 – 2.5 kgm}
20. Install valve spring (7) and valve seat (6).
21. Compress the valve spring with spring pusher

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

then install snap ring (3).
a Install the snap ring securely.
23. Install the cylinder head cover.

Cylinder head cover mounting bolt:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
PC78US-6 20-111
(13)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

a Measuring instruments for engine oil pressure PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
Symbol Part No. Part Name
1 799-101-5002 Hydraulic tester KIT
C
2 799-401-2320 Hydraulic gauge
a Measure the engine oil pressure under he fol-

lowing condition.
• Cooling water temperature: Within operating
range
1. Remove oil pressure pickup plug (1) (PT 1/8)

from the engine block under the alternator.
PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500

3. Run the engine at low idling and high idling and
measure the engine oil pressure at each speed.
2. Install oil pressure measuring nipple C3 and

connect oil pressure gauge C2 (0.98 MPa {10
kg/cm2}).
20-111-1 PC78US-6
(12)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ENGINE STOP SOLENOID

1. Install ball joint (2) to solenoid (1) and tighten 3. Supply power to solenoid (1) to turn it on.
locknut (3). a If stop lever (6) and rod end (5) of the fuel
a a: Approx. 1mm (thread) injection pump are connected before the
solenoid is turned on, the solenoid cannot
pull sufficiently (the operating current flows
continuously) and the coil will burn. Accord-
ingly, do not connect them at this time.
2. Install rod (4) and rod end (5) to ball joint (2)
temporarily.
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 In the case of PC78UU-6, serial No. 23501
or up, or PC78US-6, serial No. 5501 or up, if
solenoid (1) is connected to the power
source without using the machine wiring, do
not keep the PULL terminal cable con-
nected. (If the PULL terminal cable is kept
connected, the operating current flows con-
tinuously and the coil will burn.)
20-112 PC78US-6
(7)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
a Stop lever (6) touches the lever end on the 5. Tighten nut (7) of the joint of stop lever (6) and
service side (inside the fuel injection pump). rod end (5) and insert the cotter pin.
a Play: 0 mm a Install the rod end with grease hole (8) up.
Rod end: Grease (G2-LI)
6. Lengthen rod (4) to give play to the stop lever

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

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

a At this time, take care that rod (4) will not
turn together with locknut (9). Do not twist
stop lever (6) forcibly.
8. Start and stop the engine 2 – 3 times and check

that solenoid (6) operates smoothly to stop the
engine.
PC78US-6 20-113
(12)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL LINKAGE

1. Adjusting control linkage PC78US-6 Serial No.: 6501 and up
1) If any part was replaced, connect the cable to
the fuel injection pump governor lever se-
curely.
a Connect the cable to the hole at the end
of the injection pump governor lever.
2) Turn the starting switch to the ON position
and set the fuel control dial to the FULL posi-
tion.
a For PC78US-6, Serial No. 6501 and up,
refer to TROUBLESHOOTING, Display
and special functions of monitor panel,
and perform this procedure after enter-
ing in [03] (Adjusting governor lever)
mode.
3) Bring fuel injection pump governor lever (1)
in contact with stopper (2) on the FULL side.
4) Under this condition, pull cable (3) with force
of about 98 N {about 10 kg} and tighten nuts
(4) and (5) temporarily.
a Tighten the nuts while pulling the cable
to eliminate play.
5) Return nut (4) by 2 turns and tighten nut (5)
by 2 turns retighten them.
6) Start the engine and check that it runs at the
specified speed.

1.PC78US-6 Serial No.: 5501 – 6500
20-114 PC78US-6
(12)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
2. Adjusting control linkage finely 4) Tighten nuts (6) and (7).

PC78US-6 Serial No.: 4001 –6500 Nut: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
a At this time, check that clearance A and
If the control linkage cannot be adjusted by the B between bolt (8) and nuts (6) and (7)
method in 1. above, adjust it finely with the turn- are 5 ± 3.5 mm (1.5 – 8.5 mm).
buckle above the cable. a At this time, check that the rubber boot
• When the engine speed (high idling speed) (10) of the cable is not twisted.
is below the specified level 5) Start the engine and check that it runs at the
1) Turn the starting switch to the ON position specified speed.
and set the fuel control dial to the FULL posi-
tion.
2) Loosen nut (6) (right-hand screw) and nut (7)
(left-hand screw).
3) Turn bolt (8) counterclockwise, seeing from
the governor lever side, to eliminate the
clearance between injection pump governor
lever (1) and full stopper (2).
4) Tighten nuts (6) and (7).
Nut: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
a At this time, check that clearance A and
B between bolt (8) and nuts (6) and (7)
are 5 ± 3.5 mm (1.5 – 8.5 mm) respec-
tively.
a At this time, check that the rubber boot
(10) of the cable is not twisted.
5) Start the engine and check that it runs at the
specified speed.
• When the engine speed (low idling speed) is
above the specified speed.
1) Turn the starting switch to the ON position
and set the fuel control dial to the decelera-
tion (SLOW) position.
2) Loosen nut (6) (right-hand screw) and nut (7)
(left-hand screw).
3) Turn bolt (8) counterclockwise, seeing from
the governor lever side, to lengthen the cable
and eliminate the clearance between injec-
tion pump governor lever (1) and low idling
stopper (9).
PC78US-6 20-115
(12)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED

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

a A clearance of 0.75 – 1.00 mm is made
between the sensor tip and gear tooth tip.
3. Secure sensor (1) with nut (3).

Nut: 69 – 74 Nm {7.0 – 7.5 kgm}
20-115-1 PC78US-6
(7)
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, AND TRAVEL CIRCUITS
a Hydraulic oil temperature for measurement:
45 – 55 °C
Lower the work equipment to the ground and

stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank. Set the safety valve lock
lever to the LOCK position.
a Testing and adjusting instruments for oil pres-
sure in work equipment, swing, and travel cir-
cuits
799-101-5002 Hydraulic tester KIT
1
790-261-1203 Digital hydraulic tester
C 799-101-5160 Nipple
3 799-101-5220 Nipple
07002-11023 O-ring
Measuring hydraulic pressure in boom arm,

bucket, travel, and swing circuits
• Machine model: PC78US-6
Measuring hydraulic pressure in boom arm,

bucket, offset, and travel circuits
• Machine model: PC78UU-6
1. Measuring
1) Installing pressure gauge
2) Measuring unload pressure
i) Open the top cover of the valve and re-
Measure the hydraulic pressure while the en-
move the side cover.
gine is running at full throttle and the control
ii) Remove pressure pickup plug (1) or (2)
lever is in neutral.
(10 mm, P = 1.25) and install nipple C3,
3) Measuring pump relief pressure
then connect oil pressure gauge C1
Measure the hydraulic pressure when each
(58.8 MPa {600 kg/cm2}
actuator is relieved while the engine is run-
a Use plug (1) to measure the hydraulic
ning at full throttle.
pressure in boom, arm, and bucket cir-
cuits and use plug (2) to measure the
hydraulic pressure in the swing and
travel circuits.
20-116 PC78US-6
(12)
Measuring hydraulic pressure in swing and

blade circuits
• Machine model: PC78UU-6
1. Measuring pump relief pressure

1) Remove the top cover of the valve.
2) Remove pressure pickup plug (3) (10 mm, P
= 1.25) and install nipple C3, then connect oil
pressure gauge (58.8 MPa {600 kg/cm2}).
a See the photo.
3) Measure the hydraulic pressure when swing

or blade lower actuator is relieved while the
engine is running at full throttle.
2. Adjusting
Adjusting main relief valve for boom, arm,
bucket, offset swing, and travel circuits.
Machine model: PC78US-6
k Do not turn end cap (6) counterclock-
wise more than one revolution or end
cap (6) could fly off.
1) Loosen locknut (5) on main relief valve (4)
and adjust pressure by turning end cap (6).
a As the end cap 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 end cap:
12.5 MPa {128 kg/cm2}
Locknut: 39 – 49 Nm {4 – 5 kgm}
End cap: 39 – 49 Nm {4 – 5 kgm}
PC78US-6 20-117
(18)
Adjusting main relief valve for swing and blade Adjusting main relief valve for blade (RAISE)
(LOWER) circuits circuits (UU and US of blade specification)
k Do not turn end cap (9) counterclock- k Do not turn end cap (12) counterclock-
wise more than one revolution or end wise more than one revolution or end
cap (9) could fly off. cap (12) could fly off.
1) Loosen locknut (8) on main relief valve (7) 1) Loosen locknut (11) on main relief valve (10)
and adjust pressure by turning end cap (9). and adjust pressure by turning end cap (12).
a As the end cap is a As the end cap is
• rotated to the right, the pressure is • rotated to the right, the pressure is
heightened, and it is heightened, and it is
• rotated to the left, the pressure is low- • rotated to the left, the pressure is low-
ered. ered.
a Quantity of adjustment per turn of end cap: a Quantity of adjustment per turn of end cap:
12.5 MPa {128 kg/cm2}. 19.6 MPa {200 kg/cm2}.
Locknut: 39 – 49 Nm {4 – 5 kgm} Locknut: 39 – 49 Nm {4 – 5 kgm}
End cap: 39 – 49 Nm {4 – 5 kgm} End cap: 39 – 49 Nm {4 – 5 kgm}
20-118 PC78US-6
(18)
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING

LS VALVE
a Measuring instruments for LS valve
799-101-5160 Nipple (PT 1/8)
3 799-101-5220 Nipple (10 x 1.25 mm)
07002-11023 O-ring
C 799-401-2910 Nipple (9/16-18UNF)
4 02896-11008 O-ring
07043-00108 Plug (PT 1/8)
5 799-401-2701 Differential pressure gauge
1. Measuring LS differential pressure

1) Measuring with main relief differential pres-
sure gauge
i) Remove pump pressure pickup plug (1)
(on the high pressure side) and discon-
nect LS pressure hose (2). Install nipple
C3 to the high pressure side and nipple
C4 to the LS pressure side.
ii) Connect differential pressure gauge C5.
a Connect the high pressure side of
the differential pressure gauge to
the main relief pressure side and
connect the low pressure side to the
LS pressure side.
iii) Measure the LS differential pressure un-
der the condition in Table 1.
Table 1
Fuel Control Differential
Operation
Dial Pressure {kg/cm2}
2.5 – 4.4
FULL Set lever in neutral {25 – 45}
Curl bucket
FULL (With lever at FULL 2.11 ± 0.1
position) {21.5 ± 1}
PC78US-6 20-119
(12)
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
2) Measuring with oil pressure gauge Adjusting

a Measure with the same gauge. 1. Adjusting LS valve
i) Remove pump pressure pickup plug (1) a If the differential pressure is abnormal,
(on the high pressure side) and discon- adjust the LS valve according to the follow-
nect LS pressure hose (2) (on the low ing procedure.
pressure side) and install adapter C3. a Before loosening the locknut, be sure to
ii) Connect pressure gauge C1 (39.2 MPa make match marks.
{400 kg/cm2}). 1) Loosen locknut (3) and adjust with adjust-
a Use a pressure gauge having unit ment screw (4).
divisions of 1.0 MPa {10 kg/cm2}. (If a As the adjustment screw is
a pressure gauge of 39.2 MPa {400 • rotated to the right, the pressure is
kg/cm2} is not available, one of 58.8 heightened, and it is
• rotated to the left, the pressure is
MPa {600 kg/cm2} will do.)
lowered.
iii) Measure the pump discharge pressure
a Quantity of adjustment per turn of
under the condition in Table 1.
adjustment screw: 1.27 MPa {13 kg/
a Read the pointer correctly, facing
the gauge. cm2}.
iv) Measure the LS pressure under the con- 2) After adjusting, tighten locknut (3).
dition in Table 1. Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}
a Read the pointer correctly, facing
the gauge. a After adjusting, measure the LS differen-
LS differential pressure = (Pump tial pressure, referring to Measuring
discharge pressure) – (LS pressure) described above.
a When loosening or tightening the lock-
nut, secure adjustment screw (4) with a
spanner so that it will not be dragged.
20-120 PC78US-6
(12)
ADJUSTING PC VALVE,
TESTING AND ADJUSTING TESTING TVC-EPC SOLENOID OUTPUT PRESSURE
ADJUSTING PC VALVE TESTING TVC-EPC SOLENOID

a When the load is increased, the engine speed
OUTPUT PRESSURE
may lower or the engine speed may be normal Measuring
and working speed may be lower. If this trouble a Hydraulic oil temperature for measurement:
occurs and the pump discharge pressure and LS 45 ~ 55 °C
differential pressure are normal, adjust the pump 1) Remove pump pressure pickup plug (1) (10
PC valve according to the following procedure. mm, P = 1.25) and install nipple C3 of the oil
a Before loosening locknut, be sure to make pressure gauge kit and connect oil pressure
match marks. gauge kit and connect oil pressure gauge C1
1. Loosen locknut (1) and adjust with adjustment (5.9 MPa {60 kg/cm2}).
screw (2).
a Since the PC valve is of eccentric type, in which
direction the adjustment screw should be turned
to increase the absorption torque is unknown.
Accordingly, monitor the engine speed when BWP10640
turning the adjustment screw.
2. After adjusting, tighten locknut (1).
Locknut: 29.4 ~ 39.2 Nm {3 ~ 4 kgm}
BWP10639
2) Start the engine and measure the oil pres-
sure under the following condition.
Table 1 Measurement Condition

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
Measure- Measured
Engine Monitor Output
ment Pressure
Speed Condition MPa {kg/cm2} Current
0.54 – 0.84
FULL Neutral 410 mA
{5.5 – 8.5}
Float one 0 – 0.2

FULL side and 100 mA
{0 – 2}
run idle
2.74 – 3.53
SLOW Neutral {28 – 36} 900 mA
PC78US-6 20-121
(13)
TESTING AND ADJUSTING TESTING TVC-EPC SOLENOID OUTPUT PRESSURE

Measure- Measured
Engine Monitor Output
ment Pressure
Speed Condition MPa {kg/cm2} Current
0.93 – 1.23
FULL Neutral 510 mA
{9.5 – 12.5}
Float one 0.05 – 0.25

FULL side and 200 mA
{0.5 – 2.5}
run idle
SLOW Neutral 2.74 – 3.53 900 mA

{28 – 36}
20-121-1 PC78US-6
(13)
TESTING AND ADJUSTING MEASURING CONTROL CIRCUIT PRESSURE
MEASURING CONTROL CIRCUIT PRESSURE

Measuring
a Hydraulic oil temperature for measurement: 3) Connect nipple C3 and install oil pressure
45 – 55 °C gauge C1 (5.8 MPa {60 kg/cm2}).
k WARNING! Lower the work equipment to the

ground and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank. Set the
safety valve lock lever to the LOCK position.
1) Remove the front cover front guard plate of

the valve.
2) Remove pressure pickup plug (1) (10 mm, P
= 1.25) from the top of the solenoid valve
block.

4) Start and run the engine at full throttle and
measure the circuit pressure.
Adjusting
• If the control circuit pressure is abnormal, adjust
the control relief valve according to the following
procedure.
1) Loosen locknut (2) of relief valve (1) and ad-
just with adjustment screw (3).
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.
Machine model: PC78UU-6 a Quantity of adjustment per turn of adjustment
screw: 0.32 MPa {3.3 kg/cm2}.
Locknut: 20 – 29 Nm {2 – 3 kgm}
a After adjusting, check the set pressure ac-
cording to the procedure in 1.
20-122 PC78US-6
(5)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE

a Hydraulic oil temperature for measurement: a Measuring points
45 – 55 °C a. Blade RAISE J. LEFT offset
1. Measuring PPC valve output pressure b. Blade LOWER k. Boom RAISE
1) Disconnect hose (1) of the circuit to be mea-
c. RIGHT swing l. Boom LOWER
sured.
d. LEFT swing m. Arm OUT
e. LEFT REVERSE travel n. Arm IN
f. LEFT FORWARD travel o. Bucket DUMP
g. RIGHT REVERSE travel p. Bucket CURL
h. RIGHT FORWARD travel q. Service
i. RIGHT offset r. Service
Machine Model: PC78UU-6 STD
2) Install adapter C4 between hose (1) and el-

bow.
3) Install oil pressure gauge C1 (5.9 MPa {60
kg/cm2}) to adapter C3.
4) Run the engine at full throttle and operate the
control lever of the circuit to be measured
and measure oil pressure.
Machine Model: PC78US-6
(Blade specification)
a If the output on the control valve side is low,

measure the input pressure of the PPC valve. Of Machine Model: PC78US-6
the input pressure of the PPC valve is normal, (Blade specification + Service valve)
the PPC valve is defective.
PC78US-6 20-123
(12)
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE

Measuring 2. Measuring output pressure of ON-OFF sole-
a Hydraulic oil temperature for measurement: noid valve.
45 – 55 °C 1) Disconnect ON-OFF solenoid valve output
1. Measuring output pressure of automatic stop hose (3) and install oil pressure gauge C1
and work equipment control EPC solenoid (5.9 MPa {60 kg/cm2}), using nipple C3 in the
valve oil pressure gauge kit.
Machine model: PC78UU-6 2) Measure the output pressure of the solenoid
1) Disconnect EPC solenoid valve output hose valve under the condition in Table 2.
(1) and install oil pressure gauge C1 (5.9 a The ON-OFF solenoid valve.
MPa {60 kg/cm2}), using nipples C3 and C4 • Installed in the 3-spool soleoid valve
in the oil pressure gauge kit. assembly at the front under the floor
a The EPC solenoid valve is installed in plate PC78US-6.
the 6-spool solenoid valve assembly • Installed in the 6-spool soleoid valve
under the floor plate. assembly at the front under the floor
plate PC78UU-6.
2) Measure the output pressure under the con-

dition in Table 1.
Table 1
Oil pressure
Solenoid Name Measurement Condition Remarks
MPa {kg/cm2}
During arm in operation 3.14 ± 0.49 —

{32 ± 5}
1 Arm IN stop EPC
Stops automatically in automatic stop range 0 —
3.14 ± 0.49
During boom RAISE operation {32 ± 5} —
2 Boom RAISE stop
EPC
Stops automatically in automatic stop range 0 —
Relieving by right offset 3.14 ± 0.49 —

(Pressure is raised) {32 ± 5}
3 Left offset stop
Stopping automatically in automatic stop
range(Pressure is not raised) 0 —
20-124 PC78US-6
(12)
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
Table 2
Operation of Oil pressure
Solenoid Name Measurement Condition Operating Condition Remarks
solenoid MPa {kg/cm2}
Oil pressure is
Set safety lock lever in applied to PPC valve ON 3.14 ± 0.29
PPC FREE position. circuit. {32 ± 3}
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 arm-in 3.14 ± 0.49

lever. Brake is released. ON {32 ± 5}
Swing holding
2 brake Set swing or arm-in lever in
neutral (5 sec after Brake is applied. OFF 0
setting in neutral)
Set travel speed selector Travel speed is ON 3.14 ± 0.49

switch in Hi. increased. {32 ± 5}
Travel speed
3 selector
Set travel speed selector Travel speed is
switch in Lo. decreased. OFF 0
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).
PC78US-6 20-125
(5)
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE
ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE

a If the work equipment control lever or swing con- PC78US-6 Serial No.: 6501 and up
trol lever has excessive play, adjust it according
to the following procedure.
Lower the work equipment to the ground and

stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank. Set the safety valve lock
lever to the LOCK position.
1. Remove the PPC valve.

2. Remove boot (1).
3. Loosen locknut (2) and screw in disc (3) until it
touches the heads of 4 pistons (4).
a At this time, do not move the pistons.
4. Fix disc (3) and tighten locknut (2) to the speci-
fied torque.
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
5. Install boot (1).

a The clearance between disc (3) and piston (4) is
eliminated by the above adjustment.
PC78US-6 Serial No.: 4001 – 6500

20-126 PC78US-6
(12)
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION

1. Measuring when traveling
1) Set the machine in the travel posture.
★ For the travel posture, extend the
bucket and arm cylinder rods fully,
and hold the boom angle at 45°.
2) Travel for 10 m, then measure deviation a
when traveling for the next 20 m.
★ Measure with the engine at full throttle.
★ Install a hydraulic pressure gauge and
measure the pump discharge pressure a
the same time.
PC78US-6 20-127
b
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
2. Insert hexagonal wrench (1) (Width across

Adjusting flats: 4 mm) in adjustment plug (1) or (2).
★ Travel deviation can be corrected by draining ★ Insert the hexagonal wrench securely.
a part of the oil discharged from the pump 3. Loosen locknut (3), leaving the hexagonal
which discharges more oil with the adjust- wrench inserted.
ment plugs. ★ Before adjusting, mark the position of the
If the travel deviation is corrected by this locknut with paint.
method, however, the travel speed, work ★ Loosen the locknut, securing the hexago-
equipment speed in the compound operation, nal wrench.
and relief pressure lower since the pump dis-
• Loosening angle of locknut: Approx. 90 ~
charge is reduced.
180°
★ The following is the method of correcting
deviation applied when the machine deviates
to the right (left) in both travel directions.
★ Travel deviation can be corrected by the fol-
lowing method only when it is 200 mm or
less.
WARNING! If the adjustment plug is

loosened more than the adjustment
limit, high pressure oil spurts out. Take
care extremely.
WARNING! Lower the work equip-

ment to the ground and stop the
engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal
pressure of the hydraulic tank. 4. Correct the travel deviation by loosening
adjustment plug (1) or (2).
1. Check the position of each adjustment plug of • Quantity of correction of travel deviation
the main pump. per turn of adjustment plug: 150 mm (For
• When the machine deviates to the right: reference)
Loosen adjustment plug (1). ★ When the machine is shipped, the adjust-
• When the machine deviates to the left: ment plugs are tightened fully. Adjust the
Loosen adjustment plug (2). correction angle by the loosening angle of
the adjustment plugs.
★ Loosen only either plug. Do not loosen
both plugs at the same time. ★ If the adjustment plug is dragged when
the locknut is loosened, tighten it again.
★ The adjustable range of each adjustment
plug is 2 turns / 720 degrees from the
tightened position.
5. Tighten locknut (3).
Locknut: 2.94 ~ 4.9 Nm {0.3 ~ 0.5 kgm}
6. Check for travel deviation again. If the

machine still deviates, adjust again according
to the above procedure.
★ Do not loosen the adjustment plugs more
than the adjustable range (2 turns / 720
degrees).
20-128 PC78US-6
b
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF
TESTING AND ADJUSTING WORK EQUIPMENT
TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF

WORK EQUIPMENT
a Hydraulic oil temperature for measurement: Machine Model: PC78UU-6
45 – 55 °C
1. Work equipment cylinder
a If the hydraulic drift of the work equipment
exceeds the standard value, measure the leak-
age in the cylinder according to the following
procedure to see if the cause of the hydraulic
drift is on the cylinder side or control valve side.
• If the leakage is less than the standard
value, the cause is on the control valve side.
• If the leakage is above the standard value,
the cause is on the cylinder side.
1) Extend the rod of the cylinder to be mea-
sured and stop the engine.
2) Disconnect hoses (1) – (4) on the head side
and block the pipes on the machine side with Machine Model: PC78US-6
plugs.
1. Boom cylinder head hose
2. Arm cylinder head hose
3. Bucket cylinder head hose
4. Offset cylinder head hose
Take care not to disconnect the bottom hoses.
3) Run the engine at full throttle and apply relief

pressure to the cylinder bottom.
Machine Model: PC78UU-6
4) After 30 seconds, measure the oil leakage in

1 minute.
PC78US-6 20-129
(12)
TESTING AND ADJUSTING MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL

MOTORS
a Measuring instrument for oil leakage 2. Travel motor
1) Disconnect drain hose (3) of the travel motor
and plug the hose.
L Commercially available Measuring cylinder 2) Put a block in the grouser of the track shoe or
between the sprocket and the frame to lock
a Hydraulic oil temperature for measurement: the track shoe.
45 – 55 °C 3) Run the engine at full throttle and relieve the
1. Swing motor travel circuit.
1) Disconnect drain hose (1) of the swing motor
(on the hydraulic tank side). Since a wrong operation of a lever can cause
a Plug the hydraulic tank. an accident, make signs and confirm the opera-
2) Stick the bucket into the ground to lock the tions security.
swing mechanism.
3) Run the engine at full throttle and relieve the 4) After 30 seconds, measure the oil leakage in
swing circuit. 1 minute.
4) After 30 seconds, measure the oil leakage in a Measure the oil leakage several times, mov-
1 minute. ing the motor little by little (shifting the valve
a After measuring 1 time, swing 180° and plate and piston from the cylinder).
measure again.
20-130 PC78US-6
(12)
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

★ Since an accumulator is not installed, the
residual pressure in the piping between the
control valve and each hydraulic cylinder or
swing motor cannot be released even if the
control levers are operated. Accordingly,
when removing the above piping, observe
the following points.
1) Run the engine at low speed and lower
the work equipment to the ground, taking
care not to relieve the cylinder at the
stroke end, then stop the engine.
★ If the hydraulic cylinder is relieved at
the stroke end before the engine is
stopped, do not perform the following
work for 5 ~ 10 minutes.
2) Loosen pressure release plug (4) of the
control valve gradually to release the
residual pressure from the circuit.
PC78US-6 20-131
b
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF SWING CIRCLE BEARING

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

foot under the undercarriage during
measurement.
2. Extend the work equipment to the maximum

reach and set the bucket tip to the height of
the underside of the revolving frame.
At this time, the front part of the upper struc-
ture lowers and the rear part rises.
3. Set the dial gauge to the zero point.
6. Set the machine in the position explained in 2
above again and check that the dial gauge
indicates zero. If the dial gauge does not indi-
cate zero, repeat Steps 2 ~ 5.
20-132 PC78US-6
b
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

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

mal, run the engine at low idling and move
the machine forward by the length of track on
ground and stop slowly.
3) Test the track shoe tension again. If it is still
not normal, adjust it again.
PC78US-6 20-133
(12)
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
BLEEDING AIR FROM HYDRAULIC CIRCUIT

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

• Replacing or repairing pump
• Removing suction pipe
Q Q Q Q Q Q
• Replacing or repairing control
valve
Q Q Q Q Q
• Replacing cylinder
• Removing cylinder piping
Q Q Q
• Replacing swing motor
• Removing swing motor piping
Q Q Q
• Replacing travel motor and swivel
• Removing travel motor and swivel
Q Q Q
• Replacing or removing swing
PPC circuit parts (Swing PPC
valve, piping, pressure switch,
Q Q Q
etc.)
Note: Bleed air from the swing motor and travel motor only after the oil in the motor case is drained.
1. Bleeding air from pump 2. Bleeding air between pump and hydraulic tanks.
a If the pump is operated without filling pump a If the pump is operated without bleeding air
case with hydraulic oil, it is heated abnor- from the circuit between the pump and
mally and may be broken soon. Accordingly, hydraulic tank, it is heated abnormally and
bleed all air from the pump before operating may be broken soon. Accordingly, bleed all
the pump. air.
1) Loosen air bleeder (1) installed to the drain 1) Run the engine at medium speed (approx.
port and check that oil oozes out. 1,650 rpm)
2) After bleeding air, tighten the air bleeder. 2) Operate the work equipment slowly for about
3 Bleeder:
5 minutes to bleed air.
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).
20-134 PC78US-6
(12)
TESTING AND ADJUSTING BLEEDING AIR FROM HYDRAULIC CIRCUIT
4. Bleeding air from hydraulic cylinder

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

a Bleed air from the travel motor only after the
oil is drained from the travel motor case.
1) Run the engine at low idling and loosen drain
hose (3). If oil oozes out, tighten the drain
hose.
2) Keep the engine speed at low idling and
swing 90° and float the track a little with the
work equipment, then run idle for 2 minutes.
3) Perform Step 2 above for each side.
PC78US-6 20-135
(12)
TESTING AND ADJUSTING PROCEDURE FOR ADJUSTING INSTALLATION OF LONG ARM
PROCEDURE FOR ADJUSTING INSTALLATION OF LONG ARM

• When replacing the work equipment with the 2. Reset the input and output signals without fail.
long arm, observe the following procedure. a For details, see TROUBLESHOOTING.
a If a breaker, clamshell bucket, wide bucket, long
arm other than Komatsu genuine long arm, etc.
is installed, the interference prevention mecha-
nism does not work. take car,

1. Replace attachment selection wiring harness (1)
with one for the replaced attachment.
Table 1 Attachment selection wiring harness

Attachment selection
Specification
connector
Model
Arm Additional Part No. Color
weight PC78US-6 Serial No.: 6501 and up
Standard Installed/ 20U-06-42260 Black
Not installed • Refer to TROUBLESHOOTING, Special func-
20U-06-42260 tions of monitor panel, [18] (Setting arm crane
PC78US Installed/ (20U-06-42280 Black specification) and [19] (Setting model and
Long Not installed is also usable)
attachment), set the necessary items by operat-
20U-06-42280 Green ing the monitor panel.
Not installed 20U-06-42260 Black
20U-06-42260
Standard (20U-06-42290 Black
Installed is also usable)
20U-06-42290 White
PC78UU 20U-06-42280 Green

Not installed
20U-06-42280 Green
Long 20U-06-42310 Blue
Installed 20U-06-42280
(20U-06-42310 Green
is also usable)
20-136 PC78US-6
(12)
TESTING AND ADJUSTING TESTING AND ADJUSTING HOOD CATCH
TESTING AND ADJUSTING HOOD CATCH

Testing 2. Adjustment of stopper (3) height (at the center)
Press key lock (1) of the hood, hold knob (2), and Remove the rubber cover of hood knob (2) and
raise the hood in the opening direction to check for adjust the projection of stopper (3) until the stop-
"play". per touches bracket (6) through the hole (9) of
the hood knob.
Adjusting
a If there is "play", adjust it according to the follow-
ing procedure.
1. Open the hood, loosen nut (4) of hood stopper
(3), and reduce projection "a" of stopper (3).
PC78US-6 20-136-1
(18)
TESTING AND ADJUSTING TESTING AND ADJUSTING HOOD CATCH
3. Adjustment of hook (5) installation in fore-aft direc-

tion of the machine
Loosen mounting bolt (7) of bracket (6), move
the bracket, and tighten the mounting bolt again.
Clearance b: 0 mm (target value)
Clearance c: 0 ± 1 mm (target value)
a Close the hood and repeat the above proce-
dure until "play" has been eliminated.
At this time, ensure that the effort required to
operate the hood key lock is not increased.
(If lock bar (8) of the bracket is pressed
strongly against key lock hook (5), the effort
required to operate the key lock is increased
preventing smooth hood opening and clos-
ing operation.)
a Key lock operating effort: Max. 49.0 N {5 kg}
4. Open and close the hood several times to ensure

that "play" has been eliminated, and return the
rubber cover of knob (2).
20-136-2 PC78US-6
(18)
TESTING AND ADJUSTING REPLACEMENT PROCEDURE OF POTENTIOMETERS
REPLACEMENT PROCEDURE OF POTENTIOMETERS

PC78UU-6
a It is impossible to replace only the potentiome-
ters. Accordingly, if the potentiometers need to
be replaced, replace the case assemblies.
If the case assemblies need to be used again, fix
levers (3), (6), and (10) to the potentiometer bod-
ies before removing them.
1. Remove potentiometer assemblies (1), (4), and

(8) from the work equipment.
a Do not swing a removed potentiometer
assembly around its lever or turn the lever
unnecessarily.
• Boom potentiometer (1)
• Arm potentiometer (4)
• Offset potentiometer (8)
2. Install potentiometer assemblies (1), (4), and (8).
3. Be sure to reset input and output signals.

a For details, see TROUBLESHOOTING, Reset-
ting procedure.
a It is possible to connect arm potentiometer rod
(7) even if lever (6) of the potentiometer assem-
bly is in the opposite position, so be particularly
careful when rod (7) has been disconnected.
a If it is connected in the opposite position, error
code [E40] will be displayed when the starting
switch is turned ON, and the buzzer will sound.
a If this happens, turn the starting switch OFF and
connect the rod (7) correctly.
a When rod (7) is installed to lever (6), it may be
broken by the tightening force of the mounting
bolt. To prevent this, hold lever (6) with a span-
ner, etc. when tightening the mounting bolt.
PC78US-6 20-137
(13)
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODE
PROCEDURE FOR TESTING DIODE

a Check an assembled-type diode (8 pins) and
single diode (2 pins) in the following manner.
2. When using analog type circuit tester

a The conductive direction of each diode is 1) Switch the testing mode to resistance range.
marked on its surface as shown below. 2) Check the needle swing in case of the follow-
ing connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe (–) to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe (–)
to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
• If the needle does not swing in Case i),
but swings in Case ii): Normal (but the
breadth of swing (i.e. resistance value)
will differ depending on a circuit tester
type or a selected measurement range)
1. When using digital type circuit tester • If the needle swings in either case of i)
1) Switch the testing mode to diode range and and ii): Defective (short-circuited inter-
confirm the indicated value. nally)
a Voltage of the battery inside is displayed • If the needle does not swing in any case
with conventional circuit testers. of i) and ii): Defective (short-circuited
2) Put the red probe (+) of the test lead to the internally)
anode (P) and the black probe (–) to the cath-
ode (N) of diode, and confirm the displayed
value.
3) Determine if a specific diode is good or no
good with the indicated value.
• No change in the indicated value: No
continuity (defective).
• Change in the indicated value: Continu-
ity established (normal) (Note)
a A silicon diode shows a value between
460 and 600.
20-138 PC78US-6
(12)
TESTING AND ADJUSTING Pm-CLINIC SERVICE
Pm-CLINIC SERVICE
Model Serial No. Engine serial No. Service meter
T PC78UU-6
T PC78US-6 h
Implemented on User's name Operator's name Inspector
/ /
t Equipment
Main work equipment Optional work equipment Shoe
Boom: T Standard T( ) T Arm crane T City pad shoe
Arm: T Standard T( ) T Breaker T Road liner
Bucket: T Standard T( ) T( ) T Triple shoe
Blade: T Standard T( ) T( ) T Rubber shoe
T( )
t Oil and coolant level check

Must check item As required
T Engine coolant T Damper case oil T( )
T Engine oil T Machinery case oil T( )
T Hydraulic oil T Final drive case oil T( )
t Operation place
Ambient temperature Elevation
T °C
T °F m
t Operator's comment
t Result of visual check
t Failure code history

Code No. Symptom (Refer to SHOP MANUAL page 20-248) Indication elapsed time
h
h
h
h
h
h
h
h
h
PC78US-6 20-139
(15)
Check sheet (1/3)
Model Serial No. Service meter User's name Implemented on Inspector

T PC78UU-6
/ /
T PC78US-6 h
1. Engine
Standard Judgment
value for Service limit Measured
No. Check item Checking condition Unit
new value value Good Bad
machine
• Hydraulic oil temp.:
45 – 55°C
• Coolant temp.:
1 Engine speed rpm Min.1,800 Min.1,800
At operating range
• Hydraulic pump relief
(Arm IN relief)
At high • Coolant temp.: 0.34 – 0.54 Min.0.25
Engine oil idle At operating range MPa {3.5 – 5.5} {Min.2.5}
2 • Engine oil: SAE30 2
pressure At low {kg/cm } Min.0.18 Min.0.13
idle {Min.1.8} {Min1.3}
• Coolant temp.:
At operating range
Pa Max.490 Max.980
3 Blow-by pressure • Engine speed:
{mmH2O} {Max.50} {Max.100}
1,850rpm (Rated speed)
• Engine oil: SAE30
20-140 PC78US-6
(15)
Check sheet (2/3)

2. Work equipment speed
Standard Judgment
machine
45 – 55°C 2.9 – 3.5 Max. 4.0
• Engine speed: High idle (PC78UU) (PC78UU)
1 Boom RAISE • Bucket tooth on ground sec.
o Max. extension of 3.1 – 3.9 Max. 4.3
cylinder (PC78US) (PC78US)
(To just before cushion)
45 – 55°C
• Engine speed: High idle
2 Arm IN (*1) • Max.retraction of cylinder sec. 2.9 – 3.5 Max. 4.0
o Max. extension of
cylinder
45 – 55°C
3 Arm OUT (*1) • Max.extension of cylinder sec. 2.4 – 3.0 Max. 3.3
o Max. retraction of
cylinder
45 – 55°C
4 Bucket CURL sec. 2.7 – 3.5 Max. 3.9
• Max.retraction of cylinder
o Max. extension of
cylinder
45 – 55°C
• Time required to swing 5
5 Swing (5 turns) sec. 28 – 32 Max. 35
turns after swinging 1
turn
• Work equipment
extended fully
Low 45 – 55°C 31 – 37 Max. 41
Travel • Raise either track and
6 sec.
(5 idle turns) measure time required to
move 5 turns after finish- 22 – 28 Max. 30
High
ing 1 turn. (21 – 25) (Max. 28)
• ( ): Rubber shoe spec.
*1: Offset to right so that clearance between right end of operator's cab and bucket will be 200mm or wider. (Only PC78UU-6)
PC78US-6 20-141
(15)
Check sheet (3/3)

3. Oil pressure
Standard Judgment
machine
MPa 3.14 – 3.34 3.14 – 3.44
1 Control pressure 45 – 55°C
{kg/cm2} {32 – 34} {32 – 35}
45 – 55°C
MPa 25.5 – 27.5 25.0 – 27.9
2 Main relief pressure • Engine speed: High idle
{kg/cm2} {260 – 280} {255 – 285}
• Operation:
Arm dump relief
All levers • Hydraulic oil temp.: 2.5 – 4.4 2.5 – 4.4
in neutral 45 – 55°C {25 – 45} {25 – 45}
LS differential • Engine speed: High idle MPa
3 Bucket
pressure • Operation: Refer left line {kg/cm2}
CURL 2.01 – 2.21 2.01 – 2.21
(Lever at {20.5 – 22.5} {20.5 – 22.5}
FULL)
With • Hydraulic oil temp.: 19.6 – 21.48 19.1 – 22.1
Swing safety blade 45 – 55°C {200 – 220} {195 – 225}
MPa
4 valve relief • Engine speed: High idle
Without {kg/cm2} 22.1 – 24.0 21.6 – 24.5
pressure • Operation:
blade Swing lock switch ON {225 – 245} {220 – 250}

45 – 55°C
Travel safety valve relief MPa 25.5 – 27.5 25.0 – 27.9
5 • Engine speed: High idle
pressure {kg/cm2} {260 – 280} {255 – 285}
• Operation:
Track shoe fixed
All levers • Hydraulic oil temp.: 0.54 – 0.83 0.54 – 0.83
TVC-EPC
in neutral 45 – 55°C {5.5 – 8.5} {5.5 – 8.5}
solenoid output
pressure Float one
• Operation: Refer left line
side track 0 – 0.2 0 – 0.2
<Machine and run {0 – 2} {0 – 2}
model> idle
PC78UU:
22001 – 23500
All levers 45 – 55°C 2.74 – 3.53 2.74 – 3.53
PC78US:
in neutral • Engine speed: Low idle {28 – 36} {28 – 36}
4001 – 5500
• Operation: Refer left line MPa
6 2}
All levers • Hydraulic oil temp.: {kg/cm 0.93 – 1.23 0.93 – 1.23
TVC-EPC
in neutral 45 – 55°C {9.5 – 12.5} {9.5 – 12.5}
solenoid output
pressure Float one
side track 0.05 – 0.25 0.05 – 0.25
<Machine and run {0.5 – 2.5} {0.5 – 2.5}
model> idle
PC78UU:
23501 and up
All levers 45 – 55°C 2.74 – 3.53 2.74 – 3.53
PC78US:
in neutral • Engine speed: Low idle {28 – 36} {28 – 36}
5501 and up
20-142 PC78US-6
(15)
TROUBLESHOOTING
Points to remember when troubleshooting.................................................................................................. 20-202

Sequence of events in troubleshooting ....................................................................................................... 20-203
Precautions when carrying out maintenance .............................................................................................. 20-204
Checks before troubleshooting ................................................................................................................... 20-212
CONNECTOR TYPES AND MOUNTING LOCATIONS (PC78US-6 Serial No.: 4001 – 5500) ................. 20-214
Connector arrangement diagram (PC78US-6 Serial No.: 4001 – 5500)................................................. 20-215-1
CONNECTOR TYPES AND MOUNTING LOCATIONS (PC78US-6 Serial No.: 5501 – 6500) ................. 20-217
CONNECTOR ARRANGEMENT DIAGRAM (PC78US-6 Serial No.: 5501 – 6500)............................... 20-218-2
CONNECTOR TYPES AND MOUNTING LOCATIONS (PC78US-6 Serial No.: 6501 and up) .............. 20-218-5
CONNECTOR ARRANGEMENT DIAGRAM (PC78UU-6 Serial No.: 6501 and up)............................... 20-218-8
CONNECTOR TYPES AND MOUNTING LOCATIONS (PC78UU-6 Serial No.: 22832 – 23500) ............. 20-219
CONNECTOR ARRANGEMENT DIAGRAM (PC78UU-6 Serial No.: 22832 – 23500)........................... 20-219-3
CONNECTOR TYPES AND MOUNTING LOCATIONS (PC78UU-6 Serial No.: 23501 and up) ............ 20-219-6
CONNECTOR ARRANGEMENT DIAGRAM (PC78UU-6 Serial No.: 23501 and up)............................. 20-219-9
Connection table for connector pin numbers .............................................................................................. 20-220
Explanation of functions of electric system control mechanism .................................................................. 20-244
Display and special functions of monitor panel ........................................................................................... 20-246
TVC valve current adjustment table ......................................................................................................... 20-255-4
How to read flow of troubleshooting......................................................................................................... 20-255-6
Contents and procedure of troubleshooting ................................................................................................ 20-260
Troubleshooting for communication system (N mode)................................................................................ 20-301
Troubleshooting for controller (governor control system) (E mode)............................................................ 20-325
Troubleshooting for controller (pump control system) (C mode)................................................................. 20-351
Troubleshooting for controller (input signal system) (F mode).................................................................... 20-401
Troubleshooting for hydraulic and mechanical systems (H mode) ............................................................. 20-425
Troubleshooting for machine monitor system (M mode) ............................................................................. 20-501
PC78US-6 20-201
(13)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fit-
ted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait
for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some
idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. If components 5) Other maintenance items can be checked
are disassembled immediately after a failure externally, so check any item that is consid-
occurs: ered to be necessary.
• Parts that have no connection with the fail-
ure or other unnecessary parts will be disas- 4. Confirming the failure.
sembled. 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
the failure. a 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
2) Was there anything strange about the ma- as follows.
chine 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 infor-
this? mation.
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 be- occur again.
fore? 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 PC78US-6
(12)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC78US-6 20-203
(2)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS 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 hydraulic oil).
1. PRECAUTIONS WHEN HANDLING ELECTRIC

EQUIPMENT
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protector or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations they are fre-
quently removed and installed again, so they are
likely to suffer deformation or damage. For this
reason, it is necessary to be extremely careful
when handling wiring harnesses.
• Main failures occurring in wiring harness

(1) Faulty contact of connectors
(faulty contact between male and female).
Problems with faulty contact are likely to oc-
cur because the male connector is not prop-
erly inserted into the female connector, or
because one or both of the connectors is de-
formed or the position is not correctly
aligned, or because there is corrosion or oxi-
dation of the contact surfaces.
(2) Defective compression or soldering of con-

nectors
The pins of the male and female connectors
are in contact at the compressed terminal or
soldered portion, but there is excessive force
on the wiring, and the plating peels to cause
improper connection or breakage.
20-204 PC78US-6
(12)
(3) Disconnections in wiring

If the wiring is held and tugged and the con-
nectors are pulled apart, or components are
lifted with a crane with the wiring still con-
nected, or a heavy object hits the wiring, the
crimping compression of the connectors to
the wire may be loosened, or the soldering
may be damaged, or the wiring may be bro-
ken.
(4) High pressure water entering a connector

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

If oil or grease are stuck to the connector and
an oil film is formed on the mating surface be-
tween the male and female pins, the oil will
not let the electricity pass, and this will cause
a defective contact. If there is oil or grease or
dirt stuck to the connector, wipe it off with a
dry cloth or blow dry with air, and spray it with
a contact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is water or oil present, it will in-
crease the contamination of the points,
so clean with air until all water and oil has
been removed.
PC78US-6 20-205
(12)
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors
held by a screw, loosen the screw fully, then
hold the male and female connectors in each
hand and pull apart. For connectors which
have a lock stopper, press down the stopper
with your thumb and pull the connectors
apart.
a Never try to pull apart with one hand.
(2) When removing the connectors from the
clips, pull the connector in a parallel direction
to the clip.
a If the connector is twisted to the left and
right or up and down, the housing may
break.
(3) Action to take after removing connectors.

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or wa-
ter from getting in the connector portion.
a If the machine is left for a long time, it is
particularly easy for improper contact to
occur, so always cover the connector.
20-206 PC78US-6
(12)
• Connecting connectors
(1) Check the connector visually.
i) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
ii) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
iii) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector,
warm the inside of the wiring with a dryer,
but be careful not to make it too hot as
this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
(2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in the
connector until the stopper clicks into posi-
tion.
(3) Correct any protrusion of the boot and any

misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is out
of position, adjust it to its correct position.
a If the connector cannot be corrected eas-
ily, remove the clamp and adjust the po-
sition.
(4) If the connector clamp has been removed, be

sure to return it to its original position. Check
also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC78US-6 20-207
(12)
• Drying wiring harness

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

lows:
(1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with air,
there is the risk that oil in the air may
cause a faulty contact, so avoid blowing
with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dry-
er to dry the connector.
a Hot air from the dryer can be used, but
be careful not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connector.
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
spray it with contact restorer and reas-
semble.
20-208 PC78US-6
(12)
3) Handling control box

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

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

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

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in the circuit.
PC78US-6 20-209
(12)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

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

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dust proof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tape, or
vinyl bags to prevent any dirt or dust from enter-
ing. Never leave any openings opened or
blocked with a rag, this could cause particles or
dirt to get into the system.
Drain all oil into a container and not unto the
ground and be sure to follow the proper environ-
mental regulation for any disposal of oil.
4) Do not let any dirt, or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-210 PC78US-6
(2)
5) Change hydraulic oil when the tempera-

ture is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together
with the oil, so it is best to change the oil when
it is still warm. When changing the oil, as much
as possible of the old hydraulic oil must be
drained out. (Do not drain the oil from the
hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any
old oil is left, the contaminants and sludge in it
will mix with the new oil and will shorten the
life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and
secondary flushing is carried out with the spec-
ified 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 cir-
cuit.
The oil cleaning equipment is used to remove
the ultra fine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC78US-6 20-211
c
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Action

Value
1. Check fuel level, type of fuel — Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel — Clean, drain

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

Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
1. Check for abnormal noise, smell — Repair

equipment
Hydraulic,
2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air

1. Check battery voltage (Engine stopped) 20 - 30 V Replace
2. Check battery electrolyte level — Add or replace
3. Check for discolored, burnt, exposed wiring — Replace
Electrical equipment
4. Check for missing wiring clamps, hanging wire — Repair

5. Check for water leaking on wiring (Pay particular attention to water leak- Disconnect
— connector and dry
ing on connectors or terminals)
6. Check for blown, corroded fuses — Replace
After running for
7. Check alternator voltage (Engine running at 1/2 throttle or above) several minutes: Replace
27.5 ~ 29.5 V
8. Sound of actuation of battery relay (When starting switch is turned ON,
— —
OFF)
20-212 PC78US-6
b
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

PC78US-6 Serial No.: 4001 – 5500
a The addresses in the address column are used in the connector arrangement drawing (3-dimensional draw-
ing).
Con- Type of No. Con- Type of No.

Add- Add-
nector Connec- of Location nector Connec- of Location
ress ress
No. tor Pins No. tor Pins
SHINA-
D4 SWP 2 Diode (Engine stop solenoid) H-1 K33 5 Decelerator relay N-8
GAWA
Diode (Starting switch BR o SHINA-

D5 SWP 2 G-1 K34 5 Motor drive relay O-8
Battery relay BR) GAWA
Diode (Alternator R o Battery SUMIT-

D6 SWP 2 G-1 K42 16 Floor intermediate connector P-8
relay BR) OMO
D11 SWP 2 Diode (TVC solenoid) R-5 K45 M 1 Radio ground Q-3
Intermediate connector (Start-

D12 SWP 2 Diode (TVC solenoid) R-4 K51 AMP090 20 M-7
ing switch, light switch)
Diode (Swing holding brake

D13 SWP 2 R-4 K52 M 3 Light switch N-8
solenoid)
Diode (Air conditioner com-

D22 SWP 2 H-1 K53 M 2 Buzzer cancel switch O-8
pressor)
FB1 Fuse box R-3 K54 M 3 Rotary lamp switch P-8
Intermediate connector (Moni- Intermediate connector

K1 S1 12 N-7 M1 L 2 M-4
tor panel) (Power supply, ground)

K2 S 16 M-7 M2 X 2 M-3
tor panel) (Power supply, glow plug)
2nd travel speed selection Intermediate connector (Fuel

K3 DT 2 O-2 M3 DT 8 M-3
solenoid valve level sensor, hydraulic switch)
Intermediate connector
K11 SWP 12 Auto A/C unit N-1 M4 DT 8 M-4
(Washer, travel/swing alarm)
Intermediate connector (TVC,

K12 M 2 Resister Q-8 M5 DT 8 M-3
power supply, starting switch)
Intermediate connector (Pressure

K17 X 2 Optional power supply P-2 M6 DT 8 M-3
switch, air conditioner sensor)
K18 AMP090 2 Decelerator switch Q-2 M7 DT 8 Intermediate connector M-3
Intermediate connector (Fuel

K19 PA 9 Radio R-3 M9 DT 2 I-2
sensor)
K20 M 8 Cab inlet R-6 M13 DT 2 PPC hydraulic lock M-2
K21 S 8 Cab inlet R-6 M14 DT 2 Swing holding brake N-2
K22 DT 2 Attachment selector wire P-8 M15 DT 2 Travel speed selector M-2
Starting motor cut relay (PPC

K23 Relay 5 R-7 M16 DT 2 Engine speed sensor J-3
lock)
K26 AMP090 2 Horn switch M-7 M17 X 1 Glow plug K-8
K27 SWP 6 Fuel governor control motor N-7 M18 DT 2 Engine water temperature L-8
K28 M 3 PPC hydraulic lock switch P-2 M19 X 1 Air conditioner compressor L-7
SHINA-
K32 5 Accelerator relay O-8 M20 DT 2 TVC solenoid K-8
GAWA
20-214 PC78US-6
(12)

Add- Add-
ress ress
Pressure switch (Boom

M21 X 2 G-9 T5 Terminal 1 Alternator B L-5
RAISE)
M22 X 2 Pressure switch (Swing) I-9 T6 Terminal 1 Engine oil pressure switch L-3
M23 X 2 Pressure switch (Swing) G-9 T7 Terminal 1 Engine stop solenoid (+) K-8
M24 X 2 Pressure switch (Arm IN) H-9 T8 Terminal 1 Engine stop solenoid (-) K-9
M25 X 2 Pressure switch (Travel) I-9 T9 Terminal 1 Battery relay E A-4
M26 L 2 Fusible link C-8 T10 Terminal 1 Battery relay BR A-3
M27 L 2 Fusible link B-7 T11 Terminal 1 Battery relay M A-6
Intermediate connector (Work-

M28 SWP 6 J-9 T12 Terminal 1 Battery relay B A-5
ing lamp)
M30 X 2 Safety relay (S, R) K-3 T31 Terminal 1 Safety relay B K-3
M31 KES 2 Windshield washer C-8 T32 Terminal 1 Safety relay C J-3
M32 DT 2 Travel/Swing alarm (Optional) J-2 T33 Terminal 1 Starting motor B L-7
Air conditioner outside tem-

M33 DT 2 L-4 T34 Terminal 1 Starting motor C L-6
perature sensor (Optional)
M75 DT 2 Working lamp D-9 W04 M 6 Wiper motor M-5
M80 AMP040 2 Horn M-2 W19 2 Cigarette lighter M-5
M95 DT 24 Controller R-8 B Terminal 1 Starting switch terminal B M-9
M96 DT 40 Controller R-8 BR Terminal 1 Starting switch terminal BR M-8
M97 DT 40 Controller Q-8 ACC Terminal 1 Starting switch terminal ACC M-8
Arm ground angle alarm can-

M99 DT 2 Q-8 C Terminal 1 Starting switch terminal C M-9
cel selector
SHINA-
M100 5 Rotary lamp drive relay R-7 R1 Terminal 1 Starting switch terminal R1 N-8
GAWA
P01 AMP040 12 Monitor panel M-6 R2 Terminal 1 Starting switch terminal R2 N-8
P02 AMP040 20 Monitor panel M-6
P15 AMP040 2 Sunlight sensor (Optional) M-6
T1 Terminal 1 Revolving frame ground I-2
T2 Terminal 1 Revolving frame ground H-1
T4 Terminal 1 Alternator R L-5
PC78US-6 20-215
(7)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM

PC78US-6 Serial No.: 4001 – 5500
20-215-1 PC78US-6
(7)
PC78US-6 20-215-2
(7)
20-216 PC78US-6
(7)

PC78US-6 Serial No.: 5501 – 6500
ing).

Add- Add-
ress ress
Diode (Engine stop solenoid

D4 SWP 2 H-1 K28 M 3 PPC hydraulic lock switch P-2
HOLD)
Diode (Starting switch BR o SHINA-

D5 SWP 2 G-1 K32 5 Accelerator relay O-8
Battery relay BR) GAWA
Diode (Alternator R o Battery SHINA-

D6 SWP 2 G-1 K33 5 Decelerator relay N-8
relay BR) GAWA
SHINA-
D11 SWP 2 Diode (TVC solenoid) R-5 K34 5 Motor drive relay O-8
GAWA
SUMIT-
D12 SWP 2 Diode (TVC solenoid) R-4 K42 16 Floor intermediate connector P-8
OMO
Diode (Swing holding brake

D13 SWP 2 R-4 K45 M 1 Radio ground Q-3
solenoid)
Diode (Air conditioner com- Intermediate connector (Start-

D22 SWP 2 H-1 K51 AMP090 20 M-7
pressor) ing switch, light switch)

D25 SWP 2 G-1 K52 M 3 Light switch N-8
pull)

D26 SWP 2 H-9 K53 M 2 Buzzer cancel switch O-8
relay, coil)
FB1 Fuse box R-3 K54 M 3 Rotary lamp switch P-8

K1 S1 12 M-7 M1 L 2 M-4
tor panel) (Power supply, ground)

K2 S 16 N-7 M2 X 2 M-3
tor panel) (Power supply, glow plug)
2nd travel speed selection Intermediate connector (Fuel

K3 DT 2 O-2 M3 DT 8 M-4
solenoid valve level sensor, hydraulic switch)
K11 SWP 12 Auto A/C unit N-2 M4 DT 8 M-4
(Washer, travel/swing alarm)

power supply, starting switch)
Intermediate connector (Pressure

K17 X 2 Optional power supply P-2 M6 DT 8 M-3
switch, air conditioner sensor)
Intermediate connector (Fuel

K18 AMP090 2 Decelerator switch Q-2 M9 DT 2 I-2
sensor)
K19 PA 9 Radio R-3 M13 DT 2 PPC hydraulic lock M-2
K20 M 8 Cab inlet R-6 M14 DT 2 Swing holding brake N-2
K21 S 8 Cab inlet R-6 M15 DT 2 Travel speed selector M-2
K22 DT 2 Attachment selector wire P-8 M16 DT 2 Engine speed sensor J-3

K23 Relay 5 R-7 M17 X 1 Glow plug K-8
lock)
K26 AMP090 2 Horn switch M-7 M18 DT 2 Engine water temperature L-8
K27 SWP 6 Fuel governor control motor N-7 M19 X 1 Air conditioner compressor L-7
PC78US-6 20-217
(12)

Add- Add-
ress ress
M20 DT 2 TVC solenoid K-8 T1 Terminal 1 Revolving frame ground I-2

M21 X 2 G-9 T2 Terminal 1 Revolving frame ground H-1
RAISE)
M22 X 2 Pressure switch (Swing) I-9 T3 Terminal 1 Revolving frame ground H-1
M23 X 2 Pressure switch (Swing) G-9 T4 Terminal 1 Alternator R L-6
M24 X 2 Pressure switch (Arm IN) H-9 T5 Terminal 1 Alternator B L-6
M25 X 2 Pressure switch (Travel) I-9 T6 Terminal 1 Engine oil pressure switch L-5
M26 L 2 Fusible link C-8 HOLD Terminal 1 Engine stop solenoid (HOLD) L-2
M27 L 2 Fusible link B-7 GND Terminal 1 Engine stop solenoid (GND) L-2

M28 DT 2 J-9 T9 Terminal 1 Battery relay E A-4
ing lamp)
M30 X 2 Safety relay (S, R) J-3 T10 Terminal 1 Battery relay BR A-3
M31 KES 2 Windshield washer C-8 T11 Terminal 1 Battery relay M A-6
M32 DT 2 Travel/Swing alarm (Optional) J-2 T12 Terminal 1 Battery relay B A-5
Air conditioner outside tem- Engine stop solenoid relay

M33 DT 2 L-5 T16 Terminal 1 K-3
perature sensor (Optional) (Contact 1)
Intermediate connector (Start- Engine stop solenoid relay

M35 L 2 K-1 T17 Terminal 1 K-3
ing motor C) (Contact 2)
Engine stop solenoid relay

M36 DT 2 J-2 T31 Terminal 1 Safety relay B K-3
(Coil)
M75 DT 2 Working lamp D-9 T32 Terminal 1 Safety relay C L-5
M80 AMP040 2 Horn M-2 T33 Terminal 1 Starting motor B L-7
M95 DT 24 Controller R-8 T34 Terminal 1 Starting motor C L-6
M96 DT 40 Controller R-8 W04 M 6 Wiper motor M-5
M97 DT 40 Controller Q-8 W19 2 Cigarette lighter M-5

M99 DT 2 Q-8 B Terminal 1 Starting switch terminal B M-9
cel selector
SHINA-
M100 5 Rotary lamp drive relay R-7 BR Terminal 1 Starting switch terminal BR M-8
GAWA
P01 AMP040 12 Monitor panel M-6 ACC Terminal 1 Starting switch terminal ACC M-8
P02 AMP040 20 Monitor panel M-6 C Terminal 1 Starting switch terminal C M-9
P15 AMP040 2 Sunlight sensor (Optional) M-6 R1 Terminal 1 Starting switch terminal R1 N-8

PULL Terminal 1 L-3 R2 Terminal 1 Starting switch terminal R2 N-8
(PULL)
20-218 PC78US-6
(12)

PC78US-6 Serial No.: 5501 – 6500
20-218-2 PC78US-6
(12)
PC78US-6 20-218-3
(7)
20-218-4 PC78US-6
(7)

ing).
Add- Add-
nector Connec- of Location ress nector Connec- of Location ress
SUMIT-
ACC Terminal 1 Starting switch terminal ACC M-9 K42 16 Floor intermediate connector O-8
OMO
B Terminal 1 Starting switch terminal B M-9 K45 M 1 Radio ground Q-3
BR Terminal 1 Starting switch terminal BR M-8 K51 AMP090 20 Intermediate connector (Start- M-7
ing switch and light switch)
C Terminal 1 Starting switch terminal C M-9 K52 M 3 Light switch N-8
D4 SWP 8 Diode (Assembled-type diode) K-2 K53 M 2 Buzzer cancel switch O-8
Diode (Starting switch BR o

D5 SWP 2 R-7 K54 M 3 Rotary lamp switch O-8
Battery relay BR)
D6 SWP 2 Diode (Alternator R o Battery K55 M 3 Fuel control dial N-7

R-5
relay BR)
Rotary lamp junction Intermediate connector
F02 YAZAKI 1 2 I-9 M1 L 2 J-2
(If equipped) (Power supply)
M2 X 2 Intermediate connector J-2

F03 DT 2 Rotary lamp (If equipped) I-9
(Glow plug, ground)
FB1 — — Fuse box R-4 M3 SWP 16 Intermediate connector K-1
GND Terminal 1 Engine stop solenoid (GND) L-9 M7 DT 8 For connecting arm crane H-1
HOLD Terminal 1 Engine stop solenoid (HOLD) L-9 M9 X 2 Fuel sensor G-1
SUMIT- M13 DT 2 PPC oil pressure lock M-2

J1 20 Junction connector R-7
OMO 2
J2 SUMIT- 20 Junction connector R-7 M13 M 2 Speaker (Right) I-9

OMO 2
K1 S 12 M-7 M14 DT 2 Swing holding brake N-2
(Monitor panel)
Intermediate connector M15 DT 2 Travel speed selection N-2
K2 S 16 N-7
(Monitor panel)
K11 SWP 12 Air conditioner unit R-4 M16 DT 2 Engine speed sensor J-3
K12 M 2 Resistor Q-8 M17 X 1 Glow plug J-8
K17 X 2 Optional power supply P-2 M18 DT 2 Engine coolant temperature K-7
K18 AMP090 2 Decelerator switch Q-3 M19 X 1 Air conditioner compressor J-8
K19 PA 9 Radio R-3 M20 DT 2 TVC solenoid K-7
K20 M 8 Cab inlet R-6 M21 X 2 Pressure switch (Boom RAISE) G-9
K21 S 8 Cab inlet R-6 M22 X 2 Pressure switch (Swing) J-2
Starting motor cutout relay

K23 Relay 5 N-7 M23 X 2 Pressure switch (Swing) I-2
(PPC lock)
K26 AMP090 2 Horn switch M-6 M24 X 2 Pressure switch (Arm IN) G-9
K28 M 3 PPC oil pressure lock switch Q-2 M25 X 2 Pressure switch (Travel) J-3
K32 SHINA- 5 Accelerator relay N-2

GAWA M26 L 2 Fusible link R-5
SHINA-
K33 5 Decelerator relay N-1 M27 L 2 Fusible link R-5
GAWA
PC78US-6 20-218-5
(12)

Add- Add-
M28 DT-T 2 J-2 T9 Terminal 1 Battery relay E K-5
(Working lamp)
M30 X 2 Safety relay (S, R) L-2 T10 Terminal 10 Battery relay BR K-5
M31 KES 2 Windshield washer E-9 T11 Terminal 1 Battery relay M K-5
Travel/Swing alarm
M32 DT 2 K-2 T11 Terminal 1 Cab ground K-6
(If equipped)
M35 L 2 K-9 T12 Terminal 1 Battery relay B K-5
(Starting motor C)
M36 DT 2 Engine stop solenoid relay K-3 T16 Terminal 1 Engine stop solenoid relay L-4
(Coil) (Contact 1)
M40 T17 Terminal 1 Engine stop solenoid relay K-2

YAZAKI 1 2 Cab headlamp H-9
(Contact 2)
M41 Additional cab headlamp T31 Terminal 1 Safety relay B L-3

YAZAKI 1 2 G-9
(If equipped)
M71 M 2 Room light J-8 T32 Terminal 1 Safety relay C L-3
M73 M 2 Speaker (Left) J-8 T33 Terminal 1 Starting motor B K-7
M75 DT-T 2 Working lamp F-9 T34 Terminal 1 Starting motor C K-7
M80 AMP090 2 Horn M-3 V2 DT 12 Intermediate connector Q-8
SHINA-
M87 S 12 Air conditioner junction M-7 V3 GAWA 5 Starting motor cutout relay R-7
M88 YAZAKI 2 10 Air conditioner foot area air M-4 W03 X 2 Window limit switch I-9
outlet servo
M95 DRC26 40 Controller R-8 W04 M 6 Wiper motor M-5
SHINA- Rotary lamp drive relay W19 Terminal 2 Cigarette lighter M-4
M100 5 R-8
GAWA (If equipped)
P15 AMP040 2 Daylight sensor (If equipped) M-6
PULL Terminal 1 Engine stop solenoid (PULL) L-9
R1 Terminal 1 Starting switch terminal R1 N-9
R2 Terminal 1 Starting switch terminal R2 N-8
S2 SWP 6 Fuel governor control motor P-2
S3 DT 3 Main pump pressure sensor I-2
SHINA- Travel/Swing alarm relay

S4 GAWA 5 (If equipped) P-2
T1 Terminal 1 Revolving frame ground J-1
T4 Terminal 1 Alternator R K-7
T5 Terminal 1 Alternator B K-6
T6 Terminal 1 Engine oil pressure switch K-5
20-218-6 PC78US-6
(12)

20-218-8 PC78US-6
(17)
PC78US-6 20-218-9
(12)
20-218-10 PC78US-6
(12)

PC78UU-6 Serial No.: 22832 – 23500
ing).
Add- Add-
D4 SWP 2 Diode (Engine stop solenoid) H-1 K23 Relay 5 R-7
lock)
D5 SWP 2 G-1 K26 AMP090 2 Horn switch M-7
Battery relay BR)
D6 SWP 2 Diode (Alternator R o Battery G-1 K27 SWP 6 Fuel governor control motor M-7
relay BR)
D11 SWP 2 Diode (TVC solenoid) R-7 K28 M 3 PPC hydraulic lock switch P-2
SHINA-
D12 SWP 2 Diode (TVC solenoid) R-5 K32 5 Accelerator relay O-8
GAWA
Diode (PPC main pressure SHINA-
D13 SWP 2 lock solenoid) Q-8 K33 GAWA 5 Decelerator relay N-7

D14 SWP 2 R-4 K34 5 Motor drive relay N-8
lock solenoid) GAWA
Diode (Boom raise stop sole- SUMI-
D15 SWP 2 R-3 K42 16 Floor intermediate connector O-8
noid) TOMO
D16 SWP 2 Diode (Boom raise stop sole- R-3 K45 M 1 Radio ground Q-3
noid)
D17 SWP 2 Diode (Swing parking brake R-8 K51 AMP090 20 Intermediate connector M-7
solenoid)
D18 SWP 2 Diode (Arm IN stop solenoid) Q-8 K52 M 3 Light switch N-8
D19 SWP 2 Diode (Arm IN stop solenoid) R-5 K53 M 2 Buzzer cancel switch O-8
Diode (Left offset stop sole-

D20 SWP 2 R-5 K54 M 3 Rotary lamp switch P-8
noid)
D21 SWP 2 Diode (Left offset stop sole- R-4 K55 SHINA- 5 PPC lock cut relay Q-8
noid) GAWA
Diode (Air conditioner com- Intermediate connector
D22 SWP 2 H-1 M1 L 2 M-4
pressor) (Power supply, ground)
FB1 Fuse box R-3 M2 X 2 (Power supply, glow plug) M-3
Intermediate connector (Moni- Intermediate connector (Fuel

K1 S 12 N-7 M3 DT 8 M-4
tor panel) level sensor, hydraulic switch)
K2 S 16 Intermediate connector (Moni- M-7 M4 DT 8 Intermediate connector M-4

tor panel) (Washer, rotation sensor)
K3 DT 2 Travel speed pedal P-2 M5 DT 8 M-3
power supply, battery relay)
K11 SWP 12 Auto A/C unit P-2 M6 DT 8 Intermediate connector

M-3
(Pressure switch)
K12 M 2 Resister P-8 M7 DT 8 M-3
(Potentiometer, sensor)
K13 M 2 Resister P-8 Intermediate connector (Fuel

M9 DT 2 I-2
sensor)
K17 X 2 Optional power supply Q-3 M10 DT 2 Left offset stop EPC valve N-2
K18 AMP 2 Decelerator switch Q-2 M11 DT 2 Boom stop EPC valve O-2
090
K19 PA 9 Radio Q-3 M12 DT 2 Arm IN stop EPC valve O-2
K20 M 8 Cab inlet R-6 M13 DT 2 PPC hydraulic rock M-2
K21 S 8 Cab inlet R-6 M14 DT 2 Swing holding brake N-2
K22 DT 2 Attachment selector wire P-8 M15 DT 2 Travel speed selector N-2
PC78US-6 20-219
(12)

Add- Add-
M16 DT 2 Engine speed sensor J-3 T1 Terminal 1 Revolving frame ground I-2
M17 X 1 Glow plug K-8 T2 Terminal 1 Revolving frame ground H-1
M18 DT 2 Engine water temperature L-8 T3 Terminal 1 Revolving frame ground H-1
M19 X 1 Air conditioner compressor L-7 T4 Terminal 1 Alternator R L-5
M20 DT 2 TVC solenoid K-8 T5 Terminal 1 Alternator B L-5
M21 X 2 Pressure switch (Boom H-9 T6 Terminal 1 Engine oil pressure switch L-4
RAISE)
M22 X 2 Pressure switch (Swing) I-9 T7 Terminal 1 Engine stop solenoid (+) K-9
M23 X 2 Pressure switch (Swing) H-9 T8 Terminal 1 Engine stop solenoid (-) J-9
M24 X 2 Pressure switch (Arm IN) I-9 T9 Terminal 1 Battery relay E A-4
M25 X 2 Pressure switch (Travel) I-9 T10 Terminal 1 Battery relay BR A-3
M26 L 2 Fusible link C-8 T11 Terminal 1 Battery relay M A-6
M27 L 2 Fusible link B-7 T12 Terminal 1 Battery relay B A-5

M28 SWP 6 ing lamp) J-9 T21 Terminal 1 System cancel switch M-6
M29 DT 3 Boom angle potentiometer J-9 T22 Terminal 1 System cancel switch O-2
M30 X 2 Sefety relay (S, R) K-3 T31 Terminal 1 Safety relay B K-3
M31 KES 2 Windshield washer C-8 T32 Terminal 1 Safety relay C K-3
M32 DT 2 Travel/Swing alarm J-2 T33 Terminal 1 Starting motor B L-7
M33 DT 2 Air conditioner outside tem- L-4 T34 Terminal 1 Starting motor C L-6
perature sensor (Optional)
M71 DT 3 Offset angle potentiometer G-9 W04 M 6 Wiper motor M-6
M72 DT 3 Arm angle potentiometer A-7 W19 2 Cigarette lighter M-4
M73 DT 2 Working lamp D-9 B Terminal 1 Starting switch terminal B M-9
M74 DT 2 Working lamp G-9 BR Terminal 1 Starting switch terminal BR M-8
M80 AMP040 2 Horn M-2 ACC Terminal 1 Starting switch terminal ACC M-8
M95 DT 24 Controller R-8 C Terminal 1 Starting switch terminal C M-9
M96 DT 40 Controller R-8 R1 Terminal 1 Starting switch terminal R1 N-8
M97 DT 40 Controller Q-8 R2 Terminal 1 Starting switch terminal R2 N-8
M99 DT 2 Arm ground angle alarm can- P-8

cel selector
SHINA-
M100 5 Rotary lamp drive relay R-7
GAWA
P15 AMP040 2 Sunlight sensor (Optional) M-6
20-219-1 PC78US-6
(12)

PC78UU-6 Serial No.: 22832 – 23500
20-219-3 PC78US-6
(12)
PC78US-6 20-219-4
(12)
20-219-5 PC78US-6
(12)

ing).
Add- Add-
D4 SWP 2 H-1 K21 S 8 Cab inlet R-6
HOLD)
D5 SWP 2 G-1 K22 DT 2 Attachment selector wire P-8
Battery relay BR)
D6 SWP 2 Diode (Alternator R o Battery G-1 K23 Relay 5 Starting motor cut relay (PPC R-7
relay BR) lock)
D11 SWP 2 Diode (TVC solenoid) R-7 K26 AMP090 2 Horn switch M-7
D12 SWP 2 Diode (TVC solenoid) R-5 K27 SWP 6 Fuel governor control motor N-7
Diode (PPC main pressure

D13 SWP 2 lock solenoid) Q-8 K28 M 3 PPC hydraulic lock switch P-2

D14 SWP 2 R-4 K32 5 Accelerator relay O-8
lock solenoid) GAWA
Diode (Boom raise stop sole- SHINA-
D15 SWP 2 R-3 K33 5 Decelerator relay N-7
noid) GAWA
D16 SWP 2 Diode (Boom raise stop sole- R-3 K34 SHINA- 5 Motor drive relay N-8
noid) GAWA
D17 SWP 2 Diode (Swing parking brake R-8 K42 SUMI- 16 Floor intermediate connector O-8
solenoid) TOMO
D18 SWP 2 Diode (Arm IN stop solenoid) Q-8 K45 M 1 Radio ground Q-3
D19 SWP 2 Diode (Arm IN stop solenoid) R-5 K51 AMP090 20 Intermediate connector M-7
Diode (Left offset stop sole-

D20 SWP 2 R-5 K52 M 3 Light switch N-8
noid)
D21 SWP 2 Diode (Left offset stop sole- R-4 K53 M 2 Buzzer cancel switvh O-8
noid)
Diode (Air conditioner com-
D22 SWP 2 H-1 K54 M 3 Rotary lamp switch O-8
pressor)
Diode (Engine stop solenoid SHINA-
D25 SWP 2 pull) G-1 K55 GAWA 5 PPC lock cut relay Q-8
Diode (Engine stop solenoid Intermediate connector

D26 SWP 2 H-9 M1 L 2 M-4
relay, coil) (Power supply, ground)
FB1 Fuse box R-3 M2 X 2 Intermediate connector M-3

(Power supply, glow plug)
Intermediate connector (Moni- Intermediate connector (Fuel
K1 S 12 M-7 M3 DT 8 M-4
tor panel) level sensor, hydraulic switch)
K2 S 16 Intermediate connector (Moni- N-7 M4 DT 8 Intermediate connector M-4

tor panel) (Washer, rotation sensor)
K3 DT 2 Travel speed pedal P-2 M5 DT 8 M-3
power supply, battery relay)
K11 SWP 12 Auto A/C unit P-2 M6 DT 8 Intermediate connector M-3

(Pressure switch)
K12 M 2 Resister P-8 M7 DT 8 M-3
(Potentiometer, sensor)
K13 M 2 Resister P-8 M9 DT 2 Intermediate connector I-2

(Fuel sensor)
K17 X 2 Optional power supply Q-3 M10 DT 2 Left offset stop EPC valve N-2
AMP
K18 2 Decelerator switch Q-2 M11 DT 2 Boom stop EPC valve O-2
090
K19 PA 9 Radio Q-3 M12 DT 2 Arm IN stop EPC valve O-2
K20 M 8 Cab inlet R-6 M13 DT 2 PPC hydraulic rock M-2
PC78US-6 20-219-6
(12)

Add- Add-
M14 DT 2 Swing holding brake N-2 P01 AMP040 12 Monitor panel M-6
M15 DT 2 Travel speed selector N-2 P02 AMP040 20 Monitor panel M-5
M16 DT 2 Engine speed sensor J-3 P15 AMP040 2 Sunlight sensor (Optional) M-6

M17 X 1 Glow plug K-8 PULL Terminal 1 (PULL) L-3
M18 DT 2 Engine water temperature L-8 T1 Terminal 1 Revolving frame ground I-2
M19 X 1 Air conditioner compressor L-7 T2 Terminal 1 Revolving frame ground H-1
M20 DT 2 TVC solenoid K-8 T3 Terminal 1 Revolving frame ground H-1

M21 X 2 H-9 T4 Terminal 1 Alternator R L-6
RAISE)
M22 X 2 Pressure switch (Swing) I-9 T5 Terminal 1 Alternator B L-6
M23 X 2 Pressure switch (Swing) H-9 T6 Terminal 1 Engine oil pressure switch L-5
M24 X 2 Pressure switch (Arm IN) I-9 HOLD Terminal 1 Engine stop solenoid (HOLD) L-2
M25 X 2 Pressure switch (Travel) I-9 GND Terminal 1 Engine stop solenoid (GHD) L-2
M26 L 2 Fusible link C-8 T9 Terminal 1 Battery relay E A-4
M27 L 2 Fusible link B-7 T10 Terminal 1 Battery relay BR A-3

M28 SWP 6 J-9 T11 Terminal 1 Battery relay M A-6
ing lamp)
M29 DT 3 Boom angle potentiometer J-9 T12 Terminal 1 Battery relay B A-5

M30 X 2 Sefety relay (S, R) J-3 T16 Terminal 1 (Contact 1) K-3

M31 KES 2 Windshield washer C-8 T17 Terminal 1 K-3
(Contact 2)
M32 DT 2 Travel/Swing alarm J-2 T21 Terminal 1 System cancel switch M-6
Air conditioner outside tem-

M33 DT 2 perature sensor (Optional) L-5 T22 Terminal 1 System cancel switch O-2
Intermediate connector (Start-

M35 L 2 ing motor C) K-1 T31 Terminal 1 Safety relay B K-3

M36 DT 2 (Coil) J-2 T32 Terminal 1 Safety relay C L-5
M71 DT 3 Offset angle potentiometer G-9 T33 Terminal 1 Starting motor B L-7
M72 DT 3 Arm angle potentiometer A-7 T34 Terminal 1 Starting motor C L-6
M73 DT 2 Working lamp D-9 W04 M 6 Wiper motor M-6
M74 DT 2 Working lamp G-9 W19 2 Cigarette lighter M-4
M80 AMP040 2 Horn M-2 B Terminal 1 Starting switch terminal B M-9
M95 DT 24 Controller R-8 BR Terminal 1 Starting switch terminal BR M-8
M96 DT 40 Controller R-8 ACC Terminal 1 Starting switch terminal ACC M-8
M97 DT 40 Controller Q-8 C Terminal 1 Starting switch terminal C M-9

M99 DT 2 P-8 R1 Terminal 1 Starting switch terminal R1 N-8
cel selector
SHINA-
M100 5 Rotary lamp drive relay R-7 R2 Terminal 1 Starting switch terminal R2 N-8
GAWA
20-219-7 PC78US-6
(12)

20-219-9 PC78US-6
(12)
PC78US-6 20-219-10
(12)
20-219-11 PC78US-6
(12)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins while the terms male housing and female housing refer to the
mating portion of the housing.
X-Type Connector
Number
of Pins Male (Female Housing) Female (Male Housing) T-adapter Part
Number
1 Part Number: 08055-00181 Part Number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
Part Number: 08055-00282 Part Number: 08055-00292
BWP04703
3 799-601-7030
BWP04704
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— • Grommet: black —
• Grommet: black
• Quantity: 20 pieces • Quantity: 20 pieces
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— • Grommet: red —
• Grommet: red
20-220 PC78US-6
(1)
SWP-Type Connector
Number
Number
BWP04708
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
PC78US-6 20-221
b
SWP-Type Connector
Number
Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:
— • Grommet: black • Grommet: black —
Terminal part number: Terminal part number:
— • Grommet: red • Grommet: red —
20-222 PC78US-6
b
M-Type Connector
Number
of Pins T-adapter Part
Male (Female Housing) Female (Male Housing) Number
1 Part Number: 08056-00171 Part Number: 08056-00181 799-601-7080
BWP04718
2 BWP04717 799-601-7090
3 BWP04719 BWP04720 799-601-7110
4 BWP04721 BWP04722 799-601-7120
6 BWP04723 BWP04724 799-601-7130
8 799-601-7340
BWP04725 BWP04726
PC78US-6 20-223
(12)
S-Type Connector
Number
BWP04728
8 BWP04727 799-601-7140
10 BWP04729 BWP04730 799-601-7150

(White)
12 BWP04731 BWP04732 799-601-7350

(White)
16 BWP04733 BWP04734 799-601-7330

(White)
20-224 PC78US-6
(1)
S-Type Connector
Number
Number
BWP04736
10 BWP04735
(Blue) —
— —
12 BWP04737 BWP04738 799-601-7160

(Blue)
16 BWP04739 BWP04740 799-601-7170

(Blue)
PC78US-6 20-225
(1)
MIC-Type Connector
Number
Number
7 Body Part Number: 79A-222-2640 Body Part Number: 79A-222-2630 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
Body Part Number: 79A-222-2680 Body Part Number: 79A-222-2670
11 —
BWP04742
BWP04741
5 799-601-2710

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

20-226 PC78US-6
(12)
MIC-Type Connector
Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

(Quantity: 50 pieces) (Quantity: 50 pieces) —
PC78US-6 20-227
(1)
AMP040-Type Connector
Number
Number
BWP04752
BWP04751
8 799-601-7180
Housing Part Number: 79A-222-3430

—
(Quantity: 5 pieces)
BWP04753 BWP047544
12 799-601-7190
— Housing Part Number: 79A-222-3440

BWP04755 BWP04756
16 799-601-7210

— (Quantity: 5 pieces)
BWP04757 BWP04758
20 799-601-7220

—
a Terminal Part Number: 79A-222-3470 (For all numbers of pins).
20-228 PC78US-6
(12)
AMP070-Type Connector
Number
BWP04760
10 BWP04759 799-601-7510
— Part Number: 08195-10210
12 BWP04761 BWP04762 799-601-7520
— Part Number: 08195-12210
14 BWP04763 BWP04764 799-601-7530
— Part Number: 08195-14210
18 BWP04765 BWP04766 799-601-7540
— Part Number: 08195-18210
20 BWP04767 BWP04768 799-601-7550
— Part Number: 08195-20210
PC78US-6 20-229
b
L-Type Connector
Number
BWP04770
2 BWP04769
— — —
PA-Type Connector
Number
BWP04772
9 BWP04771
— —
BENDIX MS-Type Connector

Number
Number
BWP04774
10 BWP04773 799-601-3460
— —
20-230 PC78US-6
b
KES1 Automobile-Type Connector

Number
BWP04776
BWP04775
2 —
Part Number: 08027-10210 (Natural color) Part Number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
08027-10620 (Black) 08027-10670 (Black)
PC78US-6 20-231
b
KES1 Automobile-Type Connector

Number
BWP04784
BWP04783
8 —
08027-10820 (Black) 08027-10870 (Black)
20-232 PC78US-6
b
Socket-Type Connector for Relay

Number
BWP04786
5 BWP04785 799-601-7360
— —
BWP04788
6 BWP04787 799-601-7370
— —
PC78US-6 20-233
b
F-Type Connector
Number
BWP04786
BWP04785
4 —
— —
20-234 PC78US-6
b
The pin number is also marked on the connector (Electric wire insertion end).
Type HD30 Series Connector
(Shell
Size Body (Plug) Body (Receptacle) T-adapter
Code) Part Number
Pin (Male Terminal) Pin (Female Terminal)
Part Number: 08191-11201, 08191-11202, Part Number: 08191-14101, 08191-14102,

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

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

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part Number: 08191-22201, 08191-22202 Part Number: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
PC78US-6 20-235
b
(Shell
Size T-adapter
Body (Plug) Body (Receptacle)
Code) Part Number
18-20 Part Number: 08191-31201, 08191-31202 Part Number: 08191-34101, 08191-34102

799-601-9230
Part Number: 08191-32201, 08191-32202 Part Number: 08191-33101, 08191-33102


(4) 799-601-9240
Pin (Female Terminal) Pin (Male Terminal)
20-236 PC78US-6
b
(Shell
Code) Part Number

799-601-9250


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

08191-62205, 08191-62206 08191-63105, 08191-63106
PC78US-6 20-237
b
(Shell
Code) Part Number
Part Number: 08191-71201, 08191-71202, Part Number: 08191-74101, 08191-74102, 08191-74105,

24-21 08191-71205, 08191-71206 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
Part Number: 08191-81201, 08191-81202, 08191-81203, Part Number: 08191-84101, 08191-84102, 08191-84103,
24-22 08191-81204, 08191-81205, 08191-81206 08191-84104, 08191-84105, 08191-84106
799-601-9280
Part Number: 08191-82201, 08191-82202, 08191-82203, Part Number: 08191-83101, 08191-83102, 08191-83103,
08191-82204, 08191-82205, 08191-82206 08191-83104, 08191-83105, 08191-83106
20-238 PC78US-6
b
(Shell
Size T-adapter
Body (Plug) Body (Receptacle)
Code) Part Number

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

08191-92205, 08191-92206 08191-93105, 08191-93106
PC78US-6 20-239
b
No. DT Series Connector
of T-adapter
Pins Body (Plug) Body (Receptacle)
Part Number
2 799-601-9020
Part Number: 08192-12200 (Normal type) Part Number: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-240 PC78US-6
b
No. DT Series Connector

of T-adapter Part Num-
Pins Body (Plug) Body (Receptacle)
ber
8GR:799-601-9060
8 8B:799-601-9070
8G:799-601-9080
8BR:799-601-9090
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)
PC78US-6 20-241
(12)
No. DTM Series Connector
of T-adapter Part
Pins Body (Plug) Body (Receptacle) Number
2 799-601-9010
No. DTHD Series Connector
of T-adapter Part
Pins Body (Plug) Body (Receptacle) Number
Part Number: 08192-31200 (Contact size #12) Part Number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-242 PC78US-6
(12)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM
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
1) Working mode (Standard, E) information (Monitor panel o Controller)

2) One-touch slow-down (ON/OFF) signal (Monitor panel i Controller)
3) Travel Hi/Lo signal (Monitor panel i Controller)
4) Coolant temperature (Water temperature) information (Monitor panel o Controller)
5) Service code (Failure code) information (Controller o Monitor panel)
20-244 PC78US-6
(12)
PC78US-6 20-245
(12)
Machine model: PC78UU-6
The control mechanism of the electric system consists of the monitor panel, governor, and pump control-
ler. Those components receive signals necessary to them. The governor and pump controller output or
input the necessary signal according to the signals selected by the monitor panel to control the absorption
torque, engine output, etc.
Network information
1) Working mode (Standard, E) information (Monitor panel ! Controller)

2) One-touch slow-down (ON/OFF) signal (Monitor panel  Controller)
3) Travel Hi/Lo signal (Monitor panel  Controller)
4) Coolant temperature (Water temperature) information (Monitor panel ! Controller)
5) Service code (Failure code) information (Controller ! Monitor panel)
6) Automatic control information (Only PC78UU) (Monitor panel ! Controller)
20-245-1 PC78US-6
➄
PC78US-6 20-245-2
➄
TROUBLESHOOTING DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL

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

(1) Display
(2) Service meter unit
(3) Mode selector switch (UP)
(4) Mode selector switch (DOWN)
(5) Set switch
(6) Travel speed selector switch
(7) Working mode selector switch
(8) Buzzer cancel switch
Note) Since the switches "3, 4, and 5" are not indicated on the panel
of model US, operate the same parts as the panel of model UU.
Example)User code "E02" is displayed.
2) User Codes List
User Code Abnormal system
E02 TVC-EPC system
E03 Swing holding brake system
E05 Governor control system
E40 Angle sensor input system 

 Only PC78UU-6
EPC solenoid and PPC basic pressure lock solenoid out-
E41 
put system
20-246 PC78US-6
➄
3. Function of displaying "service code"

All trouble information items of the controller are sent to the monitor panel. All of the information items which
must display "user codes" and those which do not need display "user codes" are saved as "service codes"
in the monitor panel.
If the following operation is executed, the service code is displayed on the display of the monitor panel and
the letter "E" to indicate that the trouble is happening currently and the lapse time (service meter reading)
are displayed on the service meter unit.
1) Method of displaying and deleting service code (1) Display (5) Set switch
i) The service code is displayed by the fol- (2) Service meter unit (6) Travel speed switch
lowing procedure: (3) Mode selector switch (7) Working mode selec-
(1) Push and hold the "Buzzer cancel (UP) tor switch
switch (8)" and "Working mode se- (4) Mode selector switch (8) Buzzer cancel switch
lector switch (7)" for 2.5 seconds. (DOWN)
(2) Push the "Buzzer cancel switch (8)"
and "Mode selector switch (UP) (3)"
[or Mode selector switch (DOWN)
(4)] and set "01" tothe 2nd and 3rd
columns from the left on service
meter unit (2).
(3) Push the "Set switch (5)".
Since the switches "3, 4, and 5" are

not indicated on the panel of model
US, operate the same parts as the
panel of model UU.
Example 1)"01" is displayed on service
meter unit (2).
Example 2)"E213" happened 6 hours

ago.
a If "E213" is still happening, the
letter "E" is displayed in the 2nd
column of service meter unit (2).
If "E213" has been repaired, "E"
is not displayed.
a The lapse time is displayed in
the 3 columns from the right of
service meter unit (2).
PC78US-6 20-247
(1)
Example 3)If any service code is not iv) To stop display of the service code, push
saved, "-" is displayed in ev- the "Buzzer cancel switch (8)" and
ery column of display (1) and "Working mode selector switch (7)".
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" simultaneous-
"Mode selector switch (UP)" (3). ly, then turn ON the "starting switch"
iii) To see the previous displayed service again and push and hold the "Buzzer
code, push the "Buzzer cancel switch cancel switch (8)" for 5 seconds.
(8)" and "Mode selector switch (DOWN) a If the number of service codes
(4)". exceeds 20, they are deleted one by
one from the oldest one.
2) Service codes list
Error Code Abnormal System User Code
E101 Error history data are abnormal —
E108 Engine coolant temperature is 105°C —
E112 Short circuit in forward system of wiper motor drive —
E113 Short circuit in reverse system of wiper motor drive —
E114 Short circuit in windshield washer drive system —
E115 Wiper does not start wiping in 10 seconds —
E116 Wiper is not retracted in 10 seconds —
E203 Short circuit or grounding fault in swing holding brake solenoid system E03
E206 Short circuit or grounding fault in 2nd travel speed selection solenoid system —
E213 Disconnection in swing holding brake solenoid system —
E216 Disconnection in 2nd travel speed selection solenoid system —
E224 Defective pump pressure sensor system —
E227 Short circuit or grounding fault in engine speed sensor system —
E232 Short circuit or grounding fault in TVC-EPC Solenoid system E02
E233 Disconnection in TVC-EPC Solenoid system E02
E258 Grounding fault on power source side of all angle sensors —
E304 (*3) Short circuit or grounding fault in engine stop solenoid relay system —
E306 (*4) Defective governor feedback potentiometer —
E308 (*4) Defective fuel control dial system E05
E314 (*3) Disconnection in engine stop solenoid relay system —
E321 (*2) Grounding fault in governor control motor drive relay system E05
E323 Grounding fault in governor control accelerator relays system E05
E325 Grounding fault in governor control decelerator relays system E05
E328 Abnormality in governor control motor stal E05
E401 (*1) Disconnection on boom angle sensor (-) side E40
E402 (*1) Grounding fault or disconnection on boom angle sensor signal side or disconnection on (+) side E40
E403 (*1) Defective correction of boom angle sensor —
E404 (*1) Disconnection on arm angle sensor (-) side E40
E405 (*1) Grounding fault or disconnection on arm angle sensor signal side or disconnection on (+) side E40
E406 (*1) Defective correction of arm angle sensor —
E407 (*1) Disconnection on offset left angle sensor (-) side E40
E408 (*1) Grounding fault or disconnection on offset left angle sensor signal side or disconnection on (+) side E40
E411 (*1) Defective correction of offset left angle sensor —
E421 (*1) Short circuit or grounding fault in boom raise EPC system E41
E422 (*1) Disconnection in boom raise EPC system E41
E423 (*1) Short circuit or grounding fault in arm-in EPC system E41
E424 (*1) Disconnection in arm-in EPC system E41
E425 (*1) Short circuit or grounding fault in offset left EPC system E41
E426 (*1) Disconnection in offset left EPC system E41
20-248 PC78US-6
(12)
Error Code Abnormal System User Code

E431 (*1) Short circuit or grounding fault in PPC basic pressure lock solenoid system E41
E435 Emergency stop —
E441 (*1) Defective correction of interference prevention (Front) —
E442 (*1) Defective correction of interference prevention (Side) —
E443 (*1) Defective correction of depth display —
E501 Machine model not set —
E502 Defective machine model selection signal —
*1. PC78UU only

*2. Serial No.: PC78US: 4001 – 5500, PC78UU: 22832 – 23500
*3. Serial No.: PC78US: 5501 and up, PC78UU: 23501 and up
*4. Serial No.: PC78US: 6501 and up
PC78US-6 20-248-1
(12)
4. Function of displaying "monitoring code"

The input signals from the sensors to each component and the output signals to drive the solenoids can be
checked in real time with the monitoring codes.
If the following operation is executed, the monitoring code No. is displayed in the 3rd column through the
5th column from the left on service meter unit (2) of the monitor panel and the monitoring information is dis-
played on display (1).
1) Method of displaying monitoring code
i) The monitoring code is displayed by the (1) Display (5) Set switch
following procedure: (2) Service meter unit (6) Travel speed switch
(1) Push and hold the "Buzzer cancel (3) Mode selector switch (7) Working mode selec-
switch (8)" and "Working switch (7)" (UP) tor switch
for 2.5 seconds. (4) Mode selector switch (8) Buzzer cancel switch
(2) Push the "Buzzer cancel switch (8)" (DOWN)
and "Mode selector switch (UP) (3)"
[or Mode selector switch (DOWN)
(4)] and set "02" to the 2nd and 3rd
columns from the left on display (2).
(3) Push the "Set switch (5)".
Since the switches "3, 4, and 5" are
not indicated on the panel of model
US, operate the same parts as the
panel of model UU.
Example 1)A numerical monitoring code

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

1020 (ON/OFF input state
(1)) is displayed.
PC78US-6 20-249
(1)
ii) To see the next displayed monitoring

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

a For details of a code marked with "(6 bit)" in the Unit column, see the bit patterns table.
Component
Code No. Item Unit
Name
0001 Monitor model code — Controller
0008 S-NET connection state (6bit) Controller
0041 Water temperature sensor voltage 10 mA Controller
0042 Fuel level sensor voltage 10 mA Controller
0043 Charge voltage 100 mA Controller
0045 Sensor input 1 (6bit) Controller
0046 Sensor input 2 (6bit) Controller
0047 Output state (6bit) Controller
0048 Wiper state (6bit) Controller
0049 Spare Controller
0200 Software version No. (Monitor) Controller
Software version No.
1000 If 1.0 is displayed, version No. of controller is 1.0. Controller
(Controller)
00: Standard arm
01: Long arm
1001 Attachment selection Controller
02: Slide arm
03: Multi-changer
1010 Engine speed 10 rpm Controller
1020 ON/OFF input 1 (6bit) Controller
1024 ON/OFF input/output (6bit) Controller
Work equipment angle
1030 V Controller
sensor voltage (Boom)
1031 If 2.4 is displayed, input voltage is 2.4 V. V Controller
sensor voltage (Offset)
1032 V Controller
sensor voltage (Arm)
1033 Work equipment potentiometer slide V Controller
1040 Boom bottom pressure If 2.4 is displayed, pressure is 2.4 MPa. MPa Controller
EPC output current
1050 10 mA Controller
(TVC)
EPC output current
(Boom RAISE) If 55 is displayed, current is 55 mA. If current is
EPC output current 1 A, however, FF is displayed.
(Arm IN)
EPC output current
(Off-set LEFT)
1060 ON/OFF output (6bit) Controller
20-250 PC78US-6
(7)
3) Bit patterns list (Bits of corresponding Nos.

light up)
a [1] – [6] on digital display unit (1) are bit
Nos.
a The monitoring code No. (4 digits) is dis-
played in the 2nd column through 5th
column from the left on service meter
display unit (2).
Code No. Item Bit Details (State When Bit Lights Up)
(1) ID2 is connected.
0008 S-NET connection state
(1) Starting switch is at "ON"
(2) Starting switch is at "START"
0045 Sensor input 1
(3) Starting switch is at "PREHEAT"
(4) Light switch is at "ON"
(2) Constant bit
0046 Sensor input 2 (3) Engine oil pressure (When low)
(6) Charge level is low (Engine is stopped)
0047 State of output (1) Buzzer output
(2) Washer output (Washer switch is turned ON)
(3) Wiper output 1
0048 State of wiper (4) Wiper output 2
(5) Wiper output 3
(6) Wiper output 4
(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) (*1)
ON/OFF input 1 (2) ATT selection 1 (GND is connected) (*1)
a For detail of model selec- (3) Model selection 1 (GND is connected) (*1)
1020 tion, see Table 1.
a For detail of ATT selection, (4) ATT selection 3 (GND is connected) (*1)
see Table 2. (5) UU/US selection (GND is connected) (*1)
(6) Model selection 2 (GND is connected) (*1)
(3) Compressor signal
(4) —
1021 ON/OFF input 2
a Tier 2 selection signal (When power source
(5)
is connected) (*1)
(1) 2nd travel speed selection switch (Panel)
(3) Backup light (*1)
1022 ON/OFF input 3
(4) SET/CLEAR switch
(5) Mode selector (E) switch
(6) Mode selector (R) switch
PC78US-6 20-251
(12)
(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 (*1)
(2) Acceleration signal (*1)
(3) Motor drive power supply (*1)
1024 ON/OFF input/output
(4) Auto deceleration signal (*1)
(5) Motor relay (–)
(6) Motor relay (+)
(1) —
(2) Display selector switch (Monitor)
(3) Arm ground angle alarm cancel switch (*1)
(6) Bucket dump prohibition solenoid + Rotary lamp
Deceleration switch (*1), Overload alarm switch
(1)
(When alarm is effective) (*2)
(2) Alarm cancel
1026 ON/OFF input/output Emergency work equipment operation switch
(3)
(*1)
(4) 2nd travel speed selection switch (Pedal) (*1)
(5) Slide arm limit switch (*1)
(1) Swing holding brake switch (Brake is released)
PPC main pressure lock (Main pressure lock is
(2)
reset) (*1)
2nd travel speed is selected (Machine travels at
(4)
2nd gear speed)
(5) Travel/Swing alarm (Alarm is output)
*1. PC78US-6 Serial No.: 4001 – 6500, PC78UU-6 Seral No.: 22832 and up
20-252 PC78US-6
(12)
Table 1
Model Selection 1 Model Selection 2 UU/US Selection Signal Tier 2 Signal
PC78US-6 (*1) GND OPEN GND OPEN
Connection of power
PC78US-6 (*2) GND OPEN GND
source
PC78UU-6 (*1) GND OPEN OPEN OPEN
Connection of power
PC78UU-6 (*2) GND OPEN OPEN
source
*1. PC78US-6 Serial No.: 4001 – 5500, PC78UU-6 Seral No.: 22832 – 23500
*2. PC78US-6 Serial No.: 5501 – 6500, PC78UU-6 Seral No.: 23501 and up
Table 2
Connection table of attachment selection wires
a The bits of GND are displayed during normal operation.
Attachment Attachment Selection (1) Attachment Selection (2) Attachment Selection (3)
Standard specification
Standard arm GND OPEN OPEN
Long arm OPEN GND OPEN
Slide arm GND GND OPEN
Multi-changer OPEN OPEN OPEN
PC78US-6 20-252-1
(13)
Procedure for correcting angle sensor, preventing interference, setting depth display to 0, adjusting engine gov-
ernor, setting arm crane specification, and setting work equipment.
Back mode (When SP monitor is used)
Table 2 Method of selecting back mode and ordinary display
Back Mode
01 02 03 06 10 11 18 19
Mode These modes are set to 2 levels (Note 5)
Code Emer- Setting Setting Setting Error
Adjusting Correct- Setting Adjusting
(Note 2) gency Error preven- dis- arm Next Previ- Memory Adjusting service
Trouble Memory Monitor- engine ing
tion of played crane
work
Item ous Item Deletion service
ing governor potenti- interfer- depth to specifica- equip- meter
(Note 3) Display
lever ometer ment (Note 4) (Note 4)
ence D tion
PC78US-6 Q Q Q Q — — Q Q — — Q Q Q
(Note9) (Note6) (Note6) (Note9) (Note7)
PC78UU-6 Q Q Q Q Q — — Q Q Q
(Note8)
B Buzzer cancel Q Q Q Q Q Q Q Q Q Q Q Q Q
Working mode 3
a
selection
Q Q Q Q Q Q Q Q (Note10)
b Travel selection Q 1
(Note10)
c SET/CLEAR Q 2
(Note10)
d Model selection (E) Q 4
(Note10)
e Model selection (R) Q
Wiper selection
Washer
Continuous opera- 5
tion time (SEC) 2.5
(Note1)
Note 1) Limited to 5 seconds after the power is turned ON.
Note 2) Displayed on the service meter unit.
Note 3) A flag from the controller is a trigger.
Note 4) Used to save monitoring error.
Note 5) Select with Buzzer cancel + Working mode selection. Select next or previous items with Buzzer can-
cel + E/R. Enter each mode with the SET/CLEAR switch.
* Unnecessary entry to this mode can cause a trouble, however. When adjusting SMR, enter this mode
by a different method.
Note 6) Do not this mode for model US.
Note 7) Serial No.: 5501 and up
Note 10) Press switches 1 – 4 in order.
PC78US-6 20-253
(12)
"03" Adjusting engine governor lever

1) In this mode, set the decelerator motor cable in the engine high idling position (where it becomes shortest).
2) Use this mode to set the engine governor lever fully.
(When the starting switch is turned ON, if the system is not set in this mode, the governor motor may not
operate.)
3) If a short circuit or a grounding fault occurs in the circuit of the governor control system, the cable may move
out of the normal control range. At this time, even if the cause of the trouble is removed, the governor motor
cannot be controlled.
If this occurs, operate the panel switch in this mode to return the cable into the normal control range and
restore the governor motor control.
No. Operation Display
1) Turn the starting switch ON and set the fuel control dial The display section displays "GOV" and the service meter
to the FULL position. display section displays "GSET".
a At this time, turn the automatic decelerator (one-
touch decelerator) OFF (reset it).
2) Hold buzzer cancel switch (B) and working mode selec-
tor switch (a) for 2.5 seconds.
1 3) Set the code in the service meter section to "03".
(B) + (d): Next code
(B) + (e): Previous code
4) Press switch (c).
a Under this condition, the deceleration motor cable is
in the engine high idling position (It becomes short-
est).
<Function of restoring governor control>
Use this function for only above purpose 3).
(Do not use this function usually.)
Be sure to remove the cause of the trouble before using this
function.
5)-1. When engine speed does not rise from low idling
2 Press switch (d) several times and operate the fuel
control dial to check that the governor control is
restored.
5)-2. When engine speed does not lower from high idling
Press switch (e) several times and operate the fuel
control dial to check that the governor control is
restored.
To finish the decelerator motor adjustment, perform the
3
operation in 1-(2), and the monitor panel displays normally.
a Since US does not have displays of c, d, and UU monitor panel

e, operate the same parts with UU.
B: Buzzer cancel switch is installed to top of right

console.
20-253-1 PC78US-6
(13)
"06" Correcting angle sensor (Only UU)

The stroke end is saved for initial setting of each cylinder (portion where the angle sensor is installed).
1) Turn the starting switch ON or run the engine, and then The display section displays "S-1".
hold alarm buzzer cancel switch (B) and working mode
selector switch (a) for 2.5 seconds.
1 2) Set the code of the service meter section to "06".
Set the machine in "posture 1" and press switch (c). After switch (c) is pressed, the display section displays "ooo",
(Posture 1) and then it displays "S-2".
• 1st boom: RAISE end
• Offset boom: RIGHT end (Only UU) When normal
• Arm: IN end
If the system is not reset normally, "---" is displayed.

When abnormal
Set the machine in "posture 2" and press switch (c). After switch (c) is pressed, the display section displays
(Posture 2) "ooo", and then it displays "---".
• Offset boom: LEFT end (Only UU)
• Arm: DUMP end When normal
• Do not lower bucket to ground.
3 (Completion of setting)
When abnormal (Flashing)

If the system is not reset normally, "---" flashes.
To finish monitoring, perform the operation of 1-1), and the

4
monitor panel returns to the ordinary display state.
a If the system is not reset normally, check the ser- UU monitor panel
vice code with the error history display function
to find out the defective potentiometer.
a If the system is not reset normally, the data
before writing are deleted and the initial data are
applied. Accordingly, be sure to reset again.
a Since US does not have displays of c, d, and e,
operate the same parts with UU.
B: Buzzer cancel switch is installed to top of right

console.
PC78US-6 20-253-2
(13)
"10" Setting of prevention of interference (Only UU)

Setting of front and side stop positions and emergency stop position
1) Turn the starting switch ON or start the engine, then "F-1" is displayed on the display.
push and hold warning buzzer cancel switch (B) and
working mode selector switch (a) for 2.5 seconds.
1 2) Set the code on service meter unit to "10". Setting of front stop position
3) Push switch (c).
Set the bucket to the front automatic stop position and push After switch (c) is pushed, "ooo" is displayed on the display,
switch (c). then "S-1" is displayed.
(Setting of front stop position) When normal
2 If the data are not reset normally, "---" is displayed. When abnormal
Set the bucket to the side automatic stop position and push After switch (c) is pushed, "ooo" is displayed on the display,
switch (c). then "---" is dislayed.
(Setting of side stop position)
When normal
3
If the data are not reset normally, "---" is displayed. (Setting is completed)
When abnormal
To stop monitoring, perform the operation in 1-1), and the

4
monitor panel displays the normal items.
Monitor Panel of Model UU
a If the data are not reset normally, check the ser-
vice code with the function of displaying the fail-
ure history to find out the defective potentiometer.
a If the data are not reset normally, the data before
writing are deleted and the initial data are saved.
Be sure to reset again.
B: The buzzer cancel switch is installed above the
right console.
20-254 PC78US-6
(5)
"11" Setting of displayed depth to 0 (Only UU)

Correction of dispersion of displayed depth
1) Turn the starting switch ON or start the engine, then "d-1" is displayed on the display.
push and hold warning buzzer cancel switch (B) and
working mode selector switch (a) for 2.5 seconds.
1 2) Set the code on service meter unit to "11".
3) Push switch (c).
Set the machine to the working position in (Position 3) and After switch (c) is pushed, "ooo" is displayed on the display,
push switch (c). then "d-2" is displayed.
(Position 3) When normal

• Move bucket in
(Lower bucket to ground with its top vertical.)
If the data are not reset normally, "---" is displayed.
When abnormal
Set the machine to the working position in (Position 4) and After switch (c) is pushed, "ooo" is displayed on the display,
push switch (c). then "---" is displayed.
(Position 4) When normal

• Move arm out
(Lower bucket to ground with its top vertical.)
(Setting is completed)
3
When abnormal
If the data are not reset normally, "---" is displayed.
To stop monitoring, perform the operation in 1-1), and the

4
monitor panel displays the normal items.
Monitor Panel of Model UU
a If the data are not reset normally, check the ser-
vice code with the function of displaying the fail-
ure history to find out the defective potentiometer.
a If the data are not reset normally, the data before
writing are deleted and the initial data are saved.
Be sure to reset again.
B: The buzzer cancel switch is installed above the
right console.
PC78US-6 20-255
(5)
"19" Setting work equipment

a Since the attachments for the above machines are selected with the monitor panel, an attachment selector
connector is not installed.
a Set the specification of the work equipment (The machine with the standard arm specification does not
need to be set).
1) Hold alarm buzzer cancel switch (B) and switch (a) for The display section displays "10" and the service meter
2.5 seconds. section displays "19SET".
2) Set the code of the service meter section to "19". (If 19SET has been set, the display section displays the
(B) + (d): Next code current set value.)
1
1) Set the value of the display section to a desired value. Example) When long arm is selected
Set value Arm Remarks
0 Standard arm Controller default
1 Long arm

2) Press switch (c). After switch (c) is pressed, the display section displays
"ooo", and then it displays "---".
2
To finish selection of model, perform the operation of 1-1),

and the monitor panel returns to the ordinary display state.
After finishing setting 19SET, be sure to turn the starting
3 switch OFF once.
This setting becomes effective only after the starting switch
is turned OFF.
a Since US does not have displays of c, d, and UU monitor panel

e, operate the same parts with UU.
B: Buzzer cancel switch is installed to top of right con-

sole.
20-255-1 PC78US-6
(13)
Service adjustment
This service adjustment is set for adjustment of dispersion of components and parts and for replay to requests
of each user. Perform this adjustment for the following phenomena and users' requests.
a Basically, the following items do not need to be adjusted, since they are adjusted when delivered.
a This service adjustment is not effective when a component or a part is broken.
1) Service adjustment items table
The phenomena of the machine which need service adjustment, procedure for changing the set values, and
precautions are listed.
a Usually, each adjustment value is set to the initial value.
Service adjust- Adjustment Phenomenon of Procedure for
Precautions
ment item code/set value machine/Users' request changing set value
Change set value to Adjust to degree that work
Engine speed lowers largely dur-
ing work. decrease pump absorption equipment cycle time is not
Adjustment of torque. lengthened.
PC-EPC valve 204
current Change set value to
Work equipment speed is low. increase pump absorption Adjust to degree that engine
speed is not lowered largely.
torque.
Travel/Swing
alarm output Set for each user who wants to Alarm sounds when machine
210 Set to 211.
(If travel alarm sound alarm during swinging. travels or swings.
is installed)
Change of When bucket is in interference Since stop position becomes
emergency
stop position 220 range of cab, emergency stop Increase set value. closer to emergency stop posi-
(Front of cab) system does not operate. tion, adjust stop position, too.
Change of
emergency When bucket is in interference Since stop position becomes
230 range of cab, emergency stop Increase set value. closer to emergency stop posi-
stop position
(Side of cab) system does not operate. tion, adjust stop position, too.
• Boom RAISE end cushion • Adjust to degree that boom

does not work normally. RAISE speed is not lowered.
• Large shock is made when Decrease EPC pressure. • Boom stops to prevent inter-
boom stops to prevent interference even when engine
Adjustment of ference. speed is low.
boom RAISE
EPC valve cur- 243 • When boom RAISE end cush- • Adjust to degree that function
rent ion works, work equipment of boom RAISE end cushion is
speed is low. Increase EPC pressure. not lowered.
• When boom stops to prevent • Adjust to degree that large
interference, work equipment shock is not made when boom
speed is low. stops to prevent interference.
• Arm IN end cushion does not • Adjust to degree that arm IN
work normally. speed is not lowered.
• Large shock is made when Decrease EPC pressure. • Arm stops to prevent interfer-
arm stops to prevent interference even when engine
Adjustment of ence. speed is low.
arm RAISE 253
EPC valve cur- • When arm IN end cushion • Adjust to degree that function
rent works, work equipment speed of arm IN end cushion is not
is low. lowered.
Increase EPC pressure.
• When arm stops to prevent • Adjust to degree that large
interference, work equipment shock is not made when arm
speed is low. stops to prevent interference.
Low idling speed is extremely
Decrease set value.
Adjustment of high.
governor cable Low idling speed is extremely Adjust low idling speed to 1,130
324
stroke low (Adjustment is not neces- – 1,180 rpm.
(Low idling) (*1) sary usually since cable touches Increase set value.
stopper).
Adjustment of High idling speed is extremely
Decrease set value.
governor cable high in arm crane mode. Adjust high idling speed to 1,400
stroke 334
High idling speed is extremely – 1,600 rpm in arm crane mode.
(Arm crane Increase set value.
mode) (*1) low in arm crane mode.
Adjustment of High idling speed is extremely

Decrease set value.
governor cable high in E mode. Adjust high idling speed to 1,750
344
stroke High idling speed is extremely – 1,950 rpm in arm crane mode.
(E mode) (*1) Increase set value.
low in E mode.
Initialization of
set values
(Only contents 400 If 401 is selected, all service adjustment items are set to initial values.
of service
adjustment)
PC78US-6 20-255-2
(12)
How to improve exhaust gas color at high altitude

• Adjust the TVC current in this mode to reduce the pump absorption torque and improve the exhaust gas
color at high altitude.
a The work equipment speed, travel speed, and swing speed are lowered by the following operation.
a The following operation is not necessary for the normal work.
1) Turn the starting switch ON or run the engine and hold
buzzer cancel switch (B), travel speed shifting switch (b),
and switch (c) for 2.5 seconds.
2) Adjustment code (3) is displayed (flashed) at the left 2
positions and set value (4) is displayed (lighted) at the
1 right 1 position on display unit (1). "5-5E7" (S-SET) is
displayed on service meter unit (2).
Adjustment code "20" flashes. Set the adjustment code

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

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

console.
20-255-3 PC78US-6
(12)
TROUBLESHOOTING TVC VALVE CURRENT ADJUSTMENT TABLE
TVC VALVE CURRENT ADJUSTMENT TABLE

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

5
(+25 mA)
6 Good
(+50 mA)
7
(+75 mA)
8
(+100 mA)
PC78US-6 20-255-4
(12)
TROUBLESHOOTING HOW TO READ JUDGMENT TABLE
HOW TO READ JUDGMENT TABLE

This judgment table is a tool to see if a trouble of the machine is caused by the electrical system or the hydraulic
and mechanical system and go to a proper troubleshooting code (E-QQ, C-QQ, F-QQ, H-QQ, M-QQ, or
CR-QQ).
In the judgment table, you can judge which troubleshooting code to take by the displayed user code and service
code.
a If a trouble (warning) is displayed on the monitor panel, directly go to the troubleshooting code (M-QQ) dis-
played on the machine monitor. (See the troubleshooting of the machine monitor system.)
1. How to read controller (governor control system) and engine judgment table
• If a service code is displayed on the monitor panel, go to the troubleshooting code (E-QQ) at the bottom
line of the judgment table. (The mark of "q" is put in the place where the trouble mode and service code
are matched to each other.)
• When there is a trouble while no service codes are displayed on the monitor panel, go to the trouble-
shooting code (E-QQ or S-QQ) at the right end which is matched to the trouble mode in the judgment
table.
<Example> When trouble mode of "Engine does not start" is displayed
[Procedure] See if a servomotor is displayed on the monitor panel.
[Judgment]
1) When a service code is displayed on the monitor panel --- Carry out troubleshooting for "E3-QQ" of the
controller (governor control) system.
2) When "the engine does not start" while a service code is not displayed on the monitor panel.
When starting motor revolves ....................... Go to troubleshooting "S-2" of mechanical

system.
• Check revolution
of starting motor.
Go to troubleshooting "E-8" of electrical
When starting motor does not revolve.......... system.
PC78US-6 20-255-6
(12)
TROUBLESHOOTING HOW TO READ JUDGMENT TABLE
2. How to read controller (pump control system) and hydraulic equipment judgment table
• If a service code is displayed on the monitor panel, go to the troubleshooting code (C-QQ) at the bottom
line of the judgment table. (The mark of "q" is put in the place where the trouble mode and service code
are matched to each other.)
• When there is a trouble while no service codes are displayed on the monitor panel, check that an input
signal matched to the trouble mode in the judgment table (the input signal at the point marked with Q)
is displayed, and then;
• If the input signal is displayed normally, go to the troubleshooting code (H-QQ or C-QQ) at the right
end of the judgment table.
• If the input signal is not displayed, go to the troubleshooting code (F-QQ) at the bottom line of the
judgment table.
<Example> When trouble mode of "Machine does not swing" is displayed

[Procedure] See if a servomotor is displayed on the monitor panel.
[Judgment]
1) When a service code is displayed on the monitor panel ......... Carry out troubleshooting for "C-QQ" of
the controller (governor control) system.
2) When "the machine does not swing" while a service code is not displayed on the monitor panel
Go to troubleshooting "H-34" or "C-38) of

When there is signal........................
• Check input signal of mechanical system.
controller
(in monitoring mode). Go to troubleshooting "F-QQ" of controller input
When there is not signal..................
signal system (F mode of corresponding system).
20-255-7 PC78US-6
(12)
TROUBLESHOOTING HOW TO READ FLOW OF TROUBLESHOOTING
HOW TO READ FLOW OF TROUBLESHOOTING

1. Classification of diagnosis code Nos.
Diagnosis Code No. Objective System of Diagnosis Service Code
N-QQ Communication system
E-QQ Electric system of controller (Governor control system) 321, 323, 325, 328
C-QQ Electric system of controller (Pump control system) 232, 233
501, 502, 258, 401, 402,
F-QQ Controller (Input signal system)
404, 405, 407, 408
H-QQ Hydraulic and mechanical systems —
M-QQ Monitor panel E1-QQ system
2. How to read troubleshooting (method) for each failure mode

1) Title column
In the title column of the troubleshooting, the troubleshooting code, service code, and failure mode (trou-
ble) are entered.
2) Classification of cases
If the troubleshooting method for a failure mode (a trouble) varies with the machine model, component,
phenomenon, the failure mode (the trouble) is classified further (This work is called classification of cas-
es), execute an applicable one. (See (2) in the example.) If the cases are not classified, start trouble-
shooting from the first of the failure mode.
3) How to carry out troubleshooting
• Perform checking or measurement in the first step . Then, select either branch of YES and
NO and go to the next step . (Note: The "No." at the right shoulder of each is the reference
No. It is not the No. of the step.)
• If the branch of YES or NO is connected directly to the Cause column, take the remedy shown in
the Remedy column. (See (3) in the example.)
• Under the , the method of inspection, measurement, judgment, etc. are shown. If the result is
matched to the criterion, question, etc., take the branch of YES. If not, take the branch of NO.
• Under the , preparation work for inspection and measurement and criterion are also shown. If
your neglect the preparation work or take a wrong method of operation or handling, you may have a
wrong judgment or may damage the devices. Accordingly, read well before starting inspection and
measurement, then carry out the work in the correct order.
4) General precautions
The general precautions for troubleshooting of each failure mode (trouble) are marked with a under the
title (See (4) in the example).
The precautions marked with a are not shown in the . Be sure to take them when performing the
inspections in the .
5) Diagnostic tools
For the diagnostic tools necessary for troubleshooting, see TESTING AND ADJUSTING, Diagnostic
tools list. Prepare them before starting the work.
20-256 PC78US-6
(12)
TROUBLESHOOTING HOW TO READ FLOW OF TROUBLESHOOTING
6) Locations and connector pin Nos.

Before starting the work, check the Nos., inspection points, types, and locations of the wiring connectors
which appear in the flow of the troubleshooting for each failure mode (trouble) with the table of locations
and Nos. of connector pins.
<Example>
(1) M-1 [E101] (Error history data are abnormal) is displayed
(2) a HThis 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 discon-
nected or connected for troubleshooting. This phenomenon does not indicate an error.
(When the power supply circuit of the monitor panel is cut out while the starting switch is at the OFF
position.)
a If the service code is displayed again after the resetting operation is performed, carry out the trouble-
shooting according to the following procedure.
Cause Remedy
1
• Perform "resetting operation", then operate
After "resetting operation" is performed, is NO
machine usually and observe its condition Normal —
service code displayed again?
for a while (See Note 1).
YES
Disconnection, defective contact,

2 or short circuit with chassis Repair or
• Turn starting switch OFF. Is voltage between P01 (8) – chassis ground NO ground in wiring harness between replace
• 20 – 30 V normal? battery – battery relay B - M27 (1),
(2) – P01 (Female) (8)
YES
Defective monitor panel Replace
PC78US-6 20-259
(12)
TROUBLESHOOTING CONTENTS AND PROCEDURE OF TROUBLESHOOTING
CONTENTS AND PROCEDURE OF TROUBLESHOOTING

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

vice code.
Carry out troubleshooting

YES by engine (in S-mode).
5
Engine system Is electric system
of engine with no
failure code nor-
mal?
4
Is trouble in engine sys- • Flow of part of
YES tem or hydraulic judgment table
(Mechanical) system?
where no trou-
3 • Adjust hydraulic pres- bles are indi-
Is input/output sure, then judge by cated.
signal of controller engine speed. Carry out troubleshooting
NO normal? • Is work equipment by electric system of
NO engine (in E-mode).
always heavy and (Flow of part where there is
• Check by mon-
does engine speed no indication) (E-7 – E-9)
itoring code. lower under heavy
load?
Hydraulic (Carry out troubleshooting in H-
Mechanical System mode).
NO Troubleshoot by input sig-

nal system (F-mode).
a Judge the details by judgment table for controllers (governor control system) (pump control system).
* For the No. and contents of monitoring, see the monitoring codes table.
20-260 PC78US-6
(12)
TROUBLESHOOTING OF COMMUNICATION
SYSTEM
(N MODE)
N-1 Defective communication ................................................................................................................... 20-302
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.
PC78US-6 20-301
(1)
TROUBLESHOOTING N-1
N-1 Defective communication

PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
NO
Is operation of monitor display switch normal?
YES
Condition is normal —
• Turn starting switch ON

• Min. 0.75 V Is voltage between M96 (Female) (21) – chas- NO
• Disconnect M96 and measure sis ground normal?
voltage on wiring harness side
YES
Defective controller Replace
Disconnection or defective
Is resistance between P02 (Female) (9), (10) – NO contact in wiring harness Repair or replace
M96 (Female) (21) normal? between P02 (Female) (9),
(10) – M96 (Female) (21)
YES
a If the communication becomes defective, the following troubles occur.

• The working mode cannot be changed.
• The travel speed cannot be changed with the panel switches.
• The monitor lamp does not light up when the one-touch slow-down mechanism is turned on.
• Normal figures are not displayed on the display and service meter unit.
• A mode cannot be selected.
N-1 Electrical circuit diagram of each system
20-302 PC78US-6
(12)
TROUBLESHOOTING N-1
Cause Remedy
NO
Is operation of monitor display switch normal?
YES
Condition is normal —

• Min. 0.75 V Is voltage between M95 (Female) (18) – chas- NO
• Disconnect M96 and measure sis ground normal?
voltage on wiring harness side
YES
Is resistance between P02 (Female) (9), (10) – NO contact in wiring harness Repair or replace
M95 (Female) (18) normal? between P02 (Female) (9),
(10) – M95 (Female) (18)
YES
a If the communication becomes defective, the following troubles occur.

• The working mode cannot be changed.
• The travel speed cannot be changed with the panel switches.
• The monitor lamp does not light up when the one-touch slow-down mechanism is turned on.
• Normal figures are not displayed on the display and service meter unit.
• A mode cannot be selected.
N-1 Electrical circuit diagram of each system
PC78US-6 20-303
(12)
TROUBLESHOOTING FOR CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
Precautions for troubleshooting for controller (governor control system).................................................... 20-326

Action taken by controller when trouble occurs and problems on machine ............................................... 20-328
Judgment table for controller (governor control system) and engine .......................................................... 20-330
E- 1 Controller power supply is defective (LED of controller is turned off) ................................................ 20-332
E- 2 [E321] (Short circuit in motor drive relay) is displayed....................................................................... 20-333
E- 3 [E323] (Short circuit in accelerator relay system) is displayed........................................................... 20-334
E- 4 [E325] (Short circuit in decelerator relay system) is displayed ....................................................... 20-334-3
E- 5 [E328] (Stall of motor) is displayed .................................................................................................... 20-336
E- 6 [E227] (Trouble in engine speed sensor) is displayed ....................................................................... 20-338
E- 7 [E306] Trouble in governor motor feedback potentiometer is displayed......................................... 20-338-2
E- 8 [E308] Trouble in fuel control dial system is displayed ................................................................... 20-338-3
E- 9 One-touch slow-down mechanism does not work ............................................................................. 20-339
E-10 Engine does not start ......................................................................................................................... 20-340
a) [E304] Short circuit in engine stop solenoid relay system is displayed......................................... 20-340
b) [E314] Disconnection in engine stop solenoid relay system is displayed ..................................... 20-340
c) Engine stop solenoid system ........................................................................................................ 20-341
d) Starting system ............................................................................................................................. 20-344
E-11 Engine does not stop ...................................................................................................................... 20-349-2
PC78US-6 20-325
(12)
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM)

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

2) When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-adapter
is removed and the connector is returned, if the service code is not displayed or the monitor displays
normally, the same trouble will occur again probably. Accordingly, follow up the condition of the machine
sufficiently.
3) After finishing troubleshooting, be sure to delete the saved service code.
2. Handling of function of saving service code
When displaying a saved service code for troubleshooting, "take the notes of the all displayed items and delete
those items", then reproduce the trouble and start the troubleshooting according to the service code displayed
at this time.
(Troubles caused by wrong operation, disconnection of a connector, etc. may be saved in the memory. In this
case, you can avoid unnecessary work by performing the above operation.)
20-326 PC78US-6
(12)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND
TROUBLESHOOTING PROBLEMS ON MACHINE
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS

AND PROBLEMS ON MACHINE
PC78US-6 Serial No.: 4001 – 6500
User Code Service Code Troubled System Contents of Trouble
1) Short circuit in wiring harness between M97
E321 pin 18 – K34 pin 1.
Short circuit in motor drive relay system
(*1) 2) Short circuit in relay K34.

E323 Short circuit in accelerator relay system pin 25 – K32 pin 1.
2) Short circuit in relay K32.

E05 pin 35 – K33 pin 1.
E325 Short circuit in decelerator relay system
1) Short circuit of M97 pin 19 with power source.

Stall of motor 4) Trouble in motor.
E328 (When burn preventive function of motor oper-
ates)
1) Short circuit or disconnection in wiring har-

E304 Short circuit in engine stop solenoid relay system ness between M97 (4) – M36 (1).
— E314 2) Disconnection in wiring harness between
(*2) Disconnection engine stop solenoid relay system M36 (2) – chassis ground.
3) Trouble in M36 relay.
*1.: PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500
*2.: PC78US-6 Serial No.: 5501 – 6500
When the motor is normal, its condition can be monitored as
shown below.
• When fuel control dial is operated (Slow o Full) Displayed code [1024] : (2), (3), (4), (6), light up and motor operates, then (2),
(3), (4), (6) go off and motor stops (Only (4) keeps
lighting up).
• When fuel control dial is operated (Full o Slow) Displayed code [1024] : While only (4) is lighting up, (1), (3), (5) light up and
motor operates, then all lamps go off and motor
stops.
• In E-mode (When fuel control dial is at FULL Displayed code [1024] : While only (4) is lighting up, (3), (5) light up and
position) motor operates, then (2) lights up and (3), (5) go off
and motor stops (Only (2) and (4) keep lighting up).
• When E-mode is changed to standard motor Displayed code [1024] : While only (2), (4) are lighting up, (3), (6) light up and
(When fuel control dial is at FULL position) motor operates, then (2), (3), (6) go off and motor
stops (Only (4) keeps lighting up).
• When one-touch slow-down mechanism is Displayed code [1024] : While only (4) is lighting up, (3), (5) light up and
turned on (When fuel control dial is at FULL motor operates, then (2) lights up and (3), (4), (5) go
position) off and motor stops (Only (2) keeps lighting up).
Displayed code [1026] : When one-touch slow-down switch is turned on, (1)
lights up (This is same as in resetting operation).
turned off (When fuel control dial is at FULL motor operates, then (4) lights up and (2), (3), (6) go
20-328 PC78US-6
(16)
Action taken by controller

Normal condition Problems on machine
when trouble occurs
Between M97 pin 18 – chassis ground: Min. 1 Mz K34 pin 1 If trouble is detected, motor 1. Fuel control dial cannot be oper-
Resistance between K34 relay pin 1 – pin 2: 290 z ± 10% drive relay output, accelerator ated (For acceleration and decel-
Resistance between K34 relay pin 1, 2 – pin: 3, 5, 6 relay output, and decelerator eration).
: Min. 1 Mz relay output are stopped. 2. One-touch slow-down mecha-
Between M97 pin 25 – chassis ground: Min.: 1 Mz K32 pin 1 nism cannot be operated.
Resistance between K32 relay pin 1 – pin 2: 290 z ± 10% 3. When working mode is changed,
Resistance between K32 relay pin 1, 2 – pin 3, 5, 6 engine speed does not change.
: Min. 1 Mz
Between M97 pin 35 – chassis ground: Min. 1 Mz K33 pin 1
Resistance between K33 relay pin 1 – pin 2: 290 z ± 10%
Resistance between K33 relay pin 1, 2 – pin 3, 5, 6
: Min. 1 Mz
Motor starts and stops from slow to full and from full to slow If accelerator, decelerator, or • When signal system is troubled
in 2 seconds. one-touch slow-down mecha- Motor operates but stalls soon.
nism works for more than 10 Then, it does not operated even if
seconds, motor drive relay out- dial is moved.
put, accelerator relay output, • When motor is troubled
and decelerator relay output Motor stalls from the first, then it
are stopped. does not operate even if dial is
moved.
Relay Stop solenoid output is 1. Stop solenoid cannot be pulled
stopped. (Engine cannot be started).
M97 (female) M36 (male) Resistance
(4) – Chassis ground (1) – (2) 68 z ± 10%
Engine governor control system
*1.: PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500
PC78US-6 20-329
(12)

pin 7 – K32 pin 2.
E323 Short circuit in accelerator relay system

E325 Short circuit in decelerator relay system pin 17 – K33 pin 2.
E05
1) Short circuit of S2 pin 15 – pin 6 with power
source.
2) Trouble in motor.
Stall of motor 3) Short circuit in relay K32, K33.
E328 (When burn preventive function of motor oper-
ates)
1) Short circuit or disconnection in wiring har-

E304 Short circuit in engine stop solenoid relay system ness between M95 (20) – M36 (1).
— 2) Disconnection in wiring harness between
E314 Disconnection engine stop solenoid relay system M36 (2) – chassis ground.
3) Trouble in M36 relay.
(23) – (22)
Short circuit in wiring harness between M95
(23) – (32)
2) Disconnection in wiring harness between
M95 (22) – S2 (1)
Disconnection in wiring harness between
M95 (23) – S2 (2)
— E306 Trouble in governor motor feedback potentiome- Disconnection in wiring harness between
ter
M95 (32) – S2 (3)
3) Short circuit in wiring harness between S2
(male) (2) – (1)
Short circuit in wiring harness between S2
(male) (2) – (3)
Short circuit in wiring harness between S2
(male) (1) – (3)
4) Defective potentiometer
(13) – (22)
Short circuit in wiring harness between M95
(13) – (32)
2) Disconnection in wiring harness between
M95 (22) K55 (1)
Disconnection in wiring harness between
M95 (13) – K55 (2)
E05 E308 Fuel control dial system Disconnection in wiring harness between
M95 (32) – K55 (3)
3) Short circuit in wiring harness between K55
(male) (2) – (1)
Short circuit in wiring harness between K55
(male) (2) – (3)
Short circuit in wiring harness between K55
(male) (1) – (3)
4) Defective potentiometer
20-329-1 PC78US-6
(12)
Action taken by controller

Normal condition Problems on machine
when trouble occurs
Between M95 pin 7 – chassis ground: Min.: 1 Mz If trouble is detected, accelera- 1. Fuel control dial cannot be oper-
Resistance between K32 relay pin 1 – pin 2: 290 z ± 10% tor relay output, and decelera- ated (For acceleration and decel-
Resistance between K32 relay pin 1, 2 – pin 3, 5, 6 tor relay output are stopped. eration).
: Min. 1 Mz 2. One-touch slow-down mecha-
Between M95 pin 17 – chassis ground: Min. 1 Mz nism cannot be operated.
Resistance between K33 relay pin 1 – pin 2: 290 z ± 10% 3. When working mode is changed,
Resistance between K33 relay pin 1, 2 – pin 3, 5, 6 engine speed does not change.
: Min. 1 Mz
Motor starts and stops from slow to full and from full to slow If accelerator, decelerator, or • When signal system is troubled
in 2 seconds. one-touch slow-down mecha- Motor operates but stalls soon.
nism works for more than 10 Then, it does not operated even if
seconds, motor drive relay out- dial is moved.
put, accelerator relay output, • When motor is troubled
and decelerator relay output Motor stalls from the first, then it
are stopped. does not operate even if dial is
moved.
Relay Stop solenoid output is 1. Stop solenoid cannot be pulled
stopped. (Engine cannot be started).
M95 (female) M36 (male) Resistance
(20) – Chassis ground (1) – (2) 68 z ± 10%
Relay Calculates motor position from 1. Engine speed control accuracy

voltage just before occurrence may lower.
M95 (female) S2 (male) Resistance of trouble, then controls with it. For example,
(23) – (22) (2) – (1) 0.25 – 5 kz 1) Engine speed does not rise to
maximum level (It keeps a little
(23) – (32) (2) – (3) 0.25 – 5 kz lower).
— (1) – (2) 4 – 6 kz 2) Engine speed is not set to low
Between each pin –
idling (It keeps a little higher).
— Min. 1 Mz 3) Auto-decelerator or automatic
chassis ground
warm-up system is defective.
* Exclude the GND line, however. 4) Engine may not stop.
a Governor motor moves in
direction to stop engine but
may not to full stop position.
5) Engine may hunt.
Relay Calculates motor position from 1. Engine cannot be set in partial

voltage just before occurrence operation mode from full opera-
M95 (female) R55 (male) Resistance of trouble, then controls with it. tion mode.
(13) – (22) (2) – (1) 0.25 – 5 kz 2. Engine cannot be set in full oper-
ation mode from partial operation
(13) – (32) (2) – (3) 0.25 – 5 kz mode.
— (1) – (3) 4 – 6 kz 3. Engine may hunt.
Between each pin – 4. Output is insufficient (Maximum
chassis ground — Min. 1 Mz engine speed is insufficient).
PC78US-6 20-329-2
(12)
When the motor is normal, its condition can be monitored as shown below.
• When fuel control dial is operated (Slow o Full) Displayed code [1024] : (2), (3), (4), (6), light up and motor operates, then (2),
(3), (4), (6) go off and motor stops (Only (4) keeps
lighting up).
• When fuel control dial is operated (Full o Slow) Displayed code [1024] : While only (4) is lighting up, (1), (3), (5) light up and
motor operates, then all lamps go off and motor
stops.
• In E-mode (When fuel control dial is at FULL Displayed code [1024] : While only (4) is lighting up, (3), (5) light up and
position) motor operates, then (2) lights up and (3), (5) go off
and motor stops (Only (2) and (4) keep lighting up).
• When E-mode is changed to standard motor Displayed code [1024] : While only (2), (4) are lighting up, (3), (6) light up and
(When fuel control dial is at FULL position) motor operates, then (2), (3), (6) go off and motor
stops (Only (4) keeps lighting up).
turned on (When fuel control dial is at FULL motor operates, then (2) lights up and (3), (4), (5) go
Displayed code [1026] : When one-touch slow-down switch is turned on, (1)
lights up (This is same as in resetting operation).
turned off (When fuel control dial is at FULL motor operates, then (4) lights up and (2), (3), (6) go
Engine governor control system
20-329-3 PC78US-6
(13)
JUDGMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)
TROUBLESHOOTING AND ENGINE
JUDGMENT TABLE FOR CONTROLLER

(GOVERNOR CONTROL SYSTEM) AND ENGINE
PC78US-6 Serial No.: 4001 – 6500
Controller and Engine Items Checked/
Inspected by
Self-diagnosis Display monitoring
Short circuit in decelerator relay system

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

Disconnection in engine stop solenoid
Short circuit in engine stop solenoid
Trouble in controller power supply
Short circuit in motor drive relay
Motor drive relay output (*2)

Auto deceleration signal
Deceleration signal
Acceleration signal
Stall of motor
system (*2)
relay (*3)
relay (*3)
User E05 Monitoring Code
Code —
Service 321 323 325 328 304 314 227 1024

Code
1 Engine does not start easily
2 Engine does not start q q q
Engine speed does not rise sharply (Does not follow up accel-
3 erator pedal)
4 Engine stops
5 Engine hunts (hunting)
6 Engine output (Power) is low
7 Exhaust gas color is bad (Imperfect combustion)
8 Much oil is consumed (or exhaust gas color is bad)
9 Oil becomes dirty soon
10 Much fuel is consumed
11 Coolant contains oil or blows back or its level lowers
12 Oil pressure caution lamp lights up
13 Oil level rises
14 Coolant temperature rises too high (Overheating)
15 Abnormal sound is heard
16 Many vibrations are made
17 Engine speed does not follow up throttle valve q q q q q (*1) (*1) (*1)
18 One-touch slow-down mechanism does not work q q q q q (*1) (*1) (*1)
When working mode is changed, engine speed does not
19
change q q q q q q (*1) (*1) (*1)
20 Engine does not stop
Diagnosis code displayed when service code is displayed E-1 E-2 E-3 E-4 E-5 E-8 E-8 E-6 — — — —
Diagnosis code displayed when trouble is detected by monitoring or
— — — — — — — — — — — —
with machine monitor
q: Items corresponding to service codes.

Q: Items checked by monitoring or with machine monitor.
*1. : Items checked by monitoring.
20-330 PC78US-6
(13)
Items
Items checked/inspected by inspected
monitoring with machine
monitor
Is value in red range?

Diagnosis code displayed
Engine water temperature voltage
when service code is not dis-

played
One-touch slow-down signal
Decelerator relay output
Accelerator relay output
95 Series
Engine speed
Min. 102 °C
Min. 105 °C
Monitoring Acceleration
Code Signal
1024 1026 1010 0041 108
(S-1)
E-8 (S-2)
(S-3)
(S-4)
(S-5)
(S-6)
(S-7)
(S-8)
(S-9)
(S-10)
(S-11)
(S-12)
(S-13)
Q Q (S-14)
(S-15)
(S-16)
(*1) (*1) E-5
(*1) (*1) (*1) E-7
(*1) (*1) (*1) E-5, E-6
E-9
— — — — — — —
— — — — — M-15 M-15
*2.: PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500
*3.: PC78US-6 Serial No.: 5501 – 6500
PC78US-6 20-331
(13)

Controller and Engine Items
Checked/
Inspected by
Self-diagnosis Display monitoring
Short circuit in decelerator relay system

Short circuit in accelerator relay system

Disconnection in engine stop solenoid
Trouble in governor motor feedback

Short circuit in engine stop solenoid
Trouble in controller power supply
Trouble in fuel control dial
Auto deceleration signal

Deceleration signal
Acceleration signal
potentiometer
Stall of motor
relay
relay
User Monitoring
E05 — — E05
Code Code
Service 323 325 328 304 314 227 306 308 1024
Code
1 Engine does not start easily
2 Engine does not start q q q
3 Engine speed does not rise sharply (Does not follow up accel-
erator pedal)
4 Engine stops q q
5 Engine hunts (hunting) q q
6 Engine output (Power) is low
7 Exhaust gas color is bad (Imperfect combustion)
8 Much oil is consumed (or exhaust gas color is bad)
9 Oil becomes dirty soon
10 Much fuel is consumed
11 Coolant contains oil or blows back or its level lowers
12 Oil pressure caution lamp lights up
13 Oil level rises
14 Coolant temperature rises too high (Overheating)
15 Abnormal sound is heard
16 Many vibrations are made
17 Engine speed does not follow up throttle valve q q q q q q (*1) (*1) (*1)
18 One-touch slow-down mechanism does not work q q q q q (*1) (*1) (*1)
When working mode is changed, engine speed does not
19
change q q q q q q (*1) (*1) (*1)
20 Engine does not stop

Diagnosis code displayed when service code is displayed E-1 E-3 E-4 E-5 E-8 E-8 E-6 — — — — —
Diagnosis code displayed when trouble is detected by monitoring or
— — — — — — — — — — — —
with machine monitor
q: Items corresponding to service codes.

Q: Items checked by monitoring or with machine monitor.
*1 : Items checked by monitoring.
20-331-1 PC78US-6
(13)
Items
inspected
Items checked/inspected by monitoring
with machine
monitor
Governor motor feedback potentiometer
Is value in red range?

Diagnosis code displayed
Engine water temperature voltage when service code is not dis-
played
Fuel control dial voltage input

One-touch slow-down signal
Decelerator relay output
Accelerator relay output
95 Series
Engine speed
Min. 102 °C
Min. 105 °C
input
Monitoring Acceleration
Code Signal Monitoring
1024 1026 1010 0041 1034 1035 108
(S-1)
E-8 (S-2)
(S-3)
(*1) (*1) (S-4)
(*1) (*1) (S-5)
(S-6)
(S-7)
(S-8)
(S-9)
(S-10)
(S-11)
(S-12)
(S-13)
Q Q (S-14)
(S-15)
(S-16)
(*1) (*1) (*1) (*1) E-5
(*1) (*1) (*1) (*1) E-7
(*1) (*1) (*1) (*1) E-5, E-6
E-9
— — — — — — —
— — — — — M-15 M-15
PC78US-6 20-331-2
(12)
TROUBLESHOOTING E-1
E-1 Controller power supply is defective (LED of controller is turned off)

PC78US-6 Serial No.: 4001 – 6500
a Check that fuse 20 is not broken.
a Carry out the following troubleshooting when the starting motor revolves normally (If the starting motor does
not revolve, see E-8, 19).
Cause Remedy
• Turn starting switch ON Is voltage between M97 (Female) (1), (11) – (21), NO
• 20 – 30 V (31), (32), (33), chassis ground normal?
YES
• Turn starting switch ON Is voltage between fuse 20 and chassis ground NO contact in wiring harness
Repair or replace
• 20 – 30 V normal? between fuse 20 – battery
relay terminal B
YES
contact in wiring harness
Repair or replace
between fuse 20 – M97
(Female) (1), (11)
E-1 Electrical circuit diagram of each system
20-332 PC78US-6
(12)
TROUBLESHOOTING E-1

a Carry out the following troubleshooting when the starting motor revolves normally (If the starting motor does
not revolve, see E-8, 19).
Cause Remedy
• Turn starting switch ON Is voltage between M95 (Female) (1), (11) – (21), NO
• 20 – 30 V (31) chassis ground normal?
YES
• Turn starting switch ON Is voltage between fuse 20 and chassis ground NO contact in wiring harness
Repair or replace
• 20 – 30 V normal? between fuse 20 – battery
relay terminal B
YES
Repair or replace
between fuse 20 – M95
(Female) (1), (11)
PC78US-6 20-332-1
(12)
TROUBLESHOOTING E-2
E-2 [E321] (Short circuit in motor drive relay) is displayed

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
Cause Remedy
• Turn starting switch ON Is voltage between M97 (Female) (18) – (23) nor- NO
• Operate dial mal?
YES
Short circuit with chassis

• Disconnect M97 and K34 NO ground or negative (-) wire in
Is resistance between M97 (Female) (18) and
wiring harness between M97 Repair or replace
• Min. 1 Mz chassis ground normal? (Female) (18) – K34 (Female)
(1)
YES
Defective Relay Repair or replace
If the wiring harness between M97 (18) and K34 (1) is shorted to the coil actually, the controller output is cut
out. Accordingly, if [E321] is displayed, the controller is defective.
PC78US-6 20-333
(7)
TROUBLESHOOTING E-3
E-3 [E323] (Short circuit in accelerator relay system) is displayed

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
Cause Remedy
YES
2
(1)
YES
If the wiring harness between M97 (25) – K32 (1) is shorted to the coil actually, the controller output is cut
20-334 PC78US-6
(12)
TROUBLESHOOTING E-3
PC78US-6 Serial No.: 5501 – 6500

Cause Remedy
YES
2
(1)
YES
PC78US-6 20-334-1
(12)
TROUBLESHOOTING E-3
Cause Remedy
• Disconnect M95 and K32 Is voltage between M95 (female) (7) and chassis NO
• Turn starting switch ON ground normal?
YES
Contact of wiring harness
between M95 (female) (7) – Repair or replace
K32 (female) (2) with (+) wiring
harness
• Disconnect K32 Is resistance between K32 (male) (1) and (2) nor- NO Defective controller Replace
• 290 z ±10% mal?
YES
Defective accelerator relay Replace

(K32)
20-334-2 PC78US-6
(12)
TROUBLESHOOTING E-4
E-4 [E325] (Short circuit in decelerator relay system) is displayed

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
Cause Remedy
• Operate dial (to lower) mal?
YES
2
NO ground or negative (-) wire in
• Disconnect M97 and K33 Is resistance between M97 (Female) (35) – chas- wiring harness between M97 Repair or replace
• Min. 1 Mz sis ground normal? (Female) (35) – K33 (Female)
(1)
YES
PC78US-6 20-334-3
(12)
TROUBLESHOOTING E-4
PC78US-6 Serial No.: 5501 – 6500

Cause Remedy
• Operate dial (to lower) mal?
YES
2
NO ground or negative (-) wire in
• Disconnect M97 and K33 Is resistance between M97 (Female) (35) – chas- wiring harness between M97 Repair or replace
• Min. 1 Mz sis ground normal? (Female) (35) – K33 (Female)
(1)
YES
PC78US-6 20-335
(12)
TROUBLESHOOTING E-4
Cause Remedy
• Disconnect M95 and K33. Is voltage between M95 (female) (17) and chassis NO
• Turn starting switch ON. ground normal?
YES
Contact of wiring harness
between M95 (female) (17) – Repair or replace
K33 (female) (2) with (+) wiring
harness
• Disconnect K33. Is resistance between K33 (male) (1) and (2) nor- NO Defective controller Replace
• 290 z ± 10% mal?
YES
Defective decelerator relay Repair or replace

(K33)
20-335-1 PC78US-6
(12)
TROUBLESHOOTING E-5
E-5 [E328] (Stall of motor) is displayed

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
a Stall of the motor ias displayed when the motor does not follow up the operation of the dial in 10 seconds. In
this period, the input signal and relay output are checked by monitoring.
Cause Remedy
For state of bit, see Action taken by NO

controller when trouble occurs and Is monitored value normal?
problems on machine.
YES
2
• Max. 4 A when normal
When dial is raised Is current between K27 (Female) (1) NO
(1) side: (+), (4) side: (-) (Motor (+) and (4) (Motor (-) normal?
When dial is lowered
(1) side: (-), (4) side: (+)
YES
Defective motor Replace motor

(Drive system)
• Resistance between (1) ~ (2) of

each relay: 290 z ± 10% 3
• Operation of each relay (when
starting switch is ON)
When in neutral, (3) – (6) are Do relay of K32, K33, – K34 operate nor- NO Defective relay Replace
connected. mally?
When dial is raised, K34 and K32
(3), (5) are connected.
When dial is lowered, K34 and YES
K33 (3), (5) are connected.
between K27 (Female) (1), (4) Repair or replace
– K32 (Female) (3),
K33 (Female) (3)
4
• Is resistance between M97 (Female)
• Disconnect M97 and K27.
(19) – K27 (Female) (5), between M97 Disconnection or defective
• Resistance between pins:
(29) – K27 (Female) (6), between M97 contact in wiring harness
Max. 1 z NO between M97 (Female) (19),
(Female) (39) – K27 (Female) (3) nor- Repair or replace
• Resistance between pin and (29), (39) – K27 (Female) (5),
mal? Is resistance between each wir-
chassis and ground: (6), (3)
ing harness and chassis ground
Min. 1 Mz
normal?
YES
5
• When dial is raised
When dial is operated, is each input signal NO Defective motor (Signal sys-
Between K97 (19), (39) – (23): 24 V Replace
normal? tem)
• When dial is lowered (slowed)
Between M97 (29) – (23): 24 V
YES
20-336 PC78US-6
(7)
TROUBLESHOOTING E-5
PC78US-6 20-336-1
(7)
TROUBLESHOOTING E-5
PC78US-6 Serial No.: 5501 – 6500

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

NO
controller when trouble occurs and Is monitored value normal?
problems on machine.
YES
2
• Max. 4 A when normal
When dial is raised Is current between K27 (Female) (1) NO
(1) side: (+), (4) side: (-) (Motor (+) and (4) (Motor (-) normal?
When dial is lowered
(1) side: (-), (4) side: (+)
YES
Defective motor Replace motor

(Drive system)
• Resistance between (1) ~ (2) of

each relay: 290 z ± 10% 3
starting switch is ON)
When in neutral, (3) – (6) are NO
Do relay of K32, K33 operate normally? Defective relay Replace
connected.
When dial is raised, K32 (3), (5)
are connected.
When dial is lowered, K33 (3), (5) YES
are connected.
between K27 (Female) (1), (4) Repair or replace
– K32 (Female) (3),
K33 (Female) (3)
4
• Is resistance between M97 (Female)
• Disconnect M97 and K27.
(19) – K27 (Female) (5), between M97 Disconnection or defective
• Resistance between pins:
(29) – K27 (Female) (6), between M97 contact in wiring harness
Max. 1 z NO between M97 (Female) (19),
(Female) (39) – K27 (Female) (3) nor- Repair or replace
• Resistance between pin and (29), (39) – K27 (Female) (5),
mal? Is resistance between each wir-
chassis and ground: (6), (3)
ing harness and chassis ground
Min. 1 Mz
normal?
YES
5
• When dial is raised
When dial is operated, is each input signal NO Defective motor (Signal sys-
Between K97 (19), (39) – (23): 24 V Replace
normal? tem)
• When dial is lowered (slowed)
Between M97 (29) – (23): 24 V
YES
20-336-2 PC78US-6
(12)
TROUBLESHOOTING E-5
Electrical circuit diagram of each system
PC78US-6 20-337
(7)
TROUBLESHOOTING E-5

a Trouble in the motor stall system is displayed when the motor does not follow up in 10 seconds after the dial
is operated. In the meantime, check that the input signal and relay output are normal with the monitoring
function.
Cause Remedy
1
• Turn starting switch ON.
• Max. 4 A when normal.
When dial is heightened, mea- Is current between S2 (female) (5) (motor (+)) and NO
sure between (5) (+) and (6) (–). (6) (motor (–)) normal?
When dial is lowered, measure
between (5) (–) and (6) (+).
YES
Defective motor (drive system) Replace motor
• Disconnect K32 and K33.

• Resistance between K32 and
K33 (male) (1), (2): 290 z ± 10% 2
starting switch is ON):
NO
When in neutral, R08 and R09 Do relays K32 and K33 operate normally? Defective relay Replace
(3), (6) are connected.
When dial is heightened, R09 (3)
and (5) are connected.
YES
When dial is lowered, R08 (3)
and (5) are connected. Defective wiring harness Repair or replace
Breakage of fuse (9)
20-337-1 PC78US-6
(12)
TROUBLESHOOTING E-6
E-6 [E227] (Trouble in engine speed sensor) is displayed

PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
1
• When starting switch is OFF: 0
• When engine speed is
+5
Is monitored engine speed normal? NO
slow: 113 0
• When engine speed is at full
throttle: 202 ± 5
YES
• Disconnect M16 Is resistance between M16 (Male) (1) – (2) nor- NO Defective engine speed
Repair or replace
• 500 – 1,000 z mal? sensor
YES
• Disconnect M16 Is resistance between M96 (Female) (39) – (40) NO contact in wiring harness
Repair or replace
• 500 – 1,000 z normal? between M96 (Female) (39) –
M16 (Female) (1), (2)
YES
Defective installation of engine
Test/Adjust
speed sensor
20-338 PC78US-6
(12)
TROUBLESHOOTING E-6
Cause Remedy
1
• When starting switch is OFF: 0
• When engine speed is
+5
Is monitored engine speed normal? NO
slow: 113 0
• When engine speed is at full
throttle: 202 ± 5
YES
• Disconnect M16 Is resistance between M16 (Male) (1) – (2) nor- NO Defective engine speed
Repair or replace
• 500 – 1,000 z mal? sensor
YES
• Disconnect M16 Is resistance between M95 (Female) (6) – (32) NO contact in wiring harness
Repair or replace
• 500 – 1,000 z normal? between M95 (Female) (6),
(32) – M16 (Female) (1), (2)
YES
Defective installation of engine
Test/Adjust
speed sensor
PC78US-6 20-338-1
(12)
TROUBLESHOOTING E-7
E-7 [E306] Trouble in governor motor feedback potentiometer is displayed

a Check that the input value is normal in the monitoring mode.
Cause Remedy
1
• Reset auto-decelerator.
• Feedback potentiometer voltage:
• When fuel control dial at FULL: Is feedback potentiometer voltage of monitoring NO
4.5 – 4.7 V 1035 normal?
• When fuel control dial at SLOW:
2.7 – 3.2 V
YES
• Disconnect S2 2
• S2 (male)
Between (1) – (2): 0.36 – 3.9 kz
Is resistance between S2 (male) (1), (2), – (3) nor- NO
Between (2) – (3): 1.4 – 5.5 kz Defective decelerator motor Replace
mal?
Between (1) – (3): 5 ± 1 kz
• Between S2 (male) (1), (2), (3) –
chassis ground: Min. 1 Mz
YES
Defective wiring harness Repair or replace
20-338-2 PC78US-6
(12)
TROUBLESHOOTING E-8
E-8 [E308] Trouble in fuel control dial system is displayed

a Check that the input value is normal in the monitoring mode.
Cause Remedy
1
• Fuel control dial voltage:
• When fuel control dial at FULL:
Is fuel control dial voltage of monitoring 1034 nor- NO
0.7 V – 4.3 V
mal?
• When fuel control dial at SLOW:
0.7 V – 4.3 V
YES
• Disconnect K55. 2
• K55 (male)
Between (1) – (2): 0.25 – 5 kz
Is resistance between K55 (male) (1), (2), – (3) NO
Between (2) – (3): 0.25 – 5 kz Defective fuel control dial Replace
normal?
Between (1) – (3): 4 – 6 kz
• Between K55 (male) (1), (2), (3) –
YES
Defective wiring harness Repair or replace
PC78US-6 20-338-3
(12)
TROUBLESHOOTING E-9
E-9 One-touch slow-down mechanism does not work

PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
NO
Does deceleration monitor light up normally?
YES
See troubleshooting in E-5 —
• Disconnect K18
Is resistance between K18 (Male) (1) – (2) NO Defective one-touch decelera-
• When switch is ON: Max. 1z Replace lever assembly
normal? tor switch
When switch is OFF: Min. 1 Mz
YES
3
• Disconnect K18 contact in wiring harness
Is voltage between K18 (Male) (1) – chassis NO
• Turn starting switch ON between K18 (Female) (1) – Repair or replace
ground normal? fuse (11) or breakage of fuse
• 20 – 30 V
(11)
YES
contact in wiring harness Repair or replace
between K18 (Female) (2) –
M97 (Female) (9)
PC78US-6 20-339
(12)
TROUBLESHOOTING E-9
Cause Remedy
NO
Does deceleration monitor light up normally?
YES
See troubleshooting in E-5 —
• Disconnect K18
Is resistance between K18 (Male) (1) – (2) NO Defective one-touch decelera-
• When switch is ON: Max. 1z Replace lever assembly
normal? tor switch
When switch is OFF: Min. 1 Mz
YES
3
• Disconnect K18 Is resistance between K18 (Male) (1) – chassis NO contact in wiring harness Repair or replace
• Max. 1z ground normal? between K18 (Female) (1) –
T2
YES
M95 (Female) (34)
20-339-1 PC78US-6
(12)
TROUBLESHOOTING E-10
E-10 Engine does not start

a The signals from battery relay terminal M on the monitor screen, etc. must be normal.
a Carry out the following troubleshooting when the starting motor does not revolve.
a Before carrying out the troubleshooting, check that fuses 12, 14, 15, and 20 are normal.
a Lock the PPC hydraulic lock switch. (Raise the work equipment lever stand.)
a) [E304] Short circuit in engine stop solenoid relay system is displayed
b) [E314] Disconnection in engine stop solenoid relay system is displayed
PC78US-6 Serial No.: 5501 – 6500
Cause Remedy
• Disconnect M97.
• Resistance between M97 Is resistance between M97 (female) (4) – chassis NO
(female) (4) – chassis ground: ground normal?
68 z ± 10%
YES
2
• Disconnect M36.
• Resistance between M36 (male)
Is resistance between stop solenoid relay M36
(1) – (2): 68 z ± 10% NO
(male) (1) – (2) and between each pin and chas- Defective stop solenoid relay Replace
sis ground normal?
(1), (2) – chassis ground:
Min. 1 Mz
YES
3
• Disconnect D26
(with M36 disconnected). NO
Is resistance between M97 (female) (4) – chassis Defective wiring harness
• Resistance between M97 Repair or replace
ground normal? (Grounding fault)
(female) (4) – chassis ground:
Min. 1 Mz
YES
Defective diode D26 Replace
E-10 a), b) Electrical circuit diagram of each system
20-340 PC78US-6
(12)

Cause Remedy
• Disconnect M95.
• Resistance between M95 Is resistance between M95 (female) (20) – chas- NO
(female) (20) – chassis ground: sis ground normal?
68 z ± 10%
YES
2
• Disconnect M36.
Is resistance between stop solenoid relay M36
(1) – (2): 68 z ± 10% NO
(male) (1) – (2) and between each pin and chas- Defective stop solenoid relay Replace
sis ground normal?
(1), (2) – chassis ground:
Min. 1 Mz
YES
3
• Disconnect D4
(with M36 disconnected). NO
Is resistance between M95 (female) (20) – chas- Defective wiring harness
• Resistance between M95 Repair or replace
sis ground normal? (Grounding fault)
(female) (20) – chassis ground:
Min. 1 Mz
YES
Defective diode D4 Replace
E-10 a), b) Electrical circuit diagram of each system
PC78US-6 20-340-1
(12)
c) Engine stop solenoid system

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
a Check that fuse 15 is normal.
Cause Remedy
a See TESTING AND When engine stop solenoid linkage is adjusted, NO

ADJUSTING does engine start?
YES
Defective adjustment of
Adjust
linkage
• 20 – 29 V Is voltage between engine stop solenoid terminal NO

• Turn starting switch ON T7 – chassis ground normal?
YES
3
• Max. 1 z Disconnection or defective

Is resistance between engine stop solenoid termi- NO contact in wiring harness
• Turn starting switch OFF Repair or replace
nal T8 – chassis ground normal? between engine stop solenoid
• Disconnect T8 terminal T8 – chassis ground
YES
Defective engine stop solenoid Replace
• 20 – 29 V Is voltage between outlet of fuse (15) – chassis NO

YES
Disconnection or defective con-
tact in wiring harness between
Repair or replace
outlet of fuse (15) – M3 (3) –
solenoid terminal T7
• 20 – 29 V Is voltage between starting switch terminal ACC – NO Defective starting switch

Replace
• Turn starting switch ON chassis ground normal? (Between B – ACC)
YES
Repair or replace
between starting switch termi-
nal ACC – inlet of fuse (15)
E-10 c) Electrical circuit diagram of each system
PC78US-6 20-341
(12)
PC78US-6 Serial No.: 5501 – 6500

a Check that service codes [E304] and [E314] are not recorded in the history.
Cause Remedy

YES
Adjust
linkage

• Turn starting switch ON – chassis ground normal?
YES
3
• Max. 1 z contact in wiring harness
Is resistance between engine stop solenoid termi- NO
• Turn starting switch OFF between engine stop solenoid Repair or replace
nal GND – chassis ground normal? terminal GND – chassis
• Disconnect GND terminal
ground
YES
4
• 20 – 29 V Disconnection or defective
• Disconnect PULL terminal. Is voltage between engine stop solenoid PULL contact in wiring harness
NO between engine stop solenoid Repair or replace
• For only 3 seconds after starting terminal and chassis ground normal? PULL terminal – fusible link
switch is turned ON. M26 (male) (2)
YES

YES
Repair or replace
solenoid terminal T7

Replace
YES
Repair or replace
20-342 PC78US-6
(12)
PC78US-6 20-343
(12)

a Check that service codes [E304] and [E314] are not recorded in the history.
Cause Remedy

YES
Adjust
linkage

YES
3
• Max. 1 z contact in wiring harness
Is resistance between engine stop solenoid termi- NO
• Turn starting switch OFF between engine stop solenoid Repair or replace
nal GND – chassis ground normal? terminal GND – chassis
• Disconnect GND terminal
ground
YES
4
• Disconnect PULL terminal. Is voltage between engine stop solenoid PULL contact in wiring harness
NO between engine stop solenoid Repair or replace
• For only 3 seconds after starting terminal and chassis ground normal? PULL terminal – fusible link
switch is turned ON. M26 (male) (2)
YES

YES
Repair or replace
solenoid terminal HOLD

Replace
YES
Repair or replace
20-343-1 PC78US-6
(12)
PC78US-6 20-343-2
(12)
d) Starting System
Cause Remedy
• Min. 24 V Are battery voltage and specific gravity of NO Insufficient battery

Charge or replace
• Specific gravity: Min. 1.26 battery fluid normal? capacity
YES
2
When starting switch is turned OFF, does NO

• Turn starting switch OFF
battery relay make sound?
YES
NO
Is engaging sound of starting motor pinion heard?
YES
4
Defective contact in wiring
harness between battery (+)
• Turn starting switch ON Is voltage between starting motor terminal B – chas- terminal – battery relay ter- Repair or replace
NO minal B – battery relay termi-
• 20 – 29 V sis ground normal? nal M – starting motor
terminal B
(including battery relay)
YES
Defective starting motor Repair or Replace
(Body)
5
• Turn starting switch to START posi-
Is voltage between starting switch terminal C and NO Defective starting switch
tion. Replace
chassis ground normal? (Between terminals B and C)
• 20 – 29 V
YES
6
Is voltage between safety relay terminal S – chassis NO

a Conditions are same as 5
ground normal?
YES
Is voltage between starting motor terminal C – chas- NO

sis ground normal?
YES
Defective starting motor Repair or replace
(Electromagnetic switch)
Is voltage between safety relay terminal C – chassis NO

ground normal?
YES Disconnection or defective

between starting motor Repair or replace
safety relay terminal C –
starting motor terminal C
• Turn starting switch ON Is voltage between safety relay terminal R – chassis NO

Defective alternator Repair or replace
• Max. 13 V ground normal?
YES
Defective starting motor Replace
safety relay
To page 20-347
To page 20-345
20-344 PC78US-6
(12)
From page 20-344, 6
Cause Remedy
10
• 20 – 29 V NO
Is voltage between V2 (8) – chassis ground normal?
• Turn starting switch to START.
YES
between safety relay termi- Repair or replace
nal S – M30 (1) – M5 (4) –
V2 (Female) (8)
11
• 20 – 29 V NO
Is voltage between V2 (7) – chassis ground normal?
• Turn starting switch to START
YES
between V2 (Male) (7) – (8)
12
• 20 – 29 V Is voltage between K23 (3) – chassis ground nor- NO

• Turn starting switch to START mal?

V3 (Female) (3)
13
• 20 – 29 V Is voltage between K23 (5) – chassis ground nor- NO contact in wiring harness
between K23 (Female) (5) – Repair or replace
• Turn starting switch to START mal? K51 (6) – starting switch ter-
minal C
YES
14
• 20 – 29 V
Is voltage between K23 (1) – chassis ground nor- NO
mal?
• Lock PPC lock switch
YES
15

Is resistance between K23 (Female) (2) – chassis NO contact in wiring harness
• Turn starting switch ON Repair or replace
ground normal? between K23 (Female) (2) –
• Disconnect K23 M1 (2) – chassis ground
YES
Defective K23 relay Replace
16
• 20 – 29 V
Is voltage between k28 (3) – chassis ground nor- NO
mal?
• Lock PPC lock lever

between K28 (Male) (3) – Repair or replace
K23 (Female) (1) – chassis
ground
To page 20-346
PC78US-6 20-345
(12)
PC78US-6 Serial No.: 4001 – 5500

PC78UU-6 Serial No.: 22832 – 23500
From page 20-345, 16 Cause Remedy
17
• 20 – 29 V Is voltage between K28 (1) – chassis ground nor- NO contact in wiring harness Repair or replace
• Turn starting switch ON mal? between K28 (Male) (1) –
fuse (12)

K23 (Female) (1)

From page 20-345, 16 Cause Remedy
17
• 20 – 29 V Is voltage between K28 (1) – chassis ground nor- NO contact in wiring harness Repair or replace
• Turn starting switch ON mal? between K28 (Male) (1) –
fuse (14)

K23 (Female) (1)
20-346 PC78US-6
(12)
From page 20-344, 2
Cause Remedy
18
• Connect (-) pin of tester to (-) ter- between battery (+) terminal –
Is voltage at starting switch terminal B NO
minal of battery M27 (1), (2) – M2 (1) – fuse Replace
normal?
• 20 – 29 V (20) – K51 (1) – starting switch
terminal B (including fusible
link)
YES
19
• Disconnect terminal B Is there continuity between starting switch NO Defective starting switch Replace
• Turn starting switch to START terminals B – BR? (between terminal B – BR)
YES
20
• Set tester in diode range and Disconnection or defective

apply (+) to starting switch and (-) contact in wiring harness
Is there continuity between starting switch termi- NO between starting switch termi-
to battery relay Replace
nal BR – battery relay terminal BR? nal BR – K51 (3) – D5 (2), (1)
• Disconnect both starting switch – battery relay terminal BR
and battery relay (including diode)
YES
21
Defective contact in wiring har-

Is there continuity between chassis ground and NO ness between battery relay
• Turn starting switch OFF terminal E - revolving frame Repair or replace
battery relay terminal B?
ground terminal
YES
Defective battery relay Replace
PC78US-6 20-347
(12)
E-10 d) Electrical circuit diagram of each system

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
20-348 PC78US-6
(12)

PC78US-6 Serial No.: 5501 – 6500
PC78US-6 20-349
(12)

20-349-1 PC78US-6
(12)
E-11 Engine does not stop

PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22832 – 23500
Cause Remedy
When engine stop solenoid linkage is adjusted, NO

does engine stop?
YES
Defective adjustment of Adjust
linkage
Contact of (+) wiring harness

• Max. 1 V Is voltage between engine stop solenoid terminal NO with wiring harness between
starting switch terminal ACC – Replace or repair
• Turn starting switch OFF T7 and chassis ground normal? fuse (15) – M3 (3) – solenoid
terminal T7
YES
PC78US-6 20-349-2
(12)
PC78US-6 Serial No.: 5501 – 6500

Cause Remedy

does engine stop?
YES
linkage

• Turn starting switch OFF HOLD and chassis ground normal? fuse (15) – M3 (3) – solenoid
terminal HOLD
YES
20-349-3 PC78US-6
(12)
Cause Remedy

does engine stop?
YES
linkage

• Turn starting switch OFF HOLD and chassis ground normal? fuse (15) – M3 (5) – solenoid
terminal HOLD
YES
PC78US-6 20-349-4
(12)
PUMP CONTROL SYSTEM
(C MODE)
Precautions for troubleshooting for controller (pump control system). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352

Action taken by controller when trouble occurs and problems on machine . . . . . . . . . . . . . . . . . . . . . . . . 20-354
Judgement table for controller (pump control system) and hydraulic equipment . . . . . . . . . . . . . . . . . . . . 20-356
Electric circuit diagram of C Mode system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
C- 1 [E232] Trouble in TVC-EPC solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-359
C- 2 [E233] Trouble in TVC-EPC solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-359
C- 3 [E203] Trouble in swing holding brake solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
C- 4 [E213] Trouble in swing holding brake solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
C- 5 [E206] Trouble in 2nd travel speed selection solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-361
C- 6 [E216] Trouble in 2nd travel speed selection solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-361
C- 7 [E403] Trouble in boom angle sensor correction (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . 20-362
C- 8 [E406] Trouble in arm angle sensor correction (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
C- 9 [E411] Trouble in offset boom angle sensor correction (Only PC78UU-6). . . . . . . . . . . . . . . . . . . . 20-362
C-10 [E441] Trouble in interference prevention (front) correction (Only PC78UU-6) . . . . . . . . . . . . . . . . 20-364
C-11 [E442] Trouble in interference prevention (side) correction (Only PC78UU-6) . . . . . . . . . . . . . . . . 20-364
C-12 [E443] Trouble in depth indication correction (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-365
C-13 [E258] Short circuit in 5V system of sensor power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
C-14 [E224] Trouble in pump pressure sensor is displayed (PC78US-6: 6501 and up) . . . . . . . . . . . 20-366-3
C-15 [E401] Trouble in boom angle sensor system (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
C-16 [E402] Trouble in boom angle sensor system (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
C-17 [E404] Trouble in arm angle sensor system (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
C-18 [E405] Trouble in arm angle sensor system (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
C-19 [E407] Trouble in offset angle sensor system (Only PC78UU-6). . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
C-20 [E408] Trouble in offset angle sensor system (Only PC78UU-6). . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
C-21 [E421] Short circuit in boom raise EPC system is displayed (Only PC78UU-6) . . . . . . . . . . . . . . . 20-370
C-22 [E422] Disconnection in boom raise EPC system is displayed (Only PC78UU-6). . . . . . . . . . . . . . 20-371
C-23 [E423] Short circuit or grounding fault in arm-in EPC system is displayed (Only PC78UU-6). . . . . 20-372
C-24 [E424] Disconnection in arm-in EPC system is displayed (Only PC78UU-6) . . . . . . . . . . . . . . . . . 20-373
C-25 [E425] Short circuit or grounding fault in offset left EPC system is displayed (Only PC78UU-6). . . . . . 20-374
C-26 [E426] Disconnection in offset left EPC system is displayed (Only PC78UU-6) . . . . . . . . . . . . . . . 20-375
C-27 [E431] Short circuit or grounding fault in PPC basic pressure lock solenoid system is displayed
(Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376
C-28 Boom does not stop automatically at normal position but interferes when it is raised
(Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-377
C-29 Arm does not stop automatically at normal position but interferes when it is moved in
(Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
C-30 Offset does not stop automatically at normal position but interferes
when it is moved to left (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
C-31 Work equipment stops far or near (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
C-32 Buzzer sounds for 7 seconds while emergency work equipment operation switch
is not turned ON (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-381
C-33 Boom raise end cushion does not work at all or normally (Only PC78UU-6) . . . . . . . . . . . . . . . . . . 20-382
C-34 Arm-in end cushion does not work at all or normally (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . 20-383
C-35 Offset end cushion does not work at all or normally (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . 20-384
C-36 Work equipment stops after or before set height (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . 20-385
C-37 When depth display is reset, 0.0 m is not indicated at GL (Only PC78UU-6). . . . . . . . . . . . . . . . . . 20-386
C-38 Work equipment still moves after work equipment lock lever is set to LOCK . . . . . . . . . . . . . . . . . . 20-387
C-39 Machine does not swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
C-40 Travel speed does not rise (PC78US-6: 4001 – 6500, PC78UU-6: 22832 and up) . . . . . . . . . . . . . 20-389
C-41 Gear speed does not change automatically (PC78US-6: 6501 and up) . . . . . . . . . . . . . . . . . . . . 20-389-1
C-42 Trouble in controller power supply system (LED of controller is turned OFF) . . . . . . . . . . . . . . . 20-389-1
PC78US-6 20-351
(12)
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP
TROUBLESHOOTING CONTROL SYSTEM)
PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP

CONTROL SYSTEM)
1) When a trouble is repaired by itself or

2) When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-
adapter is removed and the connector is returned, if the service code is not displayed or the moni-
tor displays normally, the same trouble will occur again probably. Accordingly, follow up the condi-
tion of the machine sufficiently.
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 ser-
vice 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.)
20-352 PC78US-6
➀

PC78US-6 Serial No.: 4001 – 6500
Application User
Service Code Troubled System Contents of Trouble
US UU Code
1. Short circuit in wiring harness between

Short circuit in TVC-EPC solenoid system
M97 pin 16 – M20 pin 1
E232 (When emergency pump drive switch is 2. Short circuit in EPC solenoid
turned ON)
3. Wrong operation of switch
Q Q E02
1. Disconnection in wiring harness
between M97 pin 16 – M20 pin 1
Disconnection in TVC-EPC solenoid sys-
E233 2. Disconnection in EPC solenoid
tem
Short circuit in swing holding brake sole- 1. Short circuit in wiring harness between
E203 M97 pin 7 – M14 pin 2
noid system
2. Short circuit in solenoid
Q Q E03 1. Disconnection in wiring harness

Disconnection in swing holding brake sole- between M97 pin 7 – M14 pin 2
noid system 2. Disconnection in solenoid
E213
(When emergency swing holding brake 3. Disconnection in wiring harness
reset switch is turned ON) between M14 pin 1 – M97 pin 3
Short circuit in 2nd travel speed selection 1. Short circuit in wiring harness between
E206 M97 pin 27 – M15 pin 2
solenoid system 2. Short circuit in solenoid
Q Q —
Disconnection in 2nd travel speed selection
E216 solenoid system 2. Disconnection in solenoid
Q Q — E227 Trouble in engine speed sensor 2. Disconnection in sensor
E403 Trouble in boom angle sensor correction
1. Input voltage is abnormal when angle

sensor is corrected (Out of range)
— Q — E406 Trouble in arm angle sensor correction
When voltage error is out of ± 0.5 V
Voltage must be 0.3 – 4.7 V, however
Trouble in offset boom angle sensor correc-

E411
tion
1. Out of front interference prevention cor-

Trouble in interference prevention (Front) rection range
E441
correction When quantity of longitudinal adjust-
ment exceeds ± 300 mm
— Q —
1. Out of side interference prevention cor-
Trouble in interference prevention (Side) rection range
E442
correction When quantity of lateral adjustment
exceeds ± 300 mm
1. Out of depth indication correction range

— Q — E443 Trouble in depth indication correction When quantity of vertical adjustment
exceeds ± 500 mm
Short circuit in 5 V system of sensor power 1. Short circuit in wiring harness between
— Q — E258
supply
M95 pin 22 – M29 pin C, M71 pin C,
M72 pin A
20-354 PC78US-6
(12)
Action Taken by Controller When Trouble

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

1 Mz
Between M20 pin 1 – solenoid body: Min. 1
Mz
Resistance of M20 EPC solenoid (With Current does not flow in TVC-EPC solenoid.
switch directed down): 3 – 15 W When trouble is detected, TVC-EPC solenoid Accordingly, if load is large, engine speed
output is stopped.
Resistance between M97 pin 16 – M20 pin may lower to stall.
1: Max. 1 Mz
Resistance of M20 EPC solenoid: 3 – 15 z
Resistance between M20 pin 2 – M97 pin
23: Max. 1 z
Between M97 pin 7 – chassis ground: Min. 1
Mz
Mz
Resistance of M14 solenoid: 35 – 80 z
When trouble is detected, swing holding Since motor brake is not released, machine
Resistance between M97 pin 7 – M14 pin 2: brake reset solenoid output is stopped. does not swing.
Max. 1 z
Resistance between M14 pin 1 – M97 pin 3
(With switch directed down): Max. 1 z

1 Mz
Mz
Resistance of M15 solenoid: 35 – 80 z When trouble is detected, 2nd travel speed
When speed selector switch pedal is oper-
ated, travel speed does not change. (It is kept
Resistance between M97 pin 27 – M15 pin selection solenoid output is stopped. at 1st gear.)
2: Max. 1 Mz
Resistance between M15 pin 1 – M97 pin 3:
Max. 1 z
Resistance between M96 pin 40 – M16 pin When trouble is detected, constant current
1: Max. 1 z flows in TVC-EPC solenoid (600 mA). Since constant current (600 mA) is output to
TVC-EPC solenoid, work equipment speed
Resistance of M16 sensor: 500 – 1,000 z Working mode cannot be changed.
Resistance between M16 pin 2 – M96 pin Engine governor control is limited to opera- and travel speed are low.
If engine speed is low, engine may stall.
39: Max. 1 z tion of fuel control dial.
Boom RAISE end cushion does not work.
Boom angle sensor voltage for monitoring Stop position for interference prevention is
At boom RAISE end: 0.6 V wrong.
Displayed depth is wrong.
When potentiometer is corrected,
Arm angle sensor voltage for monitoring Arm IN end cushion does not work.
"———" is displayed and initial values are
Standard arm Long arm Stop position for interference prevention is
selected.
At IN end: 0.7 V 0.7 V If machine is operated without normal correc- wrong.
At OUT end: 4.1 V 3.7 V tion, it is controlled with initial values. Displayed depth is wrong.
Offset end cushion does not work.
Offset angle sensor voltage for monitoring Stop position for interference prevention is
At RIGHT end: 1.3 V
wrong.
At LEFT end: 3.7 V
Displayed depth is wrong.
When interference prevention is corrected,

"000" is displayed, then "S-1" (Side correc- When interference prevention is corrected,
tion) is displayed. "– – –" is displayed and initial values are
Stop position for interference prevention is
selected.
wrong.
When interference prevention is corrected, If machine is operated without normal correc-
tion, it is controlled with initial values.
"000" is displayed, then "– – –" (Finish of
correction) is displayed.
In depth display correction position (1), "000" is When interference prevention is corrected,
displayed, then "d-1" is displayed. "– – –" is displayed and initial values are
In depth display correction position (2), "000" is selected. Displayed depth is wrong.
displayed, then "– – –" (Finish of correction) is If machine is operated without normal correc-
displayed. tion, it is controlled with initial values.
Boom RAISE, arm IN, and offset LEFT oper-
Resistance between M95 pin 22, M29 pin C, Boom RAISE, arm IN, and offset LEFT EPC
ations cannot be executed. (They can be
M71 pin C, M72 pin A – chassis ground: Min. outputs are stopped.
1 Mz executed if emergency work equipment oper-
ation switch is turned ON, however.)
PC78US-6 20-355
(12)
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCUR AND
Application User
Code Service Code Troubled System Contents of Trouble
US UU
Disconnection on GND side of boom angle 1. Short circuit in wiring harness
E401
sensor between M95 pin 21 ~ M29 pin A
between M95 pin 22 ~ M29 pin C
— ! E40 2. Short circuit in wiring harness
Disconnection on power supply side of between M95 pin 3 ~ M29 pin B
E402 boom angle sensor/Short circuit or discon-
nection of signal line 3. Disconnection in wiring harness
between M95 pin 3 ~ M29 pin B
4. Defective M29 angle sensor (Internal
short circuit)
Disconnection on GND side of arm angle 1. Disconnection in wiring harness
E404
sensor between M95 pin 21 ~ M72 pin C

between M95 pin 22 ~ M72 pin A
2. Short circuit in wiring harness
E405 arm angle sensor/Short circuit or discon-
nection of signal line 3. Disconnection in wiring harness
short circuit)
— ! E40
E407 Disconnection on GND side of offset boom 1. Disconnection in wiring harness
angle sensor between M95 pin 21 ~ M71 pin A

between M95 pin 22 ~ M71 pin C
E408 offset boom angle sensor/Short circuit or
disconnection of signal line 3. Disconnection in wiring harness
short circuit)

E421 Short circuit in boom RAISE EPC solenoid between M97 pin 26 ~ M11 pin 2
system
2. Short circuit in EPC solenoid
between M97 pin 26 ~ M11 pin 2
E422 Disconnection in boom RAISE EPC sole-
2. Disconnection in EPC solenoid
noid system
E423 Short circuit in arm IN EPC solenoid sys- between M97 pin 5 ~ M12 pin 2
tem
— ! E41 Disconnection in arm IN EPC solenoid sys-
tem
E425 Short circuit in offset LEFT EPC solenoid between M97 pin 15 ~ M10 pin 2
system
Disconnection in offset LEFT EPC solenoid
system
Short circuit in PPC main pressure sole-
E431 between M97 pin 38 ~ M13 pin 2
noid system
1. Boom RAISE, arm IN, and offset LEFT
EPC solenoids are kept open because
When emergency stop is applied (Interfer- of dirt (In emergency stop range of
— ! — E435 ence prevention) bucket)
2. Water is in connectors in boom, arm,
or offset angle sensors
20-355-1 PC78US-6
➄
ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCUR AND

Occurs
Resistance between M95 pin 21 ~ M29 pin
A: Max. 1 MΩ
Between M95 pin 22 ~ M29 pin C: Max. 1 Ω
Resistance between M95 pin 3, M29 pin B ~
chassis ground: Min. 1 MΩ Boom RAISE, arm IN, and offset LEFT oper-
Resistance between M95 pin 3 ~ M29 pin B: Boom RAISE, arm IN, and offset LEFT EPC ations cannot be executed. (They can be
Max. 1 Ω outputs are stopped. executed if emergency work equipment
Resistance between M29 angle sensor pin A operation switch is turned ON, however.)
~ pin C: 3 ~ 7 kΩ
Resistance between M29 angle sensor pin
A, C ~ pin B (Which changes as shaft is
turned): 0 ~ 7 kΩ
C: Max. 1 Ω
A: Max. 1 Ω
Resistance between M95 pin 20, M72 pin B
~ chassis ground: Min. 1 MΩ
B: Max. 1 Ω
Resistance between M72 angle sensor pin A
~ pin C: 3 ~ 7 kΩ
A, C ~ pin B (Which changes as shaft is
turned): 0 ~ 7 kΩ
A: Max. 1 Ω
C: Max. 1 Ω
Resistance between M95 pin 14, M71 pin B
~ chassis ground: Min. 1 MΩ
B: Max. 1 Ω
Resistance between M71 angle sensor pin A
~ pin C: 3 ~ 7 kΩ
A, C ~ pin B : 0 ~ 7 kΩ (Which changes as
shaft is turned)
Resistance between M97 pin 26, M11 pin 2 ~
chassis ground: Min. 1 MΩ
Resistance of M11 EPC solenoid: 5 ~ 25 Ω
Resistance between M97 pin 26 ~ M11 pin 2: Boom RAISE EPC solenoid output is Boom cannot be raised.
Max. 1 Ω stopped.
Resistance between M11 pin 1 ~ M97 pin 23:
Max. 1 Ω

Resistance between M97 pin 5 ~ M12 pin 2: Arm IN EPC solenoid output is stopped. Arm cannot be moved IN.
Max. 1 Ω
Max. 1 Ω

Resistance between M97 pin 15 ~ M10 pin 2: Offset LEFT EPC solenoid output is stopped. Offset cannot be moved to LEFT.
Max. 1 Ω
Max. 1 Ω
Resistance between M97 pin 38, M13 pin 2 ~ PPC main pressure solenoid output is
Machine cannot operate equipment, travel,
chassis ground: Min. 1 MΩ stopped. or swing.
Resistance of M15 solenoid: 35 ~ 80 Ω
Voltage of potentiometer at each cylinder

end (Monitoring) Machine cannot operate equipment, travel,
Boom RAISE: 0.6 V ~ (LOWER) 4.3 V PPC main pressure solenoid output is or swing.
Standard arm IN: 0.7 V ~ OUT 4.1 V stopped. (It can, however, if emergency work equip-
Long arm: 0.7 V ~ 3.7 V ment operation switch is turned ON.)
Offset LEFT: 1.3 V ~ RIGHT 3.7 V
PC78US-6 20-355-2
➄

User
Service Code Troubled System Contents of Trouble
Code
1. Short circuit in wiring harness between M95 pin 9

Short circuit in TVC-EPC solenoid system – M20 pin 1
E232
(When emergency pump drive switch is turned ON) 2. Short circuit in EPC solenoid
E02
1. Disconnection in wiring harness between M95
pin 9 – M20 pin 1
E233 Disconnection in TVC-EPC solenoid system 2. Disconnection in EPC solenoid
pin 2 – M95 pin 40
1. Short circuit in wiring harness between M95 pin

E203 Short circuit in swing holding brake solenoid system 19 – M14 pin 2
E03 1. Disconnection in wiring harness between M95

Disconnection in swing holding brake solenoid sys- pin 19 – M14 pin 2
tem 2. Disconnection in solenoid
E213
(When emergency swing holding brake reset switch 3. Disconnection in wiring harness between M14
is turned ON) pin 1 – M95 pin 40
Short circuit in 2nd travel speed selection solenoid 1. Short circuit in wiring harness between M95 pin
E206 system 10 – M15 pin 2
—
pin 10 – M15 pin 2
Disconnection in 2nd travel speed selection solenoid
E216 system 2. Disconnection in solenoid
pin 1 – M95 pin 40
1. Disconnection, defective contact, short circuit, or
grounding fault in pressure sensor
2. Disconnection, defective contact, or short circuit
in wiring harness between controller M95 pin 22
– pressure sensor S3 pin B (power supply side)
— E224 Trouble in pump pressure sensor or between M95 pin (32) – S3 pin A (negative
side)
3. Disconnection, defective contact, or short circuit
in wiring harness between controller M95 pin 24
– pressure sensor S3 pin C (SIG side)
4. Defective controller

pin 6 – M16 pin 1
— E227 Trouble in engine speed sensor 2. Disconnection in sensor
pin 2 – M95 pin 32
1. Between M95 pin 22 – S2 pin 1, S3 pin B, or K55

— E258 Short circuit in 5 V system of sensor power supply
pin 1
20-355-3 PC78US-6
(12)

Occurs

Mz
Mz
Resistance of M20 EPC solenoid (when No current flows in TVC-EPC solenoid.
When abnormality is detected, controller
switch is directed down): 3 – 15 z stops outputting signal to TVC-EPC solenoid. Accordingly, if load is large, engine speed
lowers extremely and engine may stalls.
Between M95 pin 9 – M20 pin 1: Min. 1 Mz
40: Max. 1 z

1 Mz
Mz
Resistance of M14 solenoid: 35 – 80 z When abnormality is detected, controller
Since motor brake is not released, machine
stops outputting signal to swing holding brake
does not swing.
Resistance between M95 pin 19 – M14 pin reset solenoid.
2: Max. 1 z
(when switch is directed down): Max. 1 z

1 Mz
Mz
Resistance of M15 solenoid: 35 – 80 z When abnormality is detected, controller When speed selector switch or pedal is oper-
stops outputting signal to 2nd travel speed ated, travel speed is not changed (but kept at
Resistance between M95 pin 10 – M15 pin selection solenoid. 1st).
2: Max. 1 z
40: Max. 1 z
• Between M96 pin 22 – pin 32: 4.5 – 5.5 V

• Between M95 pin 24 – S3 pin C: 0.5 – 4.5 V
Controller assumes pump pressure to be 0
• Between M95 pin 24 – pin 32, between Pa {0 kg/cm2} for operation. Gear speed does not change automatically.
pin 24 – chassis ground: Min. 1 Mz
(Disconnect M95 and S3.)
Resistance between M95 pin 6 – M16 pin 1: When abnormality is detected, controller out-
puts constant current (600 mA) to TVC-EPC Since constant current (600 mA) is output to
Max. 1 z solenoid.
Resistance of M16 sensor: 500 – 1,000 z TVC-EPC solenoid, work equipment speed
Working mode cannot be changed. and travel speed are low. When engine
Engine governor can be controlled with only speed is low, engine may stall.
Max. 1 z
fuel control dial.
• Controller assumes pump pressure to be 0
Pa {0 kg/cm2} for operation.
Resistance between M95 pin 22, S2 pin 1, S3 • Controller recognizes that boom is at rais- Gear speed does not change automatically.
pin B, K55 pin 1 – chassis ground: Min. 1 Mz ing stroke end.
• Controller recognizes that arm is at dump-
ing stroke end.
PC78US-6 20-355-4
(12)
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM)
TROUBLESHOOTING AND HYDRAULIC EQUIPMENT
JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL

SYSTEM) AND HYDRAULIC EQUIPMENT
PC78US-6 Serial No.: 4001 – 6500
Part Which May Cause Trouble Self-diagnosis Display By Controller
Disconnection in 2nd travel speed selection solenoid system

Short circuit in 2nd travel speed selection solenoid system
Disconnection in swing holding brake solenoid system
Defective correction of interference prevention (Front)
Defective correction of interference prevention (Side)

Short circuit in swing holding brake solenoid system
Short circuit in 5 V system of sensor power supply

Defective correction of offset boom angle sensor
Disconnection in TVC-EPC solenoid system
Defective correction of boom angle sensor

Trouble in controller power supply system
Defective correction of arm angle sensor

Defective correction of depth display

User Code E02 E03 — — — — — — — — —
Failure Mode
Service Code 232 233 203 213 206 216 227 403 406 411 441 442 443 258
PC78US-6 — Q Q Q Q Q Q Q — — — — — — —
Machine Model
PC78UU-6 Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Machine cannot move work equipment, travel, or move
blade. q
Machine cannot raise boom, move arm in, or move offset
to left. q
Work equip-
ment, travel,
swing, blade
Speed or power of 2 or more systems of work equipment,
travel, swing, and blade is low. q q q
Engine speed lowers extremely or engine stalls. q q q
2 or more systems of work equipment, travel, swing, and
blade do not move.
Boom
Speed or power is low. Arm
Offset (Only UU)
Work equipment
Boom
Does not move. Arm
Offset (Only UU)
Travel speed or power is low. q q
Travel
Travel speed does not change. q q
Swing speed or power is low.
Swing Machine does not swing. q q
Hydraulic drift is large. q q
Boom RAISE does not stop Stops just before interfer-
automatically at correct posi- ence prevention
tion. Interferes q q
Stops just before interfer-
Arm IN does not stop automat- ence prevention
ically at correct position.
Interference Interferes q q
prevention Stops just before interfer-
LEFT Offset does not stop
automatically at correct posi- ence prevention
tion. Interferes q q
Work equipment stops far or too near. q q
Buzzer sounds for 7 seconds while emergency work
equipment operation switch is not turned ON.
Boom RAISE end cushion does not work well or at all. q
Electronic
cushion
Arm IN end cushion does not work well or at all. q
Offset end cushion does not work at all. q
Mode selection Work equipment exceeds or stops before set height.
Depth display
When depth display is reset, 0.0 M is not displayed at
ground level. q
After work equipment lock lever is set to LOCK, work equipment still moves
Diagnosis code displayed when service code is displayed E-1 C-1 C-2 C-3 C-4 C-5 C-6 E-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13
Diagnosis code displayed when trouble is detected by monitoring — — — — — — — — — — — — — — —
20-356 PC78US-6
(12)
—
—
Disconnection on GND side of boom angle sensor
C-
Disconnection on power supply side of boom angle
—
—
q q
sensor/Short circuit or disconnection of signal line
—
—
Disconnection on GND side of arm angle sensor
E40
Disconnection on power supply side of arm angle
—
—
PC78US-6
—
—
Disconnection on GND side of offset boom angle sensor
C- C- C-
Disconnection on power supply side of offset boom angle
—
—
q q q q q q
Short circuit in boom RAISE EPC solenoid system
TROUBLESHOOTING
Disconnection in boom RAISE EPC solenoid system
q q
q q
q q
q q
Short circuit in arm IN EPC solenoid system
Disconnection in arm IN EPC solenoid system
q q
q q
q q
E41
Short circuit in offset boom LEFT EPC solenoid system
Self-diagnosis Display By Controller
Disconnection in offset boom LEFT EPC solenoid system
q q
q q
q q
Disconnection in PPC main pressure solenoid system
q
—
— — — — — — — —
When emergency stop is applied (Interference prevention)
q
q
q
q q
q q
C- C- C- C- C- C- C- Nor
401 402 404 405 407 408 421 422 423 424 425 426 431 435
Boom RAISE (6)
Arm LOWER (5)
1023
Travel (3)
Swing (4)
Switch
Hydraulic
Air compressor signal input (3)

Deceleration switch signal input (1)
1021 1026
Travel speed selector pedal switch input (4)
PPC main pressure (2)
1060 Swing holding brake (1)

State of
Solenoid
2nd travel speed selection (4)
q : Items corresponding to service codes

Model selection and UU/US selection cod
14 C-15 16 17 18 C-19 20 21 22 23 24 25 26 mal — — — — — — — — — — — —

ATT selection
: Items that can only be checked by monitoring

—
Emergency work equipment operation switch input (3)
Q
Monitoring Code
— — — — — — — — F-3 F-4 F-2 F-1 F-7 F-5 F-6 — — — — — F-8 —

—
Engine speed input
—
—
Boom angle sensor voltage input
Items Checked By Monitoring
—
—
Arm angle sensor voltage input
—
—
Offset boom sensor voltage input
TVC-EPC current output
—
—
Boom RAISE EPC current output
—
—
Arm IN EPC current output
—
—
Offset LEFT EPC current output
—
—
Q Q Q Q Q Q Q Q Q Q Q Q Q Q — — — Q — — —
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
1020 1026 1010 1030 1032 1031 1050 1051 1052 1053
(12)
not
dis-
when
toring
—
—
—
AND HYDRAULIC EQUIPMENT
20-357
H-8
H-7
H-3
H-2
H-1
played
H-11
C-37
C-36
C-35
C-34
C-33
C-32
C-31
C-30
C-29
C-28
C-27
H-39
H-33
H-26
H-14
H-12
H-10
C-20
C-26
Diagno-
C-14 –
sis code
detected
by moni-
trouble is
C-38,H-34
C-39,H-28

Part Which May Cause Trouble Items Checked By
Self-diagnosis Display By Controller Monitoring
Hydraulic Switch
Disconnection in 2nd travel speed selection solenoid system

Short circuit in 2nd travel speed selection solenoid system
Disconnection in swing holding brake solenoid system
Short circuit in swing holding brake solenoid system
Short circuit in 5 V system of sensor power supply

Disconnection in TVC-EPC solenoid system
Trouble in controller power supply system
Trouble in pump pressure sensor system

Boom RAISE (6)
Arm LOWER (5)
Swing (4)
Travel (3)
User Code E02 E03 — — — — Monitoring Code
Failure Mode
Service Code 232 233 203 213 206 216 224 227 258 1023 1021
Machine Model PC78US-6 — Q Q Q Q Q Q Q Q — Q Q Q Q Q
Machine cannot move work equipment, travel, or move
blade. q
Machine cannot raise boom, move arm in, or move offset
to left. q
Work equip-
ment, travel,
swing, blade
Speed or power of 2 or more systems of work equipment,
travel, swing, and blade is low. q q q
Engine speed lowers extremely or engine stalls. q q q
2 or more systems of work equipment, travel, swing, and
blade do not move.
Boom
Speed or power is low.
Arm
Work equipment
Boom
Does not move.
Arm
Travel
Travel speed does not change. q q q
Interference Buzzer sounds for 7 seconds while emergency work
prevention equipment operation switch is not turned ON.
Mode selection Work equipment exceeds or stops before set height.
When depth display is reset, 0.0 M is not displayed at
Depth display
ground level.
After work equipment lock lever is set to LOCK, work equipment still moves
Diagnosis code displayed when service code is displayed E-1 C-1 C-2 C-3 C-4 C-5 C-6 E-6 C-13 — — — — —
Diagnosis code displayed when trouble is detected by monitoring — — — — — — — — — F-3 F-4 F-2 F-1 F-7
q : IIndicates an item corresponding to a service code.
20-357-1 PC78US-6
(12)
Items Checked By Monitoring

State of
Solenoid
Emergency work equipment operation switch input (3)
Governor feedback potentiometer voltage input

Diagno-
sis code
dis-
played
when
trouble is
not
Boom angle sensor voltage input
Arm angle sensor voltage input
detected
Fuel control dial voltage input by moni-

toring
Swing holding brake (1)
Engine speed input
Pump pressure
Monitoring Code
1026 1060 1026 1010 1030 1032 1050 1034 1035 1042
Q Q Q Q Q Q — — Q Q Q Q
C-26
C-14 –
C-20
H-1
H-2
H-3
H-7
H-8
H-11
H-12
H-26
w C-39,H-28
H-33
C-38,H-34
H-39
Q C-31
C-35
C-36
C-37
— — — — — — — — —
F-5 — — — F-8 — — — —
Q : Indicates an item to be checked by monitoring or with the machine monitor.

w : It does not correspond for serial No. 6501 and up.
: Indicates an item to be checked by only monitoring.
PC78US-6 20-357-2
(12)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM

PC78UU-6 Serial No.: 22832 – 23500
20-358 PC78US-6
(7)
PC78US-6 20-358-1
(5)
20-358-2 PC78US-6
(7)
PC78US-6 20-358-3
(7)
PC78US-6 Serial No.: 4001 – 5500
20-358-4 PC78US-6
(7)
PC78US-6 20-358-5
(7)
PC78US-6 Serial No.: 5501 – 6500
20-358-6 PC78US-6
(12)
PC78US-6 20-358-7
(7)
20-358-8 PC78US-6
(12)
PC78US-6 20-358-9
(12)
TROUBLESHOOTING C-1, C-2
C-1 [E232], C-2 [E233] Trouble in TVC-EPC solenoid system

PC78US-6 Serial No.: 4001 – 6500
a Since this error is displayed when the emergency pump drive switch is turned ON (RAISE), check that this
switch is turned OFF (LOWER).
Cause Remedy
1
• Disconnect M20
• 3 – 15 z Defective TVC-EPC solenoid
Is resistance of EPC solenoid normal and is EPC NO (Internal short circuit, disconnec- Replace
• Resistance between solenoid and solenoid insulated from chassis? tion)
YES
2
• Disconnect M97 Is resistance between M97 (Female) (16) – (23) NO tact in wiring harness between Repair or
• Resistance: 3 – 15 z normal? M97 (Female) (16), (23) – M20 replace
(Female) (1), (2)
YES
3
Short circuit with chassis ground
• Disconnect M97 Is resistance between M97 (Female) (16) – chas- NO or negative (-) wire in wiring har- Repair or
• Resistance: Min. 1 Mz sis ground normal? ness between M97 (Female) (16) replace
– M20 (Female) (1)
YES
C-1, C-2 Electrical circuit diagram of each system
PC78US-6 20-359
(12)

Cause Remedy
1
• Disconnect M20
• 3 – 15 z Defective TVC-EPC solenoid
Is resistance of EPC solenoid normal and is EPC NO (Internal short circuit, disconnec- Replace
• Resistance between solenoid and solenoid insulated from chassis? tion)
YES
2
(Female) (1), (2)
YES
3
– M20 (Female) (1)
YES
20-359-1 PC78US-6
(12)
C-3 [E203], C-4 [E213] Trouble in swing holding brake solenoid system
PC78US-6 Serial No.: 4001 – 6500
a Since this error is displayed when the emergency swing holding brake release switch is turned ON (RAISE),
check that this switch is turned OFF (LOWER).
Cause Remedy
1
• Disconnect M14
• 35 – 80 z Defective swing holding brake
Is resistance of solenoid normal and is solenoid NO solenoid (Internal short circuit, Replace
• Resistance between solenoid and insulated from chassis? disconnection)
YES
2
(Female) (2), (1)
YES
3
– M14 (Female) (2)
YES
20-360 PC78US-6
(12)

Cause Remedy
1
• Disconnect M14
• 35 – 80 z Defective swing holding brake
Is resistance of solenoid normal and is solenoid NO solenoid (Internal short circuit, Replace
• Resistance between solenoid and insulated from chassis? disconnection)
YES
2
(Female) (2), (1)
YES
3
– M14 (Female) (2)
YES
PC78US-6 20-360-1
(12)
C-5 [E206], C-6 [E216] Trouble in 2nd travel speed selection solenoid
system
PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
1
• Disconnect M15
• 35 – 80 z Defective 2nd travel speed
Is resistance of solenoid normal and is solenoid NO selection solenoid (Internal short Replace
• Resistance between solenoid – insulated from chassis? circuit, disconnection)
YES
2
(Female) (2), (1)
YES
3
– M15 (Female) (2)
YES
PC78US-6 20-361
(12)
Cause Remedy
1
• Disconnect M15
• 35 – 80 z Defective 2nd travel speed
Is resistance of solenoid normal and is solenoid NO selection solenoid (Internal short Replace
• Resistance between solenoid – insulated from chassis? circuit, disconnection)
YES
2
(Female) (2), (1)
YES
3
– M15 (Female) (2)
YES
20-361-1 PC78US-6
(12)
TROUBLESHOOTING C-7, C-8, C-9
C-7 [E403] Trouble in boom angle sensor correction

C-8 [E406] Trouble in arm angle sensor correction
C-9 [E411] Trouble in offset boom angle sensor correction
(Only PC78UU-6)
a Check by monitoring that model selection, UU/US selection code, and ATT selection code are normal.
a Check that the angle sensor are installed normally.
Cause Remedy
• Reset data again according to

Is error turned off after data are NO
potentiometer correction proce- reset again?
dure in back mode
YES
Defective correction (Wrong resetting) —
Is monitored voltage of angle sensor NO

• See Table 1 at each cylinder end normal?
YES
3
M29, M71, M72
• Between (A) – (C): 3 – 7 kz
• Between (A), (C) – (B): 0 – 7 kz Is resistance of each angle sensor NO Defective angle sensor having abnormal resis- Replace
normal? tance
(Resistance changes as shaft is
turned)
YES Disconnection or defective contact in wiring har-
ness of circuit having abnormal resistance Repair or
(Between M95 – M29, M71, M72) (See circuit dia- replace
gram)
Table 1 Voltage (V)
Position Monitoring Code Standard Arm Long Arm
Boom RAISE end 1030 0.3 – 1.1 0.3 – 1.1
Offset LEFT end 0.8 – 1.8 0.8 – 1.8

1031
Offset RIGHT end 3.2 – 4.2 3.2 – 4.2
Arm IN end 0.3 – 1.2 0.3 – 1.2

1032
Arm DUMP end 3.6 – 4.6 3.2 – 4.2
20-362 PC78US-6
(5)
TROUBLESHOOTING C-7, C-8, C-9
C-7, C-8, C-9 Electrical circuit diagram of each system
PC78US-6 20-363
➄
C-10 , C-11 [E441] Trouble in interference prevention (front) correction

C-11 [E442] Trouble in interference prevention (side) correction
(Only PC78UU-6)
★ Check by monitoring that model selection, UU/US selection code, and ATT selection code are normal.
★ Check that the angle sensors are installed normally.
Cause Remedy
• Correct potentiometer and set NO

Is error turned off after data are
interference prevention in back reset again?
mode
YES
• Quantity of longitudinal adjust- NO

ment: ± 300 mm Is quantity of adjustment in stan- Defective correction (Over-quantity of adjust- Re-set in adjustment
• Quantity of lateral adjustment: dard range? ment) range
± 300 mm
YES
Is monitored voltage of angle NO

Same as values of C-7 ~ C-9 sensor at each cylinder end nor-
mal?
YES
Defective Controller Replace
4
M29, M71, M72
• Between (A) ~ (C): 3 ~ 7kΩ NO
• Between (A), (C) ~ (B): 0 ~ 7kΩ Is resistance of each angle sensor Defective angle sensor having abnormal resis- Replace
normal? tance.
turned.)
YES Disconnection or defective contact in wiring
harness of circuit having abnormal resistance Repair or replace
(Between M95 ~ M29, M71, M72) (See circuit
diagram)
20-364 PC78US-6
➄
TROUBLESHOOTING C-12
C-12 [E443] Trouble in depth indication correction

(Only PC78UU-6)
★ Check by monitoring that model selection, UU/US selection code, and ATT selection code are normal.
★ Check that the angle sensors are installed normally.
Cause Remedy
NO
• Correct potentiometer and Is error turned off after data are
depth display in back mode. reset again?
YES
NO
• Quantity of vertical adjustment: Is quantity of adjustment in stan- Defective correction (Over-quantity of adjust- Re-set in adjustment
± 500 mm dard range? ment) range
YES
Is monitored voltage of angle NO

Same as values of C-7 ~ C-9 sensor at each cylinder end nor-
mal?
YES
Defective Controller Replace
4
M29, M71, M72
• Between (A) ~ (C): 3 ~ 7kΩ NO
• Between (A), (C) ~ (B): 0 ~ 7kΩ Is resistance of each angle sensor Defective angle sensor having abnormal resis- Replace
normal? tance.
turned.)
YES Disconnection or defective contact in wiring
harness of circuit having abnormal resistance Repair or replace
(Between M95 ~ M29, M71, M72) (See circuit
diagram)
C-12 Electrical circuit diagram of each system
PC78US-6 20-365
➄
C-13 [E258] Short circuit in 5V system of sensor power supply

(Only PC78UU-6)
a If E258 is displayed, E40 is displayed, too. Carry out the troubleshooting for E40 (C-14 – C-19), too.
Cause Remedy
1
Short circuit with chassis ground in wiring harness
• Disconnect M95 Is resistance between M95 NO between M95 (Female) (22) – M29, M71 (Female) Repair or
(Female) (22) chassis ground nor-
• Min. 1Mz (A), M72 (Female) (C) (Short circuit of sensor replace
mal? power supply with chassis ground.)
YES
• Disconnect M95, M72, M71, and Short circuit with chassis ground or negative
Is resistance between M95 NO Repair or
M29. (-) wire in wiring harness between M95 (Female)
(Female) (22) – (21)normal? replace
• Min. 1Mz (21) – M29, M71 (Female) (A), M72 (Female) (C)
YES
3
• Between (A) – (C): 3 – 7 kz
• Between (A), (C) – (B): 0 – 7 kz Is resistance of each angle sensor NO Defective angle sensor having abnormal resis- Replace
(Resistance changes as shaft is normal? tance (Internal short circuit)
turned)
YES
20-366 PC78US-6
(12)

a If E258 is displayed, E40 is also displayed.
Cause Remedy
• Disconnect M95. Grounding fault in wiring harness between M95

Is resistance between M95 (female) NO Repair or
(female) (22) – chassis ground (Grounding fault in
• Min. 1 Mz (22) and chassis ground normal? replace
sensor power supply)
YES
• Operate fuel control dial. Is voltage of fuel control dial nor- NO Defective fuel control dial potentiometer
mal? Replace
• 0.7 – 4.3 V (Internal short circuit)
(Monitoring code 1034)
YES
3
• Turn starting switch ON: 0 {0} Is monitoring value of pump pres-
• When relieved: NO Defective pump pressure sensor
sure sensor normal? Replace
(Internal short circuit)
26.5 ± 1.0 MPa {270 ± 10 kg/cm2} (Monitoring code 1042)
YES
• Start engine. Is voltage of governor feedback NO Defective governor motor feedback potentiometer
• Operate fuel control dial. potentiometer normal? Replace
(Internal short circuit)
• 2.7 – 4.7 V (Monitoring code 1035)
YES
PC78US-6 20-366-1
(12)
20-366-2 PC78US-6
(12)
C-14 [E224] Trouble in pump pressure sensor is displayed

Cause Remedy
1
• Turn starting switch ON: 0 {0]
• Relief pressure: Is monitored pump pressure nor- NO Defective controller Replace
mal? (Monitoring code 1040)
26.5 ± 1.0 MPa {270 ± 10 kg/cm2}
YES
• Disconnect S3. Is resistance between S3 (female)

(C) and chassis ground and NO Grounding fault in wiring harness between M95 – Repair or
• Disconnect M95. between S3 (female) (B) and chas- S3 replace
• Min. 1 Mz sis ground normal?
YES
• Disconnect S3. Is resistance between S3 (female) NO Repair or

• Disconnect M95. (C) and (B) and between S3 Short circuit in wiring harness between M95 – S3 replace
• Min. 1 Mz (female) (C) and (4) normal?
YES
4
Is resistance between M95 (female)
• Disconnect S3. (24) and S3 (female) (C), between NO Repair or
• Disconnect M95. M95 (female) (22) and S3 (female) Disconnect in wiring harness between M95– S3 replace
• Max. 1 z (B), and between M95 (female) (25)
and S3 (female) (A) normal?
YES
Defective pump pressure sensor Replace
PC78US-6 20-366-3
(12)
C-15 [E401], C-16 [E402] Trouble in boom angle sensor system

(Only PC78UU-6)
Cause Remedy
• 0.3 – 4.7 V Is monitored voltage of boom angle NO

(Monitoring code 1030) sensor normal?
YES
2
• Between (A) – (C): 3 – 7 kz
• Between (A), (C) – (B): 0 – 7 kz Is resistance of M29 angle sensor NO Defective boom angle sensor (Disconnection, Replace
(Resistance changes as shaft is normal? short circuit with chassis ground)
turned.)
YES
• Disconnection or defective contact in wiring
harness between M95 (Female) (22), (3) –
M29 (Female) (A), (B), (C) Repair or
• Short circuit with chassis ground or negative (-) replace
wire in wiring harness between M95 (Female)
(3) – M29 (Female) (B)
If the wiring harness between M95(3) – M29 (B) is shorted actually, the controller output is cut out. Accordingly, if [E402] is displayed,
the controller is defective.
PC78US-6 20-367
(12)
C-17 [E404], C-18 [E405] Trouble in arm angle sensor system

(Only PC78UU-6)
Cause Remedy
• 0.3 – 4.7 V Is monitored voltage of arm angle NO

(Monitoring code 1032) sensor normal?
YES
2
• Between (A) – (C): 3 – 7 kz
• Between (A), (C) – (B): 0 – 7 kz Is resistance of M72 angle sensor NO Defective arm angle sensor (Disconnection, short Replace
(Resistance changes as shaft is normal? circuit with chassis ground)
turned.)
YES
harness between M95 (Female) (21), (20), (22)
– M72 (Female) (C), (B), (A) Repair or
wire in wiring harness between M95
(Female)(20) – M72 (Female) (B)
a If the wiring harness between M95 (20) – M72 (B) is shorted actually, the controller output is cut out. Accordingly, if [E405] is displayed,
20-368 PC78US-6
(12)
C-19 [E407], C-20 [E408] Trouble in offset angle sensor system

(Only PC78UU-6)
Cause Remedy
• 0.3 – 4.7 V Is monitored voltage of offset boom NO

(Monitoring code 1031) angle sensor normal?
YES
2
• Between (A) – (C): 3 – 7 kz
• Between (A), (C) – (B): 0 – 7 kz Is resistance of M71 angle sensor NO Defective offset angle sensor (Disconnection, Replace
(Resistance changes as shaft is normal? short circuit with chassis ground)
turned.)
YES
harness between M95 (Female) (22), (14), (21)
– M71 (Female) (A), (B), (C) Repair or
wire in wiring harness between M95 (Female)
(14) – M71 (Female) (B)
a If the wiring harness between M95 (14) – M71 (B) is shorted actually, the controller output is cut out. Accordingly, if [E408] is displayed,
PC78US-6 20-369
(12)
C-21 [E421] Short circuit in boom raise EPC system is displayed

(Only PC78UU-6)
Cause Remedy
1
Is resistance between M11 (male)
• Turn starting switch OFF. (1) and (2) and between (2) and NO Defective boom raise EPC solenoid Replace
• Disconnect M11. chassis ground as shown in Table (Internal disconnection)
1?
YES
2
Is resistance between D15 (female)
• Turn starting switch OFF. (1) and chassis ground and NO Disconnection in wiring harness between D15 Repair or
• Disconnect D15 and M97. between D15 (female) (1) and M97 (female) (1) – M11 (2), M97 (23) – M11 (1) replace
(female) (23) as shown in Table 2?
YES
3
• Turn starting switch OFF. NO Grounding fault or internal short circuit in wiring
(26) and M97 (female) (23) between Repair or
harness between D15 (female) (2) – M97 (female)
• Disconnect D15 and M97. M97 (female) (26) as shown table replace
(26)
3?
YES
Table 1 Table 2 Table 3

Between M11 (male) (1) – (2) 5 – 25 z Between D15 (1) – chassis ground Min. 1 Mz Between M97 (26) – chassis ground Min. 1 Mz
Between M11 (male) (2) – chassis ground Min. 1 z Between D15 (1) – M97 (23) 5 – 25 z Between M97 (26) – M97 (23) Min. 1 Mz
20-370 PC78US-6
(12)
C-22 [E422] Disconnection in boom raise EPC system is displayed

(Only PC78UU-6)
Cause Remedy
• Turn starting switch OFF.

Is resistance between M11 (male) NO Defective boom raise EPC solenoid
• Disconnect M11. Replace
(1) and (2) normal? (Internal disconnection)
• Resistance: 5 – 25z
YES
2
• Turn starting switch OFF. NO Disconnection in wiring harness between D15
(1) and M97 (female) (23) and Repair or
(female) (1) – M11 (2), D15 (female) (2) – M97
• Disconnect D15 and M97. between D15 (female) (2) and M97 replace
(26), or M97 (23) – M11 (1)
YES
3
• Disconnect D15. NO
Is diode D15 normal? Defective diode (Disconnection) Replace
* See TESTING AND ADJUST-
ING.
YES
Table 1
Between D15 (1) – M97 (23) 5 – 25 z
Between D15 (2) – M97 (26) Max. 1 z
PC78US-6 20-371
(12)
C-23 [E423] Short circuit or grounding fault in arm-in EPC system is

displayed
(Only PC78UU-6)
Cause Remedy
1
• Turn starting switch OFF. (1) and (2) and between (2) and NO Defective arm-in EPC solenoid Replace
• Disconnect M12. chassis ground as shown in Table (Internal short circuit or grounding fault)
1?
YES
2
• Turn starting switch OFF. (1) and chassis ground Grounding fault or internal short circuit in wiring
NO Repair or
and between D19 (female) (1) and harness between D19 (female) (1) – M12 (2) or
• Disconnect D19 and M97. replace
M97 (female) (23) as shown in between M97 (23) – M12 (1)
Table 2?
YES
3
(5) and chassis ground and Repair or
• Disconnect D19 and M97. between M97 (female) (5) and M97 replace
(5)
YES

20-372 PC78US-6
(12)
C-24 [E424] Disconnection in arm-in EPC system is displayed

(Only PC78UU-6)
Cause Remedy

Is resistance between M12 (male) NO Defective arm-in EPC solenoid
• Resistance: 5 – 25z
YES
2
(1) and M97 (female) (23) and Repair or
(5), or M97 (23) – M12 (1))
YES
3
ING.
YES
Table 1
Between D19 (1) – M97 (23) 5 – 25 z
Between D19 (2) – M97 (5) Max. 1 z
PC78US-6 20-373
(12)
C-25 [E425] Short circuit or grounding fault in offset left EPC system is
displayed
(Only PC78UU-6)
Cause Remedy
1
• Turn starting switch OFF. (1) and (2) and between (2) and NO Defective offset left EPC solenoid Replace
1?
YES
2
harness between D20 (female) (1) – M10 (2) or
between M97 (23) – M10 (1)
YES
3
• Turn starting switch OFF. (15) and chassis ground and Grounding fault or internal short circuit in wiring
NO Repair or
between M97 (female) (15) and harness between D20 (female) (2) – M97 (female)
• Disconnect D20 and M97. replace
M97 (female) (23) as shown in (15)
Table 3?
YES

20-374 PC78US-6
(12)
C-26 [E426] Disconnection in offset left EPC system is displayed

(Only PC78UU-6)
Cause Remedy

Is resistance between M10 (male) NO Defective offset left EPC solenoid
• Resistance: 5 – 25 z
YES
2
((1) and M97 (female) (23) and Repair or
(15) or M97 (23) – M10 (1)
YES
3
ING.
YES
Table 1
Between D20 (1) – M97 (23) 5 – 25 z
Between D20 (2) – M97 (15) Max. 1 z
PC78US-6 20-375
(12)
C-27 [E431] Short circuit or grounding fault in PPC basic pressure lock
solenoid system is displayed
(Only PC78UU-6)
Cause Remedy
1
• Turn starting switch OFF. (1) and (2) and between (2) and NO Defective PPC oil pressure lock solenoid Replace
1?
YES
• Turn starting switch OFF. 2

• Disconnect K28.
• Reset PPC oil pressure lock
Is PPC oil pressure lock switch insu- NO
switch. Defective PPC oil pressure lock switch Replace
lated from chassis ground?
• Resistance between K28
(female) (2) and chassis ground:
Min. 1 Mz YES
3
Is resistance between K55 (female) Grounding fault or internal short circuit in wiring
• Turn starting switch OFF. (5) and chassis ground and NO harness between K55 (female) (5) – M13 (female) Repair or
• Disconnect K55 and M97. between K55 (female) (5) and M97 (2) or between M13 (female) (1) – M97 (female) replace
(female) (13) as shown in Table 2? (13)
YES
4
• Disconnect D13 and D14. Is resistance between K55 (female)
NO Grounding fault or internal short circuit in wiring
• Disconnect M97 and K55. (3) and chassis ground and between Repair or
harness between K55 (female) (3) – M97 (female)
M97 (female) (30) and chassis replace
• Reset PPC oil pressure lock (30)
ground as shown in Table 3?
switch.
YES
5
• Disconnect M97 and D13. between M97 (female) (38) and M97 replace
(38)
YES

Between M13 (male) (1) – (2) 35 – 80 z Between K55 (female) (5) – chassis ground Min. 1 Mz Between K55 (female) (3) – chassis ground Min. 1 Mz
Between M13 (male) (2) – chassis ground Min. 1 Mz Between K55 (female) (5) – M97 (female) (13) 35 – 80 z Between M97 (female) (30) – chassis ground Min. 1 Mz
Table 4
Between M97 (38) – chassis ground Min. 1 z
Between M97 (38) – M97 (13) Min. 1 z
20-376 PC78US-6
(12)

PC78UU-6 Serial No.: 22832 – 23500
PC78US-6 20-376-1
(12)

20-376-2 PC78US-6
(12)
C-28 Boom does not stop automatically at normal position but interferes
when it is raised
(Only PC78UU-6)
a Check that the UU/US selection and ATT selection are normal by monitoring code 1020.
a Check that the boom angle sensor voltage input is normal by monitoring code 1030.
a (Standard value: 0.6 V when boom is at raise end)
a Check installation of the boom angle sensor for abnormality.
Cause Remedy
1
When interference prevention
(Front) and boom angle sensor are 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 angle sensor NO Defective boom angle sensor Replace
kz (If shaft is rotated, resistance normal?
changes.)
YES
PC78US-6 20-377
(12)
C-29 Arm does not stop automatically at normal position but interferes
when it is moved in
(Only PC78UU-6)
a Check that the arm angle sensor voltage input is normal by monitoring code 1032.
(Standard value: At IN end; Standard arm = 0.7 V, Long arm = 0.7 V
At OUT end; Standard arm = 4.1 V, Long arm = 3.7 V)
a Check installation of the arm angle sensor for abnormality.
Cause Remedy
1
(Front) and arm angle sensor are NO
become normal?
YES
2
• Between (A), (C) and (B): 0 – 7 Is resistance of arm angle sensor NO Defective arm angle sensor Replace
changes.)
YES
20-378 PC78US-6
(12)
C-30 Offset does not stop automatically at normal position but interferes
when it is moved to left
(Only PC78UU-6)
a Check that the offset angle sensor voltage input is normal by monitoring code 1031.
(Standard value: At right end; 1.3 V, At left end; 3.7 V)
a Check installation of the offset angle sensor for abnormality.
Cause Remedy
1
(Front) and offset angle sensor are NO
become normal?
YES
2
• Between (A), (C) and (B): 0 – 7 Is resistance of offset angle sensor NO Defective offset angle sensor Replace
changes.)
YES
PC78US-6 20-379
(12)
C-31 Work equipment stops far or near

(Only PC78UU-6)
a Check that the voltage inputs of the boom angle sensor, arm angle sensor, and offset angle sensor are nor-
mal by monitoring codes 1030, 1032, and 1031, respectively.
(For the standard values, see C-27, C-28, and C-29.)
a Check installation of the boom angle sensor, arm angle sensor, and offset angle sensor for abnormality.
Cause Remedy
1
(Front) and interference prevention NO
(Side) are corrected again, does
condition become normal?
YES
2
• Between (A), (C) and (B): 0 – 7 Is resistance of boom, arm, and off- NO Replace defec-
Defective offset angle sensor
kz (If shaft is rotated, resistance set angle sensor normal? tive angle sensor
changes.)
YES
20-380 PC78US-6
(12)
C-32 Buzzer sounds for 7 seconds while emergency work equipment

operation switch is not turned ON
(Only PC78UU-6)
a Check that the input of the emergency work equipment operation switch is normal by monitoring code 1026.
Cause Remedy
1
• When switch is set in lower posi-
tion (Automatic returning) Is resistance of emergency work NO Defective emergency work equipment operation Replace
Between (1) and (2): Min. 1 Mz equipment operation switch normal? switch
Between (2) and (3): Max. 1z
YES
Defective monitor Replace

PC78UU-6 Serial No.: 22832 – 23500
PC78US-6 20-381
(12)

20-381-1 PC78US-6
(12)
C-33 Boom raise end cushion does not work at all or normally
(Only PC78UU-6)
a Check that the boom angle sensor voltage input is normal by monitoring code 1030.
a (Standard value: 0.6 V when boom is at raise end)
a Check that the boom raise EPC current output is normal by monitoring code 1051.)
a Check installation of the boom angle sensor for abnormality.
Cause Remedy
When boom angle sensor is cor- NO

rected again, does condition
become normal?
YES
Defective correction –
2
• Between (A), (C) and (B): 0 – 7 Is resistance of boom angle sensor NO
Defective boom angle sensor Replace
changes.)
YES
3
Is resistance between M29 (A) and Disconnection or defective contact in wiring har-
M95 (21), between M29 (B) and NO Repair or
• Normal value: Max. 1 z ness of circuit having abnormal resistance (See
M95 (3), and between M29 (C) and replace
circuit diagram)
M95 (22) normal?
YES
Defective controller
20-382 PC78US-6
(12)
C-34 Arm-in end cushion does not work at all or normally

(Only PC78UU-6)
a Check that the arm angle sensor voltage input is normal by monitoring code 1032.
(Standard value: At IN end; Standard arm = 0.7 V, Long arm = 0.7 V
At OUT end; Standard arm = 4.1 V, Long arm = 3.7 V)
a Check that the arm-in EPC current output is normal by monitoring code 1052.
a Check installation of the arm angle sensor for abnormality.
Cause Remedy
When arm angle sensor is corrected NO

again, does condition become nor-
mal?
YES
Defective correction —
2
• Between (A), (C) and (B): 0 – 7 Is resistance of arm angle sensor NO
Defective arm angle sensor Replace
changes.)
YES
3
Is resistance between M72 (A) and
M95 (22), between M72 (B) and NO Disconnection or defective contact in wiring har- Repair or
• Normal value: Max. 1 z M95 (20), and between M72 (C) and ness of circuit having abnormal resistance replace
M95 (21) normal?
YES
PC78US-6 20-383
(12)
C-35 Offset end cushion does not work at all or normally

(Only PC78UU-6)
a Check that the offset angle sensor voltage input is normal by monitoring code 1031.
(Standard value: At right end; 1.3 V, At left end; 3.7 V)
a Check that the offset left EPC current output is normal by monitoring code 1053.
a Check installation of the offset angle sensor for abnormality.
Cause Remedy
When offset angle sensor is cor- NO

rected again, does condition
become normal?
YES
2
• Between (A), (C) and (B): 0 – 7 Is resistance of offset angle sensor NO
Defective offset angle sensor Replace
changes.)
YES
3
Is resistance between M71 (A) and
M95 (21), between M71 (B) and NO Disconnection or defective contact in wiring har- Repair or
• Normal value: Max. 1 z M95 (14), and between M71 (C) and ness of circuit having abnormal resistance replace
M95 (22) normal?
YES
20-384 PC78US-6
(12)
C-36 Work equipment stops after or before set height

(Only PC78UU-6)
mal by monitoring codes 1030, 1032, and 1031, respectively. (For the standard values, see C-27, C-28,
and C-29.)
Cause Remedy
1
YES
2
• Between (A), (C) and (B): 0 – 7 NO Replace defec-
Is resistance of boom, arm, and off- Defective angle sensor having abnormal resis-
tive angle sen-
kz (If shaft is rotated, resistance set angle sensor normal? tance sor
changes.)
YES
PC78US-6 20-385
(12)
C-37 When depth display is reset, 0.0 m is not indicated at GL

(Only PC78UU-6)
mal by monitoring codes 1030, 1032, and 1031, respectively.
(For the standard values, see C-27, C-28, and C-29.)
Cause Remedy
1
YES
2
• Between (A), (C) and (B): 0 – 7 NO Replace defec-
Is resistance of boom, arm, and off- Defective angle sensor having abnormal resis-
tive angle sen-
kz (If shaft is rotated, resistance set angle sensor normal? tance sor
changes.)
YES
20-386 PC78US-6
(12)
C-38 Work equipment still moves after work equipment lock lever is set to
LOCK
PC78US-6 Serial No.: 4001 – 5500
Cause Remedy
1
• When pushed, (1) – (3) are con-
nected to each other.
Is PPC hydraulic lock switch nor- NO
• When released, (1) – (2) are con- Defective hydraulic lock switch Replace
mal?
nected to each other
(Test on switch unit)
YES
• When locked: 0 V Repair or

Is voltage between M13 (2) – chas- NO Short circuit with positive (+) wire in wiring har- replace wiring
• When released: 20 – 29 V sis ground normal? ness between K28 (2) – M13 (2) harness
YES
PC78US-6 20-387
(12)
PC78US-6 Serial No.: 5501 – 6500
Cause Remedy
1
mal?
YES

YES
Defective PPC lock solenoid valve Replace
20-387-1 PC78US-6
(12)
Cause Remedy
1
mal?
YES

YES
PC78US-6 20-387-2
(12)
Cause Remedy
1
mal?
YES
• When locked: 0 V Is voltage between M13 (2) – chas- NO

• When released: 20 – 29 V sis ground normal?
YES
• Min. 1 M z Is resistance between PPC lock cut NO Defective PPC lock cut relay Replace
• Disconnect K55. relay K55 (male) (3) and (5) normal?
YES
Short circuit with power source in wiring harness
Repair or
between M13 (female) (2) - K55 (female) (5) or replace
between K55 (female) (3) - M97 (female) (30), (38)
20-387-3 PC78US-6
(12)
C-39 Machine does not swing

PC78US-6 Serial No.: 4001 – 6500
a Carry out the following troubleshooting when [E-203] and [E-213] are not displayed.
Cause Remedy
NO
• Check swing control lever. Is bit pattern 1023 – (4) displayed? Go to F-1 —
YES
Go to H-34 —
20-388 PC78US-6
(12)

Cause Remedy
NO
• Check swing control lever. Is bit pattern 1023 – (4) displayed? Go to F-1 —
YES
Go to H-34 —
PC78US-6 20-388-1
(12)
C-40 Travel speed does not rise

PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
• 20 – 29 V
Is voltage between K3 (Female) (2) NO
• Disconnect K3
YES
2
• In 1-spool mode: Min. 1Mz
• In 2-spool mode: Max. 1z Is resistance between K3 (Male) (2) NO Defective 2nd travel speed selection switch Replace
• Turn starting switch OFF – (1) normal?
• Disconnect K3
YES
Disconnection or defective contact in wiring har- Repair or
ness between K3 (Female) (1) – M12 – chassis replace
ground
• 20 – 29 V
Is voltage between M95 (5) – chas- NO
• Turn starting switch ON Defective controller Replace
sis ground normal.
• Disconnect K3
YES
Disconnection or defective contact in wiring har- Repair or
ness between M95 (Female) (5) – K3 (Female) replace
(2)
PC78US-6 20-389
(12)
C-41 Gear speed does not change automatically

a When [E-206], [E-216], [E-224], or [E-227] is not displayed.
Cause Remedy
1
• Monitoring
FULL: 197 – 207 Is monitored value of engine speed NO
normal? Defective engine speed sensor Replace
SLOW: 113 –118 (Monitoring code: 1010)
YES
2
• Monitoring relief Is monitored value of pump pres-
25.5 – 27.5 MPa NO
sure normal? Defective pump pressure sensor Replace
{260.3 – 280.4 kg/cm2} (Monitoring code: 1042)
YES
C-42 Trouble in controller power supply system (LED of controller is

turned OFF)
a See E-1.
20-389-1 PC78US-6
(12)
(INPUT SIGNAL SYSTEM)
(F MODE)
F-1 Bit pattern 1023-(4) Swing pressure switch does not light up.............................................................. 20-402
F-2 Bit pattern 1023-(3) Travel pressure switch does not light up.............................................................. 20-404
F-3 Bit pattern 1023-(6) Boom RAISE pressure switch does not light up .................................................. 20-406
F-4 Bit pattern 1023-(5) Arm IN pressure switch does not light up ............................................................ 20-408
F-5 Bit pattern 1026-(1) Deceleration switch of left knob does not light up................................................ 20-410
F-6 Bit pattern 1026-(4) 2nd travel speed selection switch (pedal) does not light up
(US with blade and UU) ....................................................................................... 20-412
F-7 Bit pattern 1021-(3) Compressor signal does not light up ................................................................... 20-413
F-8 Bit pattern 1026-(3) Emergency work equipment operation switch does not light up
(Only PC78UU-6)................................................................................................. 20-415
removed and the connector is returned, if the monitoring code is displayed normally, the condition has
returned to normal.
a Always connect any disconnected connectors before going on to the next step.
PC78US-6 20-401
(12)
TROUBLESHOOTING F-1
F-1 Bit pattern 1023-(4) Swing pressure switch does not light up
PC78US-6 Serial No.: 4001 – 6500
k
Before operating the swing control lever (even a lit-
tle distance), stick the bucket into the ground to
lock the swing mechanism.
Cause Remedy
• Disconnect M22. 1
• Start engine.
• Set swing control lever in neu- Is resistance between M22 (Male) (1) – (2) nor- NO Defective left swing pressure
tral: Min. 1Mz mal and are they insulated from chassis Replace
switch
• Move swing control lever to ground?
swing to left: Max. 1z
• See note. YES
• Start engine.
• Set swing control lever in neu- Is resistance between M23 (Male) (1) – (2) nor- NO Defective right swing pres-
tral: Min. 1 Mz mal and are they insulated from chassis Replace
sure switch
swing to right: Max. 1 z
• See note. YES

Disconnection, defective con-
• Disconnect M95, M22, and M23. tact, or short circuit with chas-
• Between M95 – M22, M23: Is resistance between M95 (Female) (24) – NO sis ground in wiring harness
M22, M23 (Female) (2) normal and are they Repair or replace
Max. 1 z insulated from chassis ground? between M95 (Female) (24) –
• Between wiring harness – chas- M22 (Female) (2), M23
sis ground: Min. 1 z (Female) (2)
YES
4
• Start engine. Disconnection or defective
• Set swing control lever in neu- contact in wiring harness
Is voltage between M95 (24) – chassis ground NO
tral: 20 – 30 V between M22 (Female) (1), Repair or replace
normal?
• Move swing control lever: M23 (Female) (1) – chassis
Max. 1 V ground
YES
Note: This item may be judged by fitting a short connector. In this case, judge by the voltage between M95 (24)
– chassis ground.
• If 20 – 30 V : Go to YES.
• If below 1 V : Go to NO.
F-1 Electrical circuit diagram of each system
20-402 PC78US-6
(12)
TROUBLESHOOTING F-1
k
Before operating the swing control lever (even a lit-
tle distance), stick the bucket into the ground to
lock the swing mechanism.
Cause Remedy
• Start engine.
• Set swing control lever in neu- Is resistance between M22 (Male) (1) – (2) nor- NO Defective left swing pressure
tral: Min. 1Mz mal and are they insulated from chassis Replace
switch
swing to left: Max. 1z
• See note. YES
• Start engine.
• Set swing control lever in neu- Is resistance between M23 (Male) (1) – (2) nor- NO Defective right swing pres-
sure switch
swing to right: Max. 1 z
• See note. YES

• Disconnect M95, M22, and M23. tact, or short circuit with chas-
• Between M95 – M22, M23: Is resistance between M95 (Female) (25) – NO sis ground in wiring harness
M22, M23 (Female) (2) normal and are they Repair or replace
Max. 1 z insulated from chassis ground? between M95 (Female) (25) –
• Between wiring harness – chas- M22 (Female) (2), M23
sis ground: Min. 1 z (Female) (2)
YES
4
• Disconnect M95, M22 and M23. Is resistance between M22 (female) (1) and contact in wiring harness
NO
chassis ground and between M23 (female) (1) between M22 (Female) (1), Repair or replace
• Max. 1z and chassis ground normal? M23 (Female) (1) – chassis
ground
YES
– chassis ground.
• If 20 – 30 V : Go to YES.
• If below 1 V: Go to NO.
PC78US-6 20-403
(12)
TROUBLESHOOTING F-2
F-2 Bit pattern 1023-(3) Travel pressure switch does not light up
PC78US-6 Serial No.: 4001 – 6500
k
Before operating the travel lever (even a little dis-
tance), check the condition and safety around the
machine.
k
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
• Start engine.
• Set swing control lever in neu- Is resistance between M25 (Male) (1) – (2) nor- NO Defective travel pressure
mal and are they insulated from chassis Replace
tral: Min. 1 Mz switch
ground?
• Move travel lever: Max. 1 z
• See note.
YES
2
• Turn starting switch OFF. Disconnection, defective con-
• Disconnect M95 and M25. Is resistance between M95 (Female) (18) – M25 tact, or short circuit with chas-
NO
• Between M95 – M25: Max. 1 z (Female) (2) normal and are they insulated from sis ground in wiring harness Repair or replace
• Between wiring harness – chas- chassis ground? between M95 (Female) (18) –
sis ground: Min. 1 Mz M25 (Female) (2)
YES
3
• Start engine. Disconnection or defective
• Set travel lever in neutral: Is voltage between M95 (18) – chassis ground NO contact in wiring harness Repair or replace
20 – 30 V normal? between M25 (Female) (1) –
• Move travel lever: Max. 1 V chassis ground
YES
– chassis ground.
• If 20 – 30 V : Go to YES.
• If below 1 V : Go to NO.
20-404 PC78US-6
(12)
TROUBLESHOOTING F-2
k
Before operating the travel lever (even a little dis-
tance), check the condition and safety around the
machine.
k
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
• Start engine.
• Set swing control lever in neu- Is resistance between M25 (Male) (1) – (2) nor- NO Defective travel pressure
mal and are they insulated from chassis Replace
tral: Min. 1 Mz switch
ground?
• Move travel lever: Max. 1 z
• See note.
YES
2
• Disconnect M95 and M25. Is resistance between M95 (Female) (15) – M25 tact, or short circuit with chas-
NO
YES
3
• Disconnect M95, M22 and M23. Is resistance between M22 (female) (1) and NO contact in wiring harness
chassis ground and between M23 (female) (1) Repair or replace
• Max. 1 z and chassis ground normal? between M25 (Female) (1) –
chassis ground
YES
– chassis ground.
• If 20 – 30 V : Go to YES.
• If below 1 V: Go to NO.
PC78US-6 20-405
(12)
TROUBLESHOOTING F-3
F-3 Bit pattern 1023-(6) Boom RAISE pressure switch does not light up
PC78US-6 Serial No.: 4001 – 6500
k
When measuring while the engine is running,
move each lever to the degree that the work equip-
ment will not move.
Cause Remedy
1
• Start engine.
• Set boom control lever in neu-
tral: 20 – 30 V normal?
• Move boom control lever to
lower boom: Max. 1 V
YES
Defective governor or pump Replace
controller
• Start engine.
• Set boom control lever in neu- Is resistance between M21 (Male) (1) – (2) nor- NO Defective boom RAISE pres-
sure switch
• Move boom control lever to ground?
lower boom: Max. 1 z
• See note. YES
3 Disconnection, defective con-

• Turn starting switch OFF. tact, or short circuit with chas-
• Disconnect M95 – M21. Is resistance between M95 (Female) (12) – M21 sis ground in wiring harness
NO between M95 (Female) (12) –
• Between M95 – M21: Max. 1 z (Female) (2) normal and are they insulated from Repair or replace
• Between wiring harness – chas- chassis ground? M21 (Female) (2)
sis ground: Min. 1 Mz
YES
between M21 (Female) (1) –
chassis ground
– chassis ground.
• If 20 – 30 V : Go to YES
• If below 1 V : Go to NO
20-406 PC78US-6
(12)
TROUBLESHOOTING F-3
k
ment will not move.
Cause Remedy
1
• Disconnect M95, M21. Is resistance between M21 (Female) (1) – chas- NO contact in wiring harness Repair or replace
• Max. 1 z sis ground normal? between M21 (Female) (1) –
chassis ground
YES
• Start engine.
• Set boom control lever in neu- Is resistance between M21 (Male) (1) – (2) nor- NO Defective boom RAISE pres-
sure switch
• Move boom control lever to ground?
lower boom: Max. 1 z
• See note. YES
3
• Disconnect M95 – M21. Is resistance between M95 (Female) (35) – M21 tact, or short circuit with chas-
NO
YES
Defective controller Repair or replace
– chassis ground.
• If 20 – 30 V : Go to YES
• If below 1 V: Go to NO
PC78US-6 20-407
(12)
TROUBLESHOOTING F-4
F-4 Bit pattern 1023-(5) Arm IN pressure switch does not light up
PC78US-6 Serial No.: 4001 – 6500
k
ment will not move.
Cause Remedy
1
• Start engine.
• Set arm control lever in neutral:
20 – 30 V normal?
• Move arm control lever to move
arm in: Max. 1 V
YES
controller
• Start engine.
• Set arm control lever in neutral: Is resistance between M24 (Male) (1) – (2) nor- NO Defective arm IN pressure
Min. 1 Mz mal and are they insulated from chassis Replace
switch
• Move arm control lever to move ground?
arm in: Max. 1 z
• See note. YES

• Disconnect M95 – M24. tact, or short circuit with chas-
• Between M95 and M24: Is resistance between M95 (Female) (6) – M24 NO sis ground in wiring harness
(Female) (2) normal and are they insulated from Repair or replace
Max. 1 z chassis ground? between M95 (Female) (6) –
• Between wiring harness – chas- M24 (Female) (2)
YES
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
20-408 PC78US-6
(12)
TROUBLESHOOTING F-4
k
ment will not move.
Cause Remedy
1
• Disconnect M95, M24. Is resistance between M24 (Female) (1) – chas- NO contact in wiring harness Repair or replace
• Max. 1 z sis ground normal? between M24 (Female) (1) –
chassis ground
YES
• Start engine.
• Set arm control lever in neutral: Is resistance between M24 (Male) (1) – (2) nor- NO Defective arm IN pressure
Min. 1 Mz mal and are they insulated from chassis Replace
switch
• Move arm control lever to move ground?
arm in: Max. 1 z
• See note. YES

• Disconnect M95 – M24. tact, or short circuit with chas-
• Between M95 and M24: Is resistance between M95 (Female) (26) – M24 NO sis ground in wiring harness
(Female) (2) normal and are they insulated from Repair or replace
Max. 1 z chassis ground? between M95 (Female) (26) –
• Between wiring harness – chas- M24 (Female) (2)
YES
chassis ground
– chassis ground.
• If 20 – 30 V : Go to YES
• If below 1 V: Go to NO
PC78US-6 20-409
(12)
TROUBLESHOOTING F-5
F-5 Bit pattern 1026-(1) Deceleration switch of left knob does not light up
PC78US-6 Serial No.: 4001 – 6500
a Check that fuse (11) is normal.
Cause Remedy
1
• Turn knob switch ON: 20 – 30 V Is voltage between M97 (9) – chassis ground NO
• Turn knob switch OFF: normal?
Max. 1 V
YES
controller
2
• Turn starting switch ON. Is voltage between K18 (Male) (2) – chassis NO contact in wiring harness Repair or replace
• 20 – 30 V ground normal? between fuse (11) – K18 (1) –
knob switch inlet
YES

• Disconnect knob switch
terminal K18. Is resistance between K18 (Male) (1) – (2) nor- NO Defective left knob switch Replace
• Turn knob switch ON: Max. 1z mal?
• Turn knob switch OFF:
Min. 1 Mz
YES
between K18 (2) – M97
(Female) (9)
20-410 PC78US-6
(12)
TROUBLESHOOTING F-5

a Check that fuse (11) is normal.
Cause Remedy
1
• Disconnect M95.
Is resistance between M95 (34) and chassis NO
• Turn knob switch ON: Max. 1 z ground normal?
Min. 1 Mz
YES
Defective engine throttle and Replace
pump controller
2

• Disconnect knob switch terminal
K18. Is resistance between K18 (male) (1) and (2) NO Defective left knob switch Replace
• Turn knob switch ON: Max. 1 z normal?
Min. 1 Mz
YES
• Turn starting switch OFF. Disconnection or defective

Is resistance between K18 (1) and chassis NO contact in wiring harness
• Disconnect M95 and K18. ground normal? Repair or replace
between K18 (female) (1) –
• Max. 1 z chassis ground
YES
between M95 (female) (34) –
K18 (female) (2)
PC78US-6 20-411
(12)
TROUBLESHOOTING F-6
F-6 Bit pattern 1026-(4) 2nd travel speed selection switch (pedal) does not
light up (US with blade specification and UU)
PC78US-6 Serial No.: 4001 – 6500
(PC78UU-6 serial No. 6501 and up, are not equipped with this switch.)
Cause Remedy

• Disconnect 2nd travel speed
selection switch terminal K3.
NO Defective 2nd travel speed
• Turn 2nd travel speed selection Is resistance between K3 (Male) (1) – (2) normal? Replace
selection switch (pedal)
switch ON: Max. 1 z
• Turn 2nd travel speed selection
switch OFF: Min. 1 Mz YES
2
• Disconnect M95 and K3. Is resistance between K3 (Female) (2) – M95 tact, or short circuit with chas-
NO
• Between M95 – K3: Max. 1 z (Female) (5) normal and are they insulated from sis ground in wiring harness Repair or replace
sis ground: Min. 1 Mz K3 (Female) (2)
YES
• Turn starting switch ON. Disconnection or defective

Is voltage between M95 (Female) (5) – chassis NO contact in wiring harness
• Turn 2nd travel speed selection Repair or replace
ground normal? between K3 (Female) (1) –
switch ON: Max. 1 V chassis ground
YES
20-412 PC78US-6
(12)
TROUBLESHOOTING F-7
F-7 Bit pattern 1021-(3) Compressor signal does not light up

PC78US-6 Serial No.: 4001 – 6500
a Before starting measurement, check that the compressor operates normally when the air conditioner is
turned ON.
Cause Remedy

• When compressor operates Disconnection, defective con-
(= Just after air conditioner is Is voltage between M97 (Female) (10) – chassis NO tact, or short circuit with chas-
sis ground in wiring harness Repair or replace
turned ON): 20 – 30 V ground normal?
• When compressor stops K11 (Female) (8)
(= After air conditioner is turned YES
off): Max. 1 V
PC78US-6 20-413
(12)
TROUBLESHOOTING F-7

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

• When compressor operates Disconnection, defective con-
(= Just after air conditioner is Is voltage between M95 (Female) (37) – chassis NO tact, or short circuit with chas-
sis ground in wiring harness Repair or replace
turned ON): 20 – 30 V ground normal?
• When compressor stops K11 (Female) (8)
(= After air conditioner is turned YES
off): Max. 1 V
20-414 PC78US-6
(12)
TROUBLESHOOTING F-8
F-8 Bit pattern 1026-(3) Emergency work equipment operation switch

does not light up
(Only PC78UU-6)
a Before measuring, check that the work equipment moves normally when the emergency work equipment
operation switch is turned ON (the lever is raised).
a Before measuring, check that fuse (2) is normal.
Cause Remedy

• Disconnect terminals T21 and 1
T22.
• When emergency work Is resistance between T21 and T22 normal and NO Defective emergency work Replace
equipment operation switch is are they insulated from chassis ground? equipment operation switch
turned ON (lever is raised):
Max. 1 z YES
• When emergency work
equipment operation switch is
turned OFF (lever is lowered):
Min. 1 Mz

Is resistance between T21 and M97 (female) NO contact in wiring harness
• Disconnect M97 and T21. Repair or replace
(30) normal? between T21 – M97 (female)
• Resistance: Max. 1 z (30)
YES
• Turn starting switch ON. 3

• Release PPC lock lever. Disconnection, defective con-
• Disconnect M97. Is voltage between M97 (female) (30) and chas- NO tact, or grounding fault in wir- Repair or replace
• When emergency work equip- sis ground normal? ing harness between T22 –
ment operation switch is turned fuse (2)
ON (lever is raised): 20 – 30 V
YES
PC78US-6 20-415
(12)
TROUBLESHOOTING FOR HYDRAULIC AND
MECHANICAL SYSTEMS
(H MODE)
Table of hydraulic failure modes and causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428

H-1 Speed or power of 2 or more systems of work equipment (boom, arm, bucket), travel, swing,
and blade is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
a) Speed or power of all work equipment (including blade), travel, and swing is low. . . . . . . 20-430
b) Speed or power of all work equipment (excluding blade) and travel is low . . . . . . . . . . . . . 20-431
c) Speed or power of swing and blade is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
d) Speed or power of travel and blade is low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
e) Speed or power of all work equipment (excluding blade) is low . . . . . . . . . . . . . . . . . . . . . . 20-432
f) Speed or power of travel and swing is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-433
g) Speed or power of all work equipment and swing is low. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-433
H-2 Engine speed lowers extremely or engine stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
H-3 2 or more systems of work equipment (boom, arm, bucket), travel, swing, and blade do not
move. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
a) All work equipment (including blade), travel, and swing systems do not move . . . . . . . . . 20-436
b) All work equipment (excluding blade) and travel systems do not move . . . . . . . . . . . . . . . 20-437
c) Swing and blade systems do not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-437
d) Travel and blade systems do not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438
e) All work equipment (excluding blade) does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438
H-4 Abnormal sound comes out (from around pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439
H-5 Fine controllability or response is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
H-6 Hydraulic drift is large (all work equipment and blade). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-441
H-7 Boom speed or power is low (other work equipment is normal) . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
a) Boom RAISE speed or power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
b) Boom LOWER speed or power is low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-443
H-8 Arm speed or power is low (other work equipment is normal) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444
a) Arm IN speed or power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444
b) Arm OUT speed or power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445
H-9 Bucket speed or power is low (other work equipment is normal) . . . . . . . . . . . . . . . . . . . . . . . . 20-446
a) Bucket CURL speed or power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
b) Bucket DUMP speed or power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-447
H-10 Offset speed or power is low (other work equipment is normal) (Only PC78UU-6) . . . . . . . . 20-447-1
a) Offset left speed or power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-447-1
b) Offset right speed or power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-447-2
H-11 Boom does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
a) Boom does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
b) Boom does not lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-449
H-12 Arm does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
a) Arm does not move in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
b) Arm does not move out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-451
H-13 Bucket does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
a) Bucket does not curl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
b) Bucket does not dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-453
H-14 Offset boom does not move (Only PC78UU-6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-453-1
a) Offset boom left does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-453-1
b) Offset boom right does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-453-2
H-15 Hydraulic drift of boom is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
H-16 Hydraulic drift of arm is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
H-17 Hydraulic drift of bucket is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
H-18 Hydraulic drift of offset is large (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
a) Hydraulic drift of offset to left is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
b) Hydraulic drift of offset to right is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
H-19 Time lage is large (engine speed is low). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
H-20 Part loaded more moves slower in compound operation of work equipment . . . . . . . . . . . . . . 20-456
H-21 Boom RAISE speed is low in compound operation of swing and boom RAISE . . . . . . . . . . . . . 20-457
PC78US-6 20-425
➄
H-22 Travel speed lowers extremely in compound operation of travel and boom RAISE . . . . . . . . . 20-457
H-23 Speed is low in compound operation of work equipment relief and swing,
work equipment relief and work equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-457
H-24 Work equipment does not move or its speed is low in compound operation of
travel and work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
H-25 Travel deviation is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-459
a) Travel deviation is large during ordinary travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-459
b) Travel deviation is large when machine starts (but during normal ordinary travel) . . . . . . 20-460
H-26 Travel deviation is large in compound operation of travel and swing, travel and work
equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-461
H-27 Travel speed or power is low (work equipment, swing, and blade operations are normal) . . . 20-462
H-28 Machine cannot be steered sharply or steering force is insufficient . . . . . . . . . . . . . . . . . . . . . . 20-464
H-29 Travel speed does not change at all or does not change quickly . . . . . . . . . . . . . . . . . . . . . . . . . 20-465
H-30 Machine does not travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
H-30 Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-467
H-31 Overrun of travel is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-468
H-32 Travel hydraulic drift is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-468
H-33 Fine controllability or response is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-469
H-34 Swing speed or power is low (work equipment, travel, and blade operations are normal) . . . 20-470
H-35 Machine does not swing (work equipment, travel, and blade operations are normal) . . . . . . . 20-473
a) Swing speed or power is low in both directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-473
b) Swing speed or power is low in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474
H-36 Swing acceleration is low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-475
a) Swing acceleration is low in both directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-475
b) Swing acceleration is low in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-475
H-37 Overrun of swing is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-476
a) Overrun of swing is large in both directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-476
b) Overrun of swing is large in either direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-476
H-38 Large shock is made when machine stops swinging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-477
H-39 Large abnormal sound is made when machine stops swinging . . . . . . . . . . . . . . . . . . . . . . . . . 20-477
H-40 Swing hydraulic drift is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-478
H-41 Fine controllability more response of swing is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-479
H-42 Blade speed or power is low (work equipment, travel, and swing operations are normal) . . . . 20-480
H-43 Blade does not move (work equipment, travel, and swing operations are normal) . . . . . . . . . . 20-481
a) Blade does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-481
b) Blade does not lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-482
H-44 Hydraulic drift of blade is large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-483
H-45 Fine controllability or response of blade is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-484
H-46 Monitor panel displays error code and boom RAISE, arm IN, and offset LEFT
operations stop just before interference (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-485
H-47 Machine does not stop boom RAISE, arm IN, and offset LEFT operations automatically
but interferes (Only PC78UU-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-485
20-426 PC78US-6
➄
TROUBLESHOOTING TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES

C78UU, PC78US-6
Part Which May Cause Trouble Tank Hydraulic Pump Control Valve
Main relief circuit check valve

Pressure compensation valve
LS bypass choke
Main relief valve

Engine system
Control pump
LS line choke
Unload valve
Hydraulic oil
Merge valve
Servo valve
Gear pump
Logic valve
Pilot pump
PTO spline
EPC valve
PC valve
LS valve
Strainer
Orifice
Spool
Cap
Failure mode
For only standard specification (Without blade)

PC78US-6
Machine model Blade specification ●
PC78UU-6 For only standard specification ●
Failure mode
Speed or power of 2 or more systems or work equipment, travel, ● ● ● ● ● ● ● ● ● ●
and blade is low
Engine speed lowers extremely or engine stalls ● ● ● ● ● ● ●
All work equip- 2 or more systems of work equipment, travel, swing, and blade
ment, travel, ● ● ● ● ● ● ● ●
do not move
swing, blade
Abnormal sound comes out (From around pump) ● ● ● ● ● ●
Fine controllability or response is low ● ● ● ● ● ● ●
Hydraulic drift is large (All work equipment and blade)
Boom ● ●
Speed or
power of Arm ● ●
work equip- Bucket ● ●
ment is low
Offset (Only UU) ● ●
Boom ● ●
Work equip- Arm ● ●
Work equipment does
not move Bucket ● ●
ment
Offset (Only UU) ● ●
Boom ●
Hydraulic
drift of work Arm ●
equipment is Bucket ●
large
Offset (Only UU) ●
Time lag is large (When engine speed is low) ●
Part loaded more moves slower in compound operation of work
equipment
Boom RAISE speed is low in compound operation of swing and ●
boom RAISE
Compound Travel speed lowers extremely in compound operation of travel
operation and boom RAISE
Speed is low in compound operation of work equipment relief ● ●
and swing, work equipment relief and other work equipment
Work equipment does not move or its speed is low in compound
operation of travel and work equipment
Travel deviation is large ● ● ● ● ● ●
Travel deviation is large in compound operation of travel and ● ●
swing, travel and work equipment
Travel speed or power is low ● ● ● ● ● ●
Machine cannot be steered sharply or steering force is insuffi- ● ● ● ● ● ●
cient
Travel
Travel speed does not change at all or does not change quickly
Machine does not travel ● ● ●
Overrun of travel is large ●
Travel hydraulic drift is large
Fine controllability or response is low ● ● ● ● ●
Swing speed or power is low ● ●
Machine does not swing ● ●
Swing acceleration is low ● ●
Overrun or swing is large
Swing
Large shock is made when machine stops swinging ●
Large abnormal sound is made when machine stops swinging
Swing hydraulic drift is large
Fine controllability or response of swing is low ● ● ●
Blade speed or power is low ●
Blade does not move ●
Blade
Hydraulic drift of blade is large ●
Fine controllability or response of blade is low ●
Monitor panel displays error code [61] and all operations stop
Prevention of just before interference
interference Machine does not stop boom RAISE, arm IN, and LEFT offset
operations automatically but interferes
20-428 PC78US-6
➄
Swing holding brake check
●
●
●
●
●
●
valve (Logic)
●
●
PPC circuit check valve
Travel junction variable throt-
●
●
●
tle valve
PC78US-6
●
Travel LS bleed valve
●
Centralized safety valve
●
●
●
●
●
●
●
●
●
●
●
●
●
Suction valve
● ●
●
Boom lock valve
●
●
LS select valve
Control Valve
● ●
● ●
● ● ● ●
Boom assist valve
TROUBLESHOOTING
●
●
● ● ●
Gear pump circuit relief valve
●
●
●
●
● ● ●
● ● ●
Blade safety valve
●
●
Pressure release valve
●
●
●
●
Back pressure valve
●
●
Swing PPC slow return valve
● ●
● ●
● ●
● ●
● ●
Swing PPC line choke
● ●
●
2nd travel speed selection choke
●
●
●
PPC valve (Right lever) 1 ~ 0
●
●
●
●
●
●
●
●
PPC valve (Left lever) 1 ~ 0
●
●
●
●
●
●
PPC valve (Travel lever)
PPC Valve
●
PPC valve (Blade bar)
●

PPC main pressure lock sole-
●
●
●
noid
2nd travel speed selection
●
solenoid
valve
Solenoid Valve
Swing holding brake solenoid
●
●
valve
Piston motor
●
Safety valve
● ● ●
● ● ●
Check valve
● ● ●
● ● ● ●
Suction valve
● ● ● ● ●
● ● ● ● ●
Parking brake
Swing Motor
● ●
●
● ● ● ● ● ●
● ● ● ● ● ●
Reaction prevention valve
●
●
Swing machinery
●
●
●
Center swivel joint
●
●
●
●
● ●
Piston motor
● ●
●
Counterbalance valve
● ● ●
● ● ●
● ● ● ●
● ● ● ●
Check valve
2nd speed select valve and
●
piston
Parking brake
Travel Motor
● ●
● ●
Parking brake valve
● ● ●
● ● ●
● ● ●
Final drive
●
●
●
●
●
●
●
●
●
●
Hydraulic cylinder
●
●
●
●
●
PPC pressure switch
● ●
●
● ● ●
● ● ●
●
Emergency pump drive switch

H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-47
H-46
H-45
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
mode
Failure
➄
20-429
TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES
TROUBLESHOOTING H-1
H-1 Speed or power of 2 or more systems of work equipment (boom,

arm, bucket), travel, swing, and blade is low
★ Before carrying out troubleshooting, check that the oil level in the tank is proper.
★ If the engine speed lowers, carry out H-2 first.
★ If "individual factor" is indicated, a trouble which occurs less frequently than the detected trouble may
have occurred or several troubles may be combined. Accordingly, carry out troubleshooting for each of
those troubles.
★ Select a combination of systems which have low speed or power from Table 1 before going to the next
troubleshooting.
★ If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators
of each system "which has low speed or power" (H-7 ~ H-10).
! : Normal ! : Normal
Table 1 PC78US-6 without blade Table 2 PC78US-6, PC78UU-6 with blade
✕ : Speed or power is low ✕ : Speed or power is low
Work Diagnosis Work Diagnosis
Travel Swing Travel Swing Blade
Equipment Item Equipment Item
✕ ✕ ✕ Go to a ✕ ✕ ✕ ✕ Go to a
✕ ✕ ! Go to b ✕ ✕ ! ! Go to b
✕ ! ✕ Go to g ! ! ✕ ✕ Go to c
! ✕ ✕ Go to f ! ✕ ! ✕ Go to d
✕ ! ! Go to e ✕ ! ! ! Go to e
! ✕ ✕ ! Go to f
a) Speed or power of work equipment (including blade), travel, and swing systems is low
Cause Remedy
NO
Is suction strainer clogged?
YES Clogged suction strainer Clean or replace

(Defective suction by pump)
2 NO
• 3.14 ± 0.3 MPa {32 ± 3 kg/cm } Is output pressure of PPC main pressure lock sole-
• Run engine at full throttle noid valve normal?
YES
Go to H-1, b) —
NO
When control relief valve is adjusted, is trouble
repaired?
YES Defective adjustment of con- Adjust

trol valve
NO
When PPC lock solenoid valve is replaced, is trou- Defective pump control Replace
ble repaired?
YES Defective PPC main pressure Replace

lock solenoid
20-430 PC78US-6
➄
TROUBLESHOOTING H-1
b) Speed or power of all work equipment (excluding blade) and travel is low
Cause Remedy
1
• Curl bucket NO
26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is work equipment relief pressure normal?
YES
2
• Curl bucket NO Go to corresponding section in
26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is travel relief pressure normal? H-7 ~ 10, 27 —
YES
NO Defective main pump (Lower-

Does machine have blade specification? Repair or replace
ing of volumetric efficiency)
YES
NO
When blade is relieved in RAISE mode, does Defective main pump (Lower- Repair or replace
the travel speed rise? ing of volumetric efficiency)
YES
Defective boom assist valve Repair or replace
5
• Curl bucket NO
26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is travel relief pressure normal?
YES Go to corresponding section in —
H-7 ~ 10, 27
NO
When travel relief valve is adjusted or replaced,
is trouble repaired?
YES
Defective main relief valve Repair or replace
NO
Does unload valve move smoothly? Defective unload valve Repair or replace
YES
Go to diagnosis No. 3 Repair or replace
c) Speed or power of swing and blade is low
Cause Remedy
1
• Lower blade NO
21.08 ± 1.47 MPa {215 ± 15 kg/cm2} Is gear pump relief pressure normal?
H-27, 34
NO
When gear pump relief valve is adjusted or Defective gear pump Repair or replace
replaced, is trouble repaired?
YES Defective gear pump relief Adjust or replace

pressure
PC78US-6 20-431
b
TROUBLESHOOTING H-1
d) Speed or power of travel and blade is low
Cause Remedy
1
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is travel relief pressure normal?
YES Go to corresponding section —

H-27, 42
NO
• 21.08 ± 1.47 MPa {215 ± 15 kg/cm2} Is blade LOWER relief pressure normal?

H-27, 42
NO
When hose is disconnected from valve outlet and Go to corresponding section —
plugged, is relief pressure normal? H-27, 42
YES
Defective swivel joint Repair or replace
e) Speed or power of all work equipment (excluding blade) is low
Cause Remedy
NO
Is all PPC pressure normal (At PPC pressure inlet of
control valve?
YES
• 2.11 ± 0.1 MPa {21.5 ± 1 kg/cm2}

Defective adjustment of pump
• Run engine at full throttle and curl Is LS differential pressure normal? Adjust
LS valve
bucket NO
YES
NO
When compound operation of travel, work equip- Go to corresponding section in —
ment, and swing is performed, is trouble repaired? H-7 ~10
YES Defective travel pressure com-

pensation valve
NO
Is PPC pressure normal at only 1 place (When sin-
gle operation is performed)?
YES Defective check valve in PPC

circuit having normal PPC Replace
pressure
NO Leakage of PPC pressure

Is check valve at swing holding brake pressure caused by defective ball check
inlet of logic valve normal? valve

H-7 ~ 10
20-432 PC78US-6
b
TROUBLESHOOTING H-1
f) Speed or power of travel and swing is low

Carry out the troubleshooting in b) above.
★ If the PPC main pressure is judged low by troubleshooting in b) above, this trouble can occur.
g) Speed or power of all work equipment and swing is low

★ Carry out the following troubleshooting for only PC78US-6 which does not have a blade.
Cause Remedy
1
• 2.11 ± 0.1 MPa {21.5 ± 1 kg/cm2} NO Defective adjustment of pump
• Run engine at full throttle and curl Is LS differential pressure normal? Adjust
LS valve
bucket
YES
When compound operation of travel and work NO Go to corresponding section in

equipment, and swing is performed, is trouble —
H-7 ~ 10, H-34
repaired?
YES Defective travel pressure com- Replace

pensation valve
PC78US-6 20-433
b
TROUBLESHOOTING H-2
H-2 Engine speed lowers extremely or engine stalls
Cause Remedy
When bucket is relieved in CURL mode NO

and blade is relieved in RAISE mode, does
engine speed lower much?
YES
When blade is relieved in RAISE mode or NO

swing is relieved and work equipment is
operated without relieving simulta-
neously, does engine speed lower much?
YES
Execute diagnosis No. 4
3
NO
• 26.5 ± 1.45 MPa {270 ± 15 kg/cm2} Is bucket CURL relief pressure normal?
YES
NO
• 12.74 ± 1.47 MPa {130 ± 15 kg/cm2} Is blade RAISE relief pressure normal?
YES
When gear pump circuit relief valve is NO

adjusted, repaired, or replaced, is trouble
repaired?
YES Defective gear pump circuit Adjust or replace

relief valve
NO
When main relief valve is replaced, is trou-
ble repaired?
YES
Defective main relief valve Repair or replace
NO
Does monitor display error code "E02" of
TVC trouble?
YES
NO
Is TVC connector connected? Defective connection Repair
YES Defective TVC-EPC valve Replace

(Defective solenoid)
NO
When engine speed changes, does TVC Defective controller Repair or replace
current change?
YES
To next page
20-434 PC78US-6
b
TROUBLESHOOTING H-2
Cause Remedy
From previous page
10
2} NO
• 0.54 ~ 0.83 MPa {5.5 ~ 8.5 kg/cm Is output voltage of TVC-EPC solenoid nor-
• Run engine at full throttle mal?
YES
11
NO
When PC valve is adjusted, is trouble
repaired?
YES
Defective PC valve Adjust or replace
12
NO
When orifice of servo is cleaned, is trouble
repaired?
YES
Clogged orifice
13
NO
When EPC valve of TVC is replaced, is Execute diagnosis No. 11 —
trouble repaired?
YES
Defective EPC valve Repair or replace
14
NO
When pump assembly is replaced, is trou- Defective engine system —
ble repaired?
YES
Defective pump or servo Repair or replace
PC78US-6 20-435
➀
TROUBLESHOOTING H-3
H-3 2 or more systems of work equipment (boom, arm, bucket), travel,

swing, and blade do not move
★ Before carrying out troubleshooting, check that the oil level in the tank is proper.
★ Select a combination of systems which do not move from Table 1 before going to the next trouble-
shooting.
★ If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators
of each system "which does not move" (H-10 ~ 13).
! : Normal ! : Normal
Table 1 PC78US-6 without blade Table 2 PC78US-6, PC78UU-6 with blade
✕ : Speed or power is low ✕ : Speed or power is low
Work Diagnosis Work Diagnosis
Travel Swing Travel Swing Blade
Equipment Item Equipment Item
✕ ✕ ✕ Go to a ✕ ✕ ✕ ✕ Go to a
✕ ✕ ! Go to b ✕ ✕ ! ! Go to b
✕ ! ✕ Go to diagnosis ! ! ✕ ✕ Go to c
! ✕ ✕ of each system ! ✕ ! ✕ Go to d
✕ ! ! Go to e ✕ ! ! ! Go to e
! ✕ ✕ ! Go to f
a) All work equipment (including blade), travel, and swing systems do not move
Cause Remedy
NO
When engine is cranked, does oil flow out
of pump?
YES
When oil does not flow out of any of fol-

lowing pumps
• Main pump
• Gear pump
• Control pump
YES
NO
Is suction strainer clogged?
YES
Clogged suction strainer Clean or adjust
NO
Is damper or spline damaged? Defective main pump shaft Replace
YES
Defective damper or spline Replace
When oil flows out of main pump but does NO

not flow out of gear pump and control
pump.
YES
NO
Is coupling or spline between main pump Defective gear pump Replace
and gear pump damaged?
YES
Defective coupling or spline Replace
To item No. 5 on next page
20-436 PC78US-6
➄
TROUBLESHOOTING H-3
Cause Remedy
From item 3 on previous page
NO
When engine is cranked, does oil flow out of con- Defective control pump Repair or replace
trol pump?
YES
2} NO Defective PPC main pressure

• 3.14 ± 0.3 MPa {32 ± 3 kg/cm Is output pressure of PPC main pressure lock sole- lock solenoid valve or defec- Repair or replace
• Run engine at full throttle noid valve normal? tive electric system

H-10 ~ 12, 27, 32, 40
b) All work equipment (excluding blade) and travel systems do not move
Cause Remedy
NO
When engine is cranked, does oil flow out of con- Defective control Repair or replace
trol?
YES
NO Defective PPC main pressure

• 3.14 ± 0.3 MPa {32 ± 3 kg/cm2} Is output pressure of PPC main pressure lock sole- lock solenoid valve or defec- Repair or replace
• Run engine at full throttle noid valve normal? tive electric system
YES
NO
Is only 1 part of each of work equipment and travel Go to corresponding section in Repair or replace
normal? H-10 ~ 12, 27
YES Defective check valve in PPC Repair or replace

circuit having normal pressure
c) Swing and blade systems do not move

★ PC78US-6 with blade
PC78UU-6
Cause Remedy
NO
When engine is cranked, does oil flow out of Defective control pump Repair or replace
pump?
YES
NO
When gear pump circuit relief valve is adjusted or Go to corresponding section in —
replaced, is trouble repaired? H-32, 40
YES Defective gear pump circuit Adjust or replace

relief valve
PC78US-6 20-437
➄
TROUBLESHOOTING H-3
d) Travel and blade systems do not move
Cause Remedy
1
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is travel relief pressure normal?

H-27
NO
• 21.08 ± 1.47 MPa {215 ± 15 kg/cm2} Is blade relief pressure normal?

H-40
NO
When hose is disconnected from valve outlet and Go to corresponding section —
plugged, is relief pressure normal? H-27, 40
YES
Defective swivel joint Repair or replace
e) All work equipment (excluding blade) does not move
Cause Remedy
NO
• 3.14 ± 0.5 MPa {32 ± 5 kg/cm2} Are all PPC pressures normal (At connected
• Run engine at full throttle PPC pressure inlets)?

H-10 ~ 12
NO Go to corresponding section in
Is only 1 place normal? —
H-10 ~ 12
YES Defective check valve in PPC Replace

circuit having normal pressure
Note: If machine is equipped with an attach-

ment, check that attachment.
20-438 PC78US-6
➃
TROUBLESHOOTING H-4
H-4 Abnormal sound comes out (from around pump)
Cause Remedy
NO
Is oil level in hydraulic tank normal? Low hydraulic oil level Supply hydraulic oil
YES
NO
Are there bubbles in hydraulic tank?
YES
NO
When engine is stopped, do bubbles in tank disap- Low hydraulic oil level —
pear?
YES
Go to diagnosis No. 4
NO
Foreign matter: Cloth, etc. Is suction strainer clogged with foreign matter?
YES Foreign matter (Cloth, etc.) Remove

clogging suction strainer
NO
Is suction strainer clotted with metallic foreign
matter or metal chips?
YES
Defective inside pump Repair or replace
NO Re-inspect (accord-
Operate machine and observe
Is hydraulic tank cap clogged? ing to change of con-
condition for a while dition)
YES Negative pressure caused by Clean or replace cap

clogging of cap
PC78US-6 20-439
b
TROUBLESHOOTING H-5
H-5 Fine controllability or response is low

(Two or more systems have low fine controllability or response simultaneously)
★ The following troubleshooting is not applicable to travel, swing, and blade systems.
Cause Remedy
• See TESTING AND ADJUST- NO

Is LS differential pressure normal?
ING
YES
NO
Is LS line choke clogged?
YES
Clogging of LS line choke Clean or replace
NO
Is orifice of unload valve clogged?
YES Clogging of orifice of unload Clean

valve
NO Defective PC valve or servo

Is orifice of piston pump clogged? Repair or replace
piston
YES Clogging of orifice or piston Clean

pump
NO
When LS valve is adjusted, is trouble repaired? Defective LS valve Repair or replace
YES Defective adjustment of LS Adjust

valve
20-440 PC78US-6
b
TROUBLESHOOTING H-6
H-6 Hydraulic drift is large (all work equipment and blade)

★ Before carrying out troubleshooting, check that oil level in the tank is proper.
Cause Remedy
NO Leakage through pressure

Is pressure release plug of control valve tightened? Retighten
release circuit
YES
NO
Is seal of pressure release plug broken?
YES Leakage through pressure —

release circuit
NO
When centralized safety valve is replaced, is trou- Go to corresponding section in
ble repaired? H-15 ~ H-18
YES Defective concentrated safety Clean

valve
PC78US-6 20-441
➀
TROUBLESHOOTING H-7
H-7 Boom speed or power is low (other work equipment is normal)

a) Boom RAISE speed or power is low
★ When measuring the boom RAISE relief pressure, reset the interference prevention (Only PC78UU-6).
★ When the boom speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the
relief pressure and carry out troubleshooting No. 2.
★ Check that the emergency pump drive switch is turned OFF.
Cause Remedy
1
• Run engine at full throttle and set
boom in neutral: 410 mA NO
When boom is raised in monitoring mode 1050, Diagnose by F-3
• Run engine at full throttle and does current lower?
raise boom: 100 mA
YES
2} NO
• 0.54 ~ 0.83 MPa {5.5 ± 8.5 kg/cm Is output pressure of pump TVC-EPC solenoid Defective pump TVC- Replace
• Run engine at full throttle normal? EPC solenoid
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is boom relief pressure normal?
YES
Only UU 4
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2 } Is EPC valve output pressure normal?
• Run engine at full throttle (PPC pressure inlet of control valve)
YES
NO Defective operation of
Does control valve spool move smoothly? control valve spool or Repair or replace
EPC valve spool
YES
Does pressure compensation valve move pressure compensa-
smoothly? tion valve
YES
2 NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm } Defective centralized
Is boom LOWER relief pressure normal? Replace
• Run engine at full throttle safety valve
YES Defective suction

valve (Boom LOWER Repair or replace
side)
NO
When pilot hose of boom assist valve is discon-
nected, does speed rise?
YES Defective seat of

check valve of boom Repair or replace
assist valve
NO
(Move boom RAISE with arm IN When PPC hose is replaced with arm IN hose on Go to diagnosis No. 3 —
oil.) control valve side, is trouble repaired?
YES
10
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2}
NO
• Run engine at full throttle Defective boom
Is PPC valve output pressure normal? Repair or replace
• Measure at PPC pressure inlet of RAISE PPC valve
control valve
YES Defective boom cylin- Repair or replace
der packing
20-442 PC78US-6
➄
TROUBLESHOOTING H-7
b) Boom LOWER speed or power is low

★ When the boom speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the
Cause Remedy
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is boom LOWER relief pressure normal?
YES
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is PPC valve output pressure normal? (At control
• Run engine at full throttle valve PPC pressure inlet)
YES
NO Malfunction of con-
Does control valve spool move smoothly? trol valve spool or Repair or replace
EPC valve spool
YES
Does poppet of pilot piston of boom lock valve NO Malfunction of lock Repair, clean, or
move smoothly and its orifice free from clog- valve replace
ging?
YES
Malfunction of spool Check 3 again
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is boom RAISE relief pressure normal? Defective concen- Replace
• Run engine at full throttle trated safety valve

valve (Boom LOWER Repair or replace
side)
When PPC hose of control valve is replaced with NO

(Move boom LOWER with arm OUT arm DUMP, is trouble repaired? (Return it imme- Go to diagnosis No. 3 —
oil.) diately after testing.)
YES Defective boom Repair or replace

LOWER PPC valve
PC78US-6 20-443
➃
TROUBLESHOOTING H-8
H-8 Arm speed or power is low (Other work equipment is normal)

a) Arm IN speed or power is low
★ When measuring the arm IN relief pressure, reset the interference prevention (Only PC78UU-6).
★ When the arm speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
pressure and carry out troubleshooting No. 2.
Cause Remedy
1
• Run engine at full throttle and set
NO
arm in neutral: 410 mA When arm is moved IN in monitoring mode 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 {5.5 ~ 8.5 kg/cm2} Is output pressure of pump TVC-EPC solenoid NO Defective pump TVC-EPC Replace
• Run engine at full throttle. normal? solenoid
YES
3
• 26.5 ± 1.49 MPa NO

{270 ± 15 kg/cm2} Is arm IN relief pressure normal?
• Run engine at full throttle.
YES
Only UU 4
• 3.14± 0.49 MPa

Is EPC valve output pressure normal?
{32 ± 5 kg/cm2} (PPC pressure inlet of control valve)
YES
5
Does control valve spool move smoothly? control valve spool or Repair or replace
EPC valve spool
YES
6
Does pressure compensation valve move pressure compensation
smoothly? valve
YES
• 26.5 ± 1.47 MPa

NO Defective centralized
{270 ± 15 kg/cm2} Is arm OUT relief pressure normal? safety valve Replace
YES
Defective suction valve Repair or replace
(Boom LOWER side)
When PPC hose is replaced with boom RAISE NO

• (Move arm IN with boom RAISE) hose on control valve side, is trouble repaired?
(Return it immediately after testing.)
YES
When swing operation and arm IN operation are NO

Go to diagnosis No. 3 —
executed simultaneously, is trouble repaired?
YES Defective seats of swing

brake circuit check valve Repair or replace
and swing PPC slow-
return valve
To next page To next page
20-444 PC78US-6
➄
TROUBLESHOOTING H-8
From previous No.8 From previous No.4
Cause Remedy
10
• 3.14 ± 0.49 MPa NO

(32 ± 5 kg/cm2)
Is output pressure of PPC valve nor-
• Run engine at full throttle Defective arm IN PPC valve
mal?
• Measure at PPC pressure
inlet of control vaolve
YES
Repair or
Defective arm IN PPC valve replace
PC78US-6 20-444-1
➄
TROUBLESHOOTING H-8
b) Arm OUT speed or power is low

★ When the arm speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the relief
pressure and carry out troubleshooting No. 2.
Cause Remedy
• 26.5 ± 1.47 MPa NO

{270 ± 15 kg/cm2} Is arm OUT relief pressure normal?
YES
2
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is PPC valve output pressure normal? (At control NO
YES
NO Malfunction of control
Does control valve spool move smoothly? Repair or replace
valve spool
YES
4
Does pressure compensation valve move NO Malfunction of pressure Repair or replace

smoothly? compensation valve
YES
Defective arm cylinder Repair or replace
packing
• 26.5 ± 1.47 MPa

NO Defective concentrated
{270 ± 15 kg/cm2} Is arm OUT relief pressure normal? safety valve Replace
YES
(Arm IN side)
• (Move arm OUT with boom When PPC hose of control valve is replaced with NO
boom LOWER, is trouble repaired? (Return it Go to diagnosis No. 3 —
LOWER oil) immediately after testing.)
YES
Defective arm OUT PPC Repair or replace
valve
PC78US-6 20-445
➃
TROUBLESHOOTING H-9
H-9 Bucket speed or power is low (Other work equipment is nor-

mal)
a) Bucket CURL speed or power is low
★ When the bucket speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the
Cause Remedy
• 26.5 ± 1.47 MPa NO

{270 ± 15 kg/cm2} Is bucket CURL relief pressure normal?
YES
2
• 3.14 ± 0.49 MPa NO

Is PPC valve output pressure normal? (At control
{32 ± 5 kg/cm2} valve PPC pressure inlet)
YES
3
valve spool
YES
4

YES
Defective arm cylinder Repair or replace
packing
• 26.5 ± 1.47 MPa NO Defective concentrated

{270 ± 15 kg/cm2} Is bucket DUMP relief pressure normal? safety valve Replace
YES
(Bucket CURL side)
When PPC hose of control valve is replaced with NO

• (Move bucket CURL with arm IN) arm IN, is trouble repaired? (Return it immedi- Go to diagnosis No. 3 —
ately after testing.)
YES
Defective bucket CURL Repair or replace
PPC valve
20-446 PC78US-6
b
TROUBLESHOOTING H-9
b) Bucket DUMP speed or power is low

★ When the bucket speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the
Cause Remedy
• 26.5 ± 1.47 MPa NO

{270 ± 15 kg/cm2} Is bucket DUMP relief pressure normal?
YES
2
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is PPC valve output pressure normal? (At control NO
YES
3
valve spool
YES
4

YES
Defective bucket cylinder Repair or replace
packing
• 26.5 ± 1.47 MPa

NO Defective concentrated
{270 ± 15 kg/cm2} Is bucket CURL relief pressure normal? safety valve Replace
YES
(Bucket DUMP side)
• (Move bucket DUMP with arm When PPC hose of control valve is replaced with NO
arm OUT, is trouble repaired? (Return it immedi- Go to diagnosis No. 3 —
OUT oil) ately after testing.)
YES
Defective bucket DUMP Repair or replace
PPC valve
PC78US-6 20-447
➀
TROUBLESHOOTING H-10
H-10 Offset speed or power is low (other work equipment is normal)

(Only PC78UU-6)
a) Offset left speed or power is low
★ Relieve the offset left actuator in a position at which the interference prevention system does not detect
the work equipment.
★ When the offset speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the
Cause Remedy
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is offset left relief pressure normal?
YES
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is solenoid valve output pressure normal?
YES
control valve spool
YES
Does pressure compensation valve move pressure compensa- Repair or replace
YES Defective offset cylin- Repair or replace

der packing
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2 } Is offset right relief pressure normal? Defective pressure Repair or replace
• Run engine at full throttle compensation valve
YES Defective packing

seal near extraction Repair or replace
end of offset cylinder
When PPC hose and bucket CURL hose are NO

exchanged at control valve, does condition Go to troubleshooting
(Move offset left by curling bucket) —
become normal? No. 3
(Return hoses immediately after testing.)
YES
NO Defective offset left

PPC valve
Defective offset left Repair or replace

solenoid valve
20-447-1 PC78US-6
➄
b) Offset right speed or power is low

★ When the offset speed is low, if the result of troubleshooting No. 1 is "NO", take actions against the
Cause Remedy
1
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} Is offset right relief pressure normal?
YES
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is PPC valve output pressure normal?
YES
control valve spool
YES
Does pressure compensation valve move pressure compensa- Repair or replace
YES Defective offset cylin- Repair or replace

der packing
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2
} Is offset right relief pressure normal? Defective pressure Repair or replace
• Run engine at full throttle compensation valve

valve Repair or replace
(Right offset side)
When PPC hose and bucket DUMP hose are NO

(Move offset right by dumping exchanged at control valve, does condition Go to troubleshooting —
bucket) become normal? No. 3
YES Defective offset right Repair or replace

PPC valve
PC78US-6 20-447-2
➄
H-11 Boom does not move

★ Carry out the following troubleshooting, if the boom does not move when operated singly (when the
other work equipment is normal).
a) Boom does not rise
Cause Remedy
1
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is PPC valve output pressure normal? (At
• Run engine at full throttle. control valve PPC pressure inlet)
YES
Does boom lower? Repair or replace
valve spool
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When boom is raised, is pump relief pres-
• Run engine at full throttle. sure normal?
Deformation of cylinder
YES or work equipment
(Boom does not rise Repair or replace
above the deformed
part
4
NO Malfunction of spool in
Does spool move smoothly? Repair or replace
raising mode
YES Malfunction of pressure Repair or replace

compensation valve
When PPC hose of control valve is replaced NO

(Move boom lower with arm IN oil) with arm IN, is trouble repaired? (Return it Go to diagnosis No. 2 —
immediately after testing.)
YES
• 3.14 ± 0.49 MPa

Defective boom RAISE
{32 ± 5 kg/cm2} Is PPC valve output pressure normal? PPC valve Repair or replace
Defective boom EPC Repair or replace

valve
20-448 PC78US-6
➄
b) Boom does not lower

H
Cause Remedy
1
NO
• Run engine at full throttle. control valve PPC pressure inlet)
YES
Does boom rise? valve spool or seizure Repair or replace
of lock valve poppet
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When boom is lowered, is pump relief pres-
• Run engine at full throttle. sure normal?
YES
lowering mode

compensation valve

(Move boom lower with arm OUT oil) with arm OUT, is trouble repaired? (Return Go to diagnosis No. 2 —
it immediately after testing.)
YES Defective boom Repair or replace

LOWER PPC valve
NO
Is seal drain line of control valve clogged? Defective lock valve Repair or replace
YES Defective lock valve Repair or replace

caused by clogging
PC78US-6 20-449
➄
H-12 Arm does not move

★ Carry out the following troubleshooting, if the arm does not move when operated singly (when the
a) Arm does not move in
Cause Remedy
US is PPC
UU is EPC 1
NO
• Run engine at full throttle (At control valve PPC pressure inlet.)
YES
Does arm move out? Repair or replace
valve spool
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When arm is moved in, is pump relief pres-
• Run engine at full throttle sure normal?
(Arm does not move Repair or replace
more than deformed
part)
4
IN mode

compensation valve
When PPC hose of control valve is replaced NO Defective arm IN PPC

(Move arm out with boom RAISE oil) with boom RAISE, is trouble repaired? Repair or replace
valve
YES
When swing operation and arm IN operation NO

are executed simultaneously, is trouble Go to diagnosis No. 2 —
repaired?
YES Defective seats of

swing brake circuit Repair or replace
check valve and swing
PPC slow-return valve
7
NO
• 3.14 ± 0.9 MPa {32 ± 5 kg/cm2} Is PPC valve output pressure normal? Defective arm-in PPC Repair or replace
• Run engine at full throttle valve
Defective arm-in EPC Repair or replace

valve
20-450 PC78US-6
➄
b) Arm does not move out
Cause Remedy
1
NO
• Run engine at full throttle control valve PPC pressure inlet)
YES
Does arm move in? Repair or replace
valve spool
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When arm is moved out, is pump relief
• Run engine at full throttle pressure normal?
(Arm does not move Repair or replace
more than deformed
part)
OUT mode

compensation valve
When PPC hose of control valve is replaced NO Defective arm OUT PPC
(Move arm out with boom LOWER oil.) with boom LOWER, is trouble repaired? Repair or replace
valve
YES
PC78US-6 20-451
➃
H-13 Bucket does not move

★ Carry out the following troubleshooting, if the bucket does not move when operated singly (when the
a) Bucket does not curl
Cause Remedy
1
NO
• Run engine at full throttle control valve PPC pressure inlet.)
YES
Is bucket dumped? Repair or replace
valve spool
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When bucket is curled, is pump relief pres-
• Run engine at full throttle sure normal?
(Bucket does not move Repair or replace
more than deformed
part)
4
CURL mode

compensation valve

(Move bucket curl with arm IN oil) with arm IN, is trouble repaired? (Return it Go to diagnosis No. 2 —
immediately after testing.)
YES Defective bucket CURL Repair or replace

PPC valve
20-452 PC78US-6
➄
b) Bucket does not dump
Cause Remedy
1
NO
• Run engine at full throttle control valve PPC pressure inlet)
YES
Is bucket curled? Repair or replace
valve spool
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When bucket is dumped, is pump relief
• Run engine at full throttle pressure normal?
(Bucket does not move Repair or replace
more than deformed
part)
DUMP mode

compensation valve

(Move bucket dump with arm OUT) with arm OUT, is trouble repaired? (Return Go to diagnosis No. 2 —
it immediately after testing.)
YES Defective bucket DUMP Repair or replace

PPC valve
PC78US-6 20-453
➄
H-14 Offset boom does not move

(Only PC78UU-6)
★ Carry out the following troubleshooting when the offset boom does not move when it is operated sin-
gly (and the other work equipment is normal).
a) Offset boom left does not move
Cause Remedy
1
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is solenoid valve output pressure normal?
• Run engine at full throttle. (PPC pressure inlet of control valve)
YES
Does offset boom right move? Repair or replace
control valve spool
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When offset left is operated, is pump relief
• Run engine at full throttle. pressure normal?
YES Deformed cylinder or

work equipment (Work
equipment does not Repair or replace
move over deformed
part)
NO Defective operation of Repair or replace

spool
Does spool move smoothly?
YES Defective operation of

pressure compensa- Repair or replace
tion valve
When PPC hose and bucket CURL hose are NO

(Move offset left by curling bucket) —
YES
NO Defective offset left PPC

valve
YES Defective offset left EPC Repair or replace

valve
20-453-1 PC78US-6
➄
b) Offset boom right does not move
Cause Remedy
1
NO
• Run engine at full throttle. (PPC pressure inlet of control valve)
YES
Does offset boom left move? Repair or replace
control valve spool
YES
NO
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2} When offset right is operated, is pump relief
• Run engine at full throttle. pressure normal?
Deformed cylinder or
YES work equipment (Work
equipment does not Repair or replace
move over deformed
part)
4
spool
YES Defective operation of

pressure compensa- Repair or replace
tion valve
When PPC hose and bucket DUMP hose are NO

(Move offset right by dumping bucket) —
YES Defective offset right Repair or replace

PPC valve
PC78US-6 20-453-2
➄
TROUBLESHOOTING H-15, H-16
H-15 H-16 Hydraulic drift of boom is large
Cause Remedy
NO
Is leakage from hydraulic cylinder nor- Repair or
Defective cylinder piston packing
mal? replace
YES
NO
When centralized safety valve is replaced, Repair or
Defective boom lock valve
is trouble repaired? replace
YES
Defective boom lock valve Replace
H-16 Hydraulic drift of arm is large
Cause Remedy
NO
mal? replace
YES
NO
When centralized safety valve is replaced,
YES
Defective centralized safety valve Replace
NO
When suction valve is replaced with blind Defective oil-tightness of control valve Repair or
plug, is trouble repaired? spool replace
YES
Repair or
Defective centralized safety valve replace
20-454 PC78US-6
➄
TROUBLESHOOTING H-17, H18
H-17 , H-18 Hydraulic drift of bucket is large
Cause Remedy
NO
mal? replace
YES
NO
When centralized safety valve is replaced,
YES
NO
plug, is trouble repaired? spool replace
YES
Repair or
Defective suction valve replace
H-18 Hydraulic drift of offset is large (Only PC78UU-6)

a) Hydraulic drift of offset to left is large
Cause Remedy
NO
mal? replace
YES
NO
plug, does condition become normal? spool replace
YES
Repair or
b) Hydraulic drift of offset to right is large
Cause Remedy
NO
mal? replace
YES
Defective oil-tightness of control valve Repair or
spool replace
PC78US-6 20-455
➄
H-19 -20 Time lag is large (When engine speed is low)

★ Carry out the following troubleshooting, if the work equipment speed is normal.
Cause Remedy
NO
Is suction valve normal (Free from sei- Defective suction valve Replace
zure)?
YES
NO
When poppet and spring of back pressure
valve are replaced, is trouble repaired?
YES
Defective back pressure valve Replace
NO Replace
When LS valve is replaced, is trouble Defective pump servo piston pump assem-
repaired? bly
YES
Defective LS valve Replace
H-20 Part loaded more moves slower in compound operation of work

equipment
Cause Remedy
Defective counterbalance valve on Replace

lighter load side
Compound Operation Heavier Load Lighter Load

Side Side
1 Boom RAISE + Arm IN Boom RAISE Arm IN
2 Boom RAISE + Arm OUT Arm OUT Boom RAISE
3 Boom RAISE + Bucket CURL Boom RAISE Bucket CURL
4 Arm IN + Bucket DUMP Arm OUT Bucket CURL
5 Boom LOWER + Arm OUT Arm OUT Boom LOWER
20-456 PC78US-6
➄
TROUBLESHOOTING H-21, H-22, H-23
H-21 , H-22, Boom RAISE speed is low in compound operation of swing and
H-23 boom RAISE
★ Carry out the following troubleshooting, if the swing operation and boom RAISE operation are normal
when executed singly (Swing LS pressure is not generated) (Excluding PC78US-6 without blade).
When this operation is executed, the gear pump assists the boom RAISE circuit.
Cause Remedy
Defective boom assist valve or Clean or

LS select valve replace
H-22 Travel speed lowers extremely in compound operation of travel and

boom RAISE
★ Carry out the following troubleshooting, if the work equipment (Boom RAISE) operation and travel
operation are normal when executed singly.
★ Carry out the following troubleshooting, only when the boom RAISE circuit (LS) pressure is higher than
the travel circuit (LS) pressure.
Cause Remedy
Malfunction of LS bleed valve Repair or

(Clogged choke, etc.) replace
H-23 Speed is low in compound operation of work equipment relief and

swing, work equipment relief and other work equipment
Cause Remedy
Defective choke of LS bypass Replace
PC78US-6 20-457
➄
H-24 Work equipment does not move or its speed is low in compound
operation of travel and work equipment
★ Carry out the following troubleshooting, if the travel operation and work equipment operation are nor-
mal when executed singly.
Cause Remedy
When emergency swing brake release NO

Only PC78US-6 without switch is turned ON, is trouble
blade repaired?
YES
• 3.14 ± 0.49 MPa When travel and work equipment

{32 ± 5 kg/cm2} operations are executed simulta-
• Measure at control valve neously, is PPC output pressure nor-
PPC pressure inlet mal?
YES
NO
Is filter of logic valve fitting face
clogged?
YES
Malfunction of pump merge-divider valve Replace filter
caused by clogging of logic valve filter
Is swing holding brake input check NO

Only PC78US-6 without valve of logic valve clogged or
blade scratched?
YES
Malfunction of pump merge-divider valve Repair or replace
caused by leakage through logic valve
NO Malfunction of pump merge-divider valve

Does logic valve spool move caused by malfunction of logic valve Repair or replace
smoothly? spool
YES
When travel circuit is relieved and NO

work equipment is operated simulta- Go to each diagnosis item —
neously, does speed rise?
YES
Lowering of LS pressure caused by defec- Repair or replace
tive travel pressure compensation valve
20-458 PC78US-6
➄
H-25 Travel deviation is large
a) Travel deviation is large during ordinary travel

1 Cause Remedy
• Check shoe tension differ- NO

ence between both sides Is undercarriage troubled?
• Check rollers for revolution
trouble
• Check for deformation and
damage YES
Repair or
Defective undercarriage replace
• Above 3.14 ± 0.49 MPa

NO
{Above 32 ± 5 kg/cm2} Are PPC output pressures on both
• Run engine at full throttle sides normal?
• Move lever to stroke end
YES
When both hoses are exchanged at NO

pump outlet, does deviating direction
change?
YES
Adjust, repair
Wrong adjustment or breakage of pump or replace
When both hoses between control NO

valve and swivel joint are exchanged,
does deviating direction change?
YES
Is pressure at top PP pressure pickup NO

When only travel operation is port of control valve same as pump
executed pressure?
YES
Does spool of travel junction variable NO

Defective travel junction variable choke Clean or
choke valve move smoothly and is valve replace
hole free from clogging?
YES
Does spool of pump merge valve NO

Repair or
move smoothly and is hole free from Defective pump merge valve replace
clogging?
YES Check, clean,

Malfunction of logic valve repair or
replace
When both check valves of main relief NO

circuit are exchanged, does deviating
direction change?
YES
Defective check valve of main relief cir- Repair or
cuit replace
NO
Does unload valve move smoothly 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
PC78US-6 20-459
➄
From 4 on previous page From 9 on previous page From 2 on previous page Cause Remedy
10
NO
Does pressure compensation valve Repair or
Defective pressure compensation valve
move smoothly? replace
YES
11
NO
Repair or
Does travel spool move smoothly? Malfunction of spool replace
YES
12
When both hoses between swivel NO

joint and travel motor are Defective travel motor (Motor, counter- Check, repair or
exchanged, does deviating direc- balance valve, final drive) replace
tion change?
YES
Repair or
Defective swivel joint replace
13
When both PPC hose are NO

Defective PPC circuit check valve of con- Repair or
exchanged, does deviating direc- trol valve replace
tion change?
YES
14
NO
Repair or
Does lever interfere with floor? Defective PPC valve replace
YES
Abnormal PPC pressure output caused Adjust
by interference
b) Travel deviation is large when machine starts (but normal during ordinary travel)
1 Cause Remedy
When machine starts, is dragging NO

sound of brake heard from travel
motor on deviating side?
YES
Delay of release of parking brake Repair or
(Malfunction of brake, brake valve replace
NO
Does counterbalance valve of travel Go to diagnosis No. 5 in (a) above
motor move smoothly?
YES
Repair or
Malfunction of counterbalance valve replace
20-460 PC78US-6
➄
H-26 Travel deviation is large in compound operation of travel and swing,

travel and work equipment
★ Carry out the following troubleshooting, if the travel operation is normal when executed singly.
Cause Remedy
Note) 1
Does machine deviate only when NO

Note:) Only PC78US-6 without travel and swing operations are exe-
blade cuted simultaneously?
YES
• 3.14 ± 0.49 MPa NO

Is output pressure of swing holding
{32 ± 5 kg/cm2} brake solenoid normal? Defective swing holding brake solenoid Replace
YES
Seizure of filter and check valve at output
pressure inlet port of swing holding brake Replace
solenoid of rotary valve
3
Does pump merge-divider spool move NO

smoothly and is hole free from clog- Malfunction of pump merge-divider valve Repair or replace
ging?
YES
NO
Is filter of logic valve fitting face Clogging or malfunction of chock of logic Replace
clogged? valve
YES
Malfunction of logic valve caused by clog- Clean or replace
ging
PC78US-6 20-461
➄
H-27 Travel speed or power is low (Work equipment, swing, and blade
operations are normal)
★ If another part of the work equipment has a trouble, see H-1.
1 Cause Remedy
and set travel lever in neu- NO
When machine is driven in monitoring
tral: 410 mA mode 1050, does current lower?
• Drive machine with engine at
full throttle: 100 mA
YES
• Run engine at full throttle 2

and set travel lever in neu-
tral: 0.45 ~ 0.83 MPa NO
{5.5 ~ 8.5 kg/cm2} Is output pressure of TVC-EPC sole- Defective TVC-EPC solenoid Replace
noid normal?
• Drive machine with engine at
full throttle: 0 ~ 0.2 MPa
{0 ~ 2 kg/cm2} YES
NO
Is travel pressure switch connected? Omission of connection Connect
YES
Disconnection or defective controller Replace
• 26.5 ± 1.47 MPa NO

{270 ± 15 kg/cm2} Is travel relief pressure normal?
YES

port of control valve same as port
pressure?
YES

Repair or
smoothly and is hole free from clog- Malfunction pump merge-divider valve replace
ging?
YES
Repair or
Malfunction logic valve replace
• When driven on flat concrete

NO
with engine at full throttle, if Is pump pressure normal during Large resistance to travel motor and Repair or
pressure is below 11.7 MPa travel? undercarriage replace
{120 kg/cm2}
YES
Large leakage through travel motor or Repair or
swivel joint replace
NO
Above 3.14 ± 0.49 MPa Is PPC pressure normal? (At PPC pres-
{32 ± 5 kg/cm2} sure inlet of control valve)
YES
NO
Repair or
Does spool move smoothly? Malfunction of spool replace
YES
To 12 on next page To 10 on next page
20-462 PC78US-6
➄
From 8 on previous page From 9 on previous page Cause Remedy
10
NO
Does pressure compensation valve Repair or
Defective pressure compensation valve
YES
11
NO
Does unload valve move Repair or
Defective unload valve
smoothly? replace
YES
Large leakage through travel motor or
swivel joint
12
NO
When PPC circuit check valve is Repair or
Defective PPC valve
replaced, is trouble repaired? replace
YES
Defective PPC circuit check valve Replace
PC78US-6 20-463
➄
H-28 Machine cannot be steered sharply or steering force is

insufficient
1 Cause Remedy
Does engine speed lower (extremely NO

only when machine is steered during
travel)?
YES
Repair or
Defective pump servo replace

port of control valve same as port
pressure?
YES
Does spool of travel junction variable NO

Defective travel junction variable choke Repair or
choke valve move smoothly and is valve replace
hole free from clogging?
YES

Repair or
smoothly and is hole free from clog- Malfunction pump merge-divider valve replace
ging?
YES
Repair or
Malfunction of logic valve replace
Is drive pump pressure of inside NO

motor normal? (Inside pump pressure
must be below above 10 MPa {100 kg/
cm2} while machine is turning on flat
concrete with turning radius of about
5 m.)
YES
NO
Repair or
Is inside PPC pressure low? Defective PPC replace
YES
NO
Does spool move smoothly? Repair or
Malfunction of spool replace
YES
Repair or
Defective unload valve replace
NO
When main relief circuit check valve is Defective counterbalance valve of travel Repair or
replaced, is trouble repaired? motor or swivel joint replace
YES
Repair or
Defective main relief circuit check valve replace
20-464 PC78US-6
➄
H-29 Travel speed does not change at all or does not change quickly
Cause Remedy
• 31.4 ± 0.49 MPa NO Electric trouble in defective 2nd travel

Is output of 2nd travel speed selection
{32 ± 5 kg/cm2} solenoid valve normal? speed selection solenoid valve, 2nd Repair or replace
• Run engine at full throttle travel speed selection switch, etc.
YES
Is outlet choke of 2nd travel speed NO

selection solenoid valve free from Malfunction caused by clogging Repair or replace
clogging?
YES
Is output pressure of 2nd travel speed NO

selection solenoid valve at travel Defective swivel joint Repair or replace
motor inlet normal?
YES
Defective travel motor or 2nd travel Repair or replace
speed selection solenoid valve piston
PC78US-6 20-465
➄
H-30 Machine does not travel
1 Cause Remedy
• 26.5 ± 1.47 MPa NO

Does pump pressure rise to relief
{270 ± 15 kg/cm2} pressure?
YES
NO
Is foreign matter drained from final
drive?
YES
Repair or
Defective final drive replace
NO
Does counterbalance valve of travel Repair or
Defective counterbalance valve
motor operate smoothly? replace
YES
• When driven on flat concrete

NO
with engine at full throttle, if Is undercarriage deformed or dam- Repair or
pressure is below 11.7 MPa Defective undercarriage
aged? replace
{120 kg/cm2}
YES
Defective travel motor (Motor, parking Repair or
brake system) replace
See 1 5
• Above 3.14 ± 0.49 MPa NO

{Above 32 ± 5 kg/cm 2} Is PPC pressure normal?
• Run engine at full throttle (At PPC 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 NO
throttle and pump pressure
above about 10 MPa Does travel spool move smoothly? Malfunction of spool
{100 kg/cm2}, perform diagno-
sis 2.
YES
Does pressure compensation valve NO

move smoothly? Defective pressure compensation valve
YES
NO
Repair or
Does unload valve move smoothly? Defective unload valve replace
YES
Repair or
Defective travel motor or swivel joint replace
• Drive machine with boom NO

PPC pressure When PPC hose is replaced with boom
hose on control valve side, does PPC Defective PPC circuit check valve
(Return piping immediately pressure rise?
after testing)
YES
Defective PPC valve
20-466 PC78US-6
➄
H-30 Supplement
Relationship between PPC circuit check valve and "Machine does not travel"
As shown below, PPC circuit check valves (1) ~ (4) are installed to pick up the changeover signal pressure
for the pump merge-divider valve. If the checking function of these check valves is lost, the machine may
not travel.
Example: When checking function of (1) is lost

• Normal operations: "Left forward travel", "Left forward travel + Right forward travel", "Left for-
ward travel + Right reverse travel"
• Operations where machine may not travel: "Left reverse travel", "Right forward travel", "Right
reverse travel", "Left reverse travel + Right forward travel", "Left reverse travel + Right reverse
travel"
PC78US-6 20-467
➄
H-31 , H-32 Overrun of travel is large
Cause Remedy
Does PPC pressure lower immediately NO

Repair or
after lever is returned? (At PPC pressure Defective PPC replace
inlet of control valve)
YES
NO
Repair or
YES
NO
When suction valve is replaced, is trouble
repaired?
YES
Repair or
NO
When back pressure valve is replaced, is
trouble repaired?
YES
Repair or
Defective back pressure valve replace
NO
Does travel motor counterbalance valve Repair or
Defective counterbalance valve
YES
NO
Does travel motor check valve move Repair or
Defective check valve
smoothly? replace
YES
Repair or
Defective travel motor replace
H-32 Travel hydraulic drift is large

Cause Remedy
Defective parking brake or parking brake Repair or

valve of travel motor replace
20-468 PC78US-6
➄
H-33 Fine controllability or response is low
Cause Remedy
NO
When air is bled from PPC, is trouble
repaired?
YES
Air in PPC Bleed PPC
NO
Is pressure at top PP pressure pickup port
of control valve same as port pressure?
YES
Does spool of pump merge-divider valve NO

Malfunction of pump merge-divider Repair or
move smoothly and is hole free from valve replace
clogging?
YES
Repair or
Defective logic valve replace
NO
Does unload valve move smoothly and is Repair or
Malfunction of unload valve
hole free from clogging? replace
YES
NO
Does pressure compensation valve move Malfunction of pressure compensation Repair or
smoothly? valve replace
YES
NO
Repair or
YES
NO
When PPC valve is replaced, is trouble Repair or
Defective travel motor
repaired? replace
YES
Repair or
Defective PPC replace
PC78US-6 20-469
➄
H-34 Swing speed or power is low (Work equipment, travel, and blade
★ If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
Cause Remedy
Note) 1
PC78US without blade
Note) 1 1
NO
• LS differential pressure: When only swing operation is executed, Repair or
Defective LS select valve
2.1 ± 0.1 MPa {21.5 ± 1 kg/cm2} is LS pressure generated? replace
YES
NO
smoothly and is hole free from clogging? valve replace
YES
NO
YES
To 5 on next page
Note) 2 4
Note) 2 NO
PC78US with blade When work equipment is relieved, does
PC78UU speed rise?
YES
Repair or
Defective boom assist valve replace
To 5 on next page
20-470 PC78US-6
➄
H-34
From previous page Cause Remedy
Note) 1 5
Without blade
• 23 ± 1.47 MPa {235 ± 15 kg/cm2} NO
With blade Is swing relief pressure normal?
• 21.08 ± 1.47 MPa {215 ± 15 kg/cm2}
YES
NO
Does pressure rise to near relief pressure
during stable swing?
YES
NO
Defective motor unit, brake, or swing Repair or
Is swing dragging sound heard? machinery circle replace
YES
NO
Is swing brake release pressure output? Defective swing brake release solenoid Replace
YES
NO
When controller is replaced, is trouble Repair or
Malfunction of swing holding brake
repaired? replace
YES
Malfunction of controller Replace
10
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is PPC pressure at PPC control valve nor-
• Run engine at full throttle. mal?
YES
11
When fixed choke of swing PPC slow- NO

return valve is cleaned, is trouble
repaired?
YES
Clogging of choke Clean repair
Malfunction of slow return valve or replace
12
NO
Repair or
YES
Repair or
Defective swing motor replace
13
NO
When choke of swing PPC line is cleaned, Repair or
Defective PPC valve
YES
Clean repair
Clogging of choke or replace
To 14 on next page
PC78US-6 20-471
➄
From 5 on previous page Cause Remedy
14
NO
When safety valve of swing motor is
adjusted or replaced, is trouble repaired?
YES
Adjust or
Defective safety valve replace
15
When check valve and suction valve of NO

swing motor are replaced, is trouble
repaired?
YES
Repair or
Defective check valve or suction valve replace
16
NO
When reverse prevention valve is
YES
Repair or
Malfunction of reverse prevention valve replace
20-472 PC78US-6
➄
H-35 Machine does not swing (Work equipment, travel, and blade opera-
tions are normal)
★ If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
★ Carry out the following troubleshooting, if the electric system is normal. (If the electric system is defec-
tive, carry out E first.)
a) Swing speed or power is low in both directions
Cause Remedy
When swing operation and operation NO

other than boom RAISE operation are
executed, does machine move?
YES
Defective LS select valve Replace
NO
Does pressure compensation valve move Defective pressure compensation valve Replace
smoothly and is hole free from clogging?
YES
3
Without blade
• 23 ± 1.47 MPa {235 ±15 kg/cm2} NO
With Blade Is swing relief pressure normal?
• 21.08 ± 1.47 MPa {215 ± 15 kg/cm2}
YES
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is swing holding brake relief pressure Malfunction of swing holding brake
• Run engine at full throttle normal? (At motor inlet) solenoid valve
YES
Malfunction of motor unit, brake, or
swing machinery
NO
Is swing motor turning? (Judge by sound)
YES
Damage of motor shaft or swing Repair or
machinery replace
NO
When safety valve of swing motor is
adjusted or replaced, is trouble repaired?
YES
Repair or
Defective safety valve replace

swing motor are adjusted or replaced, is Go to diagnosis No. 6 —
trouble repaired?
YES
Clean repair
Defective check valve or suction valve or replace
PC78US-6 20-473
➄
b) Swing speed or power is low in either direction
Cause Remedy
1
Without blade
• 23 ± 1.47 MPa {235 ± 15 kg/cm2} NO
With Blade Is swing relief pressure normal?
• 26.5 ± 1.47 MPa {270 ± 15 kg/cm2}
YES
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Are swing brake release pressures on
• Run engine at full throttle both sides normal? (At solenoid outlet)
YES
Note that swing timer is set to 5 Defective swing motor or swing machin- Replace
seconds ery circle
When lever is moved to right and left, NO

• Since motor may be broken, Repair or
does work equipment move for 5 sec- Malfunction of spool
operate in fine control mode replace
onds?
YES
Repair or
Disconnection of wiring harness replace

Repair or
swing motor are replaced, is trouble Malfunction of spool replace
repaired?
YES
Repair or
Defective check valve or suction valve replace
20-474 PC78US-6
➄
H-36 Swing acceleration is low

a) Swing acceleration is low in both directions
Cause Remedy
NO
When swing motor safety valve is Execute diagnosis in H-34, H-41
YES
Defective swing motor safety valve Replace
b) Swing acceleration is low in either direction

Cause Remedy
Execute diagnosis in H-34, H-41
PC78US-6 20-475
➄
H-37 Overrun of swing is large

a) Overrun of swing is large in both directions
Cause Remedy
1
Without blade
• 23 ± 1.47 MPa {235 ± 15 kg/cm2} NO
With blade Is swing relief pressure normal? Defective swing motor safety valve Replace
• 21.08 ± 1.47 MPa {215 ± 15 kg/cm2}
YES
Repair or
Go to b) replace
b) Overrun of swing is large in either direction

Cause Remedy
NO
Does control valve spool move Repair or
Malfunction of control valve spool
smoothly? replace
YES
NO
When swing motor suction valve is
YES
Repair or
Defective swing motor suction valve replace
NO
YES
Repair or
Defective reverse prevention valve replace
NO
When swing motor check valve is
YES
Repair or
Defective swing motor check valve replace
When swing PPC slow-return valve, NO

Repair or
swing PPC line, and swing PPC circuit Defective PPC valve replace
choke are cleaned, is trouble repaired?
YES Clogging of swing PPC slow-return Repair or

valve, swing PPC line choke, or swing replace
PPC circuit choke
20-476 PC78US-6
➄
H-38 , H-39 Large shock is made when machine stops swinging
Cause Remedy
NO
Malfunction of control valve Repair or
Does control valve spool move smoothly? spool replace
YES
NO
When swing motor safety valve is replaced, is Go to H-34 Replace
trouble repaired?
YES
Defective swing motor Repair or
safety valve replace
H-39 Large abnormal sound is made when machine stops swinging
Cause Remedy
NO
When safety valve is replaced, is trouble Defective swing motor safety valve Replace
repaired?
YES
NO
When suction valve is replaced, is trouble
repaired?
YES
Repair or
Defective swing motor suction valve replace
NO
YES
Repair or
Defective reverse prevention valve replace
NO
Is foreign matter drained from final drive?
YES
Repair or
Defective swing machinery replace
NO
Only When back pressure compensation valve Defective swing motor, swing machin- Repair or
PC78US-6 without blade is replaced, is trouble repaired? ery, or swing circle replace
YES
Defective back pressure compensation Replace
valve
PC78US-6 20-477
➄
H-40 Swing hydraulic drift is large

★ Check that the emergency swing brake release switch is turned OFF.
Cause Remedy
When connector of swing pressure NO

switch is disconnected, is trouble
repaired?
YES
Defective swing pressure switch Replace
When connector of swing brake release NO

solenoid is disconnected, is trouble
repaired?
YES
Defective controller or wiring Replace
NO
When hose of swing brake release line is Repair or
disconnected, is trouble repaired? Defective swing motor brake replace
YES
Replace valve
Malfunction of solenoid assembly
20-478 PC78US-6
➄
H-41 Fine controllability or response of swing is low
Cause Remedy
NO
repaired?
YES
Air in PPC Bleed Air
NO
YES

clogging?
YES
Repair or
NO
YES
NO
YES
NO
Repair or
YES
NO
repaired? replace
YES
Repair or
Defective PPC valve replace
PC78US-6 20-479
➄
H-42 Blade speed or power is low (Work equipment, travel, and swing
★ If there is any other trouble in the work equipment, travel system, or swing system, see H-1.
Cause Remedy
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is blade PPC pressure normal? Defective PPC valve Repair or
• Run engine at full throttle replace
YES
NO
• 21.08 ± 1.47 MPa {215 ± 15 kg/cm2} Is blade LOWER relief pressure normal? Go to diagnosis 5 —
YES
NO
Does pump pressure reach relief pressure
during operation?
YES
NO
Is hose between control valve and cylin- Malfunction of check valve in spool or Repair or
der flattened or deformed? clogging of hole of spool replace
YES
Flattened or deformed hose Replace
NO
Execute diagnosis in H-41 (Hydraulic
Is hydraulic drift normal? —
drift of blade is large)
YES Leakage in control valve (Leakage from Repair or

line between swing valve and blade replace
valve)
20-480 PC78US-6
➄
H-43 Blade does not move (Work equipment, travel, and swing operations
are normal)
★ If there is any other trouble in the work equipment, travel system, or swing system, see H-1.
a) Blade does not rise
Cause Remedy
NO
• 3.14 ± 0.49 MPa {32 ± 5 kg/cm2} Is blade PPC pressure normal? Defective PPC valve Repair or
• Run engine at full throttle replace
YES
NO
• 21.08 ± 1.47 MPa {215 ± 15 kg/cm2} Is blade LOWER relief pressure normal?
YES
NO
Is cylinder or work equipment deformed?
YES
Repair or
Deformed cylinder or work equipment replace
NO
Repair or
Is hose flattened or deformed? Malfunction of control valve spool replace
YES
Check hydraulic drift by H-41.
YES
If trouble is not repaired by H-41 Leakage in control valve (Large leakage Repair or
from line between swing valve and replace
blade valve)
PC78US-6 20-481
➄
b) Blade does not lower
Cause Remedy
NO
Is blade held in air?
YES
NO
Repair or
Is blade PPC normal? Defective blade PPC valve replace
YES
NO
Is cylinder or work equipment deformed?
YES
Repair or
Deformed cylinder or work equipment replace
NO
Repair or
Is hose flattened or deformed? Malfunction of spool replace
YES
Is it impossible to raise machine by brac-

ing blade on ground?
YES
Execute diagnosis in H-41 (Hydraulic Repair or
drift of blade is large) replace
20-482 PC78US-6
➄
H-44 Hydraulic drift of blade is large
Cause Remedy
NO
Repair or
Is leakage from cylinder normal? Defective cylinder piston packing replace
YES
When hose is disconnected from valve NO

outlet and plugged, is hydraulic drift
large?
YES
Repair or
Large leakage through swivel joint replace
NO
• If blade is held in air and hydraulic drift When centralized safety valve is replaced,
is large is trouble repaired?
YES
NO
When suction valve is replaced with plug, Repair or
Low oil-tightness of spool
YES
Repair or
Defective suction safety valve replace
NO
• If hydraulic drift is large when machine When blade safety valve is replaced, is Repair or
Low oil-tightness of spool
body is raised with blade trouble repaired? replace
YES
Defective blade safety valve Replace
PC78US-6 20-483
➄
H-45 Fine controllability or response of blade is low
Cause Remedy
NO
repaired?
YES
Air in PPC Bleed Air
NO
YES

clogging?
YES
Repair or
NO
YES
NO
YES
NO
Repair or
YES
NO
repaired? replace
YES
Repair or
Defective PPC replace
20-484 PC78US-6
➄
H-46 , H-47 Monitor panel displays error code and boom RAISE, arm IN, and off-
set LEFT operations stop just before interference (Only PC78UU-6)
★ Check that any water is not in the potentiometer connectors (M29, M71, M72) of the boom, arm, and
offset.
Cause Remedy
Repair or
Malfunction of solenoid valve replace
H-47 Machine does not stop boom RAISE, arm IN, and offset LEFT opera-
tions automatically but interferes (Only PC78UU-6)
★ If this trouble occurs, the trouble in H-46 occurs, too.
Cause Remedy
NO
Does PPC lock solenoid valve move Malfunction of PPC lock solenoid valve Repair or
smoothly? (It does not return) replace
YES
PC78US-6 20-485
➄
TTROUBLESHOOTING FOR MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by controller when trouble occurs and problems on machine . . . . . . . . . . . . . . . . . . . . . . . . 20-502
Electric circuit diagram of M mode system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
M- 1 [E101] (Error history data are abnormal) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
M- 2 [E108] (Engine coolant temperature is 105 °C) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
M- 3 [E112] (Wiper forward output is shorted) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
M- 4 [E113] (Wiper reverse output is shorted) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
M- 5 [E114] (Contact with washer output of 24 V) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
M- 6 [E115] (Wiper does not start wiping in 10 seconds) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
M- 7 [E116] (Wiper is not retracted in 10 seconds) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
M- 8 When starting switch is turned to ON position, monitor panel segments do not light up
for 3 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
a) Monitor panel segments do not light up at all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
b) Some monitor panel segments do not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
M- 9 When starting switch is set to ON position, all monitor panel segments light up but do
not go off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
M-10 While preheating is not executed, "Preheater monitor" lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
M-11 When starting switch is set to ON position and engine is started, basic check items flash . . . . . . . 20-516
a) Alternator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
b) Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
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 . . . . . . . . . . . . . 20-520
a) Alternator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520
b) Engine oil pressure sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
a) "Engine oil" flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
b) "Charge level" flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
c) "Coolant temperature" flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525
d) "Fuel level" flashes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527
buzzer does not sound for 1 second
While caution item is flashing, buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-529
M-15 Monitor plane lamp for nighttime is not turned on (LC display is normal) . . . . . . . . . . . . . . . . . . . . 20-531
M-16 Coolant temperature gauge does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
M-17 Coolant temperature gauge is not displayed
(Gauge does not rise to 1st line during operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535
M-18 Fuel level gauge always displays full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-537
M-19 Fuel level gauge is not displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539
M-20 While engine is running, service meter does not advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-541
M-21 Trouble in fuel level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-542
M-22 Trouble in coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-544
M-23 Wiper does not operate or operates while wiper switch is turned off . . . . . . . . . . . . . . . . . . . . . . . . 20-545
a) Wiper does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-545
b) Wiper operates while wiper switch is turned off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-545
M-24 Washer motor does not operate or operates while washer switch is turned off . . . . . . . . . . . . . . . . 20-550
a) Washer motor does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-550
b) Washer operates while wiper switch is turned off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-550
M-25 Depth set 0 mode and height mode cannot be selected and set (Only PC78UU-6) . . . . . . . . . . . . 20-553
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.
PC78US-6 20-501
(12)

1. Trouble in internal memory

2. Overvoltage (Above 36 V)
— E101 Error history data are abnormal
3. Undervoltage (Above 12 V)
4. Disconnection of connector
1. Coolant temperature sensed by coolant temper-

— E108 Engine coolant temperature is 105 °C
ature sensor is above 105 °C
1. Short circuit or short circuit with chassis ground

in wiring between
— E112 Short circuit in forward system of wiper motor drive
in wiring between monitor panel P01 (Female)
(9) – wiper motor W04 (Female) (3)
3. Defective monitor panel
in wiper motor
— E113 Short circuit in reverse system of wiper motor drive
in wiring between monitor panel P01 (Female)
(10) – wiper motor W04 (Female) (1)
1. Short circuit in washer motor
2. Short circuit with power source in wiring harness
— E114 Short circuit in windshield washer drive system between monitor panel P01(Female) (3) – M31
(Female) (1)
1. Defective wiper motor
2. Disconnection, defective contact, short circuit,
or short circuit with chassis ground in wiring har-
ness between monitor panel P01 (Female) (5) –
W04 (6)
— E115 Wiper does not start wiping in 10 seconds
ness between monitor panel P01 (Female) (12)
– W04(4)
1. Defective wiper motor
ness between monitor panel P01 (Female) (5) –
W04 (6)
— E116 Wiper is not retracted in 10 seconds
ness between monitor panel P01 (Female) (12)
– W04 (4)
20-502 PC78US-6
(1)
Action Taken By Controller When Problem That Appears on Machine

Normal Condition (Voltage, Current, Resistance)
Abnormality is Detected When There is Abnormality
— 1. Service code cannot be cleared
1. If abnormality is detected contin-

uously, coolant temperature cau-
tion lamp flashes and buzzer
• Resistance between M18 (Male) (1) ~ (2): Min. 3.70 kΩ
— sounds.
(With engine started)
2. If abnormality is detected contin-
uously, engine speed is set to
low idling.
• Voltage between W04 (3) ~ (5): Max. 3 V

↕
Stops outputting to wiper motor Wiper stops
a Repeated at regular intervals.
20 ~ 30 V
• Voltage between W04 (1) ~ (5): Max. 3 V

↕
Same as [E112] Same as [E112]
a Repeated at regular intervals.
20 ~ 30 V
• Voltage between P01 (3) ~ chassis ground

1. Stops outputting to washer 1. Stops outputting to washer
When washer switch is turned OFF: 20 ~ 30 V
motor motor
When washer switch is turned ON: Max. 1 V
• Timing chart of setting wiper switch to ON and INT is

conformed to Tables 1 and 2 in M-23
• Timing chart of setting wiper switch to ON and INT is

conformed to Tables 1 and 2 in M-23
PC78US-6 20-503
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM

PC78US-6 (1/2)
Serial No.: 4001 – 6500
20-504 PC78US-6
(12)
PC78US-6 (2/2)
PC78US-6 20-505
(12)
PC78US-6 (1/2)
20-506 PC78US-6
(12)
PC78US-6 (2/2)
PC78US-6 20-507
(12)
PC78UU-6 (1/2)
20-508 PC78US-6
(12)
PC78UU-6 (2/2)
PC78US-6 20-509
(12)
TROUBLESHOOTING M-1
M-1 [E101] (Error history data are abnormal) is displayed

PC78US-6 Serial No.: 4001 – 6500
a If connector P01, connector K1, fuse 18, connector M6, connector M2, connector M27, battery relay termi-
nal B, or battery terminal in the monitor panel power supply system is disconnected or connected for trou-
bleshooting, this error is displayed. This phenomenon does not indicate an actual error, however. (When the
monitor panel power circuit is broken by turning off the starting switch.)
a If the service code is displayed again after the resetting operation, check by the following procedure.
Cause Remedy
1
• After resetting operation, operate After "resetting operation", is service code displayed NO
machine normally and observe its Normal —
again?
condition for a while. (See Note 1.)
YES
2
Disconnection, defective
contact, or short circuit with
• Turn starting switch OFF Is voltage between P01 (8) – chassis ground nor- NO chassis ground in wiring har- Repair or replace
• 20 – 30 V mal? ness between battery – bat-
tery relay B – M27 (1), (2) –
P01 (Female) (8)
YES
Note: Resetting operation: Turn the starting switch to OFF position, then turn it to the ON position again, with
the buzzer cancel switch pushed, and keep pressing the buzzer cancel switch for 5 seconds. (All the ser-
vice codes saved in the memory are deleted by this operation.)
M-1 Electrical circuit diagram of each system
20-510 PC78US-6
(12)
TROUBLESHOOTING M-1

a If connector P01, connector K1, fuse 18, connector M6, connector M2, connector M27, battery relay termi-
nal B, or battery terminal in the monitor panel power supply system is disconnected or connected for trou-
bleshooting, this error is displayed. This phenomenon does not indicate an actual error, however. (When the
monitor panel power circuit is broken by turning off the starting switch.)
a If the service code is displayed again after the resetting operation, check by the following procedure.
Cause Remedy
1
• After resetting operation, operate After "resetting operation", is service code displayed NO
machine normally and observe its Normal —
again?
condition for a while. (See Note 1.)
YES
2
• Turn starting switch OFF Is voltage between P01 (8) – chassis ground nor- NO chassis ground in wiring har- Repair or replace
• 20 – 30 V mal? ness between battery – bat-
tery relay B – M27 (1), (2) –
P01 (Female) (8)
YES
Note: Resetting operation: Turn the starting switch to OFF position, then turn it to the ON position again, with
the buzzer cancel switch pushed, and keep pressing the buzzer cancel switch for 5 seconds. (All the ser-
vice codes saved in the memory are deleted by this operation.)
PC78US-6 20-511
(12)
TROUBLESHOOTING M-2, M-3, M-4, M-5, M-6, M-7
M-2 [E108] (Engine coolant temperature is 105 °C) is displayed

Cause Remedy
1
Does coolant temperature gauge of monitor indicate NO
red range and is caution lamp flashing?
YES
See M-13, c) —
• Turn starting switch ON Is "E" attached to head of service code? NO Trouble in engine unit —
(See Note 1)
YES
Note 1: The display of the monitor panel has been reset normally. Since the coolant temperature sensor
detected coolant temperature above 105 °C, remove the cause of that temperature rise by troublshoot-
ing the engine unit.
M-3 [E112] (Wiper forward output is shorted) is displayed

a See M-23.
M-4 [E113] (Wiper reverse output is shorted) is displayed

a See M-23.
M-5 [E114] (Contact with washer output of 24 V) is displayed

a See M-24.
M-6 [E115] (Wiper does not start wiping in 10 seconds) is displayed

a See M-23.
M-7 [E116] (Wiper is not retracted in 10 seconds) is displayed

a See M-23.
20-512 PC78US-6
(12)
TROUBLESHOOTING M-8
M-8 When starting switch is turned to ON position, monitor panel segments

do not light up for 3 seconds
PC78US-6 Serial No.: 4001 – 6500
a Check that fuses 6, 13, and 18 are normal.
a) Monitor panel segments do not light up at all
Cause Remedy
1
• Turn starting switch ON Is voltage between P01 (8) – (6), (7) and between NO
• 20 – 30 V P02 (1), (2) – (6), (7) normal?
YES
2
• Turn starting switch ON Is voltage between P01 (6), (7) – chassis ground NO
• 20 – 30 V normal?
YES
3
• Turn starting switch ON NO contact, or short circuit with
Is voltage between fuse 13 – chassis ground nor- chassis ground in wiring har- Repair or replace
• 20 – 30 V mal? ness between fuse 13 – bat-
tery relay M
YES Disconnection, defective
chassis ground in wiring har- Repair or replace
ness between P01 (Female)
(7) – fuse 13
4
tery relay B
(19) – fuse 6
b) Some monitor panel segments do not light up

Cause Remedy
PC78US-6 20-513
(12)
TROUBLESHOOTING M-8

a Check that fuses 11, and 18 are normal.
a) Monitor panel segments do not light up at all
Cause Remedy
1
• Turn starting switch ON NO
Is voltage between P01 (8) – (6), (7) normal?
• 20 – 30 V
YES
2
• Turn starting switch ON Is voltage between P01 (1), (2) – (6), (7) – chassis NO
• 20 – 30 V ground normal?
YES
3
tery relay M
(8) – fuse 11
4
tery relay B
(8) – fuse 18
b) Some monitor panel segments do not light up

Cause Remedy
M-8 a) Electrical circuit diagram of each system
20-514 PC78US-6
(12)
TROUBLESHOOTING M-9, M10
M-9 When starting switch is set to ON position, all monitor panel seg-
ments light up but do not go off
Cause Remedy
M-10 While preheating is not executed, "Preheater monitor" lights up

Cause Remedy
1
• Disconnect terminal R1
Is voltage between starting switch R1 – chassis NO
• Turn starting switch ON Defective starting switch Replace
ground normal?
• Max. 1 V
YES
2
Short circuit with power
• Turn starting switch ON Is voltage between P02 (18) – chassis ground nor- NO source in wiring harness Repair or replace
• Max. 1 V mal? between starting switch R1 –
P02 (Female) (18)
YES
PC78US-6 20-515
(12)
TROUBLESHOOTING M-11
M-11 When starting switch is set to ON position and engine is started,

basic check items flash
a Inspect both alternator system and engine hydraulic system.
a) Alternator system
PC78US-6 Serial No.: 4001 – 6500
a Check monitoring code "0043". If it is 100 or larger while the engine speed is above the medium level,
the monitor panel is defective.
Cause Remedy
1
• Run engine above medium speed
Is voltage between alternator terminal R – chassis NO
level Defective alternator Replace
ground normal?
• 20 – 30 V
YES
2
• Run engine above medium speed Disconnection or defective
NO
Is voltage between P02 (11) – chassis ground nor- contact in wiring harness
level Repair or replace
mal? between alternator terminal
• 20 – 30 V R – P02 (Female) (11)
YES
20-516 PC78US-6
(12)
Cause Remedy
1
• Run engine above medium speed
level Defective alternator Replace
ground normal?
• 20 – 30 V
YES
2
• Run engine above medium speed Disconnection or defective
NO
Is voltage between P02 (11) – chassis ground nor- contact in wiring harness
level Repair or replace
mal? between alternator terminal
• 20 – 30 V R – P02 (Female) (11)
YES
PC78US-6 20-517
(12)
b) Engine oil system

PC78US-6 Serial No.: 4001 – 6500
a Carry out the following troubleshooting when the engine oil pressure is normal.
a Check bit (3) of monitoring code "0046". If it is lighting up, the monitor panel is defective.
Cause Remedy
1
When engine speed is low, if oil pressure sensor NO
• Run engine at low speed terminal T6 is disconnected, does error disap-
pear?
YES
Defective oil pressure sen- Replace
sor (Low pressure)
2
• Turn starting switch OFF ground in wiring harness
Is there continuity between P02 (7) – chassis NO
• Disconnect sensor wiring harness between P02 (Female) (7) – Repair or replace
ground normal?
and P02 sensor terminal T6
YES
M-11 b) Electrical circuit diagram of each system
20-518 PC78US-6
(12)
b) Engine oil system

Cause Remedy
1
When engine speed is low, if oil pressure sensor NO
• Run engine at low speed terminal T6 is disconnected, does error disap-
pear?
YES
Defective oil pressure sen- Replace
sor (Low pressure)
2
• Turn starting switch OFF ground in wiring harness
Is there continuity between P02 (7) – chassis NO
• Disconnect sensor wiring harness between P02 (Female) (7) – Repair or replace
ground normal?
and P02 sensor terminal T6
YES
PC78US-6 20-519
(12)

caution items and emergency stop items (excluding battery and
engine oil) flash
PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
1
• Disconnect terminal R
• Turn starting switch ON Defective alternator Replace
ground normal?
• Max. 1 V
YES
• Disconnect P02 Short circuit with power

Is voltage between P02 (Female) (11) – chassis NO source in wiring harness
ground normal? between P02 (Female) (11)
• Max. 1 V – alternator terminal R
YES
20-520 PC78US-6
(12)
Cause Remedy
1
• Disconnect terminal R
• Turn starting switch ON Defective alternator Replace
ground normal?
• Max. 1 V
YES
• Disconnect P02 Short circuit with power

Is voltage between P02 (Female) (11) – chassis NO source in wiring harness
ground normal? between P02 (Female) (11)
• Max. 1 V – alternator terminal R
YES
PC78US-6 20-521
(12)
b) Engine oil pressure sensor system

PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
1
• Turn starting switch OFF Is there continuity between sensor terminal T6 – NO Defective oil pressure sen- Replace
• Disconnect sensor terminal T6 chassis ground? sor
YES
2
• Turn starting switch OFF Disconnection or defective
Is there continuity between P02 (Female) (11) – NO contact in wiring harness
• Disconnect P02 – sensor terminal Repair or replace
sensor terminal T6? between P02 (Female) (7)
T6 – sensor terminal T6
YES
20-522 PC78US-6
(12)

Cause Remedy
1
• Turn starting switch OFF Is there continuity between sensor terminal T6 – NO Defective oil pressure sen- Replace
• Disconnect sensor terminal T6 chassis ground? sor
YES
2
Is there continuity between P02 (Female) (11) – NO contact in wiring harness
• Disconnect P02 – sensor terminal Repair or replace
sensor terminal T6? between P02 (Female) (7)
T6 – sensor terminal T6
YES
PC78US-6 20-523
(12)

caution items and emergency stop items flash (When there is not
abnormality in inspection items and engine before troubleshooting,
however)
a) "Engine oil" flashes
a Before carrying out the troubleshooting, check that the engine oil pressure is normal.
Cause Remedy
See M-11-b) —
b) "Charge level" flashes
Cause Remedy
See M-11-a) —
20-524 PC78US-6
(12)
c) "Coolant temperature" flashes

PC78US-6 Serial No.: 4001 – 6500
a Before carrying out the troubleshooting, check that the coolant temperature is normal.
Cause Remedy
1
• Start engine NO
• Set engine speed to medium or Is coolant temperature gauge in red range? Defective monitor panel Replace
higher
YES
When M18 is disconnected, does gauge indicate

• Start engine NO
only level 1 (Lowest line)?
YES Defective coolant tempera-

ture sensor system —
(See M-22)
3
• Disconnect P02 and M18 Is resistance between P02 (Female) (1) – M18 NO contact in wiring harness Repair or replace
(Female) (1) normal? between P02 (Female) (1)
• Max. 1 z – M18 (Female) (1)
between M18 (Female) (2)
– chassis ground
M-13 c) Electrical circuit diagram of each system
PC78US-6 20-525
(12)
c) "Coolant temperature" flashes

a Before carrying out the troubleshooting, check that the coolant temperature is normal.
Cause Remedy
1
• Start engine NO
• Set engine speed to medium or Is coolant temperature gauge in red range? Defective monitor panel Replace
higher
YES
When M18 is disconnected, does gauge indicate

• Start engine NO
only level 1 (Lowest line)?

(See M-22)
3
• Disconnect P02 and M18 Is resistance between P02 (Female) (1) – M18 NO contact in wiring harness Repair or replace
(Female) (1) normal? between P02 (Female) (1)
• Max. 1 z – M18 (Female) (1)
between M18 (Female) (2)
– chassis ground
M-13 c) Electrical circuit diagram of each system
20-526 PC78US-6
(12)
d) "Fuel level" flashes

PC78US-6 Serial No.: 4001 – 6500
a Before carrying out the troubleshooting, check that there is fuel in the fuel tank.
Cause Remedy
• Start engine Is fuel level gauge in red range? NO Defective monitor panel Replace
YES
2
• Start engine
• Wait for 2 minutes. (Since fuel When M9 (Female) (1) is connected to chassis NO
ground, do gauge segments light up to level 9
level fluctuates, its display is (Right end)?
delayed.)
YES
Defective fuel level sensor —
system (See M-21)
3
• Connect M9 (Female) (1) to chas- Disconnection or defective
sis ground Is voltage between P02 (2) – chassis ground nor- NO contact in wiring harness Repair or replace
• Turn starting switch ON mal? between P02 (Female) (2)
• Max. 0.3 V – M9 (Female) (1)
YES
Defective monitor panel Repair or replace
M-13 d) Electrical circuit diagram of each system
PC78US-6 20-527
(12)
d) "Fuel level" flashes

a Check that there is fuel in the fuel tank before carrying out troubleshooting.
Cause Remedy
• Start engine Is fuel level gauge in read range? NO Defective monitor panel Replace
YES
2
• Start engine.
• Wait for 2 minutes (Display is When M9 (female) (1) is connected to chassis NO
delayed since fuel level fluctu- ground, does gauge light up to level 9 (top)?
ates).
YES
system (See M-21)
3
Is resistance between P02 (female) (2) and M9 NO contact in wiring harness
• Disconnect M9 and P02. Repair or replace
(female) (1) and chassis ground normal? between P02 (female) (2) –
• Max. 1 z M9 (female) (1)
YES
4
Is resistance between M92 (female) (1) and chas- NO contact in wiring harness
• Disconnect M9. Repair or replace
sis ground normal? between M9 (female) (2) –
• Max. 1 z chassis ground
YES
M-13 d) Electrical circuit diagram of each system
20-528 PC78US-6
(12)

While caution item is flashing, buzzer does not sound
PC78US-6 Serial No.: 4001 – 6500
a Even if the charge level and fuel level among the caution items become abnormal, the buzzer does not
sound.
a The buzzer is controlled by the monitor panel and turned on when it is required to sound or when the volt-
age at P01 (11) is 20 – 30 V.
Cause Remedy
• Turn starting switch OFF 1

• Disconnect K53
• When buzzer cancel switch is ON:
Is resistance between K53 (Female) (1) – (2) nor- NO Defective buzzer cancel
Max. 1 z mal? switch Replace
• When buzzer cancel switch is
OFF: Min. 1 Mz
YES
2
• Disconnect K53 contact, or short circuit with
Is voltage between P02 (16) – chassis ground nor- NO chassis ground in wiring
mal? harness between P02
• 20 – 30 V (Female) (16) – K53 (Male)
(2)
YES
PC78US-6 20-529
(12)

a Even if the charge level and fuel level among the caution items become abnormal, the buzzer does not
sound.
a The buzzer is controlled by the monitor panel and turned on when it is required to sound or when the volt-
age at P01 (11) is 20 – 30 V.
Cause Remedy
• Turn starting switch OFF 1

• Disconnect K53
• When buzzer cancel switch is ON:
Is resistance between K53 (Female) (1) – (2) nor- NO Defective buzzer cancel
Max. 1 z mal? switch Replace
• When buzzer cancel switch is
OFF: Min. 1 Mz
YES
2
• Disconnect K53 contact, or short circuit with
Is voltage between P02 (16) – chassis ground nor- NO chassis ground in wiring
mal? harness between P02
• 20 – 30 V (Female) (16) – K53 (Male)
(2)
YES
20-530 PC78US-6
(12)
M-15 Monitor plane lamp for nighttime is not turned on (LC display is nor-
mal)
PC78US-6 Serial No.: 4001 – 6500
a Carry out the following troubleshooting when the headlamp and working lamp light up normally.
Cause Remedy
1
Is bit (4) of monitoring code "0045" turned off?
• Set monitoring code to "0045"
YES
2
• Turn starting switch ON Disconnection, defective
Is voltage between P02 (19) – chassis ground nor- NO contact in wiring harness
• Turn light switch ON Repair or replace
mal? between P02 (Female) (19)
• 20 – 30 V – K52 (Male) (1)
YES
PC78US-6 20-531
(12)

a Carry out the following troubleshooting when the headlamp and working lamp light up normally.
Cause Remedy
1
Is bit (4) of monitoring code "0045" turned off?
YES
2
• Turn starting switch ON Disconnection, defective
Is voltage between P02 (19) – chassis ground nor- NO contact in wiring harness
• Turn light switch ON Repair or replace
mal? between P02 (Female) (19)
• 20 – 30 V – K52 (Male) (1)
YES
20-532 PC78US-6
(12)
M-16 Coolant temperature gauge does not rise

PC78US-6 Serial No.: 4001 – 6500
a When the engine coolant temperature does not rise actually, inspect the engine system.
Cause Remedy
1
• Disconnect M18 When short connector is connected to M18 NO
(Female), does gauge rise 1 level by 1 and go off
• Turn starting switch ON at last?
(See M-22)
2
• Turn starting switch OFF Is there continuity between P02 (Female) (1) – NO contact in wiring harness Repair or replace
• Disconnect P02 and M18 M18 (Female) (1)? between P02 (Female) (1)
– M18 (Female) (1)
YES
3
• Turn starting switch OFF Is resistance between M18 (Female) (2) – chassis NO contact in wiring harness Repair or replace
• Disconnect M18 ground normal? between M18 (Female) (2)
– chassis ground
YES
PC78US-6 20-533
(12)

a When the engine coolant temperature does not rise actually, inspect the engine system.
Cause Remedy
1
• Disconnect M18 When short connector is connected to M18 NO
(Female), does gauge rise 1 level by 1 and go off
• Turn starting switch ON at last?
(See M-22)
2
• Turn starting switch OFF Is there continuity between P02 (Female) (1) – NO contact in wiring harness Repair or replace
• Disconnect P02 and M18 M18 (Female) (1)? between P02 (Female) (1)
– M18 (Female) (1)
YES
3
• Turn starting switch OFF Is resistance between M18 (Female) (2) – chassis NO contact in wiring harness Repair or replace
• Disconnect M18 ground normal? between M18 (Female) (2)
– chassis ground
YES
20-534 PC78US-6
(12)
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to
1st line during operation)
PC78US-6 Serial No.: 4001 – 6500
Cause Remedy
1
• Disconnect M18 NO
When M18 is disconnected, is gauge displayed?
(See M-22)
2
• Turn starting switch ON Is there continuity between P02 (Female) (1) – NO Defective monitor panel Replace
• Disconnect P02 and M18 chassis ground?
YES Short circuit with chassis

ground in wiring harness Repair or replace
between P02 (Female) (1) –
M18 (Female) (1)
PC78US-6 20-535
(12)
PC78US-6Serial No.: 6501 and up

Cause Remedy
1
• Disconnect M18 NO
When M18 is disconnected, is gauge displayed?
(See M-22)
2
• Turn starting switch ON Is there continuity between P02 (Female) (1) – NO Defective monitor panel Replace

M18 (Female) (1)
20-536 PC78US-6
(12)
M-18 Fuel level gauge always displays full

PC78US-6 Serial No.: 4001 – 6500
a Before carrying out the troubleshooting, see if the fuel tank is actually full.
Cause Remedy
1
• Wait for 2 minutes. (Since fuel When M9 is disconnected, does gauge rise 1 level NO
level fluctuates, its display is by 1 and go off at last?
delayed.)
YES
system (See M-21)
2
• Turn starting switch OFF Is there continuity between P02 (Female) (2) – NO Defective monitor panel Replace

M9 (Female) (1)
PC78US-6 20-537
(12)
PC78US-6 Serial No.: 6501 andup

a Before carrying out the troubleshooting, see if the fuel tank is actually full.
Cause Remedy
1
• Wait for 2 minutes. (Since fuel When M9 is disconnected, does gauge rise 1 level NO
level fluctuates, its display is by 1 and go off at last?
delayed.)
YES
system (See M-21)
2
• Turn starting switch OFF Is there continuity between P02 (Female) (2) – NO Defective monitor panel Replace

M9 (Female) (1)
20-538 PC78US-6
(12)
M-19 Fuel level gauge is not displayed

PC78US-6 Serial No.: 4001 – 6500
PC78UU-6Serial No.: 22832 and up
Cause Remedy
1
• Disconnect M9 When M9 (Female) (1) is connected to chassis NO
• Turn starting switch ON ground, does gauge display?
YES
(See M-21)
2
• Turn starting switch OFF Is there continuity between M9 (Female) (2) – NO contact in wiring harness Repair or replace
• Disconnect M9 chassis ground? between M9 (Female) (2) –
chassis ground
YES
PC78US-6 20-539
(12)
Cause Remedy
1
• Disconnect M9 When M9 (Female) (1) is connected to chassis NO
• Turn starting switch ON ground, does gauge display?
YES
(See M-21)
2
• Turn starting switch OFF Is there continuity between M9 (Female) (2) – NO contact in wiring harness Repair or replace
• Disconnect M9 chassis ground? between M9 (Female) (2) –
chassis ground
YES
20-540 PC78US-6
(12)
M-20 While engine is running, service meter does not advance

Cause Remedy
1
• Start engine NO
• Set engine speed to medium or Does charge level caution lamp flash? Defective monitor panel Replace
higher
YES
See M-13 c) —
PC78US-6 20-541
(12)
M-21 Trouble in fuel level sensor

PC78US-6 Serial No.: 4001 – 6500
a When carrying out the following troubleshooting, remove the fuel level sensor.
Cause Remedy
1
When float is moved up and down, does resis- NO
tance between connector (1) – flange change as
shown in Table 1?
YES
2
NO Defective sensor
Does arm move smoothly? Replace
(See Note 2)
YES
Is float cracked, broken off, or scratched badly? NO Bad contact of connector Clean or replace connector
YES
Interference of sensor in Replace (See Note 2)
tank
4
Is breakage of wiring harness detected by visual NO Defective sensor Replace
inspection?
YES
Breakage of wiring harness
(See Note 3)
(Defective clamp) Replace sensor
(Application of external
force)
Table
At upper (FULL) Approx. 12 z or below
stopper
At lower (EMPTY) stop- Approx. 85 – 110 z
per
Note1. Difference between actual fuel level and level indicated by gauge
When the gauge indicates 14 (F), the fuel level is 78 – 100%. When the former indicates 1 (E), the latter
is below 14.5%. If the machine body is slanted, the displayed fuel level is different from the actual fuel
level. Accordingly, stop the machine on a level place and check the fuel level gauge after waiting for at
least 2 minutes. (Since fuel level fluctuates, its display is delayed.)
Note2. Since the sensor may be interfering in the tank or it may be installed wrongly, install it very carefully.
Note3. Check the installation position of the connector for vibration. If it vibrates remarkably, take proper mea-
sures to suppress the vibration.
20-542 PC78US-6
(12)

a When carrying out the following troubleshooting, remove the fuel level sensor.
Cause Remedy
1
When float is moved up and down, does resis- NO
tance between connector (1) – flange change as
shown in Table 1?
YES
2
NO Defective sensor
Does arm move smoothly? Replace
(See Note 2)
YES
Is float cracked, broken off, or scratched badly? NO Bad contact of connector Clean or replace connector
YES
Interference of sensor in Replace (See Note 2)
tank
4
inspection?
YES
(See Note 3)
force)
Table
At upper (FULL) Approx. 9.5 – 11 z
stopper
At lower (EMPTY) stop- Approx. 82 – 92 z
per
Note1. Difference between actual fuel level and level indicated by gauge
When the gauge indicates 14 (F), the fuel level is 78 – 100%. When the former indicates 1 (E), the latter
is below 14.5%. If the machine body is slanted, the displayed fuel level is different from the actual fuel
level. Accordingly, stop the machine on a level place and check the fuel level gauge after waiting for at
least 2 minutes. (Since fuel level fluctuates, its display is delayed.)
Note2. Since the sensor may be interfering in the tank or it may be installed wrongly, install it very carefully.
PC78US-6 20-543
(12)
M-22 Trouble in coolant temperature sensor

Cause Remedy
1
Is resistance between temperature sensor connec- NO
tor (Male) (1) – (2) normal?
YES
Bad contact of connector Clean connector or replace
(See Note 1) sensor
2
inspection?
YES
(See Note 2)
force)
Table
Normal Temperature Approx. 37 – 50 kz
(25 °C)
100 °C Approx. 3.5 – 4.0 kz
Note1. 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.
20-544 PC78US-6
(12)
M-23 Wiper does not operate or operates while wiper switch is turned off
PC78US-6 Serial No.: 4001 – 6500
a) Wiper does not operate
a If service code "E112", "E113", "E115", or "E116" is displayed, carry out the following troubleshooting.
Cause Remedy
1
• Close front window
• Turn starting switch ON Does bit (3) of monitoring code "0049" light up? NO
YES
2
• Set wiper switch to "ON" or "INT" When wiper switch is set to "ON" or "INT" position, NO Defective monitor panel Replace
position do bits (4), (5) of monitoring code "0049" go off?
YES
3
Is voltage between pins of W04 as shown in Table NO
• Turn starting switch ON 1?
YES
Defective wiper motor Replace
4 Disconnection, defective
• Turn starting switch OFF contact, short circuit, or
Is voltage between pins of P01 (Female) – W04 NO short circuit with chassis Repair or replace
• Disconnect P02 and W04 (Male) as shown in Table 2? ground in wiring
having improper resistance
YES
5
• Max. 1 z
• Turn starting switch OFF Is resistance between rear limit switch terminals NO Defective rear limit switch or Inspection or replace
• Disconnect terminals (1), (2) of W03 (1) – (2) normal? opening of front window
W03.
YES
6
• Max. 1 z
• Turn starting switch OFF Is resistance between rear limit switch terminal Disconnection or defective
NO
W03 (1) – P02 (Female) (15), between W03 (2) – contact in wiring harness Repair or replace
• Disconnect terminals (1), (2) of chassis ground normal? having improper resistance
P02 and W03
YES
b) Wiper operates while wiper switch is turned off
Cause Remedy
1
• Turn starting switch ON Does bit (3) of monitoring code "0049" light up? NO Defective monitor panel Replace
YES
2
YES Short circuit with power
source in wiring harness
between P01 (Female) (9) – Repair or replace
W04 (Female) (3) or
between P01 (Female) (10)
– W04 (Female) (1)
PC78US-6 20-545
(12)

a) Wiper does not operate
a If service code "E112", "E113", "E115", or "E116" is displayed, carry out the following troubleshooting.
Cause Remedy
1
• Turn starting switch ON Does bit (3) of monitoring code "0049" light up? NO
YES
2
YES
3
Is voltage between pins of W04 as shown in Table NO
• Turn starting switch ON 1?
YES
Defective wiper motor Replace
4 Disconnection, defective
• Turn starting switch OFF contact, short circuit, or
Is voltage between pins of P01 (Female) – W04 NO short circuit with chassis Repair or replace
• Disconnect P02 and W04 (Male) as shown in Table 2? ground in wiring
having improper resistance
YES
5
• Max. 1 W
• Turn starting switch OFF Is resistance between rear limit switch terminals NO Defective rear limit switch or Inspection or replace
• Disconnect terminals (1), (2) of W03 (1) – (2) normal? opening of front window
W03.
YES
6
• Max. 1 W
• Turn starting switch OFF Is resistance between rear limit switch terminal Disconnection or defective
NO
W03 (1) – P02 (Female) (15), between W03 (2) – contact in wiring harness Repair or replace
• Disconnect terminals (1), (2) of chassis ground normal? having improper resistance
P02 and W03
YES
b) Wiper operates while wiper switch is turned off
Cause Remedy
1
• Turn starting switch ON Does bit (3) of monitoring code "0049" light up? NO Defective monitor panel Replace
YES
2
YES Short circuit with power
source in wiring harness
between P01 (Female) (9) – Repair or replace
W04 (Female) (3) or
between P01 (Female) (10)
– W04 (Female) (1)
20-546 PC78US-6
(12)
Table 1
Timing chart of ON-OFF operation of wiper
Item Symbol Set Time

Stop time up to next operation Tia 0.13 sec
Safety circuit during operation of
wiper Tsa 10 sec
[Safety function (1)]
Stop time up to retraction of Tip 1.5 sec
wiper blade
Safety circuit during retraction of

wiper Tsp 10 sec
Item Symbol Set Time

Stop time up to next operation Tia 4 sec
Safety circuit during operation of
wiper Tsa 10 sec
Stop time up to retraction of
Tip 1.5 sec
wiper blade
Safety circuit during retraction of

wiper Tsp 10 sec
Table 2
Diagnosis 4 Resistance
Between P01 (Female) (10) – W04 (Female) (1)
Between P01 (Female) (12) – W04 (Female) (4) Max. 1 z
Between P01 (Female) (6), (7) – W04 (Female) (5)
Between W04 (Female) (1), (3), (4), (5), (6) – GND Min. 1 Mz
PC78US-6 20-547
(7)

PC78UU-6
PC78US-6 Serial No.: 4001 – 6500
20-548 PC78US-6
(12)

PC78US-6 20-549
(12)
M-24 Washer motor does not operate or operates while washer switch is
turned off
a) Washer motor does not operate
a)-1 When [E114] is displayed
Cause Remedy
1
• Max. 1 V Short circuit with power
Is voltage between P01 (Female) (3) – M31 NO source in wiring harness
(Female) (1) – chassis ground normal? between P01 (Female) (3) –
• Disconnect P02 and M31 M31 (Female) (1)
YES
a)-2 When [E114] is not displayed

Cause Remedy
1
Is voltage between fuse 4 – M31 (Female) (2) – NO contact in wiring harness
chassis ground normal? between fuse 4 – M31
• Disconnect M31 (Female) (2)
YES
2
Is resistance between P01 (Female) (3) – M31 NO contact in wiring harness
(Female) (1) normal? between P01 (Female) (3) –
YES
3
• Max. 1 V
Is voltage between P01 (Female) (3) – chassis NO
• Turn starting switch ON Defective washer motor Replace
ground normal?
• Turn washer switch ON
YES
b) Washer operates while wiper switch is turned off

Cause Remedy
1
• Min. 1 Mz Short circuit with chassis
Is resistance between M31 (Female) (1) – chassis NO ground in wiring harness
ground normal? between P01 (Female) (3) –
YES
20-550 PC78US-6
(12)

PC78UU-6
PC78US-6 Serial No.: 4001 – 6500
PC78US-6 20-551
(12)

20-552 PC78US-6
(12)
M-25 Depth set 0 mode and height mode cannot be selected and set
(Only PC78UU-6)
a Check that each mode is selected and set while the work equipment is out of the interference zone.
Cause Remedy
1
• Bit patter 1022
(4) SET/CLEAR switch NO Defective monitor (Defec-
Is monitor normal? Replace
(5) Mode selector switch ( ) tive switch)
(6) Mode selector switch ( )
YES
2
• Turn starting switch OFF • Is there continuity between following? contact in wiring harness
NO between P02 (female) (9), Repair or replace wiring
• Disconnect P02 and M96 • P02 (9), (10) and M96 (21) (10) – M96 (female) (21) or harness
• Resistance: Max. 1 z • P02 (20) and M96 (31) between P02 (female) (20)
– M96 (female) (31)
YES
PC78US-6 20-553
(12)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ....................... 30- 2 MONITOR PANEL

PRECAUTIONS WHEN CARRYING Removal and Installation ..........................30- 66
OUT OPERATION............................................ 30- 3 AIR CONDITIONER UNIT
SPECIAL TOOL LIST....................................... 30- 7 Removal and Installation ..........................30- 67
COUNTERWEIGHT OPERATOR'S CAB
Removal and Installation ............................ 30-15 Removal and Installation ..........................30- 69
INJECTION PUMP FLOOR FRAME
CYLINDER HEAD OPERATOR'S CAB GLASS (STUCK GLASS)
MAIN PUMP FRONT WINDOW
CONTROL PUMP REVOLVING FRAME
ENGINE AND MAIN PUMP SWING CIRCLE
ENGINE HOOD ASSEMBLY WORK EQUIPMENT
Removal and Installation .........................30-34-1 Removal and Installation ..........................30- 88
HYDRAULIC OIL COOLER FIRST BOOM
RADIATOR SECOND BOOM
SWING MOTOR AND SWING MACHINERY OFFSET BRACKET
SWING MACHINERY STEEL SHOE, RUBBER PAD SHOE,
Disassembly and Assembly........................ 30-40 ROAD LINER
SWING MOTOR Expansion and Installation ........................30-100
Removal and Installation ............................ 30-50 RUBBER SHOE
CENTER SWIVEL JOINT Removal and Installation ..........................30-101
Removal and Installation ............................ 30-51 FINAL DRIVE AND TRAVEL MOTOR
Disassembly and Assembly........................ 30-52 Removal and Installation ..........................30-101
CONTROL VALVE TRAVEL MOTOR
Removal and Installation ............................ 30-53 Disassembly and Assembly......................30-103
Assembly .................................................... 30-54 IDLER
WORK EQUIPMENT PPC VALVE Assembly ..................................................30-154
Assembly .................................................... 30-55 RECOIL SPRING
TRAVEL PPC VALVE Disassembly and Assembly......................30-156
Assembly .................................................... 30-57 TRACK ROLLER
HYDRAULIC TANK Disassembly and Assembly......................30-158
Removal and Installation ............................ 30-58 HYDRAULIC CYLINDER
FUEL TANK Disassembly and Assembly......................30-161
Removal and Installation ............................ 30-61
CONTROLLER
Removal and Installation ............................ 30-65
PC78US-6 30-1
(18)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked [*1], and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation proce-
dure it applies to.
(Example)
REMOVAL OF Q Q Q ASSEMBLY ..................................Title of operation
k ...................................................................................Precautions related to safety when carrying out
the operation
1. (1) ................................................................Step in operation
a .............................................................................Technique or important point to remember
when removing (1).
2. E E E (2): ...............................................................[*1].....Indicates that a technique is listed for
use during installation
3. T T T T assembly (3)
6 .........................................................................See Lubricant and Coolant Table

INSTALLATION OF Q Q Q ASSEMBLY ..........................Title of operation
• Carry out installation in the reverse
order of removal
[*1] ......................................................................Technique used during installation
a .......................................................................Technique or important point to remember
when installing E E E (2).
• Adding water, oil ..................................................Step in operation
a .......................................................................Point to remember when adding water or oil
5......................................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOL LIST given in this manual.
30-2 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.

• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installed position, or make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, disconnect connectors by grasping the con-
nector, not the wire.
• Tag wires and hoses to show their installed position to prevent any mistake when reinstalling.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Hoses and tubes using sleeve nuts

Nominal Sleeve nut (elbow end)
Plug (nut end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
3) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
PC78US-6 30-3
(11)
4) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal
number Part 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 PC78US-6
(11)
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the coolant water level again.
• If the hydraulic equipment has been removed and installed again, add hydraulic oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for
repair, always bleed the air from the system after reassembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
4. Other precautions
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay atten-
tion to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or
when replacing the filters, check that the oil container and area around the filler of the hydraulic tank are
clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points
when disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to
be disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits
of parts that have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment
completely.
• Do not use the seal tape for the thread of the plug mounts or connectors.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment
and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassem-
bled and assembled, also carry out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping,
always bleed the air before starting the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.
PC78US-6 30-5
(11)
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 N.m {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 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
a Necessity: t: Cannot be substituted, should always be installed (used).
q: Very convenient if available, can be substituted with commercially available part.
a New/remodel:N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other mod-
els.
Blank: Tools already available for other models, used without any modification.
a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
Neces- New/
Component Symbol Part No. Part Name Qty. Sketch Nature of work, remarks
sity remodel
Installation of cylin-
der head assembly
A 1 790-331-1110 Wrench q 1 Tightening of cylinder head bolt
1 796T-226-1120 Push tool q 1 N Q Removal, installation of spacer
790-101-3400 Bearing puller q 1

2 Removal of bearing outer race
790-101-3220 Screw q 1
790-101-5201 Push tool KIT q 1
• 790-101-5281 • Plate 1
3 Installation of oil seal
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
• 790-101-5331 • Plate 1
Press fitting of sub bearing outer
4 race
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
• 790-101-5431 • Plate 1
Press fitting of main bearing
5 outer race
• 790-101-5421 • Grip 1
Disassembly, • 01010-51240 • Bolt 1

assembly of swing
machinery assem- F
bly
6 796-765-1110 Push tool t 1 N Q Press fitting of main bearing
inner race
7 792T-413-1120 Push tool t 1 N Q Press fitting of sub bearing inner

race
796-730-2300 Wrench assembly t 1
Measurement of running torque
8
of shaft
795-630-1803 Torque wrench t 1
9 790-201-2770 Spacer q 1 Installation of dust seal

Removal, installation of nut and
10 796T-226-1210 Wrench t 1 N Q measurement of starting torque
of shaft
• 790-101-5311 • Plate 1
11 Installation of oil seal
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
• 790-101-5471 • Plate 1
12 race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
PC78US-6 30-7
(11)
Neces- New/
sity remodel
• 790-101-5451 • Plate 1
Disassembly, Press fitting of main bearing
13
assembly of swing inner race
F • 790-101-5421 • Grip 1
machinery assem-
bly • 01010-51240 • Bolt 1
14 790-201-2240 Push tool q 1

race
• 790-101-5141 • Plate 1
Disassembly, 1 Press fitting of bushing
assembly of idler • 790-101-5021 • Grip 1
assembly
• 01010-50816 • Bolt 1
2 796-230-1110 Installer t 1 Installation of floating seal
• 790-101-5111 • Plate 1
L
3 Press fitting of bushing
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
Disassembly,
assembly of track Installation of floating seal
roller assembly PC78US-6
4 796-230-1120 Installer q 1 Serial No.: 4001 – 6500
PC78UU-6
Installation of floating seal
5 796T-230-1210 Installer q 1 N Q PC78US-6
791-685-8005 Compressor (B) t 1
790-201-2860 Spacer t 1
Disassembly,
assembly of recoil M 791-635-3160 Extension assembly t 1 Compression of spring
spring assembly
790-101-1600 Cylinder
(686kN{70ton}) t 1
790-101-1102 Pump t 1
Remover and
791-616-1030
installer t 1
Expansion, installa-
Pulling out and press fitting of
tion of track shoe R 790-105-1100
Cylinder
(294kN{30ton}) t 1 master pin
assembly
790-101-1102 Pump t 1
790-101-2501 Push puller KIT q 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Disassembly,
assembly of center T
swivel joint assem- • 790-101-2540 • Washer 1 Separation of rotor and shaft
bly
• 790-101-2630 • Leg 2
• 790-101-2570 • Washer 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
30-8 PC78US-6
(11)
Neces- New/
sity remodel
790-502-1003 Cylinder repair stand t 1
Disassembly, assembly of
1
hydraulic cylinder
790-101-1102 Pump t 1

Boom and
blade Removal, installa-
2 tion of cylinder
Arm, bucket head assembly
and offset
790-302-1340
Socket (Width across
flats: 80mm) t 1
Boom
Blade *1
790-102-1470
flats: 70mm) t 1 Arm *1
790-102-1320
flats: 70mm) t 1 Boom *2
Removal, installa-
3 790-302-1320 Socket (Width across
flats: 65mm) t 1 Arm *2 tion of piston
nylon nut
790-102-1330
flats: 75mm) t 1 Blade *2
790-302-1290
flats: 60mm) t 1 Bucket
790-302-1280
flats: 55mm) t 1 Offset
4 790-720-1000 Expander q 1 Expansion of piston ring
796-720-1670 Band q 1
Boom *1
07281-01279 Clamp q 1
796-720-1660 Band q 1
Disassembly, Arm *1
assembly of hydrau-
U 07281-01159 Clamp q 1
lic cylinder assem-
bly 796-720-1650 Band q 1
Installation of
5 Bucket
piston ring
07281-01029 Clamp q 1
796-720-1660 Band q 1 Offset

Boom *2
07281-01159 Clamp q 1 Arm *2
796-720-1670 Band q 1
Blade
07281-01279 Clamp q 1
• 790-101-5021 • Grip 1
Boom and
blade *1
• 01010-50816 • Bolt 1
• 790-201-1811 • Push tool 1
• 790-101-5021 • Grip 1 Arm *1 Press fitting of

6 Boom *2 cylinder head
• 01010-50816 • Bolt 1 Blade *2 bushing
• 790-201-1791 • Push tool 1
• 790-101-5021 • Grip 1
Arm *2
• 01010-50816 • Bolt 1
• 790-201-1781 • Push tool 1
*1 PC78UU-6
*2 PC78US-6
PC78US-6 30-9
(11)
Component Symbol Part No. Part Name Neces- Qty. New/ Sketch Nature of work, remarks
sity remodel
• 790-101-5021 • Grip 1 Press fitting of

Bucket and
6 cylinder head
offset
• 01010-50816 • Bolt 1 bushing
• 790-201-1771 • Push tool 1
• 790-201-1620 • Plate 1
Boom and
blade
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1610 • Plate 1
Arm
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1580 • Plate 1
Bucket and
offset
• 790-101-5021 • Grip 1
Disassembly, • 01010-50816 • Bolt 1
assembly of hydrau-
lic cylinder assem- U
bly 790-201-1500 Push tool KIT q 1
• 790-201-1620 • Plate 1 Press fitting of

7 Boom and
cylinder head dust
Blade *1
• 790-101-5021 • Grip 1 seal
• 01010-50816 • Bolt 1
• 790-201-1610 • Plate 1 Arm *1

Boom *2
• 790-101-5021 • Grip 1 Blade *2
• 01010-50816 • Bolt 1
• 790-201-1590 • Plate 1
Arm *2
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1580 • Plate 1
Bucket and
Offset
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-441-1802 Remover t 1
• 790-441-1810 • Sleeve 1
• 792-900-1530 • Screw 1
Removal of work • 796-900-1240 • Adapter 1

equipment and first V 1 Pulling out of first boom foot pin
boom assembly • 01803-13034 • Nut 1
• 01643-33080 • Washer 1
790-101-4000 Puller (490kN{50ton}) t 1
790-101-1102 Pump t 1
*1 PC78UU-6
*2 PC78US-6
30-10 PC78US-6
(11)
Component Symbol Part No. Part Name Neces- Qty. New/ Sketch Nature of work, remarks
sity remodel
791-735-1123 Sleeve t 1
790-438-1110 Screw t 1
791-735-2110 Adapter t 1
Removal of second
boom assembly
2 790-101-2540 Washer t 1
Pulling out of second boom pin
and offset bracket pin
791-112-1180 Nut t 1
790-101-2102 Puller (294kN{30ton}) t 1
790-101-1102 Pump t 1
V 790-201-2850 Spacer t 1
791-535-1170 Plug t 1
791-520-4140 Screw t 1
Removal of second
boom assembly and
790-101-2420 Adapter t 1
Pulling out of arm cylinder
3
arm cylinder assem- trunnion pin
bly 790-101-2540 Washer t 1
791-112-1180 Nut t 1
790-101-2102 Puller (294kN{30ton}) t 1
790-101-1102 Pump 1
1 793-498-1210 Lifter (Suction cup) t 2

Operator's cab Removal, installation of opera-
glass tor's cab glass (stuck glass)
2 20Y-54-13180
Adapter
(Stopper rubber) t 2
799-703-1200 Service tool KIT t 1

X
Air conditioner unit 799-703-1110
Vacuum pump
(220V) t 1
assembly and floor 3 Collection and supply of air
conditioner gas
frame assembly 799-703-1120 Vacuum pump
(240V) t 1
799-703-1400 Gas leak tester t 1
PC78US-6 30-11
(11)
Note: Komatsu cannot accept any responsibility for special

tools manufactured according to these drawings.
F-1 Push tool
F-6 Push tool
30-12 PC78US-6
(11)
F-7 Push tool
F-10 Wrench
PC78US-6 30-13
(11)
L-5 Installer
30-14 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT ASSEMBRY 8. Remove fuel filler mounting cover (9) of the fuel
tank.
PC78US-2 Serial No. : 4001 – 6500
9. Remove clamp (11) and float gauge hose (10).
PC78UU-2 Serial No. : 22001 and up Loosen the clamp of the hose connected to the
fuel filler tube on the back side of the fuel filler
REMOVAL mounting cover, then remove the tube and cover
a Stop the machine on a level place and set the together.
upper structure in parallel with the track, then a When removing the float gauge hose, check
swing to the right about 20 degrees (since the that the fuel level is below the connecting
mounting bolts are above the track) and lower position of the hose.
the work equipment to the ground and stop the
engine.
1. Remove cover (1) from the top of the hydraulic

tank.
2. Remove engine cover (2).
3. Remove the bracket of damper case breather

(3).
4. Remove 2 mounting bolts of air cleaner bracket

(4) from the right front end of weight (5).
10. Using sling [1], hang weight (5) temporarily and

remove the 3 weight mounting bolts.
11. Lift off weight assembly (5). [*1]

4 Counterweight assembly: 1,170 kg
(With auxiliary weight)
5. Remove the bolt of air conditioner hose clamp.
6. Remove radiator support bracket (7) from the

weight.
7. Remove air inlet cover (8) of the radiator, oil

cooler, etc.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
4 Weight mounting bolt:
1,150 – 1,440 Nm {118 – 147 kgm}
PC78US-6 30-15
(11)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
PC78US-2 Serial No. : 6501 and up 8. Hang counterweight (5) temporarily and remove
the 3 mounting bolts.
REMOVAL
9. Lift off weight assembly (5). [*1]
4 Counterweight assembly: 1,105 kg
a Stop the machine on a level place and set the
upper structure in parallel with the track, then
swing to the right about 20 degrees (since the
mounting bolts are above the track) and lower
the work equipment to the ground and stop the
engine.
1. Remove cover (1) from the top of the hydraulic

tank.
2. Remove engine cover (2).
3. Remove the bracket of damper case breather

(3).
4. Remove 2 mounting bolts of air cleaner bracket

(4) from the right front end of weight (5).
INSTALLATION
removal.
[*1]
4 Counterweight mounting bolt:
1,150 – 1,440 Nm {118 – 147 kgm}
5. Remove the bolt of air conditioner hose clamp.
6. Remove radiator support bracket (7) from the

weight.
7. Remove air inlet cover (8) of the radiator, oil

cooler, etc.
30-16 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY INJECTION PUMP
INJECTION PUMP ASSEMBLY 5. Remove the cylinder head cover.
6. Set the No. 1 cylinder to the compression top

REMOVAL
dead center.
PC78US-6 Serial No.: 4001 – 5500 1) Rotate the crankshaft forward with bolt (30)
PC78UU-6 Serial No.: 22001 – 23500 to match the stamped fuel injection timing
line of 1.4TOP (31) to pointer (32).
a Disconnect the wiring harness from the negative
2) Check that there is clearance in the intake
terminal of the battery.
vale and exhaust valve of the No. 1 cylinder.
a Remove the counterweight. (See REMOVAL OF
a If there is not valve clearance, rotate the
COUNTERWEIGHT.)
1. Remove the nut of the rod of engine stop sole-
noid (1) and the nut of accelerator cable (2) from
the lever side, then remove the rod and cable
assembly.
2. Remove the connectors of the air conditioner,

water temperature sensor, and glow plug and
wire harness clamp (3), then remove stop sole-
noid (1) and bracket together.
7. When the No. 1 cylinder is at the compression

top dead center, timing check hole (17) (the
drilled through hole for bolt hole on this side) of
tachometer removing opening (16) on front cover
(9) must be matched to the hole of the gear.
Insert round bar about 100 mm long (18) in the
holes to check that those holes are matched.
3. Remove injection pipe clamp (4) and loosen the

4 sleeve nuts each on the pump side and nozzle
side of injection pipe (5), then remove injection
pipe (5). [*1]
4. Remove inlet and outlet tubes (6) of the feed

pump. Remove lubrication tube (7) and rear
bracket (8) of the pump. [*2]
PC78US-6 30-17
(11)
8. Remove 6 bolts (11) used to install pump holder INSTALLATION

(10) to front cover (9).
PC78US-6 Serial No.: 4001 – 5500
9. Remove bolt (12) used to install the holder from PC78UU-6 Serial No.: 22001 – 23500
the pump side, then remove the pump assembly • Carry out installation in the reverse order to
and holder drive gear together. [*3] removal.
a When the drive gear and idler gear are
3 Sleeve nut:
installed, their marks C must be matched to [*1]
each other. Since those marks are not seen
actually, however, make match marks on the 19.6 – 24.5 Nm {2 – 2.5 kgm}
3 Outlet and inlet tube bolts of feed pump:

gear and pump in white paint when the pump [*2]
is removed.
19.6 – 24.5 Nm {2 – 2.5 kgm}
[*3]
1. If the stud bolt comes off the holder during
the removal work, apply gasket sealant to its
threaded part (indicated by the arrow) and
2 Threaded part of stud bolt:

reinstall it to the holder.
3 Stud bolt:
Gasket sealant (LG-7)
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2. When installing holder (10) to pump (13),

match the engraved lines (14) on them to
each other.
3. Before installing the pump to the front cover,

match the timing of the gear on the pump
side as shown below.
• Remove the bolt at position A of pump
holder (10) and tighten an M6 bolt 35 mm
or longer (33) to fix the gear. (Compres-
sion top dead center of No. 1 cylinder)
30-18 PC78US-6
(15)
4. When installing the pump to the front cover,

match the match marks made on the gear
and pump when the pump was removed.
Furthermore, match the stamped lines of
holder (10) and plate to each other and
tighten the mounting bolts temporarily.
PC78US-6 30-18-1
(15)
REMOVAL 4. Remove engine stop solenoid (8) and bracket

together.
PC78UU-6 Serial No.: 23501 and up 5. Remove injection pipe clamp and loosen the 4
a Disconnect the wiring harness from the negative sleeve nuts each on the pump side and nozzle
terminal of the battery. side of injection pipe (9), then remove injection
a Remove the counterweight. (See REMOVAL OF pipes (9). [*1]
COUNTERWEIGHT.)
6. Disconnect inlet and outlet hoses (10) of the feed
1. Remove the nut (1) of the rod of engine stop pump and lubrication tube (11). [*2]
solenoid and the nut of accelerator cable (2)
from the lever side, then remove the rod and 7. Remove rear braket (12) of the pump.
cable assembly.
2. Disconnect 3 terminals (PULL, HOLD, and GND)

(3) from the engine stop solenoid.
8. Remove the of cylinder head cover.
9. Set the No. 1 cylinder to the compression top

dead center.
3. Disconnect air compressor wiring connector (M19) 1) Rotate the crankshaft forward with bolt (30)
(4), coolant temperature sensor (M18) (5), glow to match the stamped fuel injection timing
plug (M17) (6), and wire harness clamp (7). line of 1.4TOP (31) to pointer (32).
2) Check that there is clearance in the intake
vale and exhaust valve of the No. 1 cylinder.
a If there is not valve clearance, rotate the
PC78US-6 30-19
(11)
10. When the No. 1 cylinder is at the compression INSTALLATION

top dead center, timing check hole (20) (the
drilled through hole for bolt hole on this side) of PC78US-6 Serial No.: 5501 and up
tachometer removing opening (19) on front cover PC78UU-6 Serial No.: 23501 and up
(12) must be matched to the hole of the gear. • Carry out installation in the reverse order to
Insert round bar about 100 mm long (21) in the removal.
holes to check that those holes are matched.
3 Sleeve nut:
[*1]
19.6 – 24.5 Nm {2 – 2.5 kgm}
3 Outlet and inlet tube bolts of feed pump:

[*2]
19.6 – 24.5 Nm {2 – 2.5 kgm}

[*3]
1. If the stud bolt comes off the holder during
the removal work, apply gasket sealant to its
threaded part (indicated by the arrow) and
2 Threaded part of stud bolt:

reinstall it to the holder.
3 Stud bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}

11. Remove 6 bolts (14) used to install pump holder
(13) to front cover (12).
12. Remove bolt (15) used to install the holder from

the pump side, then remove the pump assembly
and holder drive gear together. [*3]
a When the drive gear and idler gear are
installed, their marks C must be matched to
each other. Since those marks are not seen
actually, however, make match marks on the
gear and pump in white paint when the pump
is removed.
2. When installing holder (13) to pump (16),

match the engraved lines (17) on them to each
other.
3. Before installing the pump to the front cover,
match the timing of the gear on the pump
side as shown below.
• Remove the bolt at position A of pump
holder (13) and tighten an M6 bolt 35
mm or longer (33) to fix the gear. (Com-
pression top dead center of No. 1 cylin-
der)
30-20 PC78US-6
(15)
4. When installing the pump to the front cover,

match the match marks made on the gear
and pump when the pump was removed.
Furthermore, match the stamped lines of
holder (13) and plate to each other and
tighten the mounting bolts temporarily.
PC78US-6 30-20-1
(15)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD ASSEMBLY 5. Remove the 3 bolts and protector (8) of the air
conditioner compressor.
REMOVAL
6. Remove fuel filter (9) from the bracket.
PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22001 – 23500
a Remove the mounting bolts on both sides of the
engine hood bracket to remove the engine hood.
Loosen the coolant drain plug to drain the cool-
ant into a container.
1. Remove the 4 mounting bolts of the air intake

pipe (1) and loosen hose clamp (2) to remove air
intake pipe (1).
7. Remove 1 mounting bolt and 1 lock bolt of air

conditioner compressor (10) and loosen the
adjustment bolt to remove the belt.
8. Disconnect wiring harness connector (11) and

remove the compressor assembly and move it
so that it will not be an obstacle. Remove
bracket (12).
9. Remove coolant temperature sensor connector

(13) and glow plug connector (14). Remove the
2. Remove protector (4) of exhaust muffler (3) and
clamp and heater hose (15).
2 muffler mounting bolts (5). [*1]
3. Loosen the bolts of joint (7) of the muffler and

exhaust pipe (6) to remove the muffler assembly.
[*2]
4. Remove the 4 mounting nuts and exhaust pipe

(6).
PC78US-6 30-21
(11)
10. Remove clamp (17) of fuel injection pipes (16), 13. Loosen locknuts (30) and adjustment screws
then remove the sleeve nuts on the pump side (31). (8 places)
and nozzle side to remove the 4 injection pipes.
Remove the spill pipe on the drain side. [*3] 14. Remove the 8 mounting bolts of rocker arm (20),
and then remove the rocker arm, push rod, and
lead (21) of the glow plug.
[*6]
11. Remove the 8 mounting bolts and exhaust mani-

fold (18). [*4]
12. Remove the 3 mounting bolts and head cover 15. Remove the 17 mounting bolts of cylinder head
(19). [*5] (22), and then lift off the cylinder head assembly.
[*7]
4 Cylinder head assembly: 40 kg
16. Remove air intake manifold (23) and disassem-

ble the cylinder head.
[*8]
30-22 PC78US-6
(11)
INSTALLATION 2. 3 Rocker arm adjusting nut (25):

39.2 – 49Nm {4 – 5 kgm}
PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22001 – 23500
removal.
3 Muffler mounting bolt and nut:

[*1]
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Joint clamp mounting bolt and nut:

[*2]
1st time: 39.2 – 49 Nm {4 – 5 kgm}

2nd time:
68.6 – 122.5 Nm {7 – 12.5 kgm}
3 Sleeve nut:
[*3]
[*7]
19.6 – 24.5 Nm {2 – 2.5 kgm} 1. Tighten the cylinder head mounting bolts in
3 Manifold mounting bolt:

[*4] the following order.
1) Apply molybdenum disulphide LM-P all
34.3 – 53.9 Nm {3.5 – 5.5 kgm} over the threads and seating face of
[*5] each bolt and the seats of the cylinder
1. Insert the cylinder head cover O-ring in the head holes.
O-ring groove, taking care not to expand or 2) Turn the bolts with the fingers until they
contract it, and fit it to the cylinder head. are screwed in the threaded holes of the
2. 3 Head cover mounting bolt (26):

Apply adhesive, if necessary. cylinder head by 2 – 3 threads in the
order of [1] – [17] shown in the figure.
7.84 – 9.8 Nm {0.8 – 1.0 kgm} 3) Tighten the bolts to 68.6 ± 9.8 Nm {7 ± 1
1. 3 Rocker arm shaft mounting bolt (24):

[*6] kgm} in the order of [1] – [17] shown in
the figure.
19.6 – 29.4 Nm {2 – 3 kgm} 4) Tighten the bolts to 107.8 ± 4.9 Nm {11 ±
0.5 kgm} in the order of [1] – [17] shown
in the figure.
a (1): Exhaust side, (2): Air intake side, (3):
Front, (4): Rear
5) Make marks (f) with paint on the bolt

heads and their seats on the cylinder
head, and then tighten the bolts in the
order of [1] – [17] so that the mark of
each bolt will be at 90° +30°
0 from the mark
of the cylinder head.
PC78US-6 30-23
(11)
a After tightening the bolts, make 1 PC78US-6 Serial No.: 5501 and up
punch mark (g) on each bolt head. PC78UU-6 Serial No.: 23501 and up
a If there are 5 or more punch marks
on a bolt head, do not use that bolt
REMOVAL
k Disconnect the cable from the negative (–) ter-
again but replace it.
minal of the battery.
1. Remove the engine hood. For details, See

REMOVAL, INSTALLATION OF COUNTER-
WEIGHT.
2. Drain the coolant.
6 Coolant: 10.5 l
3. Remove air intake hose (1) between the air

cleaner and turbocharger.
4. Remove muffler protector (2).
2 Gasket sealant (LG-7)

[*8]
5. Remove 2 U-clamps (3). [*1]
6. Remove clamp (4) between the turbocharger

Apply lines of the gasket sealant 1 mm in diame-
and muffler and loosen the 4 exhaust pipe
ter as shown below.
mounting nuts on the turbocharger side. [*2]
7. Remove muffler (5).
30-24 PC78US-6
(11)
8. Remove air intake connector (6) between the tur- 12. Loosen the 2 air conditioner compressor mount-
bocharger and exhaust manifold. ing bolts and adjustment bolt and remove air
conditioner compressor belt (12).
13. Disconnect 3 hoses (13) from the fuel filter.
14. Remove air conditioner compressor (14),

bracket, and fuel filter together.
9. Disconnect wiring connectors (M17) (7), (M18)

(8), and (M19) (9).
10. Remove guard (10).
11. Remove oil feed pipe (11).

15. Disconnect 3 terminals (PULL, HOLD, and GND)
(16) and linkage mounting nut (18) from engine
stop solenoid (15).
16. Remove engine stop solenoid (15) and bracket

(17) together.
PC78US-6 30-25
(11)
17. Disconnect blow-by hose (19). 24. Loosen 2 mounting bolts of alternator (27) and
remove fan belt (28).
18. Remove fuel injection pipe clamp (20) and fuel
injection pipes (21). [*3] 25. Remove fan (29).
19. Disconnect spill hose (22). 26. Disconnect heater hoses (30) and (31).
27. Disconnect radiator upper hose (32) and lower

hose (33).
28. Remove water pump assembly (34).
20. Remove the inspection cover on the back side of

the turbocharger.
21. Disconnect turbocharger lubrication tubes (23)

and (24). [*4]
29. Loosen locknuts (40) and adjustment screws
22. Remove turbocharger and exhaust manifold (41). (8 places)
assembly (25). [*5]
30. Remove the 8 mounting bolts, rocker arm (35),
and push rod. [*7]
31. Remove lead (36) of the glow plug.
23. Remove cylinder head cover (26). [*6]
30-26 PC78US-6
(11)
32. Remove the 17 mounting bolts of cylinder head INSTALLATION

(37) and lift off the cylinder head assembly. [*8]
• Carry out installation in the reserve order to
4 Cylinder head assembly: 40 kg removal.
3 U-clamp nut:
33. Remove air intake manifold (38) from the cylin- [*1]
der head assembly.
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Mounting bolt of clamp between turbo-

[*2]
charger and muffler:

1st time: 39.2 – 49 Nm {4 – 5 kgm}
2nd time:
3 Exhaust pipe mounting nut on turbo-

68.6 – 122.5 Nm {7 – 12.5 kgm}
charger side:
27 – 34 Nm {2.8 – 3.5 kgm}
3 Fuel injection pipe sleeve nut:

[*3]
19.6 – 24.5 Nm {2 – 2.5 kgm}
3 Joint bolt of turbocharger lubrication inlet

[*4]
a See Installation of cylinder head [*8].
tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt of exhaust manihold and

[*5]
turbocharger:
34.3 – 53.9 Nm {3.5 – 5.5 kgm}
[*6]
a Insert the cylinder head cover O-ring in the
O-ring groove, taking care not to expand or
contact it, and fit it to the cylinder head.
3 Head cover mounting bolt:

Apply adhesive, if necessary.
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
3 Rocker arm shaft mounting bolt:

[*7]
3 Rocker arm adjusting nut:

19.6 – 29.4 Nm {2 – 3 kgm}
39.2 – 49 Nm {4 – 5 kgm}
PC78US-6 30-27
(11)
[*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 with the fingers until they
are screwed in the threaded holes of the
cylinder head by 2 – 3 threads in the
order of [1] – [17] shown in the figure.
3) Tighten the bolts to 68.6 ± 9.8 Nm {7 ± 1
kgm} in the order of [1] – [17] shown in
the figure.
4) Tighten the bolts to 107.8 ± 4.9 Nm {11 ±
0.5 kgm} in the order of [1] – [17] shown
in the figure.
a (1): Exhaust side, (2): Air intake side, (3):
Front, (4): Rear
5) Make marks (f) with paint on the bolt

heads and their seats on the cylinder
head, and then tighten the bolts in the
order of [1] – [17] so that the mark of
each bolt will be at 90° +30°
0 from the mark
of the cylinder head.
a After tightening the bolts, make 1
punch mark (g) on each bolt head.
a If there are 5 or more punch marks
on a bolt head, do not use that bolt
again but replace it.
30-28 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY MAIN PUMP
MAIN PUMP ASSEMBLY 3. Remove drain plug (6) from the bottom of the
suction tube of pump (5) to drain the oil.
REMOVAL 4. Remove drain plug (7) from the PTO case to
drain the oil.
a Remove the engine hood and counterweight
(See REMOVAL OF COUNTERWEIGHT). 6 Hydraulic oil: Approx. 80 l
a Swing the upper structure from the parking posi-
6 PTO: 0.5 l
tion to the right by 30 degrees and lower the
work equipment to the ground and stop the
engine (so that the hydraulic oil will be drained
easily).
k Loosen the oil filler cap of the hydraulic tank
gradually to release the residual pressure from
the hydraulic tank.
1. Remove air cleaner (1) and its bracket and air
intake hose (2).
2. Remove oil splash protector (3) from the top of

the pump and bottom plate (4) from the bottom of
the pump.
a Cover the manifold from which the air intake
pipe is removed. 5. Remove protector (9), joint (10), and 2 U-bolts
PC78US-6 Serial No.: 4001 – 5500 (11) from muffler (8), then remove muffler (8) and
PC78UU-6 Serial No.: 22001 – 23500 bracket (12). [*1]
(Since the engine mount is an obstacle to
removal of the pump, remove the bracket.)
PC78US-6 Serial No.: 4001 – 5500
PC78UU-6 Serial No.: 22001 – 23500


PC78US-6 30-29
(11)
DISASSEMBLY AND ASSEMBLY MAIN PUMP
6. Remove the wiring harness connector of TVC INSTALLATION

solenoid (13). Remove 6 hoses (14) from the
pump. [*2] • Carry out installation in the reverse order to
a Mask the removed connector and fit male or removal.
female plugs to the hoses and nipple elbows. a When assembling, take care fully so that dirt,
rust, flaw, etc. will not cause a trouble.
[*1]
1. Tighten the mounting bolts of clamp (10) of
the joint between exhaust muffler (8) and
exhaust pipe to 39.2 – 49 Nm {4 – 5 kgm}
first, then tighten to 68.6 – 122.5 Nm {7 –
12.5 kgm}.
2. Tighten the nuts of mounting U-bolts (11) of
exhaust muffler (8) to 7.8 – 9.8 Nm {0.8 – 1.0
kgm}.
[*2]
When installing the rubber hoses, be careful not
to twist them.
[*3]
7. Hang pump (5) temporarily and remove suction After supplying hydraulic oil and before starting
tube (15) and pump mounting bolts, then remove the engine, bleed air from the main pump.
pump (5). [*3]
4 Main pump assembly: 75 kg
30-30 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY CONTROLL PUMP
CONTROLL PUMP ASSEMBLY

REMOVAL
1. Remove the right side cover.
2. Remove hose (2) of control pump (1).
3. Remove the 4 mounting bolt and the control

pump assembly (1).
a Fit male or female plugs to the removed
hoses and elbows.
a If the blade or another attachment is

installed, control pump (1) is different from
the above one and cannot be removed eas-
ily. In this case, remove the counterweight,
referring to REMOVAL OF COUNTER-
WEIGHT, then remove the control pump.
INSTALLATION
removal.
PC78US-6 30-31
(11)
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
a The shapes of the parts of PC78US-6, Serial No.
5501, and up and PC78UU-6, Serial No. 23501
and up, are a little different from the shapes of
the parts in the following figures.
(See REMOVAL OF COUNTERWEIGHT).
a Swing the upper structure from the parking posi-
tion to the right by 30 degrees and lower the
work equipment to the ground and stop the
engine (so that the hydraulic oil will be drained
easily).
7. Remove the adjustment bolt of alternator (9).
the hydraulic tank.
8. Loosen the alternator mounting bolts through the
a Disconnect the cable from the negative (–) termi- hole of the partition and remove the V-belt.
nal of the battery.
9. Remove the mounting bolts to remove the alter-
1. Remove bottom plate (2) from the bottom of
nator.
main pump (1) and drain plug (3) from the bot-
(This work is required since the engine mount
tom of the suction tube to drain the hydraulic oil.
bolts cannot be removed.)
2. Loosen plug (4) of the remote hose to drain the
cooling water from the radiator.
a If the cooling water contains antifreeze, han-
dle it as harmful liquid. Do not handle it ille-
gally.
6 Hydraulic oil: 80 l
6 Cooling water: 8 l
10. Remove the wiring harnesses and connectors of

air conditioner compressor (10), stop solenoid
(11), TVC solenoid (12), water temperature
gauge, glow plug, starting motor, etc.
3. Remove the covers from the boom foot, swing

motor top, and inspection hole on the engine
side.
4. Remove wiring harness (6) of alternator (5).
5. Remove the wiring harness of hydraulic switch

(7) and the rotation sensor connector.
30-32 PC78US-6
(11)
11. Remove guard (13) of air conditioner compres- 20. Remove protector (25) of exhaust muffler (24).
sor (10) from the fan guard. Remove the clamp of the muffler and exhaust
pipe to remove the muffler. Remove the exhaust
12. Remove the mounting bolt of the adjustment bolt pipe from the exhaust manifold. [*2]
and air conditioner compressor (10).
13. Remove return hose (15) for the tank from fuel
filter (14).
14. Remove the 2 mounting bolts and fuel filter (14).
15. Remove 2 heater hoses (16) from the valves on

the thermostat side and engine block side.
21. Remove protector (26) of the pump hose.

Remove the mounting bolts and suction tube
(27) from the pump.
16. Loosen the clamps and disconnect upper hose

(17) and lower hose (18) of the radiator from the
engine.
17. Remove the 6 mounting bolts and fan (19).
18. Remove fuel hose (20) connected to the feed

pump. Remove accelerator wire (21) from the
governor lever. Loosen the locknut of bracket 22. Remove the 6 hoses (28) of pump (1).
(22) and remove the wire. [*1]
23. Remove the 4 bolts of engine support (29).
hoses and elbows.
19. Remove air cleaner (23), bracket, and air intake

hose together from the air intake manifold.
PC78US-6 30-33
(11)
24. Install the hook to engine assembly (30) and a INSTALLATION

sling to main pump (1) and lift off the engine and
pump assembly, hanging it by 3 points. • Carry out installation in the reverse order to
4 Engine • Main pump assembly: 370 kg

removal.
3 Fuel hose bolt:

[*1]
19.6 – 24.5 Nm {2 – 2.5 kgm}

[*2]
1. Tighten the mounting bolts of the clamp of the

joint between exhaust pipe and muffler to 39.2 –
49 Nm {4 – 5 kgm} first, then tighten to 68.6 –
122.5 Nm {7 – 12.5 kgm}.
2. Tighten the nuts of the mounting U-bolts of the

muffler to 7.8 – 9.8 Nm {0.8 – 1.0 kgm}.
[*3]
After installing the engine mount to the revolving
frame, apply clear lacquer to the unpainted
engine mount fitting face.
3 Mounting bolt:
249 – 309 Nm {25 – 31.5 kgm}
2 Mounting bolt:
Apply liquid adhesive LT-2
30-34 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
ENGINE HOOD ASSEMBLY INSTALLATION

REMOVAL removal.
k Park the machine on level ground, lower the
work equipment to the ground completely, [*1]
stop the engine, and set the lock lever in the • Adjust the hood catch. For details, see Testing
and adjusting, "Testing and adjusting hood
k Disconnect the cable from the negative (–)
LOCK position.
catch".
1. Open engine hood assembly (1) and lock it with

the lock bar.
a Fix the lock bar securely.
2. Remove cover (2).
3. Sling engine hood assembly (1) by passing the

sling through the hole apeared by removing
cover (2).
4. Remove lock bar (3).
5. Remove the mounting bolts for two hinges (4) and

lift off engine hood assembly (1). [*1]
4 Engine hood assembly: 30 kg
PC78US-6 30-34-1
(18)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
HYDRAULIC OIL COOLER INSTALLATION

ASSEMBLY • Carry out installation in the reverse order to
removal.
PC78US-6 Serial No.: 4001 – 6500
REMOVAL
(See REMOVAL OF COUNTERWEIGHT).
1. Disconnect the hose of reserve tank (1) from the

radiator and remove it together with the tank
bracket.
2. Remove receiver tank (2) from the frame.
3. Remove condenser (3) and arrange it and

receiver tank so that they will not be obstacles.
4. Remove net (4) of the oil cooler.
5. Remove the bottom plate of oil cooler (5) and

prepare an oil receiving container, then remove
cooler inlet hose (6) and outlet hose (7).
6. Remove condenser bracket (8). Remove the 4

bolts used to secure the brackets on the top and
bottom of the oil cooler, then remove the oil
cooler.
PC78US-6 30-35
(11)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
PC78US-6 Serial No.: 6501 and up 8. Remove the bottom plate of oil cooler (12) and
prepare an oil receiving container, and then
REMOVAL remove outlet hose (8) and cooler inlet hose (9).
a Swing the upper structure by 20 degrees. 9. Remove net bracket (10).
1. Remove the engine hood and open the vent of 10. Remove 2 mounting bolts (11) of oil cooler (12),
the hydraulic oil cooler. and then remove oil cooler (12).
2. Remove reservoir tank (1) of the radiator and its

bracket together.
3. Remove bracket (2).
4. Remove battery cover (3) and 2 batteries (4).
5. Remove condenser (5) and bind it to the vent of

the hydraulic oil cooler.
a Do not disconnect the piping.
6. Remove the oil cooler and radiator net (6).
7. Remove bracket (7).
INSTALLATION
removal.
30-36 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR ASSEMBLY 3. Remove the 6 mounting bolts and fan (5).

Loosen the clamps on the engine side and
remove upper hose (6) and lower hose (7). [*2]
PC78US-6 Serial No.: 4001 – 6500
REMOVAL
Remove the hydraulic oil cooler. For details, see
REMOVAL OF HYDRAULIC OIL COOLER. [*1]
1. Move oil cooler (2) removed from radiator (1) to

the left, without disconnecting the inlet and outlet
hoses.
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).
2. Loosen remote plug (3) on the bottom of the radi-

ator to drain the cooling water into a container.
Remove protector (4) of the air conditioner com-
pressor from fan guard (1).
6 Cooliant: Approx. 4 l
a If the coolant contains antifreeze, handle it

as harmful liquid. Do not handle it illegally.
INSTALLATION
removal.
[*1]
When installing the radiator and oil cooler, check
that the sealing material (sponge) between them
is not deformed or broken but normal.
[*2]
1. When inserting each hose, apply LG-6 to the

adapter of the mating part. When tightening
each clamp, check that it is not over the tube
lock part.
2. 3 Hose clamp: 8.8 Nm {0.9 kgm}
PC78US-6 30-37
(11)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL
1. Remove the counterweight. For details, see
Removal of counterweight. [*1]
2. Drain the coolant.

5 Coolant: Approx. 4 l
a If the coolant contains antifreeze, handle it
as harmful material according to the law.
3. Disconnect reservoir tank hose (1) of the radia-

tor.
4. Loosen the clamps of upper hose (2) lower hose

(3) on the engine side and disconnect those 13. Remove radiator (13) so that radiator outlet A will
hoses. [*2] move around shroud (7).
5. Remove cushion (4).
6. Remove fan guard (5).
8. Remove the 4 mounting bolts and shroud (7).
INSTALLATION
removal.
[*1]
9. Remove net (8). When installing the radiator and oil cooler, check
that the sealing material (sponge) between them
10. Disconnect clamp (9) and remove bracket (10). is not deformed or broken but normal.
[*2]
11. Remove plug (11) from the bottom of the radia-
tor. 2 Mating face of hose:Gasket sealant
(ThreeBond 1208E or equivalent)
12. Remove 2 radiator mounting bolts (12).
3 Hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.5 kgm}
30-38 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
SWING MOTOR AND SWING 6. Lift off swing motor and swing machinery assem-
bly (6). [*1]
4 Swing motor and
MACHINERY ASSEMBLY
swing machinery
REMOVAL assembly: 77 kg
a Extend the work equipment to the maximum

reach and lower it to the ground and stop the
engine.

the hydraulic tank.
1. Remove the top cover of the swing motor
2. Disconnect hoses (1), (2), (3), (4), and (5) of the

swing motor.
hoses and elbows.
a Record the disconnected hoses to prevent a
mistake in re-connecting them.
INSTALLATION
removal.
2 Contact faces on underside of swing

[*1]
machinery case and frame:

Apply gasket sealant (LG-6)
3 Swing machinery case mounting bolt:

245 – 308.7 Nm {25 – 31.5 kgm}
a When installing the assembly, take care not to

break the drain tube of the swing machinery
case.
3. Remove the (9) swing machinery mounting bolts. a Refilling with oil (Hydraulic tank)
Run the engine to circulate the oil through the
4. Pull the plugs out of the forcing screw holes of piping. Then, check the oil level again and add
the swing machinery and hang the body of the new oil to the specified level.
swing machinery with 2 slings wound onto it.
5. Using 2 forcing screws, disconnect the swing

motor and swing machinery assembly (6) from
the frame.
PC78US-6 30-39
(11)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
SWING MACHINERY
ASSEMBLY
PC78US-6 Serial No.: 4001 – 6500
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.
6 Swing machinery case: Approx. 2 l
2. Swing motor assembly

Remove swing motor assembly (1). 4) Drive in pin (9) to push out shaft (10).
a After removing the shaft, remove pin (9).
5) Remove thrust washer (11) from carrier (12).
3. No. 1 sun gear and No. 1 carrier assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 2 carrier (3).
3) Disassemble No. 1 carrier assembly accord-

ing to the following procedure.
i) Remove snap ring (4), thrust washer (5),
gear (6), bearing (7), and thrust washer
(8).
30-40 PC78US-6
(11)
4. No. 2 sun gear 2) Remove 2-piece collar (26).

Remove No. 2 sun gear (13).
5. Ring gear
Remove ring gear (14).
6. No. 2 carrier assembly

1) Remove No. 2 carrier assembly (15).
8. Shaft assembly
1) Set block [1] to shaft and case assembly
(27). Using push tool [2] and the press,
remove shaft assembly (28).
2) Remove sub bearing (25).

i) Remove snap ring (16), thrust washer
(17), gear (18), bearing (19), and thrust
washer (20).
ii) Drive in pin (21) to push out shaft (22).
a After removing the shaft, remove pin
(21).
iii) Remove thrust washer (23) from carrier
(24).
3) Set the shaft assembly to the press. Using

push tool [3], remove main bearing (29) and
collar (30) from shaft (31).
7. Collar
1) Set the shaft and case assembly to a press
and push sub bearing (25) with tool F1.
a Operate the press slowly and push the
bearing until the 2-piece collar can be
removed.
PC78US-6 30-41
(11)
9. Dust seal, oil seal, and bearing outer race ASSEMBLY

1) Remove dust seal (32) and oil seal (33) from
case (34). a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
1. Oil seal
Using tool F3, press fit oil seal (33) to case (34).
a Replace the oil seal with new one.
3 Lip of oil seal:Grease (G2-LI)
3 Periphery of oil seal:
2) Using tool F2, remove bearing outer races

(35) and (36) from case (34).
2. Sub bearing outer race

Using tool F4, press fit outer race (36) to case
(34).
a Press fitting force: Max. 8.82 kN {Max. 0.9
tons}
3. Main bearing outer race

(34).
tons}
30-42 PC78US-6
(11)
4. Shaft assembly
1) Install collar (30) to shaft (31).
2) Using tool F6 and the press, press fit main
bearing (29).
a Press fitting force: Max. 65.7 – 178.4 kN
{Max. 6.7 – 18.2 tons}
5. Dust seal
Using tool F9, press fit dust seal (32).
a Replace the dust seal with new one.
3) Set case assembly (37) to shaft assembly

(28).
{Max. 2.8 – 11.9 tons}
4) Using tool F7 and the press, press fit sub
bearing (25) until the 2-piece collar can be
installed.
{Max. 2.8 – 11.9 tons}
a Turning the case, press fit the bearing
slowly.
5) Install 2-piece collar (26).
6) Using tool [8] and the press, press fit shaft

(31) until 2-piece collar (26) is secured.
7) Using tool F8, measure the running torque of
the shaft.
a Running torque: Max. 19.6 Nm {Max. 2.0
kgm}
PC78US-6 30-43
(11)

1) Assemble No. 2 carrier assembly according
i) Install thrust washer (23) to carrier (24).
ii) Match shaft (22) to the pin hole of the
carrier and install it by hitting it lightly with
a plastic hammer.
iii) Insert pin (21).
a After inserting the pin, bend the pin of
the carrier.
iv) Install thrust washer (20), bearing (19),
gear (18), thrust washer (17), and snap
ring (16).

1) Assemble No. 1 carrier assembly according
i) Install thrust washer (11) to carrier (12).
ii) Match shaft (10) to the pin hole of the
carrier and install it by hitting it lightly with
a plastic hammer.
iii) Insert pin (9).
a After inserting the pin, bend the pin of
the carrier.
2) Install No. 2 carrier assembly (15) to the

shaft and case assembly.
7. Ring gear
Install ring gear (14).
2 Fitting face of ring gear:
3 Ring gear mounting bolt:
58.5 – 73.5 Nm {6 – 7.5 kgm}
8. No. 2 sun gear

Install No. 2 sun gear (13).
a Take care not to install the sun gear and
planetary gear upside down.
30-44 PC78US-6
(11)
iv) Install thrust washer (8), bearing (7), a Supplying oil and grease
gear (6), thrust washer (5), and snap ring Tighten the drain plug and supply engine oil
(4). through the oil filler.
a Apply LG-5 to the fitting part of the drain

tube.
3 Drain plug:
44.1 – 93.1 Nm {4.5 – 9.5 kgm}
a When mounting the assembly on the

machine, apply gasket sealant LG-6 to the
fitting face of the revolving frame.
2) Install No. 1 carrier assembly (3).

3) Install No. 1 sun gear (2).

Install swing motor assembly (1).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2 Fitting face of motor:
PC78US-6 30-45
(11)
DISASSEMBLY
1. Draining oil
Remove the drain plug and drain the oil from the
swing machinery.

Remove swing motor assembly (1).
4. No. 2 sun gear

Remove No. 2 sun gear (13).
5. Ring gear
Remove ring gear (14).
3. No. 1 sun gear and No. 1 carrier assembly

1) Remove No. 1 sun gear (2).
2) Remove snap ring (3).
3) Remove No. 1 carrier (4).

• Remove snap ring (16), thrust washer
(17), gear (18), bearing (19), and thrust
washer (20).
2) Using tool F10, remove nut (21).
3) Remove carrier (22).
4) Remove sub bearing (25) from carrier (22).
3) Disassemble No. 1 carrier assembly (4)
according to the following procedure.
• Remove snap ring (5), thrust washer (6),
gear (7), bearing (8), and thrust washer
(9).
30-46 PC78US-6
(11)
7. Shaft assembly 8. Oil seal, and bearing outer race

1) Set block [1] to shaft and case assembly 1) Remove oil seal (33) from case (34).
(27). Using push tool [2] and the press,
remove shaft assembly (28).
2) Using tool F2, remove bearing outer races

(35) and (36) from case (34).
2) Remove main bearing (29) and grease seal
(30) from shaft (31).
PC78US-6 30-47
(11)
ASSEMBLY 4. Shaft assembly

1) Install grease seal (30) to shaft (31).
a Clean the all parts and check them for dirt or 2) Using tool F6 and the press, press fit main
damage. Coat their sliding surfaces with engine bearing (29).
oil before installing. a Press fitting force: Max. 12.7 – 34.3 kN
{Max. 1.3 – 3.5 tons}
1. Oil seal
Using tool F11, 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:

1) Using tool F7 and the press, press fit sub
bearing (25) to No. 2 carrier (22).
{Max. 0.4 – 1.5 tons}
2) Using tool [3] and the press, press fit No. 2
carrier (22) to spline of shaft.
2. Sub bearing outer race a Press fitting force: Max. 6.08 – 26.4 kN
Using tool F12, press fit outer race (36) to case {Max. 0.62 – 2.69 tons}
(34). a Turning the case, press fit the bearing
a Press fitting force: Max. 5.88 kN {Max. 0.6 slowly.
tons}
3. Main bearing outer race

(34).
tons}
30-48 PC78US-6
(11)
3) Using tool F10, install nut (21). 6. Ring gear

2 Nut (21): LT-2
Install ring gear (14).
2 Mating face of ring gear:
3 Nut (21): 784 – 833 Nm {80 – 85 kgm}
4) Using tools F8 and F10, measure the starting
7. No. 2 sun gear
torque.
Install No. 2 sun gear (13).
a Starting torque: Max. 19.6 Nm {Max. 2.0
a Take care not to assemble the sun gear and
kgm}
planetary gear up side down.
5) Assemble the No. 2 carrier assembly accord-

1) Assemble No. 1 carrier assembly (4) accord-
• Install thrust washer (20), bearing (19),
gear (18), and thrust washer (17) to car-
• Install thrust washer (9), bearing (8),
rier (22), and then install snap ring (16).
gear (7), and thrust washer (6) to No. 1
carrier (10), and then install snap ring
(5).
PC78US-6 30-49
(11)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY, SWING MOTOR
2) Install No. 1 carrier assembly (4). SWING MOTOR ASSEMBLY

3) Install snap ring (3).
4) Install No. 1 sun gear (2).
REMOVAL
a Remove the hoses of the swing motor. For
details, see REMOVAL OF SWING MOTOR
AND SWING MACHINERY ASSEMBLY.
1. Remove the 8 swing motor mounting bolts (1).
2. Remove the swing motor assembly.

a After removing the swing motor, cover the
swing machinery.

Install swing motor assembly (1).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
INSTALLATION
removal.
a Refilling with oil (Hydraulic tank)
piping. Then, check the oil level again and add
new oil to the specified level.
a Supplying oil and grease
Tighten the drain plug and supply engine oil
through the oil filler.
a Apply LG-5 to the fitting part of the drain

tube.
3 Drain plug:
44.1 – 93.1 Nm {4.5 – 9.5 kgm}
a When mounting the assembly on the

machine, apply gasket sealant LG-6 to the
fitting face of the revolving frame.
30-50 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
CENTER SWIVEL JOINT 4. Remove the bottom plate of the center swivel.
ASSEMBLY 5. Remove the 4 travel forward/reverse and lateral

hoses, 2 2nd travel speed selection hoses, 2
REMOVAL drain hoses, etc. (4) from the underside of the
a Extend the work equipment to the maximum swivel.
engine. 6. Remove the cotter pin of the lock pin of the cen-
ter swivel from above, then pull out the lock pin
k Loosen the oil filler cap of the hydraulic tank and disconnect the lock plate.
the hydraulic tank. 7. Hang the center swivel joint temporarily and
remove the 4 mounting bolts from plate (5).
1. Remove the top cover of the center swivel joint. a Fit male or female plugs to the removed
hoses, nipples, and elbows and record the
2. Remove travel drain hose (1) and swing motor disconnected hoses to prevent a mistake in
hose (2). re-connecting them.
3. Remove 5 hoses (3) of the control valve, travel

forward/reverse, lateral hose, and 2nd travel
speed selection from the top one.
hoses, nipples, and elbows.
8. Lift off center swivel joint assembly (6).

4 Center swivel joint assembly: 18.5 kg
INSTALLATION
removal.
a When installing the rubber hoses, be careful not
to twist them.
PC78US-6 30-51
(11)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY ASSEMBLY
1. Remove cover (1). 1. Install slipper seal (7) and O-ring (6) to swivel
shaft (5).
2. Remove snap ring (2).
2. Set swivel shaft (5) to the block. Using the push
3. Using tool T, pull swivel rotor (4) and ring (3) out tool, hit swivel rotor (4) with a plastic hammer
of swivel shaft (5). lightly to install it.
a Apply grease (G2-LI) to the contact surfaces
4. Remove O-ring (6) and slipper seal (7). of swivel shaft (5) and swivel rotor (4).
a When installing the rotor, take care fully not
to damage the lips of the slipper seal and oil
seal.
3. Install ring (3) and secure it with snap ring (2).
4. Install the O-ring and cover (1).

3 Mounting bolt:
31.4 ± 2.94 Nm {3.2 ± 0.3 kgm}
a When assembling, take care fully so that dirt,

a After assembling, seal each port with a poly-
ethylene plug.
30-52 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE ASSEMBLY

REMOVAL
k Lower the work equipment to the ground and
stop the engine, then loosen the oil filler cap
the hydraulic tank.

(-) terminal of the battery.
1. Remove the top cover of the hydraulic tank.
2. Remove the right side cover.

8. Remove the 4 control valve mounting bolts from
3. Remove 5 connectors (1) of the hydraulic the underside of control valve stand (9) and lift
switches and the wiring harness bracket. off control valve assembly (10), using sling [1].
4. Remove each pilot hose (2). 4 Control valve assembly: 65 kg
5. Remove hoses (3) between the pump and

merge-divider valve.
a Mask the removed connectors.
INSTALLATION
6. Remove hoses (5), (6), and (7) of attachment
selector valve (4).
removal.
[*1]
1. When assembling, take care fully so that dirt,
2. When installing the rubber hoses, take care fully

not to twist them.
3. Bleed all air from the swing PPC circuit.
4. After assembling, flush the all piping circuit.

a The number of the control valves and pipes
of a machine equipped with an attachment
and those of Model UU are different from the
above.
7. Remove hoses (8) on the operator's cab side of
the control valve in order from the top one. [*1]
hoses and nipples.
PC78US-6 30-53
(11)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
ASSEMBLY
a When disassembling and assembling the preci-
sion parts of the hydraulic system, keep them
clean extremely and work in a clean place.
a Take care fully not to hurt your fingers with the
edges of the machines parts.
a Check the fitting surfaces of the all parts. If a
part has a scratch or a burr, replace it with new
one since it can cause a trouble. Take care fully
not to bruise or damage a part by dropping or hit-
ting it.
a Wash the all metallic parts in clean solvent and
dry them with compressed air. If they are wiped
with cloths or paper, fibers of the cloths and
paper enter the product and contaminate the
hydraulic system and can cause a trouble. 3. When loosening or tightening plug (10) of spool
Accordingly, never wipe the parts with cloths or (9) of bucket valve (8), be sure to put spool (9) in
paper. valve chest (8).
a When assembling, replace the consumable parts
such as the O-rings and seals with new ones, as 4. When loosening or tightening plugs (13) and (14)
a rule. Apply a little amount of clean grease to of spool (12) of arm valve (11), be sure to put
the O-rings. spool (12) in valve chest (11).
a Take care of the installing direction of each
spool. 5. When loosening or tightening plugs (17) and (18)
of spool (16) of boom valve (15), be sure to put
1. When loosening or tightening mounting bolt (1) spool (16) in valve chest (15).
used to install the retainer of the spool return a When tightening each of the orifices and
spring to each spool, be sure to put spool (2) in plugs described above, apply 1 drop (approx.
valve chest (3) (to prevent deformation of the 0.02 g) of LOCTITE (No. 638) to it. Thor-
spool). oughly degrease and dry the plug and the
3 : 6.9 – 9.8 Nm {0.7 – 1.0 kgm}

f e m a l e s c r e w o f t h e v a l v e c h e s t wi t h
DRYSOL. Do not apply pressure to them for
2 hours after they are tightened.
3 Orifice and plug:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
2. When loosening or tightening orifice (5) and plug

(6) of merge-divider valve (4), be sure to put
spool (7) in valve chest (4) (to prevent deforma-
tion of the spool).
30-54 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE, 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: a When assembling, clean and inspect the parts
39.2 – 49.0 Nm {4 – 5 kgm} closely and take care fully so that dirt, rust, flaw,
3rd tightening torque: etc. will not cause a trouble.
58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Combination bolt (2) tightening torque 1. When installing plug (2) to body (1), take care
29.4 – 34.3 Nm {3 – 3.5 kgm} that its tip will not enter the hole of the body 20
mm in diameter.
3 Plug (2): 4 – 9 Nm {0.4 – 0.9 kgm}
2. The head of plug (3) must no project from the

body surface.
3 Plug (3): 6 – 11 Nm {0.6 – 1.1 kgm}
3. When installing piston (8), apply grease (G2-LI)

to the outside of the piston and inside of the body
hole.
4. Install spring (5) with its small diameter side on

the shim (4) side.
• Diameter of spring (Inside diameter)
a For the tightening torque of the auxiliary valves Small diameter side: 4.9 mm
(Relief valve, suction safety valve, pressure Large diameter side: 5.55 mm
compensation valve, etc.), see STRUCTURE
AND OPERATION, MAINTENANCE STAN- 5. Different springs (6) and (7) are used for different
DARD. hydraulic ports. Take care when installing them.
a After assembling, seal each port with a nylon
PC78US-6 Serial No.: 4001 – 6500
cap, etc.
a When hanging the valve assembly, use eyebolts
(04530-10815). • Installed height: 34 mm
• Installed load
Spring (6) (P1, P2): 29 N {3 kg}
Spring (7) (P3, P4): 17.7 N {1.8 kg}

• Installed height: 32 mm
• Installed load
Spring (6) (P1, P2): 35 N {3.57 kg}
Spring (7) (P3, P4): 21.77 N {2.22 kg}
3 Bolt (9): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
6. When installing joint (10) to body (1), apply LOC-

TITE as shown below.
1) When installing the joint, apply 1 drop
(approx. 0.02 g) of LOCTITE (No. 262 or No.
648) each to 2 places of the female screw of
the body. Before installing the joint, thor-
oughly degrease and dry its male screw and
the female screw of the body with DRYSOL.
2) Drop LOCTITE to the following positions.
Female screw of body
PC78US-6 30-55
(11)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
PC78US-6 Serial No.: 4001 – 6500

3 Joint (10): 39 – 49 Nm {4 – 5 kgm}
7. Apply grease (G2-LI) to the sliding parts of joint

(10) and contact parts of disc (11) and piston (8).
2 Application rate of grease (G2-LI)
1) Sliding parts of joint: 2 - 4 cc/periphery
2) Contact parts of disc and piston: 0.3 - 0.8 cc/
place
8. When installing disc (11), adjust it so that the

play at the lever end will be 0.5 - 3 mm (200 mm
from the rotation center of the lever).
3 Nut (12):
PC78US-6 Serial No.: 4001 – 6500
PC78UU-6 Serial No.: 22001 and up PC78US-6 Serial No.: 6501 and up
98 – 127 Nm {10 – 13 kgm}
69 – 88 Nm {7 – 9 kgm}
30-56 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
TRAVEL PPC VALVE 8. Tighten each part to the following torque.

• Plug (11): 6 – 11 Nm {0.6 – 1.1 kgm}
ASSEMBLY • Bolt (12): 3.9 – 4.9 Nm {0.4 – 0.5 kgm}
(Apply LOCTITE #262.)
ASSEMBLY • Screw (13): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
a When assembling, clean and inspect the parts • Plug (14): 4 – 9 Nm {0.4 – 0.9 kgm}
closely and take care fully so that dirt, rust, flaw, • Bolt (15): 25 – 30 Nm {2.5 – 3.2 kgm}
etc. will not cause a trouble. • Bolt (16): 27 – 34 Nm {2.8 – 3.5 kgm}
1. When installing piston (1), apply grease (G2-LI)

to its outside and the inside of the body hole.
2. Install spring (2) with its small diameter side on

the shim (3) side.
• Diameter of spring (Inside diameter)
Small diameter side: 4.9 mm
Large diameter side: 5.55 mm
3. Use the insertion jig to insert bushing (4). (Do

not drive in the bushing with impact loads of a
hammer, etc.)
4. Use the insertion jig to insert pin (5). (Do not

drive in the pin with impact loads of a hammer,
etc.)
5. Apply grease (G2-LI) to the rocking part of shaft

(6) and the contact surfaces of lever (7) and pis-
ton (1) and the contact surfaces of plate (8) and
pin of lever (9).
2 Quantity of grease (G2-LI)
Rocking part of shaft:4 – 8 cc/periphery
Contact surfaces of lever and piston:
0.3 – 0.8 cc/place
Contact surfaces of plate and pin:
0.3 – 0.8 cc/place
6. Install washer (10) 1.6 mm thick first. If the dif-

ference between both sides at the stroke end of
the lever exceeds 0.7°, change the washer thick-
ness to reduce the difference to below 0.7°. (If
the washer thickness is reduced by 0.3 mm, the
stroke end angle is increased by 0.39°.)
• Thickness of washer t: 1.0, 1.3, 1.6 mm
7. After assembling, seal the ports (P1 – P4, T, P)

with nylon caps, etc.
PC78US-6 30-57
(11)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK 8. Remove hose (6) from the oil cooler and the
other hoses.
ASSEMBLY a Fit male or female plugs to the removed
hoses, elbows, etc.
PC78US-6 Serial No.: 4001 – 6500 a Record the disconnected hoses to prevent a
PC78UU-6 Serial No.: 22001 and up mistake in re-connecting them.
REMOVAL
a Swing the work equipment to a position at which
the hydraulic oil can be drained easily and lower
the work equipment to the ground.
k Stop the engine and loosen the hydraulic oil

filler cap gradually to release the residual pres-
sure from the hydraulic tank.
1. Drain the oil from the hydraulic tank.
2. Remove the top cover and right side cover of the

hydraulic tank.
9. Using sling (1), remove the mounting bolts and
3. Remove the wiring harness clamp and washer lift off hydraulic tank assembly (7).
tank (1).
4. Loosen the clamp and remove pump suction

hose (2).
6 Hydraulic tank: 64 l
INSTALLATION
removal.
a When installing the rubber hoses, be careful not
5. Remove partition cover (3) of the boom. to twist them.
6. Remove work equipment attachments selector Run the engine to circulate the oil through the
valve (4). piping. Then, check the oil level again and add
7. Remove 5 return hoses (5), including the swing
hose.
30-58 PC78US-6
(11)
PC78US-6 Serial No.: 6501 and up 6. Remove hose clamp (7) and slacken hose (8).
REMOVAL
a Swing the upper structure by to the right by 90
degrees and lower the work equipment to the
ground.
k Stop the engine and loosen the hydraulic tank

cap gradually to release the residual pressure
in the tank.
1. Drain the oil from the hydraulic tank.

6 Hydraulic tank: 70 l 7. Disconnect hoses (9) and (10).
2. Remove top cover (1), right side cover (2), and 8. Disconnect clamp (11).
cover (3) from the hydraulic tank.
9. Remove cover (12) and disconnect fuel level

3. Remove the wiring harness clamp of washer sensor connector (13) from inside.
tank (4), disconnect the washer tank, and put it
on the control valve.
4. Loosen the clamp of pump suction hose (5) and

disconnect the hose.
5. Disconnect 8 return hoses (6), including the

swing return hose.
a Install a male or female plug to each of the
disconnected hoses and elbows.
a Record the positions of the disconnected
hoses so that you can correctly connect
them again.
PC78US-6 30-59
(11)
10. Move fuel tank (14) in the direction of the arrow INSTALLATION
and stabilize it with block [1].
11. Remove the 4 mounting bolts and lift off hydrau- removal.
lic tank (15). [*1]
4 Hydraulic tank: 70 kg 2 Mounting bolt: Adhesive (LT-2)
[*1]
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a Connect the hoses so carefully that they will not

be twisted.
Add oil to the specified level. Run the engine to
circulate the oil through the piping. Then, check
the oil level again and add oil to the specified
level.
30-60 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK ASSEMBLY 7. Remove the inspection cover of fuel suction

hose (7) and drain hose (8) from the underside of
the revolving frame under the fuel tank, then
PC78US-6 Serial No.: 4001 – 4903
remove the suction hose and drain hose.
PC78UU-6 Serial No.: 22001 – 22788
REMOVAL
a Drain the fuel through the drain valve.
6 When fuel tank is full: 125 l
1. Remove the front and left deck covers.
2. Remove the mounting bolts of fuel filler mounting

cover (1) and loosen the hose clamp of the fuel
filler tube and pull out the tube.
8. Remove the 2 mounting bolts of fuel tank bracket
3. Remove the clamp and hose (2) of the fuel spill
(9) on this side from the underside of the revolv-
prevention gauge and take out cover (1).
ing frame.
4. Loosen the clamp of fuel supply hose (3) on the
9. Remove the 2 bolts of PPC hose bracket (10)
fuel tank (4) side and remove the hose from the
and move them to the left (to secure a wider
tank.
work space).
5. Remove the clamp of PPC hose (5) from the
underside of the floor.
10. Remove the nut and fuel tank band (11) on the
deeper side from the tank. [*1]
6. Remove the fuel sensor top cover of the floor
and disconnect sensor connector (6).
PC78US-6 30-61
(11)
11. Pull out and remove fuel tank (4). PC78US-6 Serial No.: 4904 – 6500
a Fuel tank air bleeding hose (12) is not PC78UU-6 Serial No.: 22789 and up
installed.
REMOVAL
6 Drain the fuel.
When fuel tank is full: 125 l
1. Remove the front and left deck covers.
2. Remove the mounting bolts of fuel filler mounting

cover (1). Loosen the hose clamp of the fuel
filler tube and pull out the tube.
3. Remove the clamp of fuel spill prevention check

gauge hose (2), and then remove the hose and
cover (1) together.
INSTALLATION
4. Loosen the clamp of fuel feed hose (3) installed
to fuel tank (4), and the remove the hose from
removal.
3 Tightening torque of tank mounting band
the tank.
(11): 5. Remove the fuel level sensor top cover on the

Nut (23): floor and disconnect sensor connector (6).
0.98 ± 0.49 Nm {0.1 ± 0.05 kgm}
Nut (24): 58.8 ± 9.8 Nm {6.0 ±1.0 kgm}
30-62 PC78US-6
(11)
6. Remove the mounting bolts of P-block (21) and 9. Remove the inspection cover of fuel suction
T-block (22) for the PPC piping from under the hose (7) and drain hose (8) from the underside of
front of the operator's cab. the revolving frame under the fuel tank, then
a Perform this work to avoid tensing the hose remove the suction hose and drain hose.
between P-block (21), T-block (22), and sole-
noid valve (A).
(In the photo, the plate is removed.)
10. Remove the 2 mounting bolts of the fuel tank

bracket (9) on this side from the underside of the
revolving frame.
7. Remove 4 operator's cab assembly mounting
bolts (27) marked with #. [*1] 11. Remove the 2 bolts of PPC hose bracket (10)
a Do not remove 6 mounting bolts (28) marked and move them to the left (to secure a wider
with . work space).
8. Install a sling to the top of the operator's cab 12. Remove the nut and fuel tank band (11) on the
assembly and lift up the operator's cab assembly deeper side from the tank. [*2]
and floor frame assembly together to about 100
mm above the chassis and stabilize them with
blocks.
a Since the wires and hoses are still con-
nected, take care not to tense any of them.
4 Operator's cab and floor frame
assembly : 480 kg
PC78US-6 30-63
(11)
13. Pull out fuel tank (4) and remove the clamp and PC78US-6 Serial No.: 6501 and up
tank air bleed hose (12), then remove the fuel
tank. REMOVAL
a Swing the upper structure by to the right by 90
degrees and lower the work equipment to the
ground.
1. Drain the fuel.

6 When fuel tank is full: 125 l
2. Remove top cover (1), right side cover (2), cover

(3), and bottom cover (4) from fuel tank (11).
INSTALLATION
removal.
3 Operator's cab mounting nut:

[*1]
235 – 309 Nm {24 – 31.5 kgm}
3 Tightening torque of tank mounting band

[*2]
3. Remove cover (5) and disconnect fuel level sen-
(11): sor connector (6) from inside.
Nut (23):
0.98 ± 0.49 Nm {0.1 ± 0.05 kgm}
Nut (24): 58.8 ± 9.8 Nm {6.0 ±1.0 kgm}
30-64 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY FUEL TANK, CONTROLLER
4. Disconnect hoses (7) and (8) from fuel tank (11). CONTROLLER ASSEMBLY
5. Disconnect fuel feed hose (9) and fuel drain
REMOVAL
hose (10) from under fuel tank (11).
PC78US-6 Serial No.: 4001 – 6500
1. Remove 4 bolt caps (2) of cover (1) at the rear of

the operator's seat.
2. Remove the 4 bolts and cover (1).
6. Sling fuel tank (11) temporarily and remove the 4

mounting bolts.
7. Lift off fuel tank (11).

4 Fuel tank: 50 kg
3. Loosen the mounting bolts and remove connec-

tors (4), (5), and (6) of controller (3).
4. Remove the 4 mounting bolts and controller

assembly (3).
INSTALLATION
removal.
3 Mounting bolt: Adhesive (LT-2)
INSTALLATION
removal.
a Do not tighten the mounting bolts of connectors
too strongly.
PC78US-6 30-65
(11)
DISASSEMBLY AND ASSEMBLY CONTROLLER, MONITOR PANEL
PC78US-6 Serial No.: 6501 and up MONITOR PANEL ASSEMBLY

(-) terminal of the battery. REMOVAL
1. Remove 4 bolt caps (2) of cover (1) at the rear of
the operator's seat.
1. Pull cover (2) of monitor panel (1) and remove
2. Remove the 4 bolts and cover (1).
the claw stopper.
2. Remove side cover (3).
3. Remove the stopper of cover (4).
3. Loosen the mounting bolts and remove connec-

tors (4) of controller (3).
4. Remove the 4 mounting bolts and controller

assembly (3).
4. Remove the 3 mounting bolts of monitor panel
(1) and connectors (5) and (6) on the back side,
then remove monitor panel assembly (1).
INSTALLATION
removal. INSTALLATION
a Do not tighten the mounting bolts of connectors
too strongly.
removal.
30-66 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
AIR CONDITIONER UNIT 8. Loosen the clamp and remove heater hose (8)
under the rear part of the operator's seat.
ASSEMBLY
9. Remove 3 wiring harness connectors (9) for the
REMOVAL air conditioner under the rear part of the opera-
a Disconnect the wiring harness from the negative tor's seat.
a Using tool X3, collect air conditioner refrigerant
(R134a). [*1]
1. Remove floor mat (1).
2. Move the right console toward the inside of the

cab.
3. Remove duct covers (2) (having the cigarette

lighter connector) and (3).
4. Remove air conditioner unit cover (4).
10. Remove duct connector (14) and 2 mounting

bolts (15) from under the rear of the operator's
seat, and then remove duct assembly (16).
5. Remove duct (5) and the rear duct.
7. Remove 2 tubes (7) and push them in under the

floor. [*2]
tubes.
PC78US-6 30-67
(11)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
11. Remove 5 mounting bolts of operator's seat INSTALLATION

stand (10).
12. Raise the operator's seat stand to 60 mm above removal.
the floor by using 4 forcing screws (11) having a Using tool X3, collect air conditioner refrigerant
screwing length of 70 – 80 mm, and the unit can (R134a).
be taken out.
a If the operator's seat stand is raised too high, [*1]
it will interfere with the wiring harnesses on 1. Connect the power cable for the compressor
both sides. after charging the air conditioner with refrig-
erant gas (R134a).
2. Do not connect the outlet and inlet hoses of

the receiver drier before the air conditioner is
charged with refrigerant gas.
3. When assembling, take care that water

(moisture), dirt, or air will not enter the air
conditioner cycle.
[*2]
1. When fitting the pipes, apply compressor oil
(SNISO 5GS) to the flared parts and threaded
parts.
2. Tighten the nuts on both ends of the refriger-

13. Remove the 3 front mounting bolts and 3 rear ant circuit hose to the following torque.
ones and air conditioner unit assembly (12).
Width
Size Dimensions across Tightening torque
of thread flats Nm {kgm}
# 08 16 X 1.5 19 11.8 – 14.7 {1.2 – 1.5}
# 11 20 X 1.5 24 19.6 – 24.5 {2.0 – 2.5}
# 14 22 X 1.5 27 29.4 – 34.3 {3.0 – 3.5}
30-68 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
OPERATOR'S CAB ASSEMBLY 7. Disconnect monitor panel connectors (8), (9),

and (10) from the right rear.
REMOVAL
8. Disconnect radio connectors (11) and (12) from
a Disconnect the wiring harness from the negative the left rear, and then disconnect radio cable
terminal of the battery. from jack (13).
1. Remove the floor mat. 9. Disconnect duct connector (14).
2. Move right console (1) toward the inside of the 10. Remove 2 mounting bolts (15) and duct assem-
cab. bly (16).
3. Remove monitor panel undercover (2).

a Disconnect cigarette lighter connector (3)
without fail.
5. Remove connector (5) and air conditioner duct

(6).
6. Disconnect washer tank hose (7).
11. Remove the seat rear cover and wiring harness

clamp (21).
12. Remove controller (22) and mounting plate (23)

together and put them down.
a Controllers (22) on
PC78US-6, serial No. 4001 – 6500, and on
PC78UU-6, serial No. 22001 and up,
are different, but they are removed by the
same procedure.
13. Remove the 6 mounting bolt on the operator's

cab floor.
14. Remove the operator's cab mount nut. [*1]
PC78US-6 30-69
(11)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
15. Using lever block [1], lift off operator's cab

assembly (24).
4 Operator's cab assembly: 280 kg
INSTALLATION
removal.
[*1]
3 Operator's cab mount nut:
235 – 309 Nm {24 – 31.5 kgm}
30-70 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
FLOOR FRAME ASSEMBLY 8. Remove 8 hoses (8) of the work equipment con-
trol valve from the couplers.
a Record the connecting mates of the hoses.
REMOVAL
a Remove the operator's cab assembly. (See 9. Disconnect 4 hoses (21) from under the blade
REMOVAL OF OPERATOR CAB.) lever.
a Using tool X3, collect air conditioner refrigerant a Record the connecting mates of the hoses.
(R134a). [*1]
1. Remove the air conditioner unit cover from the

seat.
2. Remove front deck cover (1) and left deck cover

(2).
3. Remove 8 wiring harness connectors (3) of

engine and pump control systems.
a Only 1 connector is used on PC78US-6,
serial No. 6501 and up.
4. Remove 3 solenoid connectors (4) and cable

clamp (5). 10. Remove the 4 hoses connected to travel right
and left control valves (9).
5. Remove the wiring harness connector of horn
(6). 11. Remove the 2 hoses connected to the attach-
ment control valve (10).
6. Remove 2 air conditioner gas tubes (7). (Fit
male or female plugs to the removed tubes.)
7. Disconnect 2 hoses (20).

a Record the connecting mates of the hoses.
12. Loosen the clamps and remove 2 heater hoses

(11). (At the rear of the operator's seat)
PC78US-6 30-71
(11)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
13. Remove the 4 mounting bolts used to install the INSTALLATION

floor frame to floor mount (12).
removal.
[*1]
a See INSTALLATION OF AIR CONDITIONER
UNIT ASSEMBLY.
[*2]
a See TESTING AND ADJUSTING, Adjusting fuel
control linkage.
3 Locknuts of bracket (15) (2 pieces):
9.8 – 14.7 Nm {1.0 – 1.5 kgm}
14. Open the engine top cover.
15. Remove the 2 locknuts from fuel injection pump

bracket (15). [*2]
16. Remove nut (16) and pull out accelerator wires

(14) from the injection pump through the hole of
the revolving frame toward the floor. [*2]
a This work is not necessary for PC78US-6,
serial No. 6501 and up.
17. Install 4 eyebolts (1) to floor frame (13) and lift off
the floor frame assembly.
4 Floor frame assembly: 200 kg
30-72 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (STUCK GLASS)
OPERATOR’S CAB GLASS (STUCK GLASS)
Amoung the panes of window glass on the 4 (1): Right side window glass
sides of the operator’s cab, 5 panes (1) – (5) are (2): Left side rear window glass
stuck. (3): Door upper window glass
In this section, the procedure for replacing the (4): Door lower window glass
stuck glass is explained. (5): Front window glass
When replacing front window glass (5), remove (6): Front window assembly
front window assembly (6). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the ( 7 ) : Both-sided adhesive tape
front window assembly is installed to the opera- (16) : Center trim seal
tor’s cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
PC78US-6 30-73
(11)
SPECIAL TOOLS (The figure shows the operator’s cab of a wheel

loader.)
New/Removal
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
REMOVAL
a Remove the window glass to be replaced accor-
a If the window glass is broken finaly, it may be
1. Using seal cutter [1], cut the adhesive between removed with knife [4] and a screwdriver.
broken window glass (7) and operator’s cab a Widening the cut with a screwdriver, cut the
(metal sheet) (8). adhesive and both-sided adhesive tape with
knife [4].
(The figure shows the operator’s cab of a wheel

loader.)
a If a seal cutter is not available, make holes on

the adhesive and both-sided adhesive tape with
a drill and pass a fine wire (piano wire, etc.) [2]
through the holes. Grip the both ends of the wire
with priors [3], etc. (or hold them by winding them 2. Remove the window glass.
onto something) and move the wire to the right
and left to cut the adhesive and both-sided adhe-
sive tape.
Since the wire may be broken by the frictional
heat, apply lubricant to it.
30-74 PC78US-6
(11)
INSTALLATION
1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking sur-
faces) of the operator’s cab.
a Remove the adhesive and both-sided adhe-
sive tape to a degree that they will not affect
adhesion of the new adhesive. Take care not
to scratch the painted surfaces. (If the
painted surfaces are scratched, adhesion will
be lowered.)
(The figure shows the operator’s cab of a wheel

loader.)
3. Apply primer (10).
a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after unpack-
ing it.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a refrig-
erator, leave it at the room temperature
2. Remove oil, dust, dirt, etc. from the sticking sur- for at least half a dry before stirring it. (If
faces of cab (8) and window glass (9) with white the primer is unpacked just after taken
gasoline. out of the refrigertor, water will be con-
a If the sticking surfaces are not cleaned well, densed. Accordingly, leave the primer at
the glass may not be stuck perfectly. the room temperature for a sufficient
a Clean the all back part on the back side of time.)
the window glass. 2) When reusing primer brush (11), wash it in
a After cleaning the sticking surfaces, leave white gasoline.
them for at least 5 minutes to dry. a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.
PC78US-6 30-75
(11)
3) Evenly apply paint primer to the surfaces to a As for right side window glass (1), apply
stick both-sided adhesive tapes and the sur- the primer to only the periphery of the
faces out of those surfaces on operator’s cab glass to stick the both-sided adhesive
(8) which will be coated with the adhesive. tapes and the areas out of it to apply the
2 Paint primer:
adhesive.
• Part (b)
SUNSTAR PAINT PRIMER
a After applying the primer, leave it for at
580 SUPER or equivalant
least 5 minutes (within 8 hours) to dry.
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Never apply wring primer. If the glass

primer is applied by mistake, wipe it off
with white gasoline.
a Parts to be coated with primer: Apply the
4) Evenly apply glass primer to the sticking sur-
primer all over dimension (a).
faces of window glass (9).
2 Glass primer:
• Dimension to apply primer (a): 25 mm
SUNSTAR GLASS PRIMER

580 SUPER or equivalant
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
30-76 PC78US-6
(11)
a Parts to be coated with primer: Apply the a When sticking both-sided adhesive tape (7)
primer to the sticking surfaces of window around a frame, do not lap its finishing end
glass (9) and all over dimension (d) over the starting end but make clearance e of
which will be on both-sided adhesive about 5 mm between them.
tape (7) and operator’s cab (8). 1) Stick both-sided adhesive tape (7) for right
a Do not apply the primer to the boarder side window glass (1) as shown in the figure.
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutues (within 8 hours) to dry.
a Never apply wring the primer. If the
glass primer is applied by mistake, wipe
it off with white gasoline.
a Stick both-sided adhesive tape (7a) addition-

ally for right side window glass (1).
• Positions to stick additional both-sided adhe-
sive tape for right side window glass.
(f) : 140 mm
(g) : 500 mm
4. Stick both-sided adhesive tape (7) along the

inside edge of the glass sticking section.
a Do not remove the release tape of the both-
sided adhesive tape on the glass sticking
side before stiking the glass.
a When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
PC78US-6 30-77
(11)
2) Stick both-sided adhesive tape (7) for left 4) Stick both-sided adhesive tape (7) for front
side rear window glass (2) as shown in the window glass (5) as shown i the figure.
figure. a Both-sided adhesive tape: 1,004 mm × 2
pieces
3) Stick both-sided adhesive tape (7) for door

upper window glass (3) and lower window • Details of the sticking positions are as
glass (4) as shown in the figure. follows.
(The figure shows the door upper window (h) :Stick to inside end of right and left
glass.) front frames (17).
(j) : Retract by "3.0 mm" from the end of
front frame (17).
(The figure shows the door lower window

glass.)
30-78 PC78US-6
(11)
5. Possition the new window glass.

1) Check the clearance between the window
glass and the operator’s cab on the right, left,
upper, and lower sides, and then adjust it
evenly.
2) Stick tapes [6] between window glass (9) and
operator’s cab (8) and draw positioning line
n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator’s cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the win-
dow glass and operator’s cab before
installing the window glass.
6. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
a When positioning front window glass (5), SUNSTAR PENGUINE
set its horizontal and vertical positions as
2 Adhesive (Winter):
SEAL 580 SUPER "S"
shown below.
Part (m) (Right side):Project by "3.8 mm" SUNSTAR PENGUINE
from the frame end. SEAL 580 SUPER "W"
Part (o) (Upper side):Retract by "3.0 a The using limit of the adhesive is 4 months
mm" from the frame after the date of manufacture. Do not use
end. the adhesive after this limit.
a Keep the adhesive in a dark place where the
temperaure is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
PC78US-6 30-79
(11)
1) Break aluminum seal (13) of the outlet of

adhesive cartridge (12) and install the noz-
zle.
a Apply adhesive (15) to dimensions s and

t of both-sided adhesive tape (7) of oper-
2) Cut the tip of the adhesive nozzle (14) so ator’s cab (8).
that dimension q and r will be as follows. • Dimension (s) : 10 mm
• Dimension (q) : 10 mm • Dimension (t) : 15 mm
• Dimension (r) : 15 mm a Apply adhesive (15) higher than both-
sided adhesive tape (7).
a Apply the adhesive evenly.
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient. a As for the right side window glass, apply
the adhesive to the outside of the both-
sided adhesive tape on the periphery of
the glass.
4) Remove the release tape of the both-sided

adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-
sided adhesive tape (7) of the operator’s
cab.
30-80 PC78US-6
(11)
7. Install the window glass. a After installing front window glass (5),
1) Install window glass (9), matching it to the install the center trim seal to its bottom.
lines of the positioning tapes drawn in step 5. Then, apply caulking material all around
a Sine the window glass cannot be the glass to fill part U between the glass
removed and stuck again, stick it very and center trim seal.
carefully. a When caulking, neatly arrange the form
a Stick the glass within 5 minutes after of the adhesive at the right and left ends
applying the adhesive. with a rubber spatula.
2 Adhesive:
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
Sikaflex 256HV manufactured
adhesive tape.
by Sika Japan
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by

pulling window glass (9) from inside of
the operator’s cab with suction cup X1.
(The figure shows the operator's cab of
PC200-7.)
PC78US-6 30-81
(11)
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to the primer and adhesive from the operator’s cab and
operator’s cab, insert stopper rubbers X2 to window glass.
2 places (v) at the bottom of the glass to fix a Using white gasoline, wipe off the adhesive
the glass. before it is dried up.
(The figure shows the operator's cab of PC200- a When cleaning the glass, do not give an
7.) impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene form
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
(The figure shows the operator's cab of PC200-

7.)
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape of fit them completely.
(The figure shows the operator's cab of PC200-
7.)
30-82 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
FRONT WINDOW ASSEMBLY

k Lower the work equipment to the ground and
stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor’s cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.
REMOVAL
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides). [*1]
2. Remove left lower block (1) and right lower block

(2). [*2]
5. Twist front window assembly (3) to the right and

left to remove right and left upper rollers (6) and
3. Reset the lock at the rear of the cab. (7) from the rails, and then remove front window
assembly (3).
4. Lower front window assembly (3) carefully a lit- a For (6) and (7), see the figure above.
tle. Put out rollers (4) and (5) under the right and
left sides of the front window through the portion
from which the right and left lower blocks were
removed in step 2 (the bottom of the rails).
INSTALLATION
removal.
PC78US-6 30-83
(11)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REVOLVING FRAME 5. Remove fuel filler mounting cover (4).
ASSEMBLY 6. Remove receiver drier (5) and bracket together

from the revolving frame and place them on their
REMOVAL side.
PC78US-6 Serial No.: 4001 – 6500
a Remove the work equipment assembly. (See
REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.)
a Remove the operator's cab assembly. (See
REMOVAL OF OPERATOR'S CAB ASSEMBLY.)
1. Remove the engine hood.
2. Remove air cleaner assembly (1) and bracket

hose together.
7. Remove the top cover of the center swivel joint.
3. Remove engine ventilator cover (2).
8. Remove travel drain hose (11) and swing motor
hose (12).
9. Remove 5 hoses (13) for the control valve, for-

ward and reverse, right and left, 2nd travel speed
selection, etc. in order from the top.
disconnected hoses, nipples, and elbows.
them again.
4. Hang boom cylinder assembly (3) temporarily

and remove the hoses on the head side and bot-
tom side. Pull out the mounting pin on the bot-
tom side and lift off the cylinder assembly.
30-84 PC78US-6
(11)
10. Remove the mounting bolts of swing circle outer REMOVAL

race (6) on the revolving frame, leaving 3 each at
the front and rear. [*1] PC78US-6 Serial No.: 6501 and up
a Remove the work equipment assembly. (See
REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.)
a Remove the operator's cab assembly. (See
REMOVAL OF OPERATOR'S CAB ASSEMBLY.)
1. Remove the engine hood.
2. Remove air cleaner assembly (1) and bracket

hose together.
3. Remove engine ventilator cover (2).

11. Install a sling to the boom foot mounting unit and
both sides of counterweight (7) and lift off the
revolving frame assembly, hanging it by 3 points.
a Use the hole of the revolving frame on the
left rear side from which the receiver drier
was removed.
12. Remove the remaining revolving frame mounting

bolts and lift off the revolving frame assembly.
4. Hang boom cylinder assembly (3) temporarily

and remove the hoses on the head side and bot-
tom side. Pull out the mounting pin on the bot-
tom side and lift off the cylinder assembly.
5. Remove the left deck cover.
PC78US-6 30-85
(11)
6. Remove the top cover of the center swivel joint. 10. Install sling wires to 3 points of revolving frame
assembly (7) and lift up the revolving frame tem-
7. Remove travel drain hose (11) and swing motor porarily.
hose (12). a Install the sling wires to the boom foot
mounting part and hanging hole of the coun-
8. Remove 5 hoses (13) for the control valve, for- terweight.
ward and reverse, right and left, 2nd travel speed a Install the other sling wire to the hole of the
selection, etc. in order from the top. revolving frame for the rear left side and use
a Install a male or female plug to each of the pad [1], shackles [2], etc.
disconnected hoses, nipples, and elbows.
a Record the positions of the disconnected 11. Remove the remaining revolving frame mounting
hoses so that you can correctly connect bolts and lift off revolving frame assembly (7).
them again. [*1]
9. Remove the mounting bolts of swing circle outer

race (6) on the revolving frame, leaving 3 each at
the front and rear. [*1]
INSTALLATION
removal.
2 Revolving frame mounting bolt:

[*1]
3 Revolving frame mounting bolt:

Adhesive (LT-2)
245 – 309 Nm {25 – 31.5 kgm}

Target: 279.5 Nm {28.5 kgm}
30-86 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
SWING CIRCLE ASSEMBLY INSTALLATION

REMOVAL removal.
1. Remove the revolving frame assembly. For
[*1]
2 Threads of swing circle mounting bolt:
details, see REMOVAL OF REVOLVING FRAME
ASSEMBLY.
Liquid adhesive (LT-2)
3 Swing circle mounting bolt:
2. Hang swing circle assembly (1) temporarily and
remove the 24 mounting bolts. [*1]
245 – 309 Nm {25 – 31.5 kgm}
3. Remove swing circle assembly (1). [*2] Target: 279.5 Nm {28.5 kgm}
4 Swing circle assembly: 115 kg [*2]

a Hang swing circle assembly (1) and install it to
the track frame, directing mark S of the inner
race to the just right side of the machine body as
shown below.
2 Quantity of grease to be applied to circle:
Apply sufficient quantity of
grease (G2-LI).
PC78US-6 30-87
(11)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
ASSEMBLY
REMOVAL
PC78UU-6 Serial No.: 4001 – 6500
engine.

the hydraulic tank.
1. Remove the top cover of the hydraulic tank.

6. Remove the lock plate of the boom foot pin.
2. Loosen the sleeve nut of each work equipment
7. Hang work equipment assembly (5) temporarily.
hose (1) on the right side of the boom and
remove the hose. [*1]
8. Using tool V1, remove foot pin (6). [*3]
3. Cut the bands of the wiring harness of working
lamp (2) and hydraulic tubes and remove the
connectors. Place those connectors together
with the hoses on a place where they will not be
obstacles.
hoses and tubes.
k Since an accumulator is not installed, loosen

the sleeve nut of each hose gradually and
check that oil will not spout out, then remove
the hose.
9. Lift off work equipment assembly (5).
a Check the quantity and positions of the
inserted shims.
4 Work equipment assembly: 1,110 kg
4. Remove the rod pin stopper used to hang boom

cylinder (3) temporarily and pull out rod pin (4).
[*2]
5. Lift off boom cylinder (3) onto a stable stand of

proper height.
inserted shims.
30-88 PC78US-6
(11)
PC78US-6 Serial No.: 6501 and up 8. Loosen sleeve nuts of 6 hoses (8) for work
equipment on the right side of the boom and
a Set the work equipment on the sprocket side at
remove the hoses. [*1]
the maximum reach, lower it to the ground, and
a Disconnect the hydraulic hose bands.
stop the engine.
disconnected hoses and tubes.
k Loosen the hydraulic tank cap gradually to
release the residual pressure in the tank. them again.
k Since an accumulator is not installed,
1. Remove hydraulic tank top cover (1).
loosen the sleeve nut of each hose gradu-
ally and check that oil will not spout out,
2. Remove right side cover (2) and cover (3).
and then remove the hose.
3. Remove cover (4), and then remove quilt to set
cover (4) free.
4. Sling boom cylinder (5) temporarily.
5. Remove the rod pin stopper and pull out rod pin
(6). [*2]
9. Remove boom-side plate (9) of potentiometer A

at the boom foot from the base of the boom.
10. Remove connector (10).
11. Remove 2 mounting bolts (12) of potentiometer

mounting plate/boom foot pin lock plate (11).
6. Sling boom cylinder (5) and lower it to stable
12. Remove plate (11).
supports [1] of the same height.
inserted shims.
7. Sling work equipment (7) temporarily.
PC78US-6 30-89
(11)
13. Disconnect connectors (13) and (14). INSTALLATION

14. Remove clamp (16) and work equipment wiring PC78US-6
harness (15).
15. Remove boom foot pin (17). removal.
[*1]
1. Check that the O-rings are fitted to the sealing
parts of each hose.
2. When installing the rubber hoses, take care not

to twist them.
[*2]
1. When assembling, apply LM-P to the sliding sur-
faces of the pins.
2. Supply grease until it comes out through the dust

seals on both sides of each bushing.
a When removing the pin with tool V1, remove k When aligning the pin holes, never insert
the hydraulic tank, referring to Removal of your fingers in the pin holes.
hydraulic tank. [*3] a Adjust the shims so that the clearance
between the cylinder rod head and bracket
will be less than 1 mm.
[*3]
1. When assembling, apply LM-P to the sliding sur-
faces of the pins.
2. Supply grease until it comes out through the dust

seals on both sides of each bushing.
3. After supplying grease, change the position of

the boom and supply grease further.
k When aligning the pin holes, never insert
16. Taking care of cover (4), lift and remove work your fingers in the pin holes.
equipment assembly (7) from the chassis. a Adjust the shims so that the clearance
a Check the quantity and positions of inserted between the boom and bracket will be less
spacers (18). than 1 mm.
4 Work equipment assembly: 1,340 kg a Refilling with oil (Hydraulic tank)
30-90 PC78US-6
(11)
PC78UU-6 5. Remove the connectors of the potentiometers

and working lamp of the arm and offset.
REMOVAL Remove the clamps of the wiring harness and
cut the bands to remove the wiring harness
a Reach the work equipment to the maximum on toward the boom foot. [*1]
the sprocket side and lower it to the ground, and
then stop the engine. 6. Hang boom cylinder (5) temporarily and pull out
a Connecting the wiring harness of the negative (-) rod pin (6).
terminal of the battery. a If the pin cannot be pulled out easily, prepare
k Loosen the oil filler cap of the hydraulic tank an oil receiver and loosen the sleeve nut of
gradually to release the residual pressure from the hose on the bottom side gradually to give
the hydraulic tank. some play to the rod.
1. Open right side inspection cover (1) and lock it 7. Set stable stand [1] to receive the boom cylinder
with the bar. horizontally and lift off cylinder assembly (5).
2. Remove right side cover (2).
3. Remove hose protector (3) on the right side of

the boom.
4. Remove boom cylinder protector (4).
8. Remove each work equipment hose (7) on the

right side of the boom from the joint. [*2]
k Loosen the sleeve nut of each hose gradually
and check that oil will not spout out, then
remove the hose.
hoses and tubes.
PC78US-6 30-91
(11)
9. Remove wiring harness connector (10) of poten- 13. Using tool V1, pull out first boom foot pin (13).
tiometer (9) at the boom foot. [*3]
a Mask the removed connectors. a Check the quantity and positions of the
inserted shims.
10. Remove the 2 mounting bolts of potentiometer
mounting plate which is also used as boom foot
pin lock plate (11).
11. Operating plate (11), pull the end pin of potenti-

ometer lever (12) out of the plate on the boom
side, then remove potentiometer assembly (9).
a Before removing the potentiometer, secure
its lever with a sealing tape, etc.
12. Install slings to the first boom top and bucket

tooth adapter and hang the work equipment
assembly (8) temporarily.
k Fix the offset unit securely so that the work
equipment will not offset.
14. Lift off work equipment assembly (8).
4 Work equipment assembly: 1,340 kg
30-92 PC78US-6
(11)
INSTALLATION
PC78UU-2
removal.
[*1]
When binding the electric wiring harness to the
hydraulic hoses or tubes, use double bands.
[*2]
When installing the rubber hoses, be careful not
to twist them.
[*3]
your fingers in the pin holes.
1) When assembling, apply G1-T to the sliding
surfaces of the pins.
2) Use G1-T HYPER WHITE GREASE. Supply
it until it comes out through the dust seals on
both sides of each bushing.
3) After supplying grease to the boom foot,
change the position of the arm and supply
grease further.
4) Reduce the clearance between the spacer
and arm/bucket to below 0.5 mm. Reduce
the clearance at another boss or spacer to
below 1 mm.
• Refilling with oil (Hydraulic tank)

Check the hydraulic oil level gauge and run the
engine to circulate the oil through the piping.
Then, check the oil level again and add new oil
to the specified level.
a After assembling, check that the electric system
works normally.
PC78US-6 30-93
(11)
DISASSEMBLY AND ASSEMBLY FIRST BOOM
FIRST BOOM ASSEMBLY

REMOVAL
a Remove the bucket, arm assembly, and offset
bracket assembly. (See REMOVAL OF OFFSET
BRACKET.)
a Remove the second boom assembly. (See
REMOVAL OF SECOND BOOM ASSEMBLY.)
1. Open right side inspection cover (1) and lock it

with the bar.
2. Remove right side cover (2).
3. Remove hose protector (3) on the right side of 7. Set a stable stand to receive boom cylinder (6)
the boom. horizontally and lift off the cylinder.
4. Remove boom cylinder protector (4).
8. Cut the bands of the potentiometer wiring har-

ness on the work equipment hose and remove
a Connect the wiring harness of the negative the wiring harness. [*1]
5. Start the engine and operate the boom cylinder.

Set strong and stable stand [1] to the top of the
first boom (5) and secure the boom.
a Stop the engine and disconnect the wiring
harness from the negative (-) terminal of the
battery.
gradually to relea-se the residual pressure
from the hydraulic tank.
6. Hang boom cylinder (6) temporarily and remove

the lock plate of rod pin (7) and pull out the pin.
a If the pin cannot be pulled out easily, loosen
the sleeve nut on the bottom side of cylinder
(6) gradually to give some play to the rod.
30-94 PC78US-6
(11)
9. Disconnect the 6 work equipment hoses on the 13. Using belts, hang first boom assembly (5) tem-
right side of the first boom from joints (8). porarily.
k Loosen the sleeve nut of each hose gradu-
ally and check that oil will not spout out,
then remove the hose.
hoses and tubes.
14. Using tool V1, pull out first boom foot pin (13).
10. Remove wiring harness connector (10) of poten-

tiometer (9) at the boom foot.
a Mask the removed connector.
11. Remove the 2 mounting bolts of potentiometer

mounting plate which is also used as boom foot
pin lock plate (11).
12. Operating plate (11), pull the end pin of potenti-

ometer lever (12) out of the plate on the boom
side, then remove potentiometer assembly (9).
a Before removing the potentiometer, secure
its lever with a sealing tape, etc.
PC78US-6 30-95
(11)
15. Lift of first boom assembly (5). [*2] INSTALLATION

4 First boom assembly: 320 kg • Carry out installation in the reverse order to
removal.
[*1]
When binding the potentiometer wiring harness
to the hydraulic hoses, use double bands.
[*2]
2) Use G1-T HYPER WHITE GREASE.
3) Supply grease to the second boom joint with
the machine at the central offset position,
then supply further with the machine at the
right offset position. In each position, supply
grease with the bucket lowered to the ground
and with the bucket floated.
the clearance at another spacer to below 1
mm.
5) When installing the rubber hoses, take care
not to twist them.
a Check that the hydraulic oil level is normal.
a Check that the electric system works nor-
mally.
30-96 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY SECOND BOOM
SECOND BOOM ASSEMBLY 6. Hang second boom (10) temporarily and remove
the upper and lower mounting pins (11).
REMOVAL
7. Lift off second boom assembly (10). Removing
a Remove the bucket, arm assembly, and offset the second boom, remove hose (12) installed
bracket assembly. (See REMOVAL OF OFFSET through it. [*2]
BRACKET.)
1. Remove 2 hoses (2) of offset cylinder (1).

Remove the clamp and pull out the cylinder
toward the boom side.
k Loosen the sleeve nut of each hose gradually
and check that oil will not spout out, then
remove the hose.
hoses and cylinder tubes.
2. Hang offset cylinder (1) temporarily and remove

the lock plate of cylinder bottom pin (3) and then
lift off offset cylinder (1). [*1]
4 Offset cylinder assembly: 55 kg
INSTALLATION
3. Remove the 4 clamps of potentiometer wiring
harness (5) installed to the inside of offset link
removal.
(4).
[*1] [*2]
4. Remove connector (7) of offset potentiometer (6)
and the bolt of potentiometer lever (8).
2) Use G1-T HYPER WHITE GREASE.
5. Hang offset link (4) temporarily and pull out
mounting pin (9) and lift off the offset link assem-
bly.
4 Offset link assembly: Approx. 30 kg
then supply further with the machine at the
right offset position. In each position, supply
mm.
5) When installing the rubber hoses, be careful
not to twist them.
a Check that the hydraulic oil level is normal.
a Check that the electric system works nor-
mally.
PC78US-6 30-97
(11)
DISASSEMBLY AND ASSEMBLY OFFSET BRACKET
OFFSET BRACKET
ASSEMBLY
REMOVAL
engine.
the hydraulic tank.
(-) terminal of the battery. (Connect it when nec-
essary, however.)
6. Remove the 2 hoses of arm cylinder (10).
k Loosen the sleeve nut of each hose gradu-
1. Remove the 2 bucket cylinder hoses.
k Loosen the sleeve nut of each hose gradually and check that oil will not spout out,
ally and check that oil will not spout out, then remove the hose.
then remove the hose.
a Fit male or female plugs to the removed hoses and cylinder tubes.
hoses and cylinder tubes.
7. Hang arm cylinder (10) temporarily. Remove
2. Disconnect arm potentiometer rod (1) and wiring both lock plates of mounting pins (11) and pull
harness connector (2) and remove wiring har- out mounting pins (11) on both sides.
ness clamp (3). Lift off arm cylinder assembly (10).
4 Arm cylinder assembly: 95 kg
3. Remove bracket (4) and pull out wiring harness
(5) and 2 hoses (6) toward the offset bracket.
8. Remove arm cylinder hose bracket (12) to set
the hoses and wiring harnesses free.
9. Remove the clamp of potentiometer wiring har-

ness (13) and pull the wiring harness out of the
bracket.
4. Hang the arm and bucket assembly temporarily

and remove arm cylinder rod pin (7) and arm foot
pin (8). [*1]
5. Lift off arm and bucket assembly (9).

a When removing the arm, take care that the
arm potentiometer lever will not interfere with
another part.
4 Arm and bucket assembly:
Approx. 500 kg
30-98 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY OFFSET BRACKET
10. Hang offset bracket (14) temporarily and remove INSTALLATION

offset cylinder rod pin (15) and rod pin (16) from
bracket (14). • Carry out installation in the reverse order to
removal.
11. Pull out the upper and lower mounting pins (18)
used to install the offset bracket to second boom [*1] [*2]
(17). 1) When assembling, apply G1-T to the sliding
12. Lift off offset bracket assembly (14). [*1] 2) Use G1-T HYPER WHITE GREASE.
4 Offset bracket assembly: 135 kg

a When removing the bracket, take care not to then supply further with the machine at the
damage the hydraulic hoses. right offset position. In each position, supply
mm.
5) When installing the rubber hoses, be careful
not to twist them.
a After installing the work equipment, check
that the hydraulic oil level is normal.
a After installing the work equipment, check
that the electric system works normally.
PC78US-6 30-99
(11)
DISASSEMBLY AND ASSEMBLY STEEL SHOE, RUBBER PAD SHOE, ROAD LINER
STEEL SHOE, RUBBER PAD

SHOE, ROAD LINER
ASSEMBLY
EXPANSION
1. Stop the machine so that the master pin will be
between the idler and carrier roller and the track
shoe can be expanded forward and backward.
2. Lower the work equipment to the ground and

loosen lubricator (1) to lower the track shoe ten-
sion. [*1]
k Since the internal pressure of the adjustment
cylinder is very high, do not loosen the lubrica-
tor more than 1 turn. If the grease does not
come out easily, move the machine forward and INSTALLATION
in reverse.
removal.
[*1]
a Adjust the tension of the steel shoe and road
liner. For details , s ee TESTING AND
ADJUSTING, Testing and adjusting track
shoe tension.
3. Using tool R, pull out the master pin.
4. Remove tool R and move the machine forward

so that the temporary pin will be in front of the
idler and set block [1].
5. Pull out the temporary pin and move the

machine in reverse to expand track shoe (2).
30-100 PC78US-6
(11)
DISASSEMBLY AND ASSEMBLY RUBBER SHOE, FINAL DRIVE AND TRAVEL MOTOR
RUBBER SHOE ASSEMBLY FINAL DRIVE AND TRAVEL

MOTOR ASSEMBLY
REMOVAL
1. Lower the work equipment to the ground and REMOVAL
loosen lubricator (1) to lower the track shoe ten- 1. Expand the track shoe assembly. (See EXPAN-
sion. [*1] SION OF TRACK SHOE.)
k Since the internal pressure of the adjust-
ment cylinder is very high, do not loosen 2. Swing the work equipment by 90 degrees from
the lubricator more than 1 turn. If the the parking position and raise the machine body
grease does not come out easily, move the by pressing the work equipment against the
machine forward and in reverse. ground and set block [1] between the track frame
and track link to float sprocket (1) above the link
tread.
2. Swing the work equipment by 90 degrees and
k Lower the work equipment to the ground

raise the machine body a little.
3. Put steel pipes in rubber shoe (2) and turn the and stop the engine. Loosen the oil filler
sprocket in the reverse direction. If the rubber cap of the hydraulic tank to release the
shoe is floated from the idler by the steel pipes, residual pressure from the hydraulic tank.
slide off the rubber shoe sideways.
3. Remove travel motor side cover (2).
INSTALLATION
removal.
[*1]
a Adjust the rubber shoe tension. For details,
see TESTING AND ADJUSTING, Testing
and adjusting track shoe tension.
PC78US-6 30-101
(16)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE AND TRAVEL MOTOR
4. Hang final drive and travel motor assembly (3) INSTALLATION

temporarily.
removal.
[*1]
2 Final drive and travel motor assembly
mounting bolt: Liquid adhesive (LT-2)
3 Final drive and travel motor assembly:
245 – 309 Nm {25 – 31.5 kgm}
a Bleed air from the travel motor. For details,

see TESTING AND ADJUSTING, Bleeding
air from each part.
• Refilling with oil (Hydraulic tank)

a Add oil through the oil filler to the specified level.
5. Remove 4 travel motor hoses (4). Run the engine to circulate the oil through the
a Remove the nipples. system. Then, check the oil level again.
a Stop the hoses with plugs.
6. Remove 14 final drive and travel motor assembly

mounting bolts (5). [*1]
7. Lift off the final drive and travel motor assembly.

4 Final drive assembly: 105 kg
30-102 PC78US-6
(16)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR

GM09VN2
CONTENTS
Sectional drawing, single view drawing, and parts list

1. Sectional drawing of assembly ........................................................................................................ 30-105
2. Single view disassembly drawing of reduction gear assembly ........................................................ 30-107
3. Parts list ........................................................................................................................................... 30-109
Outline of maintenance
1. Tools..................................................................................................................................................30-112
2. Tightening torque ..............................................................................................................................30-117
3. Weight table ......................................................................................................................................30-117
Disassembly.................................................................................................................................................30-118
Maintenance standard................................................................................................................................. 30-133
Assembly .................................................................................................................................................... 30-135
Performance test......................................................................................................................................... 30-152
Clearance adjustment parts dimension table .............................................................................................. 30-153
PC78US-6 30-103
(16)
SECTIONAL DRAWING, SINGLE VIEW DRAWING

1. SECTIONAL DRAWING OF ASSEMBLY
PC78US-6 30-105
(16)
30-106 PC78US-6
(16)
2. SINGLE VIEW DISASSEMBLY DRAWING OF REDUCTION GEAR ASSEMBLY
PC78US-6 30-107
(16)
30-108 PC78US-6
(16)
3. PARTS LIST
Model NABTSCO Serial number KOMATSU Serial number
GM09VN 505D0000-02-GD TZ505D000002GD
Sym- Adjustment
Parts name NABTESCO Parts number KOMATSU Parts number Q'ty Class
bol symbol
Reduction gear unit 502D1000-00 TZ502D1000-00
Spindle kit 500D1102-00 TZ500D1102-00 1 F 20

• Spindle assembly 500D1132-00 TZ500D1132-00 1 F 20
2 •• Spindle 500D1002-00 TZ500D1002-00 1 X
3 •• Hold flange 500D1003-00 TZ500D1003-00 1 X
19 • Reamer bolt 500D1019-00 TZ500D1019-00 3 B
RV gear assembly 500D1104-00 TZ500D1104-00 1 F 20

• RV gear kit 500D1204-00 TZ500D1204-00 1 F 20
4 •• RV gear A 500D1004-00 TZ500D1004-00 1 X
5 •• RV gear B 500D1005-00 TZ500D1005-00 1 X
9 • Crankshaft 410D1009-00 TZ410D1009-00 3 X
12 • Spacer 910B1012-00 TZ910B1012-00 6 X
22 • Tapered roller bearing 500D1102-00 TZ500D1102-00 6 X
23 • Needle roller bearing 410D1023-00 TZ410D1023-00 6 X
Spur gear kit 502D1107-00 TZ502D1107-00 1 C

7 • Spur gear 502D1007-00 TZ502D1007-00 3 X
Floating seal kit ES100-204x232x32-B TZES20423232-B 1 C

31 • Floating seal ES100-204-B TZES100-204-B 2 X
1 Hub 500D1001-00 TZ500D1001-00 1 E 3,20

6 Input gear 502D1006-00 TZ502D1006-00 1 B
8 Cover 500D1008-00 TZ500D1008-00 1 B
15 Shaft 500D1015-00 TZ500D1015-00 1 B
17 Pin 500D1017-00 TZ500D1017-00 28 B
18 Ring 810B1018-00 TZ810B1018-00 1 B
20 Snap ring 860A1013-00 TZ860A1013-00 3 E
t: Above 1.75, below 1.80

O <Interval: 0.05> (Select from 15 kinds)
t: Above 2.45, below 2.50
21 Ball bearing 500D1021-00 TZ500D1021-00 2 E 3,20

24 C-ring for shaft JIS B 2804-jig19 TZJB2804-S19 1 A
25 C-ring for shaft JIS B 2804-jig25 04064-02512 6 A
28 O-ring JIS B 2401-P8-90 07000-11008 2 A
29 O-ring JIS B 2401-G230-70 07000-15230 1 A
30 O-ring JIS W 1516-G35-70 TZJW1516-G35-5 1 A
33 Flanged plug 410D1033-00 TZ410D1033-00 1 B
34 Plug 810B2021-00 TZ810B2021-00 2 B
35 O-ring JIS B 2401-P14-90 07000-12014 3 A
36 Steel ball JIS B 1501-3/8 04260-00952 1 A
43 Parallel pin JIS B 1354-8 x 22 TZJB1354-8-22 2 A
PC78US-6 30-109
(16)
Sym- Adjustment
bol symbol
Hydraulic motor 500D2000-00-G TZ500D200000-G 1
Piston kit 500D2105-00 TZ500D2105-00 1 C

• Piston assembly 500D2140-00 TZ500D2140-00 9 X
105 •• Piston 500D2005-00 TZ500D2005-00 1 X
106 •• Shoe 500D2006-00 TZ500D2006-00 1 X
Piston assembly 500D2070-00 TZ500D2070-00 1 C

161 • Piston 500D2071-00 TZ500D2071-00 1 X
162 • Shoe 500D2072-00 TZ500D2072-00 1 X
102 Shaft 500D2002-00 TZ500D2002-00 1 B

103 Swash plate 500D2003-00-G TZ500D200300-G 1 B
104 Cylinder block 500D2004-00 TZ500D2004-00 1 B
107 Retainer plate 500D2007-00 TZ500D2007-00 1 B
108 Thrust ball 500D2008-00 TZ500D2008-00 1 B
109 Timing plate 500D2009-00 TZ500D2009-00 1 B
110 Washer 500D2010-00 TZ500D2010-00 2 B
112 Piston 500D2012-00 TZ500D2012-00 1 B
113 Spring 500D2013-00 TZ500D2013-00 8 B
114 Spring 500D2014-00 TZ500D2014-00 1 B
115 Friction plate 500D2015-00 TZ500D2015-00 2 B
116 Mating plate 500D2016-00 TZ500D2016-00 2 B
132 Oil seal 15Z-22X42X10 TZ15Z-22-42-10 1 A
135 O-ring 500D2035-00 TZ500D2035-00 1 B
141 O-ring 500D2039-00 TZ500D2039-00 1 B
146 Round R-ring IRTW-36 TZIRTW-36 1 A
149 Deep groove ball bearing 880A2029-00 TZ880A2029-00 1 B
150 Deep groove ball bearing JIS B 1521-6301 06000-06301 1 A
151 Needle roller 500D2098-00 TZ500D2098-00 3 B
176 Pivot 500D2076-00 TZ500D2076-00 2 B
177 Parallel pin 263B2077-01 TZ263B2077-01 2 B
185 Spring 844B2085-00 TZ844B2085-00 1 B
Control valve 505D4000-02-D TZ505D400002-D 1
Rear flange assembly 505D4100-02-D TZ505D410002-D 1 C

• Rear flange kit 505D4101-02-D TZ505D410102-D 1 C
201 •• Rear flange 505D4001-00 TZ505D4001-00 1 X
223 •• Spool 505D4050-00-A TZ505D405000-A 1 X
• Spool kit 502D4110-00 TZ502D4110-00 1 C
271 •• Spool 502D4069-00 TZ502D4069-00 1 X
272 •• Oil stopper AOS-4 TZAOS-4 1 X
221 • Plug 100A2021-00 TZ100A2021-00 1 B
222 • Plug 810B2021-00 TZ810B2021-00 1 B
224 • Plug 860A2051-00 TZ860A2051-00 2 B
225 • Spring retainer 869A2052-00-B TZ869A205200-B 2 B
227 • Valve 500D4054-00 TZ500D4054-00 2 B
228 • Spring 860A2056-00 TZ860A2056-00 2 B
230 • Spring 500D4055-00 TZ500D4055-00 2 B
236 • O-ring JIS B 2401-P26-90 TZJB2401-P26-90 2 A
30-110 PC78US-6
(16)
Sym- Adjustment
bol symbol
238 • O-ring JIS B 2401-P18-90 07000-12018 2 A
252 • Hexagon socket head plug GM-1/8-S TZGM1-8-S 3 A
268 • Steel ball JIS B 1501-3/16 TZJB1501-3-16 1 A
273 • O-ring 07002-12034 07002-12034 1 A
275 • Hexagon socket head plug GDL-1/16-S TZGDL1-16-S 5 A
279 • Filter 976B2079-00 TZ976B2079-00 1 B
280 • Orifice S0505 TZS0505 1 A
281 • Spring 500D4089-00 TZ500D4089-00 1 B
282 • Plug 610B2021-00 TZ610B2021-00 2 B
283 • Flanged plug 571B2079-00 TZ571B2079-00 1 B
292 • O-ring JIS B 2401-P14-90 07000-12014 1 A
299 • Nameplate 850A0006-00 TZ850A0006-00 1 B
242 Parallel pin JIS B 1354-4 x 10 TZJB1354-4-10 2 A

245 Hexagon socket head bolt JIS B 1176-M12 x 32-12.9 TZJB1176M12-32 6 A
(Notes)
1. An assembly in the part name column must not be disassembled further and must be handled as a part, as
a rule.
2. A kit in the part name column must not be disassembled further, although it can be disassembled, and must
be handled as a part similarly to an assembly, as a rule.
3. The category shows the supply range of parts for repair.
A: Parts can be supplied (Parts replaceable with ones that are conformed to JIS and available in Japan or
ones which are supplied by original manufacturer and commercially available)
B: Parts can be supplied (Replaceable parts that we can supply)
C: Parts can be supplied (Replaceable parts that we can supply by assembly or kit for parts replacement)
E: Parts can be supplied conditionally (Replaceable parts that can be supplied loose for parts replacement
on condition that clearance will be adjusted as specified)
F: Parts can be supplied conditionally (Replaceable parts that can be supplied by assembly or kit for parts
replacement on condition that clearance will be adjusted as specified)
X: Parts cannot be supplied (Parts that cannot be supplied loose but can be supplied by assembly or kit)
4. A number in the adjustment symbol column indicates a part that needs specified clearance adjustment
when it is replaced.
5. When snap rings (20) are to be used for repair of parts which need clearance adjustment, we will supply
them as a set in which they are classified by the thickness.
PC78US-6 30-111
(16)
OUTLINE OF MAINTENANCE
1. TOOLS
1) Standard tools
Applicable parts
(Title No. of structural drawing/ Name Type/Standard Q'ty
disassembly drawing)
33,34,221,245,252,275,282 Torque wrench Nominal torque: 1,800, dial type 1
19,224 Torque wrench Nominal torque: 5,500, dial type 1
275 Hexagonal wrench Nominal size: 4 1
252 Hexagonal wrench Nominal size: 5 1
33,34,222 Hexagonal wrench Nominal size: 8 1
245,282 Hexagonal wrench Nominal size: 10 1
252 Hexagon socket Nominal size: 5, Insertion angle: 12.7 1
33,34,222 Hexagon socket Nominal size: 8, Insertion angle: 12.7 1
245,282 Hexagon socket Nominal size: 10, Insertion angle: 12.7 1
19,224 Socket Nominal size: 36, Insertion angle: 12.7 1
221 Socket Nominal size: 30, Insertion angle: 12.7 1
19 Extension bar Insertion angle: 12.7 1
221 Spanner Nominal size: 30 1
224 Spanner Round type strong spanner 1
1,21 Hammer Nominal size: 12 1
8,102 Plastic hammer L = About 300 1
24,25 Snap ring pliers For shaft 1
20,146 Snap ring pliers For hole 1
1 Center punch [20] ø9.5 x 100 1
21 Pin punch ø3 x 150 1
For slinging travel motor, 1, 2 Sling Hook, wire rope 1 set
Cleaning of travel motor and parts Washing brush 1
Cleaning of travel motor and parts Wire brush 1
Draining of lubricating oil and
Common vat
hydraulic oil Container 3
W450 x D300 x H120
Receiving of steel balls (36, 268)
For making match mark Marker Oil-based, white 1
17 Wire basket 1 piece
Removal of parts Rubber mat 1
149 Leather gloves 1 pair
Addition of oil Can For hydraulic oil and lubricating oil 2
30-112 PC78US-6
(16)
2) Devices
Applicable parts
Disassembly and assembly of travel
Common work stand 1 set
motor
Cleaning of travel motor and parts Washing tank For rough washing and finish washing 1 set
104,149 Press stand Pressing capacity: Min. 200 kg 1 set
Heating temperature: Min. 100 °C
149 Heating tank 1 set
Capacity: 500 x 500 x 500
Portable electric drill
1 Electric drill [21] 1
(Max. drill diameter: ø10)
1 Drill ø2 1
Disassembly of travel motor, 161,
162, 112 Compressed air Pressure: 0.29 – 0.49 MPa
Drying of washed parts
3 Lathe 1 set
3) Measuring tools
Applicable parts
For adjustment of snap ring [20] Thickness gauge [17] Measurement range: 0.04 – 0.3 mm 2
Measurement range: 0 – 25 mm
For adjustment of snap ring [20] Outside micrometer [18] 1
Minimum division: 0.01 mm
For adjustment of preload on ball Unit type depth micrometer Measurement range: 0 – 25 mm
1
bearing [21] [19] Minimum division: 0.01 mm
PC78US-6 30-113
(16)
4) Tools to be manufactured Name: Holder [4]

Name: Work stand for travel motor [1] • A tool to pull out deep groove ball bearing (149)
• A work stand for easier and safer disassembly from shaft (102).
and assembly of the travel motor.
Name: Holder [5]

Name: Fixer [2] • A tool to insert oil seal (132) in oil seal hole of
• A tool to connect spindle (2) and hub (1). spindle (2).
Name: Holder [3] Name: Holder [6]

• A tool to insert spring (114), washer (110) and • A tool to fit tapered roller bearing (22) securely.
round type R-ring (146) in cylinder block (104). Apply it to the outer race of tapered roller bearing
• A tool to remove spring (114) from cylinder block (22) installed to crankshaft [9] of the RV gear
(104). assembly and hit it lightly with a hammer to fit the
bearing.
30-114 PC78US-6
(16)
Name: Main bearing preload adjustment jig [7] Name: Long eyebolt [10]
• A tool to press fit ball bearing (21) to hub (1). • A tool to sling the travel motor, spindle (2) and
• A tool to measure the axial clearance of ball hub (1).
bearing (21).
Use "A"
Hub M14
Spindle M16
Travel motor M16
Name: Steel bar [8]

• A tool to take out ring (18) from hub (1).
Name: Spatula [11]

• A tool to remove timing plate (109) from rear
flange (201).
Name: Eyebolt for PF [9]

• A tool used together with wires and a crane to
remove cover (8) from hub (1).
• The thread size must be PF3/8.
Name: Pin punch [12]

• A tool to remove the outer race of ball bearing
(21).
PC78US-6 30-115
(16)
Name: Cover removing jig [13] Name: Floating seal installer [16]
• A jig to remove cover (8) from hub (1). • A tool to install floating seal (31) to spindle (2).
Name: Floating seal installer [14]

• A tool to install floating seal (31) to hub (1).
Name: Floating seal installer [15]

• A tool to install floating seal (31) to hub (1) and
spindle (2).
30-116 PC78US-6
(16)
2. TIGHTENING TORQUE
Applicable parts Bolt/Nut used Width across flats of Tightening torque

(Structural drawing) Name Nominal size hexagon (Nm {kgm})
794 ± 49.0
19 Reamer bolt M24 P2.0 36
{81 ± 5.0}
58.8 ± 9.81
33 Flanged plug PF3/8 8
{6.0 ± 1.0}
58.8 ± 9.81
34,222 Plug PF3/8 8
{6.0 ± 1.0}
78.5 ± 9.81
221 Plug M20 P1.5 30
{8.0 ± 1.0}
353 ± 39.2
224 Plug M30 P1.5 36
{36 ± 4.0}
Hexagon socket head 102 ± 15.7

245 M12 P1.75 10
bolt {10.4 ± 1.6}
Hexagon socket head 12.3 ± 2.45

252 PF1/8 5
plug {1.25 ± 0.25}
Hexagon socket head 9.81 ± 1.96

275 NPTF1/16 4
plug {1.0 ± 0.2}
98.1 ± 19.6
282 Plug PT1/2 10
{10 ± 2.0}
3. WEIGHT TABLE
Applicable parts
Name Weight (kg)
(Structural drawing)
Travel motor assembly Approx. 81
1 Hub 19
2 Spindle 27
201 Rear flange assembly 9.7
PC78US-6 30-117
(16)
a Refer index number to "SECTIONAL DRAWING, 7) Replace each seal once the travel motor is
SINGLE VIEW DRAWING", if it is not shown in disassembled as a rule, even if they are not
figure at each procedure. damaged. Prepare new seals before starting
the disassembly.
DISASSEMBLY 8) The photos and drawings of typical models
are shown in this manual. Even if they are
1. Preparation different from the model being disassembled,
Perform the following preparation before disas- the disassembly procedure is not different.
sembling.
1) Preparation of work stand
• Prepare a work stand for the travel
motor.
• The work stand must be so rigid that the
internal parts of the travel motor can be
disassembled and assembled on it and
must have sufficient area for placing the
parts.
• Spread a rubber sheet, vinyl sheet, etc.
over the work stand.
2) Preparation of tools and materials
Prepare the tools and materials shown in "1.
Tools" of "OUTLINE OF MAINTENANCE".
2. General precautions for work

k The disassembled internal parts are coated
with hydraulic oil and thus slippery. If they
slip off your hands, they can injure you and
themselves. Accordingly, handle them with
extreme care.
k Kerosene and other combustible materials
are used to wash the parts. Since they are
flammable and can cause a fire and a burn,
handle them with extreme care.
1) Fully understand the inspection items and

the type of the detected trouble before disas-
sembling, and then work according to the
disassembly procedure.
2) Since the parts are made very precisely, han-
dle them with extreme care not to hit them
against each other or drop them.
3) Even if a part sticks firmly and cannot be
removed, do not hit or pry it off forcibly. If it is
removed so, it may not be installed again
because of burrs made on its surfaces when
removed and the performance of the travel
motor may decrease. Accordingly, work
carefully and patiently.
4) If the travel motor is left disassembled half-
way or fully, their parts may be rusted by
moisture and dirt. If it is obliged to stop the
work, take rust and dirt prevention measures.
5) When disassembling, make a match mark on
each mating section.
6) While disassembling, arrange the removed
parts so that they will not be damaged or lost.
30-118 PC78US-6
(16)
3. Cleaning of travel motor 4. Installation of travel motor

1) Install the eyebolts [10] to the holes for 1) Set the travel motor on the work stand.
installing spindle (2). a While setting the bolt holes of hub (1) to
a Install the 2 eyebolts symmetrically to the those of the work stand [1], insert the
spindle installation holes. travel motor in the mounting hole of the
2) Install wires to the eyebolts, sling the travel work stand slowly.
motor with a crane, and carry it to the wash-
ing tank.
2) Install the travel motor to the work stand so

that 2 hexagon socket head bolts [20] will be
3) Clean each part of the travel motor with a car set symmetrically.
k Tighten the hexagon socket head bolts
washing brush.
a Clean the space between hub (1) and
sufficiently. If they are not tightened
spindle (2) (where the floating seal is
sufficiently, the travel motor may fall and
installed) very carefully since dirt and
hurt you when it is reversed.
sand are accumulated in it.
PC78US-6 30-119
(16)
5. Draining of lubricating oil 6. Removal of cover

1) Reverse the travel motor. 1) Reverse the travel motor.
2) Loosen flanged plug (33) (1 piece) and plugs 2) Make match mark (a) at the mating section of
[34] (2 pieces). hub (1) and cover (8) with an oil-based
a If flanged plug (33) and plugs (34) are marker.
removed and the travel motor is
reversed, the oil will flow out. Accord-
ingly, just loosen those plugs to the
degree that you can remove them with
the fingers but do not remove them.
3) Locate the abutment joint of ring (18) and

make a punch hole for drilling on outside of
hub (1) about 20 mm inward from the end of
ring (18) with a punch [20] and a hammer.
3) Reverse the travel motor.

a When draining the lubricating oil, place a
container under the work stand.
4) Remove flanged plug (33) (1 piece) and
plugs (34) (2 pieces) from cover (8) to drain
the lubricating oil.
5) Remove O-ring (35) from flanged plug (33)
(1 piece).
6) Remove O-rings (35) from plugs (34) (2
pieces).
a Do not reuse removed O-rings (35).
30-120 PC78US-6
(16)
4) Using electric drill [21], drill a hole 2mm in 7) Tighten the 2 central bolts of the cover
diameter from outside of hub (1) toward ring removing jig [13] into the bolt holes for install-
(18). ing flanged plugs (33) and (34).
a Apply a drill to the punch hole and make a If cover (8) cannot be removed because
a hole accurately until the ring (18) is of the resistance of O-ring (29), hit the
pushed and floated above cover (8). rim of the cover lightly with a plastic ham-
a Clean the punch hole off. mer and sling the cover.
5) Insert the steel bar [8] in the hole to push out 8) Apply a block to the 2 outer bolts of the cover
ring (18). removing jig [13] and tighten those bolts, and
a At this time, the end of ring (18) is cover (8) floats gradually.
pushed out of cover (8) by the steel bar. 9) Remove O-ring (29) from cover (8).
a Do not reuse removed O-ring (29).
6) Hold the end of ring (18) pushed out of cover

(8) and take the ring (18) out of the ring
groove of hub (1).
PC78US-6 30-121
(16)
7. Removal of input gear 2) Remove spur gears (7) (3 pieces) from

1) Remove shaft c-ring (24) from shaft (15). crankshaft (9).
k If the pliers' noses come off the holes of
the c-ring, the c-ring may fly out. Take
care.
3) Remove hole c-rings (25) (3 pieces) from

crankshaft (9).
2) Remove steel ball (36) and input gear (6) the c-ring, the c-ring may fly out. Take
from shaft (15). care.
8. Removal of spur gear 9. Removal of shaft

1) Remove hole c-rings (25) (3 pieces) from 1) Remove shaft (15).
crankshaft (9).
the c-ring, the c-ring may fly out. Take
care.
30-122 PC78US-6
(16)
10. Removal of rear flange 5) Remove rear flange (201) from spindle (2).
1) Reverse the travel motor. a Hold the rear flange with your both hands
a This work is performed so that the plugs and lift it up slowly to remove. If it is hit
will be removed easily when the inside of or pried off forcibly, timing plate (109)
the rear flange is disassembled. At this may fall and may be damaged. Take
time, loosen the plugs to the degree that care.
you can remove them with the fingers.
a If the rear flange is not being disassem-
bled, do not loosen the plugs.
2) Loosen 2 plugs (282).
6) Remove 2 pieces of parallel pins (43) from

spindle (2).
3) Loosen 2 plugs (224).

4) Loosen hexagon socket head bolts (245) (6
pieces) and remove them from rear flange
(201).
7) Remove 2 pieces of O-rings (28) and (30)

from spindle (2).
a Do not reuse removed O-rings (28) and
(30).
PC78US-6 30-123
(16)
11. Disassembly of rear flange parts 4) Remove deep groove ball bearing (150) from
1) Place rear flange (201) on the work stand rear flange (201).
with its mating face to spindle (2) up.
2) Remove timing plate (109) from rear flange
(201).
a The timing plate may not be removed
easily because of fitting force of oil to the
rear flange. In this case, insert a spatula
[11] in the molded groove to raise the
timing plate, and the timing plate comes
off. If a screwdriver or another sharp tool
is inserted between the mating faces, the
mating faces may be scratched and oil
may leak. Accordingly, do not use a
sharp tool such as a screwdriver.
12. Disassembly of brake valve in rear flange

1) Remove 2 pieces of plugs (224) from rear
flange (201).
2) Remove O-rings (236) from plugs (224).
a Do not reuse removed O-rings (236).
3) Remove 2 pieces of parallel pins (242) from

rear flange (201).
3) Remove 2 spring retainers (225) and 2

springs (228) from rear flange (201).
4) Remove spool (223) from rear flange (201).
a Slant rear flange (201) toward either plug
hole, and spool (223) slides down. Hold
its end and take it out.
30-124 PC78US-6
(16)
5) Remove plugs (282) (2 pieces) from rear 14. Disassembly of parking brake section
k If compressed air is supplied suddenly, pis-
flange (201).
6) Remove O-ring (238) from plug (282).
ton (112) may jump out spindle (2) and hurt
a Do not reuse the removed O-ring (238).
you. Accordingly, put a protection cover on
7) Remove 2 springs (230) and 2 valves (227)
piston (112).
from rear flange (201).
1) Supply compressed air through the passage
for the parking brake on spindle (2) to take
spindle (2) out of piston (112).
2) Take O-rings (135) and (141) out of piston

(112).
a Do not reuse removed O-rings (135) and
(141).
13. Taking pilot valve out of rear flange

1) Remove plug (222), spool (271) and spring
(281) in order from rear flange (201).
2) Take O-ring (292) out of plug (222).
a Do not reuse removed O-ring (292).
PC78US-6 30-125
(16)
15. Disassembly of hydraulic motor parts 6) Remove piston assembly (piston (105) and
a When the travel motor is placed on its side, shoe (106)) and retainer plate (107) from cyl-
oil will flow out. Accordingly, place a con- inder block (104).
tainer under the travel motor. a Hold retainer plate (107) and remove it
1) Turn the travel motor 90 degrees. and piston assembly (piston (105) and
2) Drain the oil from the travel motor. shoe (106)) together.
3) Take out mating plates (116) and friction a Piston (105) and shoe (106) are made
plates (115) (2 pieces each). one by narrowing the spherical part of
the piston. It is impossible to separate
the piston and shoe without damaging
the shoe. If either of them needs to be
replaced, replace them as a set. (Here-
inafter, the set of these parts is refereed
to as the piston assembly.)
4) Hold cylinder block (104) with your both

hands and give it 2 – 3 turns in both direc-
tions to disconnect shoe (106) from swash
plate (103).
a If cylinder block (104) is pulled out as it
is, shoe (106) is left on the swash plate
(103) and the parts (piston, shoe, etc.) 7) Pull out piston assembly ((105) and (106))
sticking to cylinder block (104) come off from retainer plate (107). (9 sets)
and fall into spindle (2). Take care.
5) Pull out cylinder block (104) from shaft (102).
30-126 PC78US-6
(16)
8) Take thrust ball (108) out of cylinder block

(104).
9) Take rollers (151) (3 pieces) out of cylinder

block (104).
3) Take round R-ring (146), washer (110), spring

(114) and washer (110) out of cylinder block
(104).
16. Removal of spring in cylinder block
1) Place cylinder block (104) on the press
stand.
a Remove the spring (114) only when it
needs to be replaced.
a When removing the spring (114), align
holder [3] with washer (110) so that the
spring will not scratch the cylinder block
(104).
a Cover the cylinder block (104) with a
vinyl sheet so that its surface will not be
damaged.
2) Place holder [3] on washer (110). While
pressing holder [3] with the press, remove
round R-ring (146) with snap ring pliers from
the snap ring groove of cylinder block (104).
k If the press is loosened suddenly, the
spring may jump out and hurt you.
Accordingly, loosen the press slowly.
PC78US-6 30-127
(16)
17. Removal of swash plate k In the following case, the 2nd speed
1) Remove swash plate (103) from shaft (102). piston assembly may jump out because
a When swash plate (103) is removed, of compressed air and may hurt you.
pivot (176) may stick to it. Accordingly, place a protection cover on
the part from which the piston assembly
will jump out.
4) Supply compressed air through the passage
of spindle (2) to take 2nd speed selector pis-
ton assembly (piston and shoe) and spring
(185) out of spindle (2).
• Piston (161)
Piston assembly
• Shoe (162)
a Compressed air: 0.29 – 0.49 MPa {3 – 5

kg/cm2}
2) Pull shaft (102) out of spindle (2). At this

time, deep groove ball bearing (149) comes
off together with shaft (102).
k If the shaft end on the reduction gear
unit side is hit lightly with a plastic ham-
mer in advance, the shaft can be pulled
out easily. If the shaft end is hit
strongly, however, the shaft may jump
out. Take care.
3) Take 2 pivots (176) and 2 parallel pins (177)
out of spindle (2).
18. Removal of deep groove ball bearing

a Remove deep groove ball bearing (149) only
when it needs to be replaced.
1) Place holder [4] on the press stand and put
shaft (102) in it.
2) Hold the end of shaft (102) with the press
and remove deep groove ball bearing (149)
from shaft (102).
a Do not reuse deep groove ball bearing
(149).
30-128 PC78US-6
(16)
19. Removal of hold flange 5) Make match marks (a) on snap rings (20)
1) Turn the travel motor 90 degrees. and hold flange (3) with an oil-based marker.
2) Tighten holders [2] (3 pieces) into hub (1) a Make the match marks so that you can
and spindle (2) to fix. At this time, install the install the snap rings to the same posi-
holders [2] symmetrically. tions.
k If hold flange (3) is removed without
tightening the holders [2], spindle (2)
will separate from hub (1) and fall from
the work stand. Accordingly, be sure to
install the holders [2].
6) Turn the travel motor 90 degrees.

7) Loosen reamer bolts (19) (3 pieces).
a Adhesion is applied to the bolt holes for
reamer bolts (19). When the reamer
bolts are loosened, they may be seized
because of the adhesive and disassem-
bly may become difficult. Accordingly,
loosen reamer bolts (19) as slowly as
the snap ring, the snap ring may fly out possible. If they become heavy before
and hurt you. Take care. they are removed, do not loosen them
forcibly but tighten them and then loosen
4) Remove snap rings (20) (3 pieces) from hold
again slowly.
flange (3).
a Although the reamer bolts are tightened
to torque of 794 ± 49.0 Nm {81.0 ± 5.0
kgm}, more torque is required to loosen
them because of the adhesive applied to
the threaded parts.
PC78US-6 30-129
(16)
8) Turn the travel motor 90 degrees again to 20. Removal of holders

return it to the original position. 1) Reverse the travel motor.
9) Remove hold flange (3) from spindle (2). 2) Remove the holders [2] (3 pieces).
10) Make match marks (b) on hold flange (3) and 21. Removal of spindle
spindle (2) with an oil-based marker. 1) Place a clean container under the travel
a Make the match marks so that you can motor.
assemble hold flange (3) and spindle (2) 2) Install the eyebolts [10] symmetrically to the
to the same positions as before. holes for installing spindle (2).
a The holes for reamer bolts (19) (3 3) Install hooks to the eyebolts [10] and sling
pieces) on spindle (2) are made simulta- spindle (2) to remove it from hub (1). At this
neously. time, floating seal (31) and outer race and oil
a Replace spindle (2) and hold flange (3) seal of tapered roller bearing (22) come off,
as an assembly. (Hereinafter, this too.
assembly is referred to as the spindle
assembly.)
22. Removal of ball bearing, RV gear assembly

and pin
1) Remove floating seal (31) from hub (1).
30-130 PC78US-6
(16)
2) Hit the end of pin (17) with a pin punch [12] 4) Reverse the travel motor.
and a hammer to remove ball bearing (21) 5) Remove ball bearing (21).
from hub (1). At this time, RV gear assembly a When removing ball bearing (21), hit 3 –
(RV gear A (4), RV gear B (5), crankshaft (9), 4 places of the periphery at the pin end
tapered roller bearing (22), needle roller lightly and evenly so that the ball bearing
bearing (23) and spacer (12)) and pin (17) will not be scratched.
can be removed, too.
a When removing ball bearing (21), hit 3 –
4 places of the periphery at the pin end
lightly and evenly so that the ball bearing
will not be scratched.
a If the fitted part of ball bearing (21)
comes off hub (1), ball bearing (21), RV
gear assembly and pin (17) fall from hub
(1). Accordingly, place a container under
the work stand and spread a rubber mat
on it so that the parts will not be dam-
aged.
3) Remove ball bearing (21), RV gear assembly
and pin (17) which fell into the container. RV
gear A (4) and RV gear B (5) of the RV gear 23. Removal of spindle parts
assembly are separated from crankshaft (9). 1) Remove oil seal (132) from spindle (2).
a Remove tapered roller bearing (22), nee- a Never reuse removed oil seal (132).
dle roller bearing (23) and spacer (12)
from crankshaft (9) only when they need
to be replaced.
2) Take floating seal (31) out of spindle (2).
PC78US-6 30-131
(16)
3) Take outer races (3 pieces) of tapered roller k Kerosene is combustible. Take care
bearing (22) out of spindle (2). extremely that kerosene will not catch
a The outer race of tapered roller bearing fire and you will not be burnt or injured
(22) may stick to the spindle because of by the fire.
the lubricating oil and it may not be
3) Put the internal parts in the rough washing
removed easily. In this case, give a light
tank filled with kerosene and clean them.
impact to the center of the mounting hole
of spindle (2) with an aluminum bar, and
the oil film is broken and the outer race
can be removed easily.
26. Finish cleaning

1) Put each part in the finish washing tank filled
with kerosene and turn it slowly to clean to its
inside.
24. Disassembly of hold flange parts
2) Wipe off kerosene from each part with clean
1) Take the outer race of tapered roller bearing
cloths.
(22) out of hold flange (3).
a Blow compressed air against the inside
of hub (1), spindle (2) and hold flange (3)
to dry in a clean and dry place. After dry-
ing each part, apply hydraulic oil to them.
a Dry the inside of rear flange (201),
hydraulic motor parts and RV gear
assembly in air of a clean and dry place.
After drying each part, apply hydraulic oil
to them.
a If pins (17) (28 pieces) are handled
roughly, they contact with each other and
their surfaces may be scratched and
some of them may be lost. Accordingly,
handle them with extreme care.
25. Rough cleaning of parts

1) Separate hub (1), spindle (2), cover (8) and
rear flange (201) (4 parts) from the other
parts (hereinafter, referred to as the internal
parts).
2) Put hub (1), spindle (2), cover (8) and rear
flange (201) in the washing tank and clean
them.
a Remove all dirt and sand from these
parts.
a If the dirty parts are washed in the oil
t a n k i m m e d i a t e l y, t h e y m a y b e
scratched. Accordingly, leave them sub-
merged in the oil until dirt, grease, etc.
come off and float.
30-132 PC78US-6
(16)
When disassembling and servicing the GM motor, observe the following standard. Handle the parts carefully
and do not scratch the moving parts and sliding parts, in particular.
1. Seals
Replace the seals (O-rings, oil seals and floating seals) once the travel motor is disassembled as a rule,
even if they are not damaged.
2. Maintenance standard for wear parts

1) If a part has an extreme outside damage, replace it.
2) If a part has the following trouble (phenomenon), replace it.
Standard value Tolerance

Part No. Part name Phenomenon
(Standard dimension) (Judgment value)
Spindle kit
(2) Spindle • There is serious damage on outside.
(3) Hold flange • Surface is scuffed or worn abnormally.
(19) Reamer bolt
RV gear assembly
(4) RV gear A • RV gear tooth surface is worn
(5) RV gear B unevenly.
(9) Crankshaft • When crankshaft (9) is rotated, each
(22) Tapered roller bearing part does not move smoothly.
(23) Needle roller bearing
• Periphery of end face is worn abnor-
(20) Snap ring
mally.
• There is press mark.
(21) Ball bearing • Surface is flaking.
• Worn unevenly.
Rear flange kit
(201) Rear flange • There is flaw on sliding surface against
spool (223).
• Clearance to spool is wide.
• There is flaw on contact surface Clearance in Clearance in
against valve (227). diameter 9 – 5 µ diameter 35 µ
• Depth to contact surface against valve
(227) is large.
• There is flaw on periphery.
(223) Spool • Periphery is worn unevenly.
• Contact surface against oil seal (132)
(102) Shaft
is worn.
• Spline is worn.
• Spline is worn.
(104) Cylinder block • Inside surface is worn remarkably.
• There are flaws and uneven wear on
sliding surface against timing plate
(109).
Piston assembly • There is clearance axial between pis-
(105) Piston ton (105) and shoe (106).
Clearance 0.04 mm Clearance 0.14 mm
(106) Shoe • Shoe is worn abnormally.
• Shoe is worn unevenly.
• Periphery of end face is worn
(107) Retainer plate
unevenly.
• Spherical sliding surface against
(108) Thrust ball
retainer plate (107) is worn unevenly.
PC78US-6 30-133
(16)
Standard value Tolerance

Part No. Part name Phenomenon
(Standard dimension) (Judgment value)
• There is trace of seizure and uneven
(109) Timing plate
wear on sliding surface.
• Both end faces are worn unevenly.
(115) Friction plate Braking torque Braking torque
• Specified torque cannot be obtained.
(116) Mating plate 97.1 Nm {9.9 kgm} 97.1 Nm {9.9 kgm}
• There is trace of seizure.
(227) Valve • There is flaw on seat surface.
(149) Deep groove ball bearing • There is press mark.
• Surface is flaking.
(150) Deep groove ball bearing • Worn unevenly.
30-134 PC78US-6
(16)
ASSEMBLY 3. Assembly procedure

a If any part was replaced, the preload on the
Carry out assembly in the reverse order to disas- ball bearing and the thickness of the snap
sembly as a rule. rings must be adjusted before assembly.
Accordingly, check to see if any of the follow-
1. Preparation ing parts was replaced before starting
Prepare the work stand, tools and materials as in assembly.
preparation for disassembly. 1) Replacement parts that need adjustment of
preload on ball bearing ------ Hub (1), spindle
2. General precautions for work (2), hold flange (3) and ball bearing (21)
1) Observe the general precautions for disas- 2) Replacement parts that need adjustment of
sembly. thickness of snap ring ------ Spindle (2), hold
2) Before assembling, remove metal chips and flange (3), crankshaft (9), spacer (12) and
foreign matter from all the parts and check tapered roller bearing (22)
that a burr, a bruise, etc. are not made on a When assembling after replacing the above
any part. If there is any burr or bruise, parts, be sure to perform the necessary
remove it with an oilstone. adjustment. If the parts are installed without
3) Replace the O-rings, oil seals and floating adjustment, the travel motor will malfunction
seals with new ones. and will be broken in a short period.
4) Replace the reamer bolts with new ones as a
rule. If it is obliged to reuse them, remove all
adhesive from them. If there is any flaw on a
reamer bolt seat, remove it with an oilstone.
5) Since reamer bolt holes of spindle (2) and
the threaded parts of reamer bolts (19) are
coated with adhesive when assembled,
degrease them.
6) When installing the O-rings, oil seals and
floating seals, take care not to damage them.
(Apply a little grease to them so that they will
be installed smoothly.)
7) Be sure to coat the moving parts and sliding
parts of the hydraulic motor and valves with
clean hydraulic oil (NAS Standard Class 9 or
higher) before assembling.
8) Do not put on cloth gloves for assembly
work. (A fiber can cause a malfunction.)
9) Tighten bolts and plugs to the torque shown
in "2. Tightening torque table" of "OUTLINE
OF MAINTENANCE".
10) After finishing assembly, plug all the ports to
prevent dirt from entering them.
11) The photos and drawings of typical models
are shown in this manual. Even if they are
different from the model being disassembled,
the assembly procedure is not different.
PC78US-6 30-135
(16)
4. Assembly of hub section 4) Insert ball bearing (21) in hub (1).

1) Install 2 eyebolts [10] symmetrically to the a Apply the pin punch [12] to the periphery of
bolt holes of hub (1). ball bearing (21) and hit it lightly all around
2) Install hooks and wires to the eyebolts and to press fit the bearing little by little.
sling hub (1) with the crane and set it on the
work stand.
a While setting the bolt holes of hub (1) to
those of the work stand, insert the hub in
the mounting hole of the work stand
slowly.
5) Using floating seal installer [14] and [15],

install floating seal (31) to hub (1).
3) Install hub (1) to the work stand by tightening

the hexagon socket head bolts symmetri-
cally.
k Tighten the hexagon socket head bolts
sufficiently. If they are not tightened
sufficiently, the travel motor may fall and
hurt you when it is reversed.
5. Assembly of spindle section

1) Apply hydraulic oil to the O-ring of floating
seal (31) and install the floating seal to the
floating seal groove of spindle (2) by using
floating seal installer [15] and [16].
a Remove the O-ring from the floating seal
and apply hydraulic oil to it thinly.
a Fit the O-ring first to the groove of the
spindle and then install the floating seal
so that its surface will be parallel with the
spindle groove surface.
30-136 PC78US-6
(16)
2) Fit outer races (3 pieces) of tapered roller 6. Installation of RV gear assembly

bearing (22) to their respective mounting 1) Insert RV gear A (4) in hub (1).
holes in spindle (2).
2) Fit crankshafts (9) (3 pieces) to the outer

3) Install 2 eyebolts [10] symmetrically to spin- race mounting holes of tapered roller bear-
dle (2). ings (22) in spindle (2).
4) Install hooks and wires to the eyebolts, sling a At this time tapered roller bearing (22),
spindle (2) with the crane, and insert it in hub needle roller bearing (23) and spacer
(1) slowly. (12) are installed to the crankshaft.
5) Tighten hub (1) and spindle (2) with the fixers 3) Insert RV gear (5) in hub (1).
[2]. At this time, tighten the fixers symmetri- a Since the tooth phases of RV gear A (4)
cally. and RV gear B (5) are matched to each
6) Reverse the travel motor. others, set the punch holes on the end
a If travel motor is reversed without tight- faces to the same position when install-
ening the fixers, spindle (2) will separate ing.
from hub (1) and fall from the work stand.
Accordingly, be sure to install the fixers.
PC78US-6 30-137
(16)
4) Insert pins (17) (28 pieces) between the pin

groove of hub (1) and tooth space of the
gear.
a When inserting pins (17), apply lubricat-
ing oil to them.
8. Tightening of reamer bolts

1) Apply anti-seize compound to the reamer
part of reamer bolt (19) and apply adhesive
to the threaded part the reamer bolt.
5) Insert ball bearing (21) in hub (1). a If the threaded part of the reamer bolt (19)
a Apply the pin punch to the periphery of is stained with oil or grease, degrease it.
ball bearing (21) and hit it lightly all After degreasing and drying thoroughly,
around to press fit the bearing little by lit- apply adhesive to the threaded part.
tle. a Tighten 3 reamer bolts (19) evenly little
by little. If only one of them is tightened
first, hold flange (3) will slant and ball
bearing (21) cannot be fitted correctly to
hold flange (3) and the reamer bolts (19)
may be seized. Take care.
2) Tighten reamer bolts (19) (3 pieces) until
hold flange (3) is fitted to ball bearing (21)
perfectly.
3) Tighten reamer bolts (19) (3 pieces) to the
specified torque.
3 Tightening torque:
794 ± 49.0 Nm {81.0 ± 5.0 kgm}
7. Installation of hold flange

1) Check to see if hub (1), spindle (2), hold
flange (3) and ball bearings (21) (2 pieces)
are replaced with new ones.
a If none of the above parts is replaced, go
to next step 2).
a If any of the above parts is replaced, per-
form "22. Adjustment of preload on ball
bearing (Pages 30-149 – 150)" and then
go to next step 2).
2) Fit hold flange (3) to the inner race of ball
bearing (21) in hub (1).
a When fitting hold flange (3) to ball bear-
ing (21), line up the match marks on
spindle (2) and crankshaft (9) so that the
hold flange will be installed to the same
position as before.
a If hold flange (3) is not fitted easily to the
inner race of ball bearing (21), hit it lightly
and evenly with a plastic hammer to fit it.
30-138 PC78US-6
(16)
4) Reverse the travel motor. 3) Install shaft c-rings (25) (3 pieces) to c-ring
5) Remove fixers (3 pieces). grooves on crankshaft (9).
7) Fit the outer race of tapered roller bearing
(22) to hold flange (3).
10. Installation of spur gears

1) Install spur gears (7) (3 pieces) to crankshaft
(9), while setting the match marks on them.
9. Installation of snap rings a When installing spur gears (7) (3 pieces)
1) Check to see if spindle (2), hold flange (3), to crankshaft (9), set the match marks
crankshaft (9), tapered roller bearing (22) (M) (punch holes) on them as shown
and spacer (12) are replaced with new ones. below.
a If none of the above parts is replaced, go
to next step 2).
a If any of the above parts is replaced, per-
form "(20) Adjustment of axial clearance
of tapered roller bearing (Pages 30-150 –
30-151)" and then go to next step 2).
a When replacing only snap ring (20),
select the same thickness as ever or sim-
ilar thickness to it from the prepared 15
thicknesses.
2) Install snap ring (20) to the snap ring groove
in hold flange (3).
a When installing 3 snap rings (20), line up
the match marks on them and those on
hold flange (3). If snap ring (20) is
replaced, fit new one of the thickness
selected in the previous step to the snap
ring groove.
PC78US-6 30-139
(16)
2) Install shaft c-rings (25) (3 pieces) to the c- 12. Installation of shaft

k When inserting the shaft, put on leather
ring grooves on crankshaft (9).
gloves to avoid burning your hands.
a Insert deep groove ball bearing (149) until it
is fitted to the flange surface of shaft (102).
1) Put deep groove ball bearing (149) in an
oven and heat it at 100 ± 10 °C for 10 min-
utes and then install it to shaft (102).
11. Insertion of oil seal

2) Apply lithium grease to the lip of oil seal
(132) and press fit oil seal (132) to the oil
seal fitting hole of spindle (2) with holder [5]
and a hammer.
2) Insert parallel pins (177) (2 pieces) in the pin
holes of spindle (2).
3) Apply lithium grease to pivots (176) (2
pieces) to prevent them from falling and fit
them to parallel pin (177) of spindle (2).
4) Install spring (185) and piston assembly (pis-
ton (161) and shoe (162)) to spindle (2).
5) Turn the travel motor 90 degrees.
30-140 PC78US-6
(16)
6) Install shaft (102). 9) Install swash plate (103) to spindle (2).

a Fit shaft (102) to spindle (2) slowly and a Apply grease to mating faces of swash
carefully, taking care not to damage the plate (103) and spindle (2).
lip of oil seal (132). Damage of the lip a When installing swash plate (103) to
can cause oil leakage and travel motor spindle (2), set its pivot mounting holes
breakage in a short period. to pivots (176) (2 pieces) fitted to spindle
7) Fit shaft (102) to spindle (2). (2).
8) Apply lithium grease to the spline of shaft
(102).
13. Assembly of cylinder block

1) Insert washer (110), spring (114), washer
(110) and round R-ring (146) in cylinder block
(104) in order.
2) Place cylinder block (104) on the press
stand.
PC78US-6 30-141
(16)
3) Place holder [3] on washer (110). While 4) Install 9 piston assemblies ((105) and (106))
holding it with the press, install round R-ring to cylinder block (104).
(146) to the snap ring groove of cylinder a Fit retainer plate (107) to the spherical
block (104) with the snap ring pliers. part of thrust ball (108).
a Cover cylinder block (104) with a vinyl
sheet so that its contacting face to timing
plate (109) will not be damaged.
5) Install cylinder block (104) to shaft (102).

a Align the spline hole of cylinder block
(104) with the spline shaft of shaft (102).
a After installing the cylinder block, rotate it
with the hand and check that it has no
play. If it has any play, inspect and elimi-
nate it.
14. Assembly of hydraulic motor parts

1) Fit rollers (151) (3 pieces) to the holes of cyl-
inder block (104).
2) Place thrust ball (108) on cylinder block
(104).
3) Fit 9 piston assemblies to retainer plate
(107).
a After assembling, soak the whole assem-
bly in hydraulic oil.
30-142 PC78US-6
(16)
15. Assembly of parking brake section

a Before installing friction plate (115), soak it in
hydraulic oil.
1) Slant the work stand 90 degrees.
2) Install friction plate (115) and mating plate
(116) alternately to the outside grooves of
cylinder block (104).
3) Install O-rings (135) and (141) to the O-ring
grooves of piston (112).
a At this time, thinly apply grease to O-
rings (135) and (141).
16. Assembly of brake valve parts in rear flange

1) Install O-rings (238) (2 pieces) to plugs (282)
(2 pieces).
a Apply grease to O-rings (238).
2) Install valve (227) and spring (230) to rear

flange (201).
a At this time, apply grease to connect
valve (227) and spring (230) by the adhe-
sion of the grease.
3) Tighten plugs (282) into rear flange (201).
4) Slant the travel motor 90 degrees. 4) After inserting plugs (282) (2 pieces), tighten
5) Install piston (112) in spindle (2). them lightly into rear flange (201) with the
a If piston (112) cannot be installed in spin- hexagonal wrench.
dle (2) because of resistance of O-rings
(135) and (141), hit the end of the piston
(112) lightly with a plastic hammer.
a When installing piston (112), take care
not to damage the O-rings.
PC78US-6 30-143
(16)
5) Insert spool (223) in rear flange (201). 8) Screw plugs (224) (2 pieces) into rear flange
a Apply hydraulic oil to the spool and insert (201).
the spool in the rear flange. a When tightening the plugs into the rear
a When installing the spool, align the rear flange, take care not to deform the
flange hole with the spool shaft so that springs.
the inside surface of the rear flange and 9) Tighten plugs (224) (2 pieces) lightly into rear
the outside surface of the spool will not flange (201) with the spanner.
be damaged by contacting.
a Contact damage of the hole of the rear
flange and the outside of the spool can
cause internal leakage and decrease of
the travel motor performance after
assembly. Take care.
17. Assembly of rear flange parts

1) Installation of rear flange parts
i) Place the rear flange with the mating
face to spindle (2) down.
ii) Insert spring (281) and spool (271) in
rear flange (201).
6) Install rings (236) to plugs (224). a When tightening the plug into the rear
a Apply grease to O-rings (236). flange, take care not to deform the
7) Install spring retainers (225) and springs spring.
(228) to plugs (224).
30-144 PC78US-6
(16)
iii) Install O-ring (292) to plug (222). 4) Apply grease to the mating faces of timing
a Apply grease to O-ring (292). plate (109) and rear flange (201).
iv) Tighten plug (222) into rear flange (201) 5) Install timing plate (109) to rear flange (201)
to the specified torque. by using parallel pins (242) as guides.
a Install timing plate (109) until it is fitted to
rear flange (201).
58.8 ± 9.8 Nm {6.0 ± 1.0 kgm}
a Fit the timing plate to the rear flange so
that it will not fall from the rear flange
when the rear flange is installed to spin-
dle (2).
2) Apply hydraulic oil to deep groove ball bear-

ing (150) and fit deep groove ball bearing
(150) to rear flange (201).
18. Connection of rear flange and spindle
1) Fit O-rings (30) and (28) to the O-ring
grooves of spindle (2).
a Fit O-ring (30) without applying grease to
it. If grease is applied at this time, it may
ooze out through the joint of the rear
flange and spindle while the travel motor
is running, and the operator may mistake
it for oil leakage. Accordingly, do not
apply grease.
3) Fit parallel pins (242) (2 pieces) to the pin

holes of rear flange (201).
PC78US-6 30-145
(16)
2) Fit parallel pins (43) (2 pieces) to spindle (2). 5) Tighten hexagon socket head bolts (245) (6
3) Pour hydraulic oil of 0.5 l into spindle (2). pieces) into spindle (2) to the specified
torque.
102 ± 15.7 Nm {10.4 ± 1.6 kgm}
a When installing rear flange (201) to spin-

dle (2), install springs (113) (8 pieces) to
the rear flange. At this time, fix springs
(113) with grease so that they will not fall 6) Tighten plugs (282) to the specified torque.
from the rear flange.
4) While setting parallel pins (43) (2 pieces) fit-
98.1 ± 19.6 Nm {10 ± 2.0 kgm}
ted to spindle (2) to the pin holes of rear
flange (201), install rear flange (201) to spin-
dle (2).
7) Tighten plugs (224) to the specified torque.

353 ± 39.2 Nm {36 ± 4.0 kgm}
30-146 PC78US-6
(16)
19. Assembly of input gear

2) Install shaft (15) to shaft (102).
3) Install input gear (6) to shaft (15).
a When installing input gear (6), mesh it
with 3 spur gears (7). If it is not meshed,
check and correct it.
20. Assembly cover

1) Pour lubricating oil of 1.3 l into hub (1).
2) Install O-ring (29) to the O-ring groove of
cover (8).
a Apply grease to O-ring (29).
3) Install cover (8) to hub (1).

4) Install shaft c-ring (24) to the snap ring a Line up the match marks on cover (8)
groove of shaft (15). and hub (1).
5) Coat steel ball (36) with grease and place it a While hitting the periphery of cover (8)
on the hollow part of input gear (6). lightly with a plastic hammer, install cover
(8). If the cover is hit strongly, the O-ring
will be broken and oil will leak. Take
care.
PC78US-6 30-147
(16)
4) Fit ring (18) to the ring groove of hub (1). 21. Removal of travel motor
1) Remove the travel motor mounting bolts from
the work stand.
5) Fit O-ring (35) to flanged plug (33).

Tighten flanged plug (33) into cover (8) to the
tightening torque. 2) Tighten eyebolts [10] (2 pieces) into the bolt
holes of spindle (2).
a Install the 2 eyebolts symmetrically.
58.8 ± 9.81 Nm {6 ± 1.0 kgm}
3) Install hooks and wires to the eyebolts and
6) Fit O-ring (35) to plug (34). remove the travel motor from the work stand
Tighten plug (34) into cover (8) to the tighten- with the crane.
ing torque.
58.8 ± 9.81 Nm {6 ± 1.0 kgm}
30-148 PC78US-6
(16)
22. Adjustment of preload on ball bearing

a A proper preload must be given to ball bear-
ing (21) to secure a proper service life.
Accordingly, if a part which affects the pre-
load is replaced, assemble the travel motor
temporarily according to the following proce-
dure and check the preload. If the GM motor
is assembled without checking the preload, it
will malfunction and will be broken in a short
period. Take care extremely.
a Parts which affect preload on ball bearing
Hub (1), spindle (2), hold flange (3), ball
bearing (21)
a If none of the above parts is replaced, skip
this step and go to 7-2) in page 30-138.
a The procedure for checking and adjusting
the preload is described below.
Procedure for adjusting preload on ball bearing

1) Install the main bearing preload adjustment
jig [7] to spindle (2) and tighten the special
nut to press fit ball bearing (21) to hub (1).
3 Tightening torque of special nut:
58.8 Nm {6 kgm}
2) Insert a depth micrometer [19] in the mea-
surement hole of the main bearing preload
adjustment jig [7] to measure depth A.
3) Since dimension B of the main bearing pre-
load adjustment jig [7] is known, clearance C
can be given by the following formula.
A: Measured value
C=A–B B: Dimension of jig
C: Specified dimension
PC78US-6 30-149
(16)
4) Obtain dimension D of hold flange (3). 6) Remove the main bearing preload adjust-
5) Adjust hold flange (3) from the result of 2) – ment jig [7] from spindle (2).
4), according to the following procedure.
Dimension C is the specified dimension
of the hold flange.
i) When dimension D of actual hold flange
(3) is at least 0.02 mm less than speci-
fied dimension C, cut face E of hold
flange (3) to the specified dimension with
a lathe, etc.
ii) When dimension D of actual hold flange
(3) is in the tolerance (± 0.02 mm) of
specified dimension C, use hold flange
(3) as it is.
iii) When dimension D of actual hold flange
(3) is at least 0.02 mm more than speci- 7) After adjusting the hold flange by the adjust-
fied dimension C, replace the spindle ment work in i), ii) and iii), go to 7-2) in page
assembly with new one. A new hold 30-138.
flange (3) has adjustment allowance.
a Since the hold flange and spindle are dis- 23. Adjustment of axial clearance of tapered roller
assembled together, they are an assem- bearing
bly. Accordingly, it is not allowed to a If any on the following parts is replace, the
replace only the hold flange. The hold axial clearance of tapered roller bearing (22)
flange and spindle must be replaced must be adjusted to the specification value
together. This assembly of these parts is by adjusting the thickness of snap ring (20).
called the spindle assembly. GM motor is assembled without adjusting the
a When replacing the spindle assembly, axial clearance, it will malfunction and will be
perform the disassembly and assembly b r o k e n i n a s h o r t p e r i o d . Ta k e c a r e
procedure again. extremely.
Spindle (2), hold flange (3), crankshaft (9),
spacer (12), tapered roller bearing (22)
a If none of the above parts is replaced, the
snap ring does not need to be adjusted. In
this case, go to step 9 in page 30-139.
a The procedure for adjusting the axial clear-
a n c e o f t h e ta p e r e d r o l l e r b e a r i n g i s
described below.
1) Lightly hit the outer race of tapered roller
bearing (22) installed to crankshaft (9) with a
hammer and holder [6].
a Perform this step to insert the RV gear
assembly in spindle (2) securely.
30-150 PC78US-6
(16)
2) Install thinnest snap ring (20) to the snap ring 4) Insert a thickness gauge [17] between snap
groove in hold flange (3). ring (20) and tapered roller bearing (22) to
measure the clearance.
5) Measurement of snap ring thickness
• Set thickness of snap ring (Max.)
Thickness of Thickness of
Max. = thickness + current snap
gauge ring
• Set thickness of snap ring (Min.)

Thickness of Thickness of
Min. = thickness + current snap – 0.05
gauge ring
3) Lightly hit the periphery of snap ring (20) with

the hammer and holder [6].
a Check that the RV gear assembly is
inserted in spindle (2) securely.
6) After deciding the snap ring (20) thickness,

select one from the snap rings of 15 thick-
nesses and install it to hold flange (3).
(See 6. Clearance adjustment parts dimen-
sion table)
7) After installing the snap ring of the selected
thickness, go to 9-2) in page 30-139.
PC78US-6 30-151
(16)
PERFORMANCE TEST
• After finishing maintenance of the GM motor, test its performance according to the following procedure.
1. Necessary measuring tools
1 Pressure gauge --- For 3.43 MPa {35 kg/cm2} 2 pieces

2 Measuring cylinder --- For 5 l 1 piece
3 Stopwatch 1 piece
2. Test procedure
Installation and piping Install GM motor to machine (frame) and fit piping.
1 Do not install tracks, however.
of GM motor
[Since GM motor performance test (no-load operation) is being performed]
Notes) 1. Fit piping so that pressure gauge can be installed (to main circuit)
and drainage from hydraulic motor can be measured.
2. Do not install GM motor by hitting it with hammer but installed

it carefully by using bolt holes.
GM motor speed Pressure Turning direction Operating time

Running-in of GM
2
motor 1 10 rpm
No-load Left/Right 1 minute each
or more
2 20 rpm
3 GM motor speed
Preparation operation before test … Continue preparation operation until temperature rises as follows.
1 Hydraulic oil temperature: 45 ― 55 °C
Outside temperature of reduction gear hub: 40 ― 80 °C
Performance test ………………Measure following items and judge result.

Criteria — GM motor drive pressure … Max.1.57 MPa at 10 rpm
2 … (Max.16 kg/cm² at 10 rpm)
Hydraulic motor drainage … Max. 0.5 /min at 10 rpm
OK NG
Install tracks. Disassemble and

adjust again.
30-152 PC78US-6
(16)
CLEARANCE ADJUSTMENT PARTS DIMENSION TABLE

Part name Dimensions
Snap ring (20)
Classification
Dimension (T)
symbol
X Above 1.75, below 1.80
Y Above 1.80, below 1.85
Z Above 1.85, below 1.90
A Above 1.90, below 1.95
B Above 1.95, below 2.00
C Above 2.00, below 2.05
D Above 2.05, below 2.10
E Above 2.10, below 2.15
F Above 2.15, below 2.20
G Above 2.20, below 2.25
H Above 2.25, below 2.30
I Above 2.30, below 2.35
J Above 2.35, below 2.40
K Above 2.40, below 2.45
L Above 2.45, below 2.50
PC78US-6 30-153
(16)
DISASSEMBLY AND ASSEMBLY IDLER
IDLER ASSEMBLY a When installing the floating seal, thoroughly

clean, degrease, and dry the parts marked
with the thick lines (the load ring and faces in
ASSEMBLY
contact with the load ring).
1. Using tool L1, press fit bushings (9) and (10) to
idler (4).
a Press fitting force: 26 – 53 kN {2.6 – 5.4 tons}
a When inserting the floating seal assembly in

the housing, use the push jig. This push jig
must push the load ring.
2. Fit the O-ring and install support (7) to shaft (5) [1]: Cylindrical push jig
with dowel pin (8).
a The metallic faces of the floating seal which

3. Using tool L2, install floating seal (6) to idler (4) are in contact with each other must be free
and assembly of shaft (5) and support (7). from dirt.
a Apply oil to the sliding surface of the floating a After the floating seal is inserted, check that
seal and take care that dirt will not stick to it does not slant more than 1 mm and its pro-
that surface. jection is as follows.
30-154 PC78US-6
(16)
DISASSEMBLY AND ASSEMBLY IDLER
4. Install the assembly of shaft (5) and support (7) 6. Using tool L2, install floating seal (3) to idler (4)
to idler (4). and support (2).
a Apply oil to the sliding surfaces of the floating
seal and take care that dirt will not stick to
the floating seal.
a Degrease the contact faces of the floating
seal and O-ring.
5. Supply oil between shaft (5) and idler (4).
6 Quantity of oil: 60 cc (EO-30CD)
7. Fit the O-ring and install support (2) with dowel

pin (1).
PC78US-6 30-155
(16)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
RECOIL SPRING ASSEMBLY 3) Apply hydraulic pressure slowly. After the

spring is compressed, remove nut (5).
a Compress the spring until the nut is loos-
DISASSEMBLY
ened.
1. Remove lubricator (1). a Release the hydraulic pressure slowly to
eliminate the spring force.
2. Remove yoke piston assembly (3) from recoil
spring assembly (2). 4) Remove pilot (7) and cylinder (8) from spring
(6).
3. Disassembly of recoil spring assembly a Remove O-ring (13) from the cylinder.
1) Remove set bolt (4).
4. Disassembly of yoke piston assembly
1) Remove wear ring (10) from yoke piston (9).
2) Remove snap ring (11) and U-packing (12).
2) Set recoil spring assembly (2) to tool M.

k Since the installing load of the spring is
heavy and dangerous, set the spring
securely.
a Installing load of spring:
69.2 kN {7,061 kg} (Rubber shoe)
47.4 kN {4,837 kg} (Steel shoe)
30-156 PC78US-6
(16)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY 4) Apply hydraulic pressure slowly to compress

the spring. Tighten nut (5) so that the install-
1. Assembly of yoke piston assembly ing length of the spring will be a.
1) Fit U-packing (12) to yoke piston (9) and a Installing length a of spring:
secure it with snap ring (11). 283 mm (Rubber shoe)
2) Install wear ring (10). 323 (Steel shoe)
2. Assembly of recoil spring assembly 2 Nut:

1) Fit O-ring (13) to cylinder (8). Lubricant containing molybdenum
2) Install cylinder (8) and pilot (7) to spring (6). disulphide (LM-P)
3) Set recoil spring (2) to tool M. 5) Remove recoil spring assembly (2) from tool
M.
6) Install set bolt (4).
3 : 58.8 – 73.5 Nm {6 – 7.5 kgm}
7) Fill cylinder (8) with grease (G2-L1).
a Quantity of grease (G2-L1):
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.
2 Sliding parts of yoke piston and wear
ring: Grease (G2-L1)
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.
PC78US-6 30-157
(16)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
TRACK ROLLER ASSEMBLY 5. Remove floating seal (7a) from roller (5), then
remove floating seal (7b) from shaft and collar
assembly (6).
DISASSEMBLY
1. Remove pin (2) from track roller assembly (1),
then remove collar (3).
6. Pull out pin (8) and remove collar (10) from shaft
(9).
2. Remove floating seal (4a) from collar (3). 7. Remove the O-ring from shaft (9).
3. Remove floating seal (4b) from roller (5). 8. Remove bushings (11) and (12) from roller (5).
4. Remove shaft and collar assembly (6) from roller

(5).
30-158 PC78US-6
(16)
ASSEMBLY a The metallic faces of the floating seal which are

in contact with each other must be free from dirt.
a When installing the floating seal, thoroughly a Thoroughly clean the parts to be in contact with
clean, degrease, and dry the parts marked with the supplied oil. After cleaning them, the dirt
the thick lines (the load ring and faces in contact remaining on these parts of 1 roller assembly
with the load ring). must be below 25 mg and the size of the dirt
Check that the contact surfaces of the floating must be below 0.3.
seal are free from dirt. a Set plug (2) on the outside of the machine body.
a When inserting the floating seal assembly in the 1. Using tool L3, press fit bushing (12) to roller (5).
housing, use the push jig. This push jig must a Press fit bushing (11) similarly.
push the load ring.
• PC78US-6 Serial No. : 4001 – 6500 2. Fit the O-ring to shaft (9), then install collar (10)
PC78UU-6 Serial No. : 22001 and up and pin (8) to shaft (9).
Tool L4 ( 80 mm)
• PC78US-6 Serial No. : 6501 and up
Tool L5 ( 70 mm)
a After the floating seal is inserted, check that it

does not slant more than 1 mm and its projection
a is as follows.
• PC78US-6 Serial No. : 4001 – 6500
PC78UU-6 Serial No. : 22001 and up
a : 5 – 7 mm
• PC78US-6 Serial No. : 6501 and up
a : 6 – 10 mm
a In steps 3, 4, and 7 below, use tool L5

instead of tool L4 for PC78US-6, serial No.
6501 and up.
PC78US-6 30-159
(16)
3. Using tool L4, press fit floating seal (7b) to shaft 8. Install collar (3) to shaft (9), then install pin (2).
(9).
9. Fill the roller with oil and tighten plug (13).
5 Track roller:
4. Using tool L4, press fit floating seal (7a) to roller
(5).
PC78US-6 Serial No.:4001 – 6500
a Press fit floating seal (4b) similarly.
PC78UU-6 Serial No.:22001 and up
210 – 230 cc (GO-140)
PC78US-6 Serial No.:6501 and up
160 – 180 cc (GO-140)
5. Install shaft and collar assembly (6) to roller (5).
6. Turn over the assembly of roller (5) and shaft (6).
7. Using tool L4, install floating seal (4a) to collar

(3).
30-160 PC78US-6
(16)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
ASSEMBLY
DISASSEMBLY
1. Cylinder assembly
1) Set cylinder assembly (1) to tool U1.
2) Using a hydraulic pump or a power wrench
and tool U2, loosen head assembly (2).
3) Remove piston assembly (6) from piston rod

(5).
4) Remove head assembly (2).
3) Pull out piston rod assembly (3).

a Place an oil pan, etc. under the cylinder
to receive the oil.
5) Remove cap (6) and take out 9 balls (7), then

remove plunger (8).
• Perform this work for only arm cylinder.
a Since cap (6) is made of nylon, tighten a
screw into it and pull it out with pliers.
2. Piston rod assembly

1) Set piston rod assembly (3) to tool U1.
and tool U3, remove nylon nut (4).
a Width across flats of nut:
Cylinder Boom Arm Bucket Offset Blade
Width 80 *1 75 *1
across 60 55 75
flats 70 *2 65 *2
*1 : PC78UU-6
*2 : PC78US-6
PC78US-6 30-161
(16)
3. Disassembly of piston assembly ASSEMBLY

1) Remove wear ring (9).
2) Remove piston ring (10). a Apply engine oil to the sliding surfaces of each
a Apply a screwdriver, etc. to the piston part and take care not to damage the packing,
ring and hit it with a hammer to break off dust seals, O-rings, etc.
the piston ring. a Do not insert the backup ring forcibly. Heat it in
water at 50 – 60°C, then insert it carefully.
1. Assembly of cylinder head assembly

1) Using tool U6, press fit bushing (16).
2) Install rod packing (15).
3) Using tool U7, install dust seal (14) and
secure it with snap ring (13).
4) Fit O-ring (12).
5) Fit the backup ring and O-ring (11).
4. Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (11).
2) Remove O-ring (12).
3) Remove snap ring (13) and dust seal (14).
4) Remove rod packing (15).
5) Remove bushing (16).
30-162 PC78US-6
(16)
2. Assembly of piston assembly 2) Install head assembly (2) to piston rod (5).
1) Using tool U4, expand piston ring (10). 3) Install piston assembly (6) to piston rod (5).
a Set the piston ring to tool U4 and revolve
the handle by 8 – 10 turns to expand the
piston ring.
2) Using tool U5, contract piston ring (10).
4) Set piston rod assembly (3) to tool U1.

5) Using tool U3, tighten nylon nut (4).
2 Nylon nut:
Liquid adhesive
3) Install wear ring (9).
(Equivalent to LOCTITE 262)
3 Nylon nut:
a Take care not to open the closed gap of
the ring too much.
Cylinder name Tightening torque
Boom *1 3.97 ± 0.4 kNm {405 ± 40.5 kgm}
Boom *2 2.60 ± 0.26 kNm {265 ± 26.5 kgm}
Arm *1 4.12 ± 0.41 kNm {420 ± 42.0 kgm}
Arm *2 2.65 ± 0.26 kNm {270 ± 27.0 kgm}
Bucket 2.16 ± 0.22 kNm {220 ± 22 kgm}
Offset 1.42 ± 0.14 kNm {145 ± 14.5kgm}
Blade 3.14 ± 0.31 kNm {320 ± 32.0 kgm}

*1 : PC78UU-6, *2 : PC78US-6
3. Piston rod assembly

1) Set plunger (8) to the piston rod and install 9
balls (7) and secure them with cap (6).
a Check that there is some play at the
plunger tip.
• Perform this work for only arm cylinder.
PC78US-6 30-163
(16)
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.

and tool U2, tighten head assembly (2).
3 Head assembly:
Cylinder Tightening torque

name
Boom *1 980 ± 98 Nm {100 ± 10 kgm}
Boom *2 961 ± 96.1 Nm {98 ± 9.8 kgm}
Arm *1 1,107 ± 110 Nm {113 ± 11.2 kgm}
Arm *2 785 ± 78.5 Nm {80 ± 8.0 kgm}
1st time: Tighten to 1,176 – 1,372 Nm

{120 – 140 kgm}.
2nd time: Loosen to 0 Nm {0 kgm}.
Bucket 3rd time: Tighten to 392 Nm {40 kgm}
4th time: Apply angle tightening
(Tighten periphery of cylin-
der head by 3.5 – 4.5 mm).
Offset 931 ± 93.1 Nm {95 ± 9.5 kgm}
Blade 1.03 ± 0.10 Nm {105 ± 10.5 kgm}

*1: PC78UU-6
*2: PC78US-6
a After assembling, clean each part and mask the

piping ports and pin hole.
30-164 PC78US-6
(16)
50 OTHER SPECIFICATIONS
PC78US-6 (For Norway & EU)............................ 50-3
PC78US-6 50-1
(10)
PC78US-6 (For Norway & EU)
MACHINE MODEL SERIAL NUMBER

PC78US-6 4809 and up (For Norway)
PC78US-6 4809 and up (For EU)
• This section contains only information related to the Norway specification.

For other information, see the PC78US-6 Shop Manual.
PC78US-6 50-3
(10)
CONTENTS
GENERAL
Specification dimensions drawing .............................................................................................................. 50- 5
Working range drawing .............................................................................................................................. 50- 6
Specifications ........................................................................................................................................... 50-6-2
Weight table .............................................................................................................................................. 50-10
STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD

Arrangement of hydraulic components ..................................................................................................... 50-12
Solenoid valve........................................................................................................................................ 50-13-1
Accumulator for PPC.............................................................................................................................. 50-13-5
Dimensions of each part of work equipment ............................................................................................. 50-14
Boom hydraulic anti-burst valve ................................................................................................................ 50-16
Electric control system .............................................................................................................................. 50-21
General system diagram ........................................................................................................................... 50-22
Overload alarm function ............................................................................................................................ 50-24
Overload alarm pressure sensor............................................................................................................... 50-25
Meter display unit ...................................................................................................................................... 50-26
TROUBLESHOOTING
Connector types and mounting locations ................................................................................................ 50-101
Connector arrangement diagram ............................................................................................................ 50-104
Explanation of functions of electric system control mechanism .............................................................. 50-108
Dysplay and special functions of monitor panel ...................................................................................... 50-109
Troubleshooting for controller pump control system (C mode) ............................................................... 50-117
Troubleshooting for machine monitor system (M mode) ......................................................................... 50-133
50-4 PC78US-6
(14)
SPECIFICATION DIMENSIONS DRAWING
Item Unit PC78US-6
Machine weight kg 7,325

Bucket capapcity m3 0.20
(*1) KOMATSU 4D95LE-2 Diesel engine
Engine model —
(*2) KOMATSU S4D95LE-3-A Diesel engine
Rated engine output kW{HP}/rpm 40.5 {54.0}/1,850
B Overall height mm 2,870 (2,730)
D Shoe width mm 450
F Overall length of track mm 2,840
G Distance between tumbler centers mm 2,235
Minimum ground clearance mm 360
Travel speed (Low/High) km/h 3.0/4.5
Figures in ( ): EU specification
*1. Serial No.: 4809 – 5500
PC78US-6 50-5
(10)
GENERAL WORKING RANGE DRAWING
WORKING RANGE DRAWING
Unit: mm
Working range PC78US-6
A Max. digging reach 6,920
B Max. digging depth 4,710
C Max. digging height 7,600
D Max. vertical wall depth 4,030
E Max. dumping height 5,490
Min. swing radius of work
F equipment 2,050
G Max. reach at ground level 6,790

H Max. blade lifting height 380
I Max. blade lowering depth 245
50-6 PC78US-6
(10)
SPECIFICATIONS
Machine model PC78US-6

Bucket capacity m3 0.20
Machine weight kg 7,325
Max. digging depth mm 4,710
Max. vertical wall depth mm 4,030
Working range
Max. digging reach mm 6,920

Max. reach at ground level mm 6,790
Max. digging height mm 7,600
Max. dumping height mm 5,490
Performance
Max. blade lifting height mm 380

Max. blade lowering depth mm 245
Max. digging force (Bucket) kN {kg} 61.29 {6,250}
Max. slope angle for swing deg. 19.0
Travel speed (Low/High) km/h 3.0/4.5
Gradeability deg. 35
Ground pressure kPa {kg/cm2} 32.4 {0.33}
Overall length (for transport) mm 6,265
Overall width mm 2,330
Overall height (for transport) mm 2,850
Overall height (for operation) mm 2,870
Ground clearance of counterweight mm 760
Min. ground clearance mm 360
Tail swing radius mm 1,240
Dimension
Min. swing radius of work equipment mm 2,050

Height of work equipment at min. swing radius mm 5,500
Overall width of track mm 2,320
Overall length of track mm 2,840
Distance between tumbler centers mm 2,235
Track gauge mm 1,870
Machine cab height mm 1,745
Blade width × height mm 2,320 × 470
50-6-2 PC78US-6
(10)
PC78US-6
5501 and up
0.20
7,325
4,710
4,030
6,920
6,790
7,600
5,490
380
245
61.29 {6,250}
10.0
19.0
3.0/4.5
35
32.4 {0.33}
6,265
2,330
2,850
2,870
760
360
1,240
2,050
5,500
2,320
2,840
2,235
1,870
1,745
2,320 × 470
PC78US-6 50-6-3

Model 4D95LE-2
4-cycle, water-cooled, in-line vertical type,
Type
direct injection
No. of cylinders - bore × stroke mm 4-95 × 115
kW/rpm 40.5/1,850
Rated output {HP/rpm} {54.0/1,850}
Performance
Nm/rpm 226/1,500
Engine

g/kWh
Battery (*1) 12 V, 55 Ah × 2
Undercarriage
Type × No. Variable-capacity piston pump × 1

Hydraulic pump
{cc} Gear pump × 2

Discharge
80× 2+60+12.7
Set pressures
(Work equipment, travel) MPa 26.5 {270}
(Swing, blade) {kg/cm2} 21.1 {215}
(Control) 3.1 {32}
Hydraulic system
Type × No. 7-spool type × 1

valve
Control method Hydraulically assisted

Travel motor

Swing motor

50-6-4 PC78US-6
(13)
PC78US-6 PC78US-6
6501 and up 5501 – 6500

S4D95LE-3-A S4D95LE-3-A
4-cycle, water-cooled, in-line vertical type, 4-cycle, water-cooled, in-line vertical type,
direct injection, with turbocharger direct injection, with turbocharger
4-95 × 115 4-95 × 115
3.26 {3,260} 3.26 {3,260}
40.5/1,850 40.5/1,850
{54.0/1,850} {54.0/1,850}
237/1,500 237/1,500
{24.2/1,500} {24.2/1,500}
2,020 2,020
1,130 1,130
227 {169} 227 {169}
24 V, 3.0 kw 24 V, 3.0 kw
24 V, 35 A 24 V, 35 A
12 V, 55 Ah × 2 12 V, 55 Ah × 2
ALW-4 CF29-3
Assembly-type triple grouser, 39 on each side Assembly-type triple grouser, 39 on each side
Variable-capacity piston pump × 1 Variable-capacity piston pump × 1

Gear pump × 2 Gear pump × 2
80× 2+60+12.7 80× 2+60+12.7
26.5 {270} 26.5 {270}

21.1 {215} 21.1 {215}
3.1 {32} 3.1 {32}
7-spool type × 1 7-spool type × 1
Hydraulically assisted Hydraulically assisted
Variable-capacity piston motor Variable-capacity piston motor

(with brake valve, parking brake) × 2 (with brake valve, parking brake) × 2
Fixed-capacity piston motor Fixed-capacity piston motor

(with safety valve, pivot shaft brake) × 1 (with safety valve, pivot shaft brake) × 1
Box-shaped, open Box-shaped, open

Tank return side Tank return side
Air-cooled (CF42) Air-cooled (CF40-1)
PC78US-6 50-7
(13)

Boom cylinder

Stroke mm 858
Arm cylinder

Stroke mm 865
Hydraulic system

Bucket cylinder

Stroke mm 710
Blade cylinder

Stroke mm 130
50-8 PC78US-6
(6)
PC78US-6
5501 and up
ø 115
ø 65
858
2,143
1,285
ø 100
ø 60
865
2,193
1,328
ø 90
ø 55
710
1,765
1,055
ø 130
ø 65
130
679
549
PC78US-6 50-9
(6)
WEIGHT TABLE
This mass list is for reference in handling or transporting these components.
Unit: kg
Serial Number 4809 – 5500 5501 – 6500 6501 and up

Engine assembly (without water and oil) 403 404 404
• Engine (without water and oil) 300 300 300
• Engine mount 30 30 30
• PTO 7 7 7
• Hydraulic pump 66 67 67
Cooling assembly (without coolant and oil) 29 29 29
• Radiator (without coolant) 6.3 6.3 5.8
• Oil cooler (without oil) 5.2 5.2 5.5
Revolving frame 930 930 984
Operator's cab 260 260 260
Operator's seat 18 18 18
Fuel tank (without fuel) 11 11 48
Hydraulic tank (without hydraulic oil) 75 75 70
Control valve 58 58 58
Counterweight 800 800 732
Additional counterweight (OPT) 220 220 220
Swing motor (Including brake valve) 22 22 22
Swing circle 104 104 104
Swing machinery 47 47 46
Center swivel joint 17 17 17
Track frame assembly (without track shoe) 1,142 1,142 1,142
• Track frame 779 779 779
• Idler assembly 54 × 2 54 × 2 54 × 2
• Recoil spring assembly 40 × 2 39 × 2 39 × 2
• Carrier roller 3.4 × 2 3.4 × 2 3.4 × 2
• Track roller 13 × 10 13 × 10 12.4 × 10
• Travel motor (with reduction gears) 81 × 2 81 × 2 81 × 2
• Sprocket 19 × 2 19 × 2 19 × 2
Track shoe assembly
• City pad shoe (450 mm) 410 × 2 410 × 2 410 × 2
• Road liner (450 mm) 450 × 2 450 × 2 450 × 2
• Rubber shoe (450 mm) 385 × 2 385 × 2 385 × 2
• Triple grouser (600 m) 495 × 2 495 × 2 495 × 2
50-10 PC78US-6
(13)
Unit: kg
Serial Number 4809 – 5500 5501 – 6500 6501 and up

Boom assembly 418 418 418
Long arm assembly 240 240 240
Bucket link assembly 56 56 54
Bucket assembly (with side cutter) 210 210 204
Blade assembly 374 374 358
Boom cylinder assembly 86 86 86
Arm cylinder assembly 72 72 72
Bucket cylinder assembly 51 51 51
Blade cylinder assembly 46 46 46
PC78US-6 50-11
(10)
ARRANGEMENT OF HYDRAULIC COMPONENTS

PC78US-6 Serial No.: 4809 – 6500

10. Accumulator 19. Boom hydraulic anti-burst valve
50-12 PC78US-6
(14)
1. Bucket cylinder 11. Blade PPC valve (Blade specification)

2. Arm cylinder 12. Accumulator
10. Left work equipment PPC valve 19. Boom hydraulic anti-burst valve
PC78US-6 50-13
(14)
SOLENOID VALVE
PC78US-6
a The diagram shows a machine equipped with the
accumulator
50-13-1 PC78US-6
(14)
A1: To accumulator (for PPC circuit)

A2: From control pump
B1: To PPC valve
B2: To 2nd travel speed selection valve

Solenoid valve
5. Push pin
6. Valve spool
7. Return spring
8. Valve body

9. Adjustment screw
10. Locknut
11. Guide
12. Return spring
13. Valve spool
PC78US-6 50-13-2
(14)
PPC LOCK SOLENOID VALVE

2-STAGE TRAVEL SPEED SELECTOR SOLENOID VALVE
SWING HOLDING BRAKE SOLENOID VALVE
Operation
When solenoid is de-energized (circuit is broken) When solenoid is energized (circuit is made)
• While a signal current does not flow from the • If a signal current flows from the PPC hydraulic
PPC hydraulic lock switch or travel speed boost lock switch or travel speed boost pedal to sole-
pedal, solenoid (1) is de-energized. noid (1), solenoid (1) is energized.
Accordingly, spool (2) is pressed up by spring • Accordingly, spool (2) is pushed down by push
(3). pin (4).
• Under this condition, port A is closed and the • Under this condition, the pilot hydraulic oil flows
pilot hydraulic oil does not flow into the actuator. through port A, spool (2), and port B into the
At the same time, the oil from the actuator is actuator.
drained through ports B and T into the tank. At the same time, port T is closed and the oil
does not flow into the tank.
50-13-3 PC78US-6
(14)
When signal current is 0 (When coil is de-ener- Control relief valve

gized and circuit cut out)
• If the signal current flowing from the controller • If the pressure of the hydraulic oil from the con-
into coil (1) becomes 0, coil (1) is deenergized. trol pump rises, the oil in port A pushes spool (1).
• As a result, spool (2) is pressed up by return The reaction force of spool (1) compresses
spring (4). spring (2) and moves spool (1) to the right to
• Accordingly, port A is closed and the pressurized open ports A and T to relieve the circuit.
oil from the PPC valve does not flow into the Set pressure: 3.1 MPa {32 kg/cm²}
control valve.
At this time, the oil from the control valve is
drained through ports B and T into the tank.
Signal current is 0 o increased o maximum

• The valve operates in the order of 3, 2, and 1
explained above.
PC78US-6 50-13-4
(14)
MAINTENANCE STANDARD ACCUMULATOR FOR PPC
ACCUMULATOR FOR PPC

1. Gas plug
(for PPC circuit) 2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
• The accumulator is installed to the PPC lock
solenoid valve. Even if the engine is stopped
while the work equipment is raised, the work
equipment can be lowered under its weight by
applying the pilot oil pressure to the control valve
to operate with the pressure of the nitrogen gas
compressed in the accumulator.
Specifications
Gas used: Nitrogen gas
Volume of gas: 300 cc
Gas pressure: 1.18 MPa {12 kg/cm²} (at 80 °C)
Max. using pressure: 6.86 MPa {70 kg/cm²}
50-13-5 PC78US-6
(14)
DIMENSIONS OF EACH PART OF WORK EQUIPMENT

ARM SECTION
PC78US-6 Long arm
*1. Serial No.: 4809 – 4927
50-14 PC78US-6
(6)
Unit: mm
PC78US-6
No. Allowance
Shaft Hole
– 0.030 + 0.100
1 – ø 60 – 0.100 0
+1.0
Arm side 71.5
2 0
Cylinder head side 70 ± 1.2
– 0.030 + 0.100
3 – ø 60 – 0.100 0
+0.5
Boom side 220
0
4
– 0.5
Arm side 220
– 1.0
5 – 228.2 ± 2.0
6 – 239.5 ± 1.0
7 – 465.5 ± 1.0
8 – 2,250 –
9 – 2,702.7 ± 3.0
10 – 1,652.1 ± 1.3
11 – 259 ± 0.3
12 – 7.6 ± 0.5
13 – 395.1 ± 0.1
14 – 342 ± 0.1
15 – 312.2 –
16 – 1,066.9 –
– 0.225 0
17 – ø 50 – 0.285 – 0.150
– 1.0
Link side 200
– 2.0
18
+2.0
Bucket side 200
0
– 0.225 0
19 – ø 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 –
PC78US-6 50-15
➂
MAINTENANCE STANDARD BOOM HYDRAULIC ANTI-BURST VALVE
BOOM HYDRAULIC ANTI-BURST VALVE
V : From control valve

T : To hydraulic tank
CY : To hydraulic cylinder
PI : From PPC valve
PCY : For pressure pickup and equalizer circuits
50-16 PC78US-6
➂
PC78US-6 Serial No.: 4809 – 6765
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
Basic dimensions Allowable limits

Free length × Installed Installed
7 Check valve spring Installed load Free length
Outside diameter length load
13.7 N 11.0 N If damaged or
16.4 × 8.9 11.5 — deformed,
{1.4 kg} {1.12 kg}
22.6 N 18.0 N replace spring
8 Spool return spring 19.1 × 8 14.0 —
{2.3 kg} {1.84 kg}
55.4 N 44.3 N
9 Spool return spring 24.8 × 16.8 22.5 —
{5.65 kg} {4.52 kg}
PC78US-6 50-17
(13)
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
Basic dimensions Allowable limits

Free length × Installed Installed
7 Check valve spring Installed load Free length
Outside diameter length load
15.1 N 12.1 N If damaged or
31.9 × 5.4 26.5 — deformed,
{1.54 kg} {1.23 kg}
22.6 N 18.0 N replace spring
8 Spool return spring 19.1 × 8 14.0 —
{2.3 kg} {1.84 kg}
55.4 N 44.3 N
9 Spool return spring 24.8 × 16.8 22.5 —
{5.65 kg} {4.52 kg}
50-17-1 PC78US-6
(13)
Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the oil
from flowing back from the work equipment cylinder
to prevent sudden fall of the work equipment.
Operation
1. When the work equipment is in neutral
[When piping is normal]
• Check valve (5) is closed by the work equip-
ment cylinder holding pressure applied
through port CY to chamber b.
• When the work equipment is in neutral, no
pilot pressure is applied from the PPC valve
to port PI. Accordingly, pilot spool (1) is
moved to the left end by the force of springs
(2) and (3), then chambers a and b are shut
off from each other.
• Accordingly, oil does not flow from the main
valve to the work equipment cylinder, thus
the work equipment cylinder is held.
• If the pressure in the work equipment cylin-
der rises high abnormally, work equipment
cylinder holding pressure Pb operates safety
valve (4).
[When piping bursts]

• Even if piping A between the main valve and
work equipment cylinder bursts, chamber a
is shut off from chanber b as in the case
where the piping is normal. Accordingly, the
work equipment cylinder is held.
• When the engine is stopped and the work
equipment is held in air, if port PCY is
opened, oil in chamber b flows out through
orifice (7) and port PCY. Accordingly, the
work equipment lowers slowly.
50-18 PC78US-6
(13)
2. When oil is sent from main valve to cylinder

• If pressure Pa of the oil sent from the main
valve to chamber a is higher than the total of
pressure Pb in chamber b connected to the
work equipment cylinder and the force of
spring (6), check valve (5) opens and cham-
bers a and b are connected to each other
and the oil flows from the main valve to the
work equipment cylinder.

• If piping A between the main valve and the
work equipment cylinder bursts, the oil in
chamber a flows out through the burst part
and pressure Pa in chamber a lowers.
• If Pa lowers below the total of pressure Pb in
chamber b and the force of spring (6), check
valve (5) closes and chambers a and b are
shut off from each other. Accordingly, pres-
sure Pb in the cylinder is held and the work
equipment does not fall suddenly.
PC78US-6 50-19
(13)
3. When oil is returned from work equipment

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

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

position, spool (1) returns to the left end to
shut off chambers a and b from each other.
Accordingly, the work equipment stops.
50-20 PC78US-6
(13)
ELECTRIC CONTROL SYSTEM
Engine control function
Engine and pump compound

control function
Overheat prevention function
Swing control function
Travel control function
PPC lock function
(*1)
Electric Automatic gear shift system
control system
(*1)
Overload alarm function
Error code display and alarm function
Self-diagnosis function
Error code memory func
*1. For PC78US-6 Serial No.: 6501 and up
PC78US-6 50-21
(10)
MAINTENANCE STANDARD GENERAL SYSTEM DIAGRAM
GENERAL SYSTEM DIAGRAM

PC78US-6 Serial No.: 4809 – 5500
a This drawing shows the PC78US-6 of blade specification.
50-22 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
11. PPC lock switch
13. Safety relay
20. Monitor panel
21. Travel speed boost pedal [Blade specification]
22. Travel alarm
26. TVC-EPC valve
30. Blade PPC valve [Blade specification]
36. Starting motor
39. Hydraulic pump
39a. Servo piston
39b. LS valve
39c. TVC valve
40. Control valve
41. Travel motor
42. Swing motor
43. Overload alarm actuation switch
44. Overload alarm pressure sensor
PC78US-6 50-23
(10)
PC78US-6 Serial No.: 5501 – 6500
50-23-1 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
11. PPC lock switch
13. Safety relay
19. Monitor panel
20. Travel speed boost pedal (Blade specification)
21. Travel alarm
25. TVC-EPC valve
36. Starting motor
39. Hydraulic pump
39a. Servo piston
39b. LS valve
39c. TVC valve
40. Control valve
41. Travel motor
42. Swing motor
PC78US-6 50-23-2
(10)
50-23-3 PC78US-6
(10)
1. Battery
2. Battery relay
3. Fusible link
4. Starting switch
5. Fuse box
6. Controller
11. PPC lock switch
13. Safety relay
19. Monitor panel
21. Travel alarm
25. TVC-EPC valve
36. Starting motor
39. Hydraulic pump
39a. Servo piston
39b. LS valve
39c. TVC valve
40. Control valve
41. Travel motor
42. Swing motor
PC78US-6 50-23-4
(10)
MAINTENANCE STANDARD OVERLOAD ALARM FUNCTION
OVERLOAD ALARM FUNCTION

PC78US-6 Serial No.: 4809 – 6500

2. Battery relay a. Power supply of controller
3. Fusible link b. Power supply of solenoids
4. Starting switch c. Power supply of monitor panel
6. Controller e. Overload alarm actuation signal
7. Monitor panel f. Overload alarm pressure signal
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.
50-24 PC78US-6
(10)
MAINTENANCE STANDARD OVERLOAD ALARM PRESSURE SENSOR
OVERLOAD ALARM PRESSURE SENSOR
1. Plug
2. Sensor
3. Connector
Function
• One pressure sensor is installed to the boom cyl-
inder bottom circuit to sense the hydraulic pres-
sure on the boom cylinder bottom side.
PC78US-6 50-25
(10)
MAINTENANCE STANDARD METER DISPLAY UNIT
METER DISPLAY UNIT
Display
No. Display type Display item Display range Display method color Remarks
Time is measured while engine is running

1 Service meter 0-99999.9 h (alternator is generating) (Lamp always lights
up even if starting switch is at OFF position.)
If electric control system has trouble, 3 alpha-
[*1] numerics (user code, service code) is dis- Blue LCD
Display 3 alphanumerics
2 played. In depth 0 set mode, depth from
datum plane is displayed.
See above Segment of corresponding level and all seg-
3a Gauge
Coolant
Above set [Monitor lamp blinks when 8th level lights up
temperature
3b Monitor temperature (above 99°C). Monitor lamp blinks and alarm Red LED
(99°C) buzzer sounds when 9th level lights up.]
See above Segment of corresponding level and all seg-

4a Gauge Blue LCD
Fuel level
Below set level [Monitor lamp blinks and alarm buzzer sounds
4b Monitor when 1st level lights up (below 30 liters).] Red LED
(30 liters)
Lamp lights up for about 30 seconds when
starting switch is turned to HEAT position, then
5 Preheating During preheating
blinks (for about 10 seconds) to show that pre-
Pilot heating is finished and then goes off. Green
When one-touch
One-touch Lamp lights up when one-touch decelerator
6 decelerator
deceleration operates.
operates
Below set pressure Lamp
7 Overload
(14.7 MPa {150 kg/cm2})
Lamp lights up when starting switch is turned
When charging is to ON position and goes off after engine starts.
defective (charge Lamp is turned off when normal and on when
8 Caution Charge level Red
voltage < battery abnormal.
voltate) (If trouble occurs while engine is running,
buzzer sounds.)
Engine oil Below set pressure
9
pressurre (49 kPa {0.5 kg/cm2})
*1: For the display method of the marked items, see ELECTRIC CONTROL SYSTEM.
50-26 PC78US-6
(10)
TROUBLESHOOTING
Serial No.: 4809 – 5500
ing).
Connector Type of No. of Connector Type of No. of
Location Address Location Address
No. Connector Pins No. Connector Pins
D4 SWP 2 Diode (Engine stop G-1 K45 M 1 Radio ground Q-3

solenoid)
Diode (Starting switch Intermediate connector
D5 SWP 2 G-1 K51 AMP 090 20 (Starting switch, light M-7
BR ->Battery relay BR)
switch)
Diode (Alternator R ->
D6 SWP 2 G-1
Battery relay BR) K52 M 3 Light switch N-8
D11 SWP 2 Diode (TVC solenoid) R-5
K53 M 2 Buzzer cancel switch O-8
K54 M 3 Beacon switch P-8
Diode (Swing holding
D13 SWP 2 R-4 SHINA-
brake solenoid) Additional working lamp
K55 5 Q-8
GAWA relay
Diode (Air conditioner
D22 SWP 2 H-1
compressor) Intermediate connector
M1 L 2 M-4
(Power supply, ground)
Overload warring can-
E01 M 2 R-4
cel switch Intermediate connector
M2 X 2 (Power supply, glow M-3
F02 DT 2 Beacon lamp I-9 plug)
FBI Fuse R-3 M3 DT 8 (Fuel level sensor, M-4
hydraulic switch)
Intermediate connector Intermediate connector
K1 S1 12 N-7
(Monitor panel) M4 DT 8 (Washer, travel/swing M-4
alarm)
K2 S 16 (Monitor panel) M-7 Intermediate connector
M5 DT 8 (TVC, power supply, M-3
2nd travel speed selec- starting switch)
K3 DT 2 O-2
tion solenoid valve
M6 DT 8 (Pressure switch, air M-3
K11 SWP 12 Auto A/C unit N-2 conditioner sensor)
For connection of boom
bottom pressure sensor
K17 X 2 Optional power supply P-2 M9 DT 2 Intermediate connector I-2
K18 AMP 090 2 Decelerator switch Q-2 M13 DT 2 PPC hydraulic lock M-2
K19 PA 9 Radio R-3 M14 DT 2 Swing holding brake N-2
K20 M 8 Cab inlet R-6 M15 DT 2 Travel speed selector M-2
K21 S 8 Cab inlet R-6 M16 DT 2 Engine speed sensor J-3
Attachment selector M17 X 1 Glow plug K-9

K22 DT 2 P-8
wire
Starting motor cut relay Engine water tempera-
K23 Relay 5 R-7 M18 DT 2 L-9
(PPC lock) ture
Air conditioner com-
K26 AMP 090 2 Horn switch M-7 M19 X 1 L-8
pressor
Fuel governor control M20 DT 2 TVC solenoid K-9
K27 SWP 6 N-7
motor
PPC hydraulic lock Pressure switch (Boom
K28 M 3 P-2 M21 X 2 G-9
switch RAISE)
SHINA- Pressure switch
K32 5 Accelerator relay O-8 M22 X 2 J-9
GAWA (Swing)
K33 5 Decelerator relay N-8 M23 X 2 G-9
GAWA (Swing)
SHINA- Pressure switch (Arm
K34 5 Motor drive relay O-8 M24 X 2 H-9
GAWA IN)
SUMIT- Floor intermediate con- Pressure switch
K42 16 P-8 M25 X 2 I-9
OMO nector (Travel)
PC78US-6 50-101
(7)

M26 L 2 Fusible link C-8 T31 Terminal 1 Safety relay B K-3
M27 L 2 Fusible link B-7 T32 Terminal 1 Safety relay C J-3
M28 SWP 6 J-9 T33 Terminal 1 Starting motor B L-8
(Working lamp)
M30 X 2 Safety relay (S•R) K-4 T34 Terminal 1 Starting motor C L-7
M31 KES 2 Windshield washer C-8 V2 DT 12 Intermediate connector O-2
Travel/Swing alarm
M32 DT 2 J-3 W04 M 6 Wiper motor M-5
(Optional)
Air conditioner outside
M33 DT 2 temperature sensor L-5 W19 2 Cigarette lighter M-5
(Optional)
Starting switch termi-
YAZAKI B Terminal 1 M-9
M40 2 Working lamp (cab) H-9 nal B
7222-1424
YAZAKI BR Terminal 1 M-8
M41 2 Working lamp (cab) G-9 nal BR
7222-1424
M42 YAZAKI 2 Working lamp (cab) J-9 ACC Terminal 1 M-8
7222-1424 nal ACC
SUMIT- Starting switch termi-

C Terminal 1 M-9
M45 OMO 6189- Alternator L-5 nal C
0443
R1 Terminal 1 nal R1 N-8
M75 DT 2 Working lamp D-9
M76 DT 2 Working lamp (Boom) E-9 R2 Terminal 1 nal R2 N-8
M80 AMP 090 2 Horn M-2
Boom bottom pressure

M92 DT 3 I-2
sensor (Optional)
M95 DT 24 Controller R-8
M97 DT 40 Controller Q-8
P01 AMP 040 12 Monitor panel M-6
Sunlight sensor
P15 AMP 040 2 M-6
(Optional)
T5 Terminal 1 Alternator B L-6
Engine oil pressure

T6 Terminal 1 switch L-4
Engine stop solenoid

T7 Terminal 1 K-9
(+)
T8 Terminal 1 Engine stop solenoid (-) K-9
T9 Terminal 1 Battery relay E A-4
T10 Terminal 1 Battery relay BR A-3
T11 Terminal 1 Battery relay M A-6
T12 Terminal 1 Battery relay B A-5
50-102 PC78US-6
(12)

Serial No.: 4809 – 5500
50-104 PC78US-6
(7)
PC78US-6 50-105
(7)
50-106 PC78US-6
(4)
Serial No.: 5501 – 6500

ing).
Diode (Engine stop SUMIT- Floor intermediate con-
D4 SWP 2 H-1 K42 16 P-8
solenoid, HOLD) OMO nector
Diode (Starting switch
D5 SWP 2 G-1 K45 M 1 Radio ground Q-3
BR ->Battery relay BR)
D6 SWP 2 Diode (Alternator R -> G-1

Battery relay BR) K51 AMP 090 20 (Starting switch, light M-7
switch)
K52 M 3 Light switch N-8
K53 M 2 Buzzer cancel switch O-8
Diode (Swing holding
D13 SWP 2 R-4
brake solenoid) K54 M 3 Beacon switch P-8
Diode (Air conditioner
D22 SWP 2 H-1 SHINA-
compressor) Additional working lamp
K55 5 Q-8
GAWA relay
D25 SWP 2 Diode (Engine stop G-1
solenoid PULL) Intermediate connector
M1 L 2 M-4
(Power supply, ground)
Diode (Engine stop
D26 SWP 2 H-9
solenoid relay coil) Intermediate connector
M2 X 2 (Power supply, glow M-3
Overload warring can- plug)
EU1 M 2 cel switch R-4
F02 DT 2 Beacon lamp J-9 M3 DT (Gr) 8 (Fuel level sensor, M-4
hydraulic switch)
FBI Terminal Fuse box R-3 Intermediate connector

M4 DT (G) 8 (Washer, travel/swing M-4
alarm)
GND Terminal 1 Engine stop solenoid L-3
(GND) Intermediate connector
M5 DT (Gr) 8 (TVC, power supply, M-3
Engine stop solenoid starting switch)
HOLD Terminal 1 (HOLD) L-2
Intermediate connector M6 DT (B) 8 (Pressure switch, air M-3
K1 S1 12 (Monitor panel) M-7 conditioner sensor)
Intermediate connector M7 DT (G) 8 For connection of boom M-3
K2 S 16 (Monitor panel) N-7 bottom pressure sensor
2nd travel speed selec- M9 DT 2 Intermediate connector I-2
K3 DT 2 O-2
tion solenoid valve
K11 SWP 12 Auto A/C unit N-2 M13 DT 2 PPC hydraulic lock M-2
K12 M 2 Resister Q-8 M14 DT 2 Swing holding brake N-2
K17 X 2 Optional power supply P-2 M15 DT 2 Travel speed selector M-2
K18 AMP 090 2 Decelerator switch Q-2 M16 DT 2 Engine speed sensor J-3
K19 PA 9 Radio R-3 M17 X 1 Glow plug K-9
M18 DT 2 Engine water tempera- L-9

K20 M 8 Cab inlet R-6 ture
Air conditioner com-
K21 S 8 Cab inlet R-6 M19 X 1 L-8
pressor
Attachment selector M20 DT 2 TVC solenoid K-9
K22 DT 4 P-8
wire
Starting motor cut relay Pressure switch (Boom
K23 Relay 5 R-7 M21 X 2 RAISE) G-9
(PPC lock)
Pressure switch
K26 AMP 090 2 Horn switch M-7 M22 X 2 I-9
(Swing)
Fuel governor control M23 X 2 Pressure switch G-9
K27 SWP 6 N-7 (Swing)
motor
PPC hydraulic lock M24 X 2 Pressure switch (Arm H-9
K28 M 3 P-2 IN)
switch
K32 5 Accelerator relay O-8 M25 X 2 (Travel) I-9
GAWA
SHINA- M26 L 2 Fusible link C-8
K33 5 Decelerator relay N-8
GAWA
PC78US-6 50-107
(12)

M27 L 2 Fusible link B-7 Terminal: Engine stop

T16 Terminal 1 solenoid relay K-3
(Contact 1)
M28 DT 2 I-9
(Working lamp) Terminal: Engine stop
M30 X 2 Safety relay (S•R) J-3 (Contact 2)
M31 KES 2 Windshield washer C-8 T31 Terminal 1 Safety relay B K-4
Travel/Swing alarm T32 Terminal 1 Safety relay C L-5

M32 DT 2 J-2
(Optional)
Air conditioner outside T33 Terminal 1 Starting motor B L-8
M33 DT 2 temperature sensor L-6
(Optional)
T34 Terminal 1 Starting motor C L-7
M35 L 2 (Starting motor C) K-1
V2 DT 12 Intermediate connector O-2
M36 DT 2 J-2
relay (Coil)
W04 M 6 Wiper motor M-5
YAZAKI
M40 2 Working lamp (cab) H-9
7222-1424
W19 2 Cigarette lighter M-5
M41 YAZAKI 2 Working lamp (cab) H-9
7222-1424
B Terminal 1 nal B M-9
M42 YAZAKI 2 Working lamp (cab) J-9
7222-1424
BR Terminal 1 Starting switch termi- M-8
SUMIT- nal BR
M45 OMO 6189- 3 Alternator L-5
0443 Starting switch termi-
ACC Terminal 1 M-8
nal ACC
M75 DT 2 Working lamp D-9
C Terminal 1 M-9
nal C
M76 DT 2 Working lamp (Boom) E-9
R1 Terminal 1 N-8
nal R1
M80 AMP 090 2 Horn M-2
Boom bottom pressure R2 Terminal 1 N-8
M92 DT 3 I-2 nal R2
sensor
M97 DT 40 Controller Q-8
Sunlight sensor
P15 AMP 040 2 M-6
(Optional)
PULL Terminal 1 L-3
(PULL)
Engine oil pressure

T6 Terminal 1 L-6
switch
50-107-1 PC78US-6
(12)
Serial No.: 5501 – 6500
50-107-3 PC78US-6
(12)
PC78US-6 50-107-4
(7)
50-107-5 PC78US-6
(7)

ing).
Diode (Assembled-type Intermediate connector
D4 SWP 8 H-1
diode) M3 DT (Gr) 8 (Fuel level sensor, M-4
hydraulic switch)
Diode (Starting switch
D5 SWP 2 G-1
BR ->Battery relay BR) For connection of boom
M7 DT (G) 8 M-3
bottom pressure sensor
D6 SWP 2 Diode (Alternator R -> G-1
Battery relay BR)
M9 X 2 Fuel level sensor
Overload warring can-
EU1 M 2 R-4
cel switch
M13 DT 2 PPC hydraulic lock M-2
F02 DT 2 Beacon lamp J-9
M14 DT 2 Swing holding brake N-2
FBI Terminal Fuse box R-3
M15 DT 2 Travel speed selector M-2
GND Terminal 1 L-3
(GND)
M16 DT 2 Engine speed sensor J-3
HOLD Terminal 1 Engine stop solenoid L-2
(HOLD)
M17 X 1 Glow plug K-9
K1 S1 12 M-7
(Monitor panel) M18 DT 2 Engine water tempera- L-9
ture
K2 S 16 (Monitor panel) N-7 Air conditioner com-
M19 X 1 L-8
pressor
K11 SWP 12 Auto A/C unit N-2
M20 DT 2 TVC solenoid K-9
K12 M 2 Resister Q-8
M21 X 2 G-9
RAISE)
K17 X 2 Optional power supply P-2
Pressure switch
M22 X 2 (Swing) I-9
K18 AMP 090 2 Decelerator switch Q-2 Pressure switch
M23 X 2 G-9
(Swing)
K19 PA 9 Radio R-3 Pressure switch (Arm
M24 X 2 H-9
IN)
K20 M 8 Cab inlet R-6 Pressure switch
M25 X 2 I-9
(Travel)
K21 S 8 Cab inlet R-6
M26 L 2 Fusible link C-8
K23 Relay 5 Starting motor cut relay R-7
(PPC lock)
M27 L 2 Fusible link B-7
K26 AMP 090 2 Horn switch M-7
M28 DT 2 I-9
(Working lamp)
PPC hydraulic lock
K28 M 3 P-2
switch
M30 X 2 Safety relay (S•R) J-3
SHINA-
K32 5 Accelerator relay O-8
GAWA
M31 KES 2 Windshield washer C-8
SHINA-
K33 GAWA 5 Decelerator relay N-8 Travel/Swing alarm
M32 DT 2 J-2
(Optional)
SUMIT- Floor intermediate con-
K42 16 P-8
OMO nector Intermediate connector
M35 L 2 K-1
(Starting motor C)
K45 M 1 Radio ground Q-3
M36 DT 2 relay (Coil) J-2
K51 AMP 090 20 (Starting switch, light M-7 YAZAKI
switch) M40 2 Working lamp (cab) H-9
7222-1424
K52 M 3 Light switch N-8 M41 YAZAKI 2 Working lamp (cab) H-9
7222-1424
K53 M 2 Buzzer cancel switch O-8 M42 YAZAKI 2 Working lamp (cab) J-9
7222-1424
K54 M 3 Beacon switch P-8 SUMIT-

M45 OMO 6189- 3 Alternator L-5
0443
SHINA- Additional working lamp
K55 5 Q-8
GAWA relay M75 DT 2 Working lamp D-9
M1 L 2 Intermediate connector M-4

(Power supply, ground) M76 DT 2 Working lamp (Boom) E-9
M2 X 2 (Power supply, glow M-3 M80 AMP 090 2 Horn M-2
plug)
PC78US-6 50-107-6
(12)

M92 DT 3 Boom bottom pressure I-2

sensor M13 M 2 Speaker (Right)
M95 DT 24 Controller R-8 M71 M 2 Room light
P01 AMP 070 12 Monitor panel M-6 M73 M 2 Speaker (Left)
P02 AMP 040 20 Monitor panel M-6 Air conditioner unit

M87 S 12 junction
Sunlight sensor Air conditioner foot
P15 AMP 040 2 M-6 M88 YAZAKI 2 10
(Optional) area air outlet servo
PULL Terminal 1 L-3
(PULL) S1 M 3 Fuel control dial
T1 Terminal 1 Revolving frame ground I-2 Fuel governor control

S2 SWP 6
motor
T2 Terminal 1 Revolving frame ground H-2 Main pump pressure
S3 DT 3
sensor
SHINA- Travel/Swing alarm
S4 GAWA 5
relay (If equipped)
SHINA- Starting motor cutout
V3 GAWA 5 relay
Engine oil pressure
T6 Terminal 1 L-6
switch
W03 X 2 Window limit switch
Terminal: Engine stop

(Contact 1)
Terminal: Engine stop

(Contact 2)
T31 Terminal 1 Safety relay B K-4
T32 Terminal 1 Safety relay C L-5
T33 Terminal 1 Starting motor B L-8
T34 Terminal 1 Starting motor C L-7
V2 SWP 12 Intermediate connector O-2
W04 M 6 Wiper motor M-5
W19 Terminal 2 Cigarette lighter M-5

B Terminal 1 M-9
nal B

BR Terminal 1 M-8
nal BR

ACC Terminal 1 nal ACC M-8

C Terminal 1 M-9
nal C

R1 Terminal 1 nal R1 N-8

R2 Terminal 1 N-8
nal R2
J1 SUMIT- 20 Junction connector

OMO 2
J2 SUMIT- 20 Junction connector

OMO 2
50-107-7 PC78US-6
(12)
50-107-9 PC78US-6
(12)
PC78US-6 50-107-10
(12)
50-107-11 PC78US-6
(12)
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL
TROUBLESHOOTING MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM

CONTROL MECHANISM
Serial No.: 4809 – 6500
output, etc.
Network information

50-108 PC78US-6
(12)
EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL
TROUBLESHOOTING MECHANISM
output, etc.
Network information

PC78US-6 50-108-1
(12)
DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL

1. Diagnostic function of lamps, gauges, and buzzer
If the starting switch is turned ON, all the lamps and gauges light up for about 3 seconds and the
buzzer sounds for about 1 second to check the monitor panel, then the monitor panel displays nor-
mally (A lamp which does not light up at this time is broken).
2. Function of displaying "user code"

All trouble information items of the controller are sent to the monitor panel. An emergent informa-
tion 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.
★ The lamps other than display (1), service meter unit (2), and lighting parts (solid parts in the follow-
ing illustration) are turned OFF.
1) Display of User Code

(1) Display
(2) Service meter unit
(3) Mode selector switch (UP)
(4) Mode selector switch (DOWN)
(5) Set switch
(6) Travel speed selector switch
Note) Since the switches "3, 4, and 5" are not indi-
cated on the panel of model US, operate the
same parts as the panel of model UU.
Example) User code "E02" is displayed.
2) User Codes List
User Code Troubled System
E02 TVC-EPC system
E03 Swing holding brake system
E05 Governor control system
PC78US-6 50-109
3. Function of displaying "service code"

All trouble information items of the controller are sent to the monitor panel. All of the information
items which must display "user codes" and those which do not need display "user codes" are saved
as "service codes" in the monitor panel.
If the following operation is executed, the service code is displayed on the display of the monitor
panel and the letter "E" to indicate that the trouble is happening currently and the lapse time (service
meter reading) are displayed on the service meter unit.
1) Method of displaying and deleting service code (1) Display (5) Set switch
i) The service code is displayed by the fol- (2) Service meter unit (6) Travel speed
lowing procedure: (3) Mode selector switch
a. Push and hold the "Buzzer cancel switch (7) Working mode
switch (8)" and "Working mode selector (UP) selector switch
switch (7)" for 2.5 seconds. (4) Mode selector (8) Buzzer cancel
b. Push the "Buzzer cancel switch (8)" and switch
switch
"Mode selector switch (UP) (3)" [or (DOWN)
Mode selector switch (DOWN) (4)] and
set "01" to the 2nd and 3rd columns
from the left on service meter unit (2).
c. Push the "Set switch (5)".
* Since the switches "3, 4, and 5" are not indi-

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

★ If "E213" is still happening, the let-
ter "E" is displayed in the 2nd col-
umn of service meter unit (2). If
"E213" has been repaired, "E" is
not displayed.
★ The lapse time is displayed in the 3
columns from the right of service
meter unit (2).
50-110 PC78US-6
Example 3) If any service code is not saved, "-" is dis-

played in every column of display (1) and
service meter unit (2).
ii) To see the next displayed service code, push the
"Buzzer cancel switch (8)" and "Mode selector switch
(UP)" (3).
iii) To see the previous displayed service code, push the
"Buzzer cancel switch (8)" and "Mode selector switch
(DOWN) (4)".
iv) To stop display of the service code, push the "Buzzer
cancel switch (8)" and "Working mode selector switch
(7)".
v) To delete the saved service codes, press the "Buzzer
cancel switch (8)" and turn OFF the "starting switch"
simultaneously, then turn ON the "starting switch" again
and push and hold the "Buzzer cancel switch (8)" for 5
seconds.
a If the number of service codes exceeds 20, they are
deleted one by one from the oldest one.
2) Service codes lit

Error Code Troubled System User Code
E101 Error history data are abnormal –
E108 Engine coolant temperature is 105°C –
E112 Short circuit in forward system of wiper motor drive –
E113 Short circuit in reverse system of wiper motor drive –
E114 Short circuit in windshield washer drive system –
E115 Wiper does not start wiping in 10 seconds –
E116 Wiper is not start retracted in 10 seconds –
E203 Short circuit or short circuit with chassis ground in swing holding brake solenoid E03
system
E206 Short circuit or short circuit with chassis ground in 2nd travel speed selection sole- E03
noid system
E213 Disconnection in swing holding brake solenoid system –
E216 Disconnection in 2nd travel speed selection solenoid system –
E218 Defective communication between monitor panel and controller –
E227 Short circuit or disconnection in engine speed sensor system –
E232 Short circuit or short circuit with chassis ground in TVC-EPC solenoid system E02
E233 Disconnection in TVC-EPC solenoid system E02
E251 Short circuit with chassis ground or disconnection on boom bottom pressure sen- –
sor (overload sensor) signal side or (+) side or disconnection on (-) side.
E258 Short circuit with chassis ground on all angle sensor power supply side –
E304 (*2) Short circuit or short circuit with chassis ground in engine stop solenoid relay system –
E314 (*2) Disconnection in engine stop solenoid relay system –
E306 (*3) Governor feedback potentiometer –
E308 (*3) Trouble in fuel control dial system E05
E321 (*1) Short circuit with chassis ground in governor control motor drive relay system E05
E323 Short circuit with chassis ground in governor control accelerator relay system E05
E325 Short circuit with chassis ground in governor control decelerator relay system E05
E328 Stall of governor conveyor motor E05
*1. Serial No.: 4809 – 5500
*2. Serial No.: 5501 – 6500
PC78US-6 50-111
(12)
4. Function of displaying "monitoring code"

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

i) The monitoring code is displayed by the following (2) Service meter unit (6) Travel speed
procedure: (3) Mode selector switch
a. Push and hold the "Buzzer cancel switch (8)" switch (7) Working mode
and "Working switch (7)" for 2.5 seconds. (UP) selector switch
b. Push the "Buzzer cancel switch (8)" and "Mode (4) Mode selector (8) Buzzer cancel
selector switch (UP) (3)" [or Mode selector switch switch
switch (DOWN) (4)] and set "02" to the 2nd and (DOWN)
3rd columns from the left on display (2).
c. Push the "Set switch (5)".
* Since the switches "3, 4, and 5" are not indi-
Example 1) A numerical monitoring code

(Engine speed: 2,050 rpm) is displayed.
Example 2) A bit pattern monitoring code 1020

(ON/OFF input state (1)) is displayed.
50-112 PC78US-6
(4)
ii) To see the next displayed monitoring code,

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

a For details of a code marked with "(6 bit)" in the Unit column, see the bit patterns table.
Code No. Item Unit Component Name
0001 Monitor model code – Controller
0008 S-NET connection state (6 bit) Controller
0041 Water temperature sensor voltage 10 mA Controller
0042 Fuel level sensor voltage 10 mA Controller
0043 Charge voltage 100 mA Controller
0045 Sensor input 1 (6 bit) Controller
0046 Sensor input 2 (6 bit) Controller
0047 Output state (6 bit) Controller
0048 Wiper state (6 bit) Controller
0049 Spare Controller
0200 Software version No. (Monitor) Controller
Software version No. (Con-
1000 troller) If 1.0 is displayed, version No. of controller is 1.0. Controller
00: Standard arm

1001 Attachment selection 01: Long arm Controller
02: Slide arm
03: Multi-changer
1010 Engine speed 10 rpm Controller
1020 ON/OFF input 1 (6 bit) Controller
1024 ON/OFF input/output (6 bit) Controller
1060 ON/OFF output (6 bit) Controller
PC78US-6 50-113
(12)
3) Bit patterns list (Bits of corresponding Nos. light up)

a [1] – [6] on digital display unit (1) are bit Nos.
a The monitoring code No. (4 digits) is displayed in
the 2nd column through 5th column from the left
on service meter display unit (2).
0008 S-NET connection state
(1) Starting switch is at "ON"
(2) Starting switch is at "START"
0045 Sensor input 1
(3) Starting switch is at "PREHEAT"
(4) Light switch is at "ON"
(2) Constant bit
0046 Sensor input 2 (3) Engine oil pressure
(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
(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 selection, (3) Model selection 1 (GND is connected)
1020 see Table 1.
For detail of ATT selection, (4) ATT selection 3 (GND is connected)
*see Table 2. (5) UU/US selection (GND is connected)
(6) Model selection 2 (GND is connected)
(3) Compressor signal
1021 ON/OFF input 2 (4) Arm crane is installed (Power supply is connected)
(5) a Tier 2 selection signal (Power supply is connected)
(1) 2nd travel speed selection switch (Panel)
(3) Backup light
1022 ON/OFF input 3
(4) SET/CLEAR switch
(5) Mode selector ( ) switch
(6) Mode selector ( ) switch
(a) Serial No.: 5501 and up
50-114 PC78US-6
(7)
(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
(4) Auto deceleration signal
(5) Motor relay (-)
(6) Motor relay (+)
(1) Crane mode switch (Monitor)
(2) Display selector switch (Monitor)
(3) Arm ground angle alarm cancel switch
(6) Bucket dump prohibition solenoid + Rotary lamp
(1) Deceleration switch
(2) Overload warning cancel switch "OFF"
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)
Table 1
Model Selection 1 Model Selection 2 Selection Signal Tire 2 signal
PC78US-6 GND OPEN GND OPEN

PC78US-6 GND OPEN GND Power supply is connected
Tire 2 (a)
(a) Serial No.: 5501 and up
Table 2
* 1: Connection of the attachment selection wires is shown.
(The bits of GND are displayed during normal operation.)
Connection table of attachment selection wires

Attachment Attachment Selection (1) Attachment Selection (2) Attachment Selection (3)
Standard specification
Standard arm GND OPEN OPEN
Long arm OPEN GND OPEN
Slide arm GND GND OPEN
Multi-changer OPEN OPEN OPEN
PC78US-6 50-115
(12)
Procedure for correcting angle sensor, preventing interference, and setting depth display to 0
Back mode (When SP monitor is used)
Table 1 Method of selecting back mode and ordinary display

Back Mode
01 02
Mode Code
Emergency These modes are set to 2 levels (Note 8) Error
(Note 3)
Trouble Error Memory Next Previous item Memory
Monitoring Deletion
(Note 4) Display item (Note 6) (Note 6)
PC78US-6 – –
B Buzzer cancel
Working mode
a
selection
b Travel
c SET/CLEAR
Model selection
d
( )
Model selection
e
( )
Wiper selection
Washer
Continuous
operation time 2.5 5 (Note 1)
(SEC)
Note 1) Limited to 5 seconds after the power is turned ON.

Note 3) Displayed on the service meter unit.
Note 4) A flag from the controller is a trigger.
Note 6) Used to save monitoring error.
Note 8) Select with Buzzer cancel + Working mode selection. Select next or previous items with Buzzer cancel
+ / . Enter each mode with the SET/CLEAR switch.
* Since the switches "c, d, and e" are not indicated on the panel of model US, operate the same parts as the
panel of model UU.
50-116 PC78US-6
(4)
TROUBLESHOOTING FOR CONTROLLER PUMP
CONTROL SYSTEM
(C MODE)
Precautions for troubleshooting for controller (pump control system) ......................................................... 50-118
Action taken by controller when trouble occurs and problems on machine ................................................ 50-120
Judgement table for controller (pump control system) and hydraulic equipment ........................................ 50-122
Electric circuit diagram of C Mode system .................................................................................................. 50-124
C- 1 [E232] Trouble in TVC-EPC solenoid system ................................................................................. 50-125
C- 2 [E233] Trouble in TVC-EPC solenoid system ................................................................................. 50-125
C- 3 [E203] Trouble in swing holding brake solenoid system ................................................................. 50-127
C- 4 [E213] Trouble in swing holding brake solenoid system ................................................................. 50-127
C- 5 [E206] Trouble in 2nd travel speed selection solenoid system ....................................................... 50-129
C- 6 [E216] Trouble in 2nd travel speed selection solenoid system ....................................................... 50-129
C- 7 [E251] Trouble in boom pressure sensor (overload sensor) system............................................... 50-131
C- 8 [E258] Short circuit in 5 V system of sensor power supply ........................................................50-132- 1
C- 9 Work equipment still moves after work equipment lock lever is set to LOCK ............................50-132- 4
C-10 Machine does not swing.............................................................................................................50-132- 7
C-11 Travel speed does not rise .........................................................................................................50-132- 9
C-12 Gear speed does not change automatically...............................................................................50-132-10
C-13 Trouble in controller power supply (LED of controller is turned OFF) ........................................50-132-10
PC78US-6 50-117
(12)
TROUBLESHOOTING (PUMP CONTROL SYSTEM)

(PUMP CONTROL SYSTEM)
1) When a trouble is repaired by itself or
2) When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-
adapter is removed and the connector is returned, if the service code is not displayed or the monitor
displays normally, the same trouble will occur again probably. Accordingly, follow up the condition of
the machine sufficiently.

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.)
50-118 PC78US-6
(4)

Serial No.: 4809 – 6500
User
Application Service Code Troubled System Contents of Trouble
Code
Short circuit in TVC-EPC 1. Short circuit in wiring harness between

solenoid system (When M97 pin 16 – M20 pin 1
E232
emergency pump drive 2. Short circuit in EPC solenoid
switch is turned ON) 3. (Wrong operation of switch)
E02
1. Disconnection in wiring harness between
M97 pin 16 – M20 pin 1
Disconnection in TVC-EPC
solenoid system
M20 pin 2 – M97 pin 23

Short circuit in swing hold-
E203 M97 pin 7 – M14 pin 2
ing brake solenoid system
E03 Disconnection in swing 1. Disconnection in wiring harness between

holding brake solenoid sys- M97 pin 7 – M14 pin 2
tem 2. Disconnection in solenoid
E213
(When emergency swing 3. Disconnection in wiring harness between
holding brake reset switch M14 pin 1 – M97 pin 3
is turned ON) 4. (Wrong operation of switch)
Short circuit in 2nd travel 1. Short circuit in wiring harness between

E206 speed selection solenoid M97 pin 27 – M15 pin 2
system 2. Short circuit in solenoid
-- 1. Disconnection in wiring harness between

Disconnection in 2nd travel M97 pin 27 – M15 pin 2
E216 speed selection solenoid 2. Disconnection in solenoid
system 3. Disconnection in wiring harness between
M15 pin 1 – M97 pin 3

M96 pin 40 – M16 pin 1
Trouble in engine speed
-- E227 2. Disconnection in sensor
sensor
M16 pin 2 – M96 pin 39
Short circuit in 5 V system 1. Short circuit in wiring harness between

-- -- E258
of sensor power supply M95 pin 22 – M92 pin B.

M95 pin 22 – M92 pin B
Trouble in boom bottom
2. Short circuit or disconnection in wiring har-
-- E251 pressure sensor (overload
ness between M95 pin 2 – M92 pin C
sensor) system
M95 pin 21 – M92 pin A
50-120 PC78US-6
(12)
Action Taken by Controller When

Trouble Occurs

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

Mz
Resistance of M14 solenoid: 35 - 80 z
When trouble is detected, swing Since motor brake is not
Resistance between M97 pin 7 – M14 pin 2: holding brake reset solenoid output released, machine does not
Max. 1 z is stopped. swing.

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

Resistance between M96 pin 40 – M16 pin 1: Since constant current (600 mA)
current flows in TVC-EPC solenoid
Max. 1 z is output to TVC-EPC solenoid,
(600 mA). Working mode cannot be
Resistance of M16 sensor: 500 – 1,000 z work equipment speed and travel
changed. Engine governor control is
Resistance between M16 pin 2 – M96 pin 39: speed are low. If engine speed is
limited to operation of fuel control
Max. 1 z low, engine may stall.
dial.
Overload alarm is turned ON. Overload alarm is turned ON.

Resistance between M95 pin 22, M92 pin B –
• Buzzer sounds. • Buzzer sounds.
• Caution lamp flashes. • Caution lamp flashes.
Resistance between M95 pin 22 – M92 pin B:

Max. 1 z
Overload alarm is turned ON. Overload alarm is turned ON.
Resistance between M95 pin 2 – M92 pin C:
• Buzzer sounds. • Buzzer sounds.
Max. 1 z
• Caution lamp flashes. • Caution lamp flashes.
Resistance between M95 pin 2, M92 pin C –
Resistance between M95 pin 21 – M92 pin A:
Max. 1z
PC78US-6 50-121
(12)
User
Application Code Service Code Troubled System Contents of Trouble
Short circuit in TVC-EPC 1. Short circuit in wiring harness between

solenoid system (When M95 pin 9 – M20 pin 1
E232 emergency pump drive 2. Short circuit in EPC solenoid
switch is turned ON) 3. (Wrong operation of switch)
E02
M95 pin 9 – M20 pin 1
E233 Disconnection in TVC-EPC 2. Disconnection in EPC solenoid
solenoid system 3. Disconnection in wiring harness between
M20 pin 2 – M95 pin 40

E203 Short circuit in swing hold- M95 pin 19 – M14 pin 2
ing brake solenoid system 2. Short circuit in solenoid
E03 Disconnection in swing 1. Disconnection in wiring harness between

holding brake solenoid sys- M95 pin 19 – M14 pin 2
E213 tem 2. Disconnection in solenoid
(When emergency swing 3. Disconnection in wiring harness between
holding brake reset switch M14 pin 1 – M95 pin 40
is turned ON) 4. (Wrong operation of switch)
Short circuit in 2nd travel 1. Short circuit in wiring harness between

E206 speed selection solenoid M95 pin 10 – M15 pin 2
system 2. Short circuit in solenoid
--
Disconnection in 2nd travel M95 pin 10 – M15 pin 2
E216 speed selection solenoid 2. Disconnection in solenoid
system 3. Disconnection in wiring harness between
M15 pin 1 – M95 pin 40
1. Disconnection, defective contact, short cir-

cuit, or grounding fault in pressure sensor
2. Disconnection or defective contact in wir-
ing harness between controller M95 pin 22
– pressure sensor S3 pin B (power supply
-- E224 – side) or between M95 pin 32 – S3 pin A
(negative side)
3. Disconnection or defective contact in wir-
ing harness between controller M95 pin 24
– pressure sensor S3 pin C (SIG side)
4. Defective controller

Trouble in engine speed M95 pin 6 – M16 pin 1
-- E227 sensor 2. Disconnection in sensor
M16 pin 2 – M95 pin 32

M95 pin 22 – M92 pin B
-- -- E258 Short circuit in 5 V system M95 pin 22 – S1 pin 1
of sensor power supply M95 pin 22 – S3 pin B
M95 pin 22 – S2 pin 1

Trouble in boom bottom M95 pin 22 – M92 pin B
-- E251 pressure sensor (overload 2. Short circuit or disconnection in wiring har-
sensor) system ness between M95 pin 33 – M92 pin C
M95 pin 32 – M92 pin A
50-121-1 PC78US-6
(12)
Action Taken by Controller When

Normal Condition Trouble Occurs Problems on Machine

Mz
Mz
Resistance of M20 EPC solenoid (With switch Current does not flow in TVC-
directed down): 3 – 15 z When trouble is detected, TVC-EPC EPC solenoid. Accordingly, if load
solenoid output is stopped. is large, engine speed may lower
Resistance between M95 pin 9 – M20 pin 1: to stall.
Max. 1 Mz
Max. 1 z

Mz
Mz
When trouble is detected, swing Since motor brake is not
holding brake reset solenoid output released, machine does not
Resistance between M95 pin 19 – M14 pin 2: is stopped. swing.
Max. 1 z

Mz
Resistance of M15 solenoid: 35 – 80 z When speed selector switch
When trouble is detected, 2nd travel pedal is operated, travel speed
Resistance between M95 pin 10 – M15 pin 2: speed selection solenoid output is does not change. (It is kept at 1st
Max. 1 Mz stopped. gear.)
Max. 1 z
Between M95 pin 22 – pin 32: 4.5 – 5.5 V

Between M95 pin 24 – S3 pin C: 0.5 – 4.5 V Controller assumes pump pressure Gear speed does not change
Resistance between M95 pin 24 – pin 32,
between pin 24 – chassis ground: Min. 1 Mz to be 0 Pa {0 kg/cm2} for operation. automatically.
(Disconnect M95 and S3)
Resistance between M95 pin 6 – M16 pin 1: When trouble is detected, constant Since constant current (600 mA)
Max. 1 z current flows in TVC-EPC solenoid is output to TVC-EPC solenoid,
Resistance of M16 sensor: 500 – 1,000 z (600 mA). Working mode cannot be work equipment speed and travel
Resistance between M16 pin 2 – M95 pin 32: changed. Engine governor control is speed are low. If engine speed is
Max. 1 z limited to operation of fuel control low, engine may stall.
dial.
Resistance between M95 pin 22 – M92 pin B, Overload alarm is turned ON. Overload alarm is turned ON.
S2 pin 1, S3 pin B, S1 pin 1 – chassis ground: • Buzzer sounds. • Buzzer sounds.
Min. 1 Mz • Caution lamp flashes. • Caution lamp flashes.
Resistance between M95 pin 22 – M92 pin B:

Max. 1 z
Resistance between M95 pin 33 – M92 pin C: Overload alarm is turned ON. Overload alarm is turned ON.
Max. 1 z • Buzzer sounds. • Buzzer sounds.
Resistance between M95 pin 2, M92 pin C – • Caution lamp flashes. • Caution lamp flashes.
Resistance between M95 pin 32 – M92 pin A:
Max. 1z
PC78US-6 50-121-2
(12)

AND HYDRAULIC EQUIPMENT
Serial No.: 4809 – 6500
Disconnection in swing holding brake
Trouble in engine speed sensor sys-

Disconnection in TVC-EPC solenoid
Short circuit in 5 V system of sensor

Short circuit in swing holding brake
Disconnection in 2nd travel speed

Short circuit in TVC-EPC solenoid
Trouble in boom bottom pressure

sensor (overload sensor) system
Short circuit in 2nd travel speed
selection solenoid system
Boom RAISE (6)

solenoid system
solenoid system
power supply
system
system
tem
Monitor-
User Code E02 E03 – – – – ing Code
Failure Mode Service Code 232 233 203 213 206 216 227 251 258 1023
Machine Model PC78US-6 Q Q Q Q Q Q Q Q – Q
Machine cannot move work equipment,
travel, or move blade.
Machine cannot raise boom, move arm in. q

Work equip- Speed or power of 2 or more systems of
ment, travel, work equipment, travel, swing, and blade is q q q
swing, blade low.
Engine speed lowers extremely or engine
stalls. q q q
2 or more systems of work equipment,
travel, swing, and blade do not move.
Boom (*1)
Speed or power is
low. Arm
Work equip-
ment
Work equipment does Boom
not move. Arm
Travel
Travel speed does not change. q q
Mode Work equipment exceeds or stops before
selection set height.
Overload Alarm does not stop sounding. q

warning Alarm does not start sounding.
After work equipment lock lever is set to LOCK, work
equipment still moves
Diagnosis code displayed when service code is dis-
C-1 C-2 C-3 C-4 C-5 C-6 E-6 C-7 C-8 –
played
Diagnosis code displayed when trouble is detected by
monitoring – – – – – – – – – F-3
q : Items corresponding to service codes.

Q : Items checked by monitoring or with machine monitor.
*1 : For the diagnosis codes E and F, see Section 20
*2 : Items checked by monitoring
50-122 PC78US-6
(12)
Items checked by monitoring
Hydraulic switch State of solenoid
Overload warning cancel signal input

Travel speed selector pedal switch

Diagno-

sis code
Emergency work equipment

Model selection and UU/US
dis-
operation switch input (3)

played


when
trouble is
Engine speed input

not
detected
selection code
ATT selection
by moni-
toring
Arm IN (5)
Travel (3)
Swing (4)
input (4)
(2)
Monitoring Code
1023 1021 1026 1060 1020 1026 1010 1050 1026 1040
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
(*2) (*2) –
(*2) –
(*2) (*2) (*2) H-1
(*2) (*2) (*2) H-2
(*2) (*2) H-3
H-7
(*2) H-8
H-10
H-11
(*2) H-23
(*2) (*2) C-11, H-25
H-30
(*2) (*2) C-10, H-31
(*2) (*2) H-36
(*2) (*2) –
(*2) (*2) –
H-8
– – – – – – – – – – – – – – – –
F-4 F-2 F-1 F-7 F-5 F-6 – – – – – F-8 – – – –
PC78US-6 50-123
(12)
Trouble in pump pressure sensor sys-

Disconnection in swing holding brake
Trouble in engine speed sensor sys-

Disconnection in TVC-EPC solenoid
Short circuit in 5 V system of sensor

Short circuit in swing holding brake
Disconnection in 2nd travel speed

Short circuit in TVC-EPC solenoid
Trouble in boom bottom pressure

sensor (overload sensor) system
Short circuit in 2nd travel speed
Boom RAISE (6)

solenoid system
solenoid system
power supply
system
system
tem
tem
Monitor-
User Code E02 E03 – – – – – ing Code
Failure Mode Service Code 232 233 203 213 206 216 224 227 251 258 1023
Machine Model PC78US-6 Q Q Q Q Q Q Q Q Q – Q
Machine cannot move work equipment,
travel, or move blade.
Machine cannot raise boom, move arm in. q

Work equip- Speed or power of 2 or more systems of
ment, travel, work equipment, travel, swing, and blade is q q q
swing, blade low.
Engine speed lowers extremely or engine
stalls. q q q
2 or more systems of work equipment,
travel, swing, and blade do not move.
Speed or power is Boom (*1)

low. Arm
Work equip-
ment
Work equipment does Boom
not move. Arm
Travel
Travel speed does not change. q q q
Mode Work equipment exceeds or stops before
selection set height.
Overload Alarm does not stop sounding. q

warning Alarm does not start sounding.
After work equipment lock lever is set to LOCK, work
equipment still moves
Diagnosis code displayed when service code is dis-
played C-1 C-2 C-3 C-4 C-5 C-6 – E-6 C-7 C-8 –
Diagnosis code displayed when trouble is detected by

monitoring – – – – – – – – – – F-3
q : Items corresponding to service codes.

Q : Items checked by monitoring or with machine monitor.
*1 : For the diagnosis codes E and F, see Section 20
*2 : Items checked by monitoring
50-123-1 PC78US-6
(12)
Items checked by monitoring
Hydraulic switch State of solenoid
Overload warning cancel signal input

Governor feedback voltage input

Diagno-
Fuel control dial voltage input

sis code
Emergency work equipment

dis-
operation switch input (3)

played


when
trouble is
Engine speed input

not
Pump pressure
detected
by moni-
toring
Arm IN (5)
Travel (3)
Swing (4)
(2)
Monitoring Code
1023 1021 1026 1060 1026 1010 1050 1026 1040 1034 1035 1042
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
(*2) –
(*2) (*2) H-1
(*2) (*2) H-2
(*2) H-3
H-7
(*2) H-8
H-10
H-11
(*2) H-23
(*2) (*2) (*2) (*2) (*2) C-11, H-25
H-30
(*2) (*2) C-10, H-31
(*2) (*2) H-36
(*2) (*2) –
(*2) (*2) –
H-8
– – – – – – – – – – – – – – – –
F-4 F-2 F-1 F-7 F-5 – – – F-8 – – – – – – –
PC78US-6 50-123-2
(12)
ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM

Serial No.: 4809 – 5500
50-124 PC78US-6
(7)
Serial No.: 5501 – 6500
PC78US-6 50-124-1
(12)
50-124-2 PC78US-6
(12)
C-1 [E232], C-2 [E233] Trouble in TVC-EPC solenoid system

Serial No.: 4809 – 6500
Cause Remedy
1
• Disconnect M20
Is resistance of EPC solenoid
• 3 – 15 z NO Defective TVC-EPC solenoid (internal
normal and is EPC solenoid Replace
• Resistance between solenoid short circuit, disconnection)
insulated from chassis?
and chassis ground: Min.1 Mz
YES
2
Disconnection or defective contact in Repair or
• Disconnect M97 Is resistance between M97 NO
wiring harness between M97 (Female)
• Resistance: 3 – 15 z (Female) (16) – (23) normal? replace
(16), (23) – M20 (Female) (1), (2)
YES
3 Short circuit with chassis ground or

• Disconnect M97 Is resistance between M97 (Female) NO negative (–) wire in wiring harness Repair or
• Resistance: Min. 1 Mz (16) – chassis ground normal? between M97 (Female) (16) – M20 replace
(Female) (1)
YES
PC78US-6 50-125
(12)

Cause Remedy
1
• Disconnect M20
Is resistance of EPC solenoid
• 3 – 15 z NO Defective TVC-EPC solenoid (internal
normal and is EPC solenoid Replace
• Resistance between solenoid short circuit, disconnection)
insulated from chassis?
and chassis ground: Min.1 Mz
YES
2
Disconnection or defective contact in Repair or
• Disconnect M95 Is resistance between M95 NO
wiring harness between M95 (Female)
• Resistance: 3 – 15 z (Female) (9) – (40) normal? replace
(9), (40) – M20 (Female) (1), (2)
YES
3 Short circuit with chassis ground or

• Disconnect M95 Is resistance between M95 (Female) NO negative (–) wire in wiring harness Repair or
• Resistance: Min. 1 Mz (16) – chassis ground normal? between M95 (Female) (9) – M20 replace
(Female) (1)
YES
50-126 PC78US-6
(12)
C-3 [E203], C-4 [E213] Trouble in swing holding brake solenoid system
Serial No.: 4809 – 6500
Cause Remedy
1
• Disconnect M14
Is resistance of solenoid normal
• 35 – 80 z NO Defective swing holding brake solenoid Replace
and is solenoid insulated from
• Resistance between solenoid (internal short circuit, disconnection)
chassis?
and chassis ground: Min. 1 Mz
YES
2
Disconnection or defective contact in
• Disconnect M97 Is resistance between M97 NO wiring harness between M97 (Female) Repair or
• Resistance: 35 – 80 z (Female) (7) – (3) normal? (7), (3) – M14 (Female) (2), (1) replace
YES
3
Short circuit with chassis ground or
Is resistance between M97
• Disconnect M97 NO negative (–) wire in wiring harness Repair or
(Female) (7) – chassis ground
• Resistance: Min. 1 Mz between M97 (Female) (7) – M14 replace
normal?
(Female) (2)
YES
PC78US-6 50-127
(12)

Cause Remedy
1
• Disconnect M14
Is resistance of solenoid normal
• 35 – 80 z NO Defective swing holding brake solenoid Replace
and is solenoid insulated from
• Resistance between solenoid (internal short circuit, disconnection)
chassis?
and chassis ground: Min. 1 Mz
YES
2
YES
3
normal?
(Female) (2)
YES
50-128 PC78US-6
(12)
C-5 [E206], C-6 [E216] Trouble in 2nd travel speed selection solenoid sys-
tem
Serial No.: 4809 – 6500
Cause Remedy
1
• Disconnect M14
Is resistance of solenoid normal Defective 2nd travel speed selection
• 35 – 80 z NO
and is solenoid insulated from solenoid (internal short circuit, Replace
• Resistance between solenoid
chassis? disconnection)
– chassis ground: Min. 1 Mz
YES
2
YES
3
normal?
(Female) (2)
YES
PC78US-6 50-129
(12)
Cause Remedy
1
• Disconnect M14
Is resistance of solenoid normal Defective 2nd travel speed selection
• 35 – 80 z NO
and is solenoid insulated from solenoid (internal short circuit, Replace
• Resistance between solenoid
chassis? disconnection)
– chassis ground: Min. 1 Mz
YES
2
YES
3
normal?
(Female) (2)
YES
50-130 PC78US-6
(12)
TROUBLESHOOTING C-7
C-7 [E251] Trouble in boom bottom pressure sensor (overload sensor)

system
Serial No.: 4809 – 6500
Cause Remedy
1
When normal: There is a bit. Disconnection in wiring harness Repair or
Is signal input of overload alarm NO
When reset: There is not a bit. between M97 (20) – fuse box (10) or replace
reset switch normal?
(Monitoring code 1026 (2)) defective switch
YES
• 0 – 26.5 MPa 2
(If boom circuit is relieved at
Is boom cylinder bottom pressure NO
RAISE end, pressure
sensor signal normal?
changes.)
(Monitoring code 1040) YES
3
Is resistance between M95 (2)
and M92 (C), between M95 (21)
Disconnection or short circuit in wiring
and M92 (A), and between M95 NO harness between M95 (2) – M92 (C), Repair or
• Disconnect M95 and M92. (22) and M92 (B) below 1 z?
M95 (21) – M92 (A), or M95 (22) – replace
Is resistance between M95 (2),
M92 (B)
(22), M92 (C), (B) and chassis
ground above 1 Mz?
YES
Defective pressure sensor Replace
PC78US-6 50-131
(12)
TROUBLESHOOTING C-7
Cause Remedy
1
When reset: There is not a bit. between M95 (Famale) (5) – EU1 replace
(Monitoring code 1026 (2)) (Famale) (2) or defective switch
YES
• 0 – 26.5 MPa 2
RAISE end, pressure
changes.)
3
and M92 (B), between M95 (32)
and M92 (A), and between M95 NO harness between M95 (22) – M92 (B), Repair or
• Disconnect M95 and M92. (33) and M92 (C) below 1 z?
M95 (32) – M92 (A), or M95 (33) – replace
M92 (C)
(33), M92 (B), (C) and chassis
ground above 1 Mz?
YES
50-132 PC78US-6
(12)
TROUBLESHOOTING C-8
C-8 [E258] short circuit in 5 V system of sensor power supply

Serial No.: 4809 – 6500
Cause Remedy
1
When reset: There is not a bit. between M97 (20) – fuse box (10) or replace
(Monitoring code 1026 (2)) defective switch
YES
• 0 – 26.5 MPa 2
RAISE end, pressure
changes.)
3
and M92 (C), between M95 (21)
and M92 (A), and between M95 NO harness between M95 (2) – M92 (C), Repair or
• Disconnect M95 and M92. (22) and M92 (B) below 1 z?
M95 (21) – M92 (A), or M95 (22) – replace
M92 (B)
(22), M92 (C), (B) and chassis
ground above 1 Mz?
YES
PC78US-6 50-132-1
(12)
TROUBLESHOOTING C-8

a If E258 is displayed, E40 is also displayed.
Cause Remedy
1
Is resistance between M95 Grounding fault in wiring harness
• Disconnect M95. NO between M95 (female) (22) – chassis Repair or
(female) (22) and chassis ground
• Min. 1 Mz ground (Grounding fault in sensor replace
normal?
power supply)
YES
2
• Operate fuel control dial. Is voltage of fuel control dial NO Defective fuel control dial
Replace
• 0.7 – 4.8 V normal? (Monitoring code: 1034) potentiometer (Internal short circuit)
YES
3
• Turn starting switch ON: 0 {0} Is monitored value of pump
• When relieved: pressure sensor normal? NO Defective pump pressure sensor
26.5 ± 1.0 MPa Replace
(Monitoring code: 1042) (Internal short circuit)
{270 ± 10 kg/cm2}
YES
4
• Start engine. Is voltage of governor feedback
NO Defective governor motor feedback
• Operate fuel control dial. potentiometer normal? Replace
potentiometer (Internal short circuit)
• 2.7 – 4.7 V (Monitoring code: 1035)
YES
• Turn starting switch ON: 0 {0}

5
• When relieved by raising Is monitored value of boom
NO Defective boom bottom pressure
boom: bottom pressure sensor normal? Replace
sensor (Internal short circuit)
26.5 ± 1.0 MPa (Monitoring code: 1040)
{270 ± 10 kg/cm2} YES
50-132-2 PC78US-6
(12)
TROUBLESHOOTING C-8
PC78US-6 50-132-3
(12)
TROUBLESHOOTING C-9
C-9 Work equipment still moves after work equipment lock lever is set to
LOCK
Serial No.: 4809 – 5500
Cause Remedy
• When pushed, (1) – (2) are 1

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
Short circuit with positive (+) wire in Repair or
• When locked: 0 V Is voltage between M13 (2) – NO wiring harness between K28 (2) – replace wiring
• When released: 20 – 29 V chassis ground normal? harness
M13 (2)
YES
50-132-4 PC78US-6
(12)
TROUBLESHOOTING C-9
Serial No.: 5501 – 6500
Cause Remedy

normal?
2
M13 (2)
YES
PC78US-6 50-132-5
(12)
TROUBLESHOOTING C-9
Cause Remedy

normal?
2
M13 (2)
YES
50-132-6 PC78US-6
(12)
C-10 Machine does not swing

Serial No.: 4809 – 6500
Cause Remedy
• Check swing control lever NO

Is bit pattern 1023 – (4) displayed? Go to F-1 (See Section 20.) –
YES
Go to H-31 (See Section 20.) –
PC78US-6 50-132-7
(12)
Cause Remedy
• Check swing control lever NO

Is bit pattern 1023 – (4) displayed? Go to F-1 (See Section 20.) –
YES
Go to H-31 (See Section 20.) –
50-132-8 PC78US-6
(12)
C-11 Travel speed does not rise

Serial No.: 4809 – 6500
Cause Remedy
1
• 20 – 29 V
Is voltage between K3 (Female) NO
(2) – chassis ground normal?
• Disconnect K3
YES
2
• In 1-spool mode: Max. 1 Mz
• In 2-spool mode: Max. 1 Mz Is resistance between K3 (Male) NO Defective 2nd travel speed selection
Replace
• Turn starting switch OFF (2) – (1) normal? switch
• Disconnect K3
YES Disconnection or defective contact in
Repair or
wiring harness between K3 (Female)
replace
(1) – M12 – chassis ground
3
• 20 – 29 V
Is voltage between M95 (5) – NO
• Turn starting switch ON. Defective controller Replace
chassis ground normal?
• Disconnect K3
YES Disconnection or defective contact in
wiring harness between M95 (Female) Repair or
(5) – K3 (Female) (2) replace
PC78US-6 50-132-9
(12)
C-12 Gear speed does not change automatically

a When [E-206], [E-216], [E-224], or [E-227] is not displayed.
Cause Remedy
1
• Monitoring
Is monitored value of engine
FULL: 197 – 207 NO
speed normal? Defective engine speed sensor Replace
SLOW: 113 – 118
(Monitoring code: 1010)
YES
2
• Monitoring relieved: Is monitored value of pump
NO
25.5 – 27.5 MPa pressure normal? Defective pump pressure sensor Replace
{260.3 – 280.4 kg/cm2} (Monitoring code: 1042)
YES
C-13 Trouble in controller power supply (LED of controller is turned OFF)

a See E-1. (See Section 20.)
50-132-10 PC78US-6
(12)
TROUBLESHOOTING FOR MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by controller when trouble occurs and problems on machine ...........................................................
Electric circuit diagram of M mode system ...................................................................................................... 134
M- 1 [E101] (Error history data are abnormal) is displayed ...............................................................................
M- 2 [E108] (Engine coolant temperature is 105°C) is displayed ......................................................................
M- 3 [E112] (Wiper forward output is shorted) is displayed................................................................................
M- 4 [E113] (Wiper reverse output is shorted) is displayed................................................................................
M- 5 [E114] (Contact with washer output of 24 V) is displayed..........................................................................
M- 6 [E115] (Wiper does not start wiping in 10 seconds) is displayed ...............................................................
M- 7 [E116] (Wiper is not retracted in 10 seconds) is displayed ........................................................................
M- 8 When starting switch is turned to ON position, monitor panel segments do not light up
for 3 seconds .............................................................................................................................................
a) Monitor panel segments do not light up at all ........................................................................................
b) Some monitor panel segments do not light up ......................................................................................
M- 9 When starting switch is set to ON position, all monitor panel segments light up but
do not go off ...............................................................................................................................................
M-10 While preheating is not executed, "Preheater monitor" lights up ...............................................................
M-11 When starting switch is set to ON position and engine is started, basic check items flash ............ 50-136
a) Alternator system........................................................................................................................ 50-136
b) Engine oil pressure system ........................................................................................................ 50-137
caution items and emergency stop items (excluding battery and engine oil) flash ......................... 50-138
a) Alternator system........................................................................................................................ 50-138
b) Engine oil pressure sensor system............................................................................................. 50-139
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) ..................................................................................................................
a) "Engine oil" flashes ................................................................................................................................
b) "Charge level" flashes ...........................................................................................................................
c) "Coolant temperature" flashes ...............................................................................................................
d) "Fuel level" flashes ................................................................................................................................
While caution item is flashing, buzzer does not sound ..............................................................................
M-15 Monitor planel lamp for nighttime is not turned on (LC display is normal) .................................................
M-16 Coolant temperature gauge does not rise .................................................................................................
M-17 Coolant temperature gauge is not displayed (Gauge does not rise to 1st line during operation) ..............
M-18 Fuel level gauge always displays full.........................................................................................................
M-19 Fuel level gauge is not displayed...............................................................................................................
M-20 While engine is running, service meter does not advance ........................................................................
M-21 Trouble in fuel level sensor ........................................................................................................................
M-22 Trouble in coolant temperature sensor ......................................................................................................
M-23 Wiper does not operate or operates while wiper switch is turned off.........................................................
a) Wiper does not operate .........................................................................................................................
b) Wiper operates while wiper switch is turned off.....................................................................................
M-24 Washer motor does not operate or operate while washer switch is turned off ..........................................
a) Washer motor does not operate ............................................................................................................
b) Washer operates while wiper switch is turned off ..................................................................................
a For items marked with , see page 20-501.
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.
PC78US-6 50-133
(7)
TESTING AND ADJUSTING ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM

Serial No.: 4809 – 5500
50-134 PC78US-6
(7)
PC78US-6 50-135
(4)
Serial No.: 5501 – 6500
50-135-1 PC78US-6
(12)
PC78US-6 50-135-2
(7)
50-135-3 PC78US-6
(12)
Light • NORWAY: STD

• EU: 2 = STD 1 = OPT
PC78US-6 50-135-4
(12)

basic check items flash
Serial No.: 4809 – 6500
Cause Remedy
1
• Disconnect M45
• Run engine above medium Is voltage between M45 (Male) NO Replace
Defective alternator
speed level (3) – chassis ground normal?
• 20 – 30 V
YES
2
• Run engine above medium Disconnection or defective contact in
Is voltage between P02 (11) – NO Repair or
speed level wiring harness between M45 (Female)
chassis ground normal? replace
• 20 – 30 V (3) – P02 (Female) (11)
YES
50-136 PC78US-6
(12)
Cause Remedy
1
• Disconnect M45
• Run engine above medium Is voltage between M45 (Male) NO Replace
Defective alternator
speed level (3) – chassis ground normal?
• 20 – 30 V
YES
2
• Run engine above medium Disconnection or defective contact in
Is voltage between P02 (11) – NO Repair or
speed level wiring harness between M45 (Female)
chassis ground normal? replace
• 20 – 30 V (3) – P02 (Female) (11)
YES
PC78US-6 50-137
(12)
b) Engine oil pressure system

Serial No.: 4809 – 6500
Cause Remedy
1
When engine speed is low, if oil
• Run engine at low speed pressure sensor terminal T6 is NO
disconnected, does error
disappear?
YES
Defective oil pressure sensor
Replace
(Low pressure)
2
• Turn starting switch OFF Short circuit with chassis ground in
Is there continuity between P02 NO Repair or
• Disconnect sensor wiring wiring harness between P02 (Female)
(7) – chassis ground normal? replace
harness and P02 (7) – sensor terminal T6
YES
50-137-1 PC78US-6
(12)
b) Engine oil pressure system

Cause Remedy
1
When engine speed is low, if oil
• Run engine at low speed pressure sensor terminal T6 is NO
disconnected, does error
disappear?
YES
Defective oil pressure sensor
Replace
(Low pressure)
2
• Turn starting switch OFF Short circuit with chassis ground in
Is there continuity between P02 NO Repair or
• Disconnect sensor wiring wiring harness between P02 (Female)
harness and P02 (7) – sensor terminal T6
YES
PC78US-6 50-137-2
(12)

caution items and emergency stop items (excluding battery and
engine oil) flash
Serial No.: 4809 – 6500
Cause Remedy
1
• Disconnect M45
Is voltage between M45 (Male) NO Replace
• Turn starting switch ON Defective alternator
• Max. 1 V
YES
2
• Disconnect P02 Short circuit with power source in
Is voltage between P02 (Female) NO Repair or
• Turn starting switch ON wiring harness between P02 (Female)
• Max. 1 V (11) – M45 (Female) (3)
YES
50-138 PC78US-6
(12)
Cause Remedy
1
• Disconnect M45
Is voltage between M45 (Male) NO Replace
• Turn starting switch ON Defective alternator
• Max. 1 V
YES
2
• Disconnect P02 Short circuit with power source in
Is voltage between P02 (Female) NO Repair or
• Turn starting switch ON wiring harness between P02 (Female)
• Max. 1 V (11) – M45 (Female) (3)
YES
PC78US-6 50-139
(12)

Serial No.: 4809 – 6500
Cause Remedy
1
• Turn starting switch OFF Is there continuity between
NO
• Disconnect sensor terminal sensor terminal T6 – chassis Defective oil pressure sensor Replace
T6 ground?
YES
2
• Turn starting switch OFF Is there continuity between P02 Disconnection or defective contact in
NO Repair or
• Disconnect P02 – sensor (Female) (7) – sensor terminal wiring harness between P02 (Female)
(7) – sensor terminal T6 replace
terminal T6 T6?
YES
50-140 PC78US-6
(12)

Cause Remedy
1
• Turn starting switch OFF Is there continuity between
NO
• Disconnect sensor terminal sensor terminal T6 – chassis Defective oil pressure sensor Replace
T6 ground?
YES
2
• Turn starting switch OFF Is there continuity between P02 Disconnection or defective contact in
NO Repair or
• Disconnect P02 – sensor (Female) (7) – sensor terminal wiring harness between P02 (Female)
(7) – sensor terminal T6 replace
terminal T6 T6?
YES
PC78US-6 50-141
(12)
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM

PC78US-6 Serial No.: 4001 – 6500 (Blade-less specification)........... 90- 3
PC78US-6 Serial No.: 6501 and up (Blade-less specification).......... 90-3-2
PC78US-6 (Additional attachment circuit)........................................... 90- 5
PC78US-6 Serial No.: 4001 – 6500 (Blade specification) .................. 90- 7
PC78US-6 Serial No.: 6501 and up (Blade specification) ................. 90-7-2
PC78US-6 Serial No.: 4809 – 6500 (Norway & EU specification) ..... 90-7-4
PC78US-6 Serial No.: 6501 and up (Norway & EU specification) ..... 90-7-6
PC78UU-6.......................................................................................... 90-7-8
ELECTRICAL CIRCUIT DIAGRAM

PC78US-6 Serial No.: 4001 – 5500 (1/2)........................................... 90- 9
PC78US-6 Serial No.: 4001 – 5500 (2/2)............................................90-11
PC78US-6 Serial No.: 5501 – 6500 (1/2)........................................... 90-13
PC78US-6 Serial No.: 5501 – 6500 (2/2)........................................... 90-15
PC78US-6 Serial No.: 6501 and up (1/2)....................................... 90-15-2
PC78US-6 Serial No.: 6501 and up (2/2)....................................... 90-15-4
PC78US-6 Serial No.: 4809 – 5500
(Norway & EU specification) (1/2) ..................................................... 90-17
PC78US-6 Serial No.: 4809 – 5500
PC78US-6 Serial No.: 5501 – 6500
PC78US-6 Serial No.: 5501 – 6500
(Norway & EU specification) (1/2) .................................................. 90-23-2
(Norway & EU specification) (2/2) .................................................. 90-23-4
PC78UU-6 Serial No.: 22832 – 23500 (1/2)....................................... 90-25
PC78UU-6 Serial No.: 22832 – 23500 (2/2)....................................... 90-27
PC78UU-6 Serial No.: 23501 and up (1/2)......................................... 90-29
PC78UU-6 Serial No.: 23501 and up (2/2)......................................... 90-31
PC78US-6 90-1
HYDRAULIC CIRCUIT DIAGRAM *1. Serial No.: 4001 – 4248 *3. Serial No.: 4001 – 5500
PC78US-6 Serial No.: 4001 – 6500 (Blade-less specification) *2. Serial No.: 4249 and up *4. Serial No.: 5501 and up
PC78US-6 90-3
(10)
PC78US-6 (Additional attachment circuit)
PC78US-6 90-5
PC78US-6 Serial No.: 6501 and up (Blade-less specification)
PC78US-6 90-3-2
(10)
PC78US-6 Serial No.: 4001 – 6500 (Blade specification) *1. Serial No.: 4001 – 4248 *3. Serial No.: 4001 – 5500
*2. Serial No.: 4249 and up *4. Serial No.: 5501 and up
PC78US-6 90-7
(10)
PC78US-6 Serial No.: 6501 and up (Blade specification)
PC78US-6 90-7-2
(10)
PC78US-6 Serial No.: 4809 – 6500 (Norway & EU specification) *1. Serial No.: 4809 – 5500
PC78US-6 90-7-4
(14)
PC78US-6 Serial No.: 6501 and up (Norway & EU specification)
PC78US-6 90-7-6
(14)
PC78UU-6 *1. Serial No.: 22832 – 23500
PC78US-6 90-7-8
(10)
PC78US-6 Serial No.: 4001 – 5500 (1/2)
PC78US-6 90-9
PC78US-6 Serial No.: 4001 – 5500 (2/2)
PC78US-6 90-11
PC78US-6 Serial No.: 5501 – 6500 (1/2)
PC78US-6 90-13
(10)
PC78US-6Serial No.: 5501 – 6500 (2/2)
PC78US-6 90-15
(10)
PC78US-6 Serial No.: 6501 and up (1/2)
PC78US-6 90-15-2
(10)
PC78US-6 Serial No.: 6501 and up (2/2)
PC78US-6 90-15-4
(10)
PC78US-6 Serial No.: 4809 – 5500 (Norway & EU specification) (1/2)
PC78US-6 90-17
(10)
PC78US-6 90-19
(10)
PC78US-6 90-21
(10)
PC78US-6 90-23
(10)
PC78US-6 Serial No.: 6501 and up (Norway & EU specification) (1/2)
PC78US-6 90-23-2
(10)
PC78US-6 Serial No.: 6501 and up (Norway & EU specification) (2/2)
PC78US-6 90-23-4
(10)
PC78UU-6 Serial No.: 22832 – 23500 (1/2)
PC78US-6 90-25
PC78UU-6 Serial No.: 22832 – 23500 (2/2)
PC78US-6 90-27
PC78UU-6 Serial No.: 23501 and up (1/2)
PC78US-6 90-29
PC78UU-6 Serial No.: 23501 and up (2/2)
PC78US-6 90-31

SM Pc78uu-6 Sebm025118 PDF

Uploaded by

Copyright:

Available Formats

You might also like

SM Pc78uu-6 Sebm025118 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM Pc78uu-6 Sebm025118 PDF

Uploaded by

Copyright:

Available Formats

SEBM025118

MACHINE MODEL SERIAL NUMBER

PC78UU-6 22832 and up

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . 10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

50 OTHER SPECIFICATIONS (PC78US-6 For Norway) . . . . . . . . . . . . 50-1

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

! The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting