TESTING AND ADJUSTING LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING

LIST OF DEVICES FOR TESTING, ADJUSTING, & TROUBLESHOOTING

Items to Be Sym-
Part No. Part Name Remarks
Tested/Adjusted bol

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

B 799-101-1500 Digital thermometer -50 – 1,200 °C
temperature

Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa

799-101-5002 Hydraulic tester kit
1 {25, 60, 400, 600 kg/cm2}

790-261-1203 Digital hydraulic tester Pressure gauge 58.8 MPa {600 kg/cm2}

2 799-401-2320 Hydraulic gauge Pressure gauge 1.0 MPa {10 kg/cm2}

799-101-5160 Nipple PT1/8

3 799-101-5220 Nipple 10 mm P = 1.25

Oil pressure C
07002-11023 O-ring —

(Both male and female) 9/16-18 UNF

799-401-2910 Nipple
(Female: PT1/8)
4
02896-11008 O-ring —

07043-00108 Nipple PT1/8 (Hexagon hole)

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 —

2 795-102-2102 Spring pusher —

Fuel injection timing O Commercialy
3 Dial guage —
available

20-102 PC78MR-6
(3)
TESTING AND ADJUSTING MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

1. When measuring engine speed during operation 2. When measuring engine speed during measure-
a Measure the engine speed under the follow- ment of compression pressure
ing condition. 1) Remove the cover for setting the injection
ï Cooling water temperature: Within oper- timing of the injection pump from the timing
ating range gear case and install gear box A2.
ï Hydraulic oil temperature: 45 ñ 55 YC
1) Remove clamp (1) of the high pressure injec-
tion pipe and install sensor [1] of multi-
tachometer A to injection pipe (2).

2) Install bracket [3] of multi-tachometer A1 to

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

PC78MR-6 20-103
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR

MEASURING EXHAUST GAS COLOR

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

When installing and removing the measuring

instrument, take care not to touch a hot part.

1. Measuring with handy smoke checker G1

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

2. Measuring with smoke meter G2

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

20-104 PC78MR-6
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

a Measuring instruments for valve clearance 1) Insert feeler gauge F in clearance (b)
between rocker arm (2) and valve stem (3)
Symbol Part No. Part name
and adjust the clearance with adjustment
F Commercially available Feeler gauge screw (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 feeler 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-
pression top dead center.
a After tightening the locknut, check the
a Rotate the crankshaft with the crank pulley
valve clearance again.
mounting bolt.
a After adjusting all of the valves marked
a When the No. 1 cylinder is at the compres-
with q, go to the next procedure.
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

3. While the No. 1 cylinder is at the compression
top dead center, adjust the valve clearances
top dead center, adjust the valve clearances
marked with Q in the valve arrangement draw-
marked with q in the valve arrangement drawing
ing.
according to the following procedure.
a Adjust the valve clearance according to step
4 above.

6. After finishing adjustment, return the removed

parts.
Cylinder head cover mounting bolt:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}

PC78MR-6 20-105
(3)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

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

5. Set the multi-tachometer to the engine.

a See Measuring engine speed.

20-106 PC78MR-6
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE

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

2. Connect the nozzle to the gauge by the hose.

3. Set the working mode in the ACTIVE mode, run

the engine at full throttle, and relieve the arm
dump circuit.

4. When the gauge pointer is stabilized, measure

the blow-by pressure.
Do not touch a hot part or a rotary part dur-
ing measurement.

PC78MR-6 20-107
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING

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

2) Check that cylinder No. 1 is at the compres-

si on top de ad ce nter by the fo ll owi ng
method. If the following condition is not
obtained, turn the crankshaft one more turn.
a If the fuel injection pump is removed:
Check that mark C is seen at the tooth tip 5. Remove the timing check pin and tighten each
of the idler gear (2). bolt.
a If the fuel injection pump is installed to
the engine: Remove the head cover and
check that (both air intake valve and
exhaust valve of cylinder No. 1 have the
valve clearance).

20-108 PC78MR-6
(3)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

Adjustment by delivery valve method 4. Using spring pusher O2, compress the valve
(When installing a repaired or replaced fuel injection spring and remove valve cotter (5).
pump, when checking after disassembling or replac- 5. Loosen spring pusher O2 and remove spring
ing the gear train) seat (6) and valve spring (7).

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.

PC78MR-6 20-109
(3)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

7. Apply dial gauge O3 to the valve stem end and

turn the crankshaft forward or in reverse to set
the dial gauge to 0 when its pointer starts turning
in reverse.
8. Turn the crankshaft about 45 degrees in reverse
from the compression top dead center of cylinder
No. 1.
9. Turn the crankshaft forward so that the dial
gauge indicates standard dimension b.
a This dimension corresponds to the set angle
of the fuel injection timing.
Fuel injection timing and standard dimension b
BTDC °(Deg) 5 ± 0.75
b mm 0.3 ± 0.08
12. Set the fuel injection lever to the FULL position.
13. Loosen the nut at the oblong hole of the injection
pump mounting flange, then loosen the injection
pump mounting bolts (14).

10. Disconnect fuel injection pipe (10) of cylinder No.

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

20-110 PC78MR-6
(3)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

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.
• Dimension when cylinder is at top dead cen-
ter: 0 ± 0.08 mm

18. Remove the delivery valve holder (11) and install

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

Delivery valve holder:

39.2 – 44.1 Nm {4 – 4.5 kgm}

19. Connect fuel injection pipe (3).

Sleeve nut:
19.6 – 24.5 Nm {2 – 2.5 kgm}

20. Install valve spring (7) and valve seat (6).

21. Compress the valve spring with spring pusher

O2 and install valve cotter (5).

22. Install air intake rocker arm (4) of cylinder No. 1,

then install snap ring (3).
Install the snap ring securely.

23. Install the cylinder head cover.

Sleeve nut:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}

PC78MR-6 20-111
(3)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE

a Measure the engine oil pressure under he follow- 3. Run the engine at low idling and high idling and
ing condition. measure the engine oil pressure at each speed.
ï Cooling water temperature: Within operating
range

1. Remove oil pressure pickup plug (1) (PT 1/8)

from the engine block under the alternator.

2. Install oil pressure measuring nipple C3 and con-

nect oil pressure gauge C2 (0.98 MPa {10 kg/
cmb}).

20-112 PC78MR-6
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID

ADJUSTING ENGINE STOP SOLENOID

1. Install ball joint (2) to solenoid (1) and tighten 3. Supply power to solenoid (1) to turn it on.
locknut (3). a If stop lever (6) and rod end (5) of the fuel
a a: Approx. 1mm (thread) injection pump are connected before the
solenoid is turned on, the solenoid cannot
pull sufficiently (the operating current flows
continuously) and the coil will burn. Accord-
ingly, do not connect them at this time.

2. Install rod (4) and rod end (5) to ball joint (2) tem-
porarily.
a Screwing depth b of rod in ball joint:
Approx. 12.5 mm
a Screwing depth c of rod end in rod: 4. Check that solenoid (1) is turned on, then con-
Approx. 10.0 mm nect rod end (5) to stop lever (6) and adjust the
length of rod (4) so that the stop lever will touch
the lever end on the service side.
a If solenoid (1) is connected to the power
source without using the machine wiring, do
not keep the PULL terminal cable connected.
(If the PULL terminal cable is kept con-
nected, the operating current flows continu-
ously and the coil will burn.)

PC78MR-6 20-113
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID

a Stop lever (6) touches the lever end on the 5. Tighten nut (7) of the joint of stop lever (6) and
service side (inside the fuel injection pump). rod end (5) and insert the cotter pin.
a Play: 0 mm a Install the rod end with grease hole (8) up.

Rod end: Grease (G2-LI)

6. Lengthen rod (4) to give play to the stop lever

end on the service side.
a Play d: 1.0 ñ 2.0 mm (loosen rod by 1/2 ñ 1
turn.)

a When adjusting the length of rod (4), do not

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

20-114 PC78MR-6
 ADJUSTING ENGINE STOP SOLENOID,
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE

7. Tighten locknut (8). ADJUSTING FUEL CONTROL

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

PC78MR-6 20-115
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE

2. Adjusting control linkage finely 4) Tighten nuts (6) and (7).

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

Nut: 8.8 ñ 10.8 Nm {0.9 ñ 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 ñ 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.
ï When the engine speed (low idling speed) is
above the specified speed.
1) Turn the starting switch to the ON position
and set the fuel control dial to the decelera-
tion (SLOW) position.
2) Loosen nut (6) (right-hand screw) and nut (7)
(left-hand screw).
3) Turn bolt (8) counterclockwise, seeing from
the governor lever side, to lengthen the cable
and eliminate the clearance between injec-
tion pump governor lever (1) and low idling
stopper (9).

20-116 PC78MR-6
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEED SENSOR

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

Threads: Hydraulic sealant

2. Return sensor (1) by 1/2 ñ 2/3 turns.

a A clearance of 0.75 ñ 1.00 mm is made
between the sensor tip and gear tooth tip.

3. Secure sensor (1) with nut (3).

Nut: 69 ñ 74 Nm {7.0 ñ 7.5 kgm}

PC78MR-6 20-117
 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

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

Measuring hydraulic pressure in boom arm,

bucket, travel, and swing circuits

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

Measuring hydraulic pressure in swing and

blade circuits

1. Measuring pump relief pressure

1) Remove the top cover of the valve.
2) Remove pressure pickup plug (3) (10 mm, P
= 1.25) and install nipple C3, then connect oil
pressure gauge (58.8 MPa {600 kg/cmb}).
a See the photo.
3) Measure the hydraulic pressure when swing
or blade lower actuator is relieved while the
engine is running at full throttle.

20-118 PC78MR-6
 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

2. Adjusting
Adjusting main relief valve for boom, arm,
bucket, swing, and travel circuits.
ï Remove cap (2) of main relief valve (1) and
loosen locknut (3), then adjust with adjust-
ment screw (4).
a As the adjustment screw is
ï rotated to the right, the pressure is
heightened, and it is
ï rotated to the left, the pressure is low-
ered.
a Quantity of adjustment per turn of adjustment
screw: 12.5 MPa {128 kg/cmb}

Locknut: 39 ñ 49 Nm {4 ñ 5 kgm}
Cap: 39 ñ 49 Nm {4 ñ 5 kgm}

PC78MR-6 20-119
 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

2. Adjusting Adjusting main relief valve for blade (RAISE)

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

20-120 PC78MR-6
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE

MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING

LS VALVE
1. Measuring LS differential pressure 2) Measuring with oil pressure gauge
1) Measuring with main relief differential pres- a Measure with the same gauge.
sure gauge i) Remove pump pressure pickup plug (1)
i) Remove pump pressure pickup plug (1) (on the high pressure side) and discon-
(on the high pressure side) and discon- nect LS pressure hose (2) (on the low
nect LS pressure hose (2). Install nipple pressure side) and install adapter C3.
C3 to the high pressure side and nipple ii) Connect pressure gauge C1 (39.2 MPa
C4 to the LS pressure side. {400 kg/cmb}).
ii) Connect differential pressure gauge C5. a Use a pressure gauge having unit
a Connect the high pressure side of divisions of 1.0 MPa {10 kg/cmb}. (If a
the differential pressure gauge to the pressure gauge of 39.2 MPa {400 kg/
main relief pressure side and con- cmb} is not available, one of 58.8
nect the low pressure side to the LS MPa {600 kg/cmb} will do.)
pressure side. iii) Measure the pump discharge pressure
iii) Measure the LS differential pressure under the condition in Table 1.
under the condition in Table 1. Read the pointer correctly, facing the
gauge.
Table 1 iv) Measure the LS pressure under the con-
Fuel Control Differential dition in Table 1.
Operation a Read the pointer correctly, facing the
Dial Pressure {kg/cmb}
gauge.
Set lever in 2.5 ñ 4.4 a LS differential pressure = (Pump dis-
FULL
neutral {25 ñ 45} charge pressure) ñ (LS pressure)
Curl bucket
2.11 ñ 0.1
FULL (With lever at
{21.5 ñ 1}
FULL position)

PC78MR-6 20-121
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE

Adjusting
1. Adjusting LS valve
a If the differential pressure is abnormal, adjust
the LS valve according to the following pro-
cedure.
a Before loosening the locknut, be sure to
make match marks.
1) Loosen locknut (3) and adjust with adjust-
ment screw (4).
a As the adjustment screw is
ï rotated to the right, the pressure is
heightened, and it is
ï rotated to the left, the pressure is
lowered.
a Quantity of adjustment per turn of adjust-
ment screw: 1.27 MPa {13 kg/cmb}.
2) After adjusting, tighten locknut (3).

Locknut: 29.4 ñ 39.2 Nm {3 ñ 4 kgm}

a After adjusting, measure the LS differen-

tial pressure, referring to Measuring
described above.
a When loosening or tightening the lock-
nut, secure adjustment screw (4) with a
spanner so that it will not be dragged.

20-122 PC78MR-6
TESTING AND ADJUSTING ADJUSTING PC VALVE

ADJUSTING PC VALVE TESTING TVC-EPC SOLENOID

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

Locknut: 29.4 ñ 39.2 Nm {3 ñ 4 kgm}

2) Start the engine and measure the oil pres-

sure under the following condition.

Table 1 Measurement Condition

Measure- Measured
Engine Monitor Output
ment Pressure MPa
Speed Current
Condition {kg/cmb}
0.54 ñ 0.84
FULL Neutral 410 mA
{5.5 ñ 8.5}
Float one
0 ñ 0.2
FULL side and 100 mA
{0 ñ 2}
run idle
2.74 ñ 3.53
SLOW Neutral 900 mA
{28 ñ 36}

PC78MR-6 20-123
TESTING AND ADJUSTING MEASURING CONTROL CIRCUIT PRESSURE

MEASURING CONTROL CIRCUIT PRESSURE

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

Locknut: 20 ñ 29 Nm {2 ñ 3 kgm}

a After adjusting, check the set pressure

according to the procedure in 1.

3) Connect nipple C3 and install oil pressure

gauge C1 (5.8 MPa {60 kg/cmb}).

20-124 PC78MR-6
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE OUTPUT PRESSURE

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

2) Install adapter C4 between hose (1) and

elbow.
3) Install oil pressure gauge C1 (5.9 MPa {60
kg/cmb}) to adapter C3.
4) Run the engine at full throttle and operate the
control lever of the circuit to be measured
and measure oil pressure.

a If the output on the control valve side is low,

measure the input pressure of the PPC valve. Of
the input pressure of the PPC valve is normal,
the PPC valve is defective.

PC78MR-6 20-125
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE

TESTING SOLENOID VALVE OUTPUT PRESSURE

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

2) Measure the output pressure under the con-

dition in Table 1.

Table 1
Oil pressure
Solenoid Name Measurement Condition Remarks
MPa {kg/cmb}
3.14 ± 0.49
While boom is swinging to right ó
{32 ± 5}
1 Swing right stop EPC
1.13 ± 0.29
Stroke end ó
{11.5 ± 3}
3.14 ± 0.49
While boom is swinging to left ó
Boom swing stop {32 ± 5}
2
EPC 1.13 ± 0.29
Stroke end ó
{11.5 ± 3}

20-126 PC78MR-6
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE

Table 2
Operation of Oil pressure
Solenoid Name Measurement Condition Operating Condition Remarks
solenoid MPa {kg/cmb}
Oil pressure is
Set safety lock lever in 3.14 ± 0.29
applied to PPC valve ON ó
PPC FREE position. {32 ± 3}
circuit.
1 oil pressure-
ssure lock Oil pressure is not
Set safety lock lever in
applied to PPC valve OFF 0 ó
LOCK position.
circuit.
Operate swing or boom 3.14 ± 0.49
Brake is released. ON ó
swing or arm-in lever. {32 ± 5}
Swing hold-
2 Set swing or arm-in lever
ing brake
in neutral (5 sec after Brake is applied. OFF 0 ó
setting in neutral)
Set travel speed selector Travel speed is 3.14 ± 0.49
ON ó
Travel speed switch in Hi. increased. {32 ± 5}
3
selector Set travel speed selector Travel speed is
OFF 0 ó
switch in Lo. decreased.
Note: Operation of solenoid valve is as follows;
When ON: Power is applied (Hydraulic oil is generated).
When OFF: Power is not applied (Hydraulic oil is 0).

PC78MR-6 20-127
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE

ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE

If the work equipment control lever or swing control
lever has excessive play, adjust it according to the
following procedure.
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 bolt (1).
3. Loosen locknut (2) and screw in disc (3) until it
touches the heads of 4 pistons (4).
a At this time, do not move the pistons.
4. Fix disc (3) and tighten locknut (2) to the speci-
fied torque.

Locknut: 98 ñ 127 Nm {10 ñ 13 kgm}

5. Install boot (1).

a The clearance between disc (3) and piston
(4) is eliminated by the above adjustment.

20-128 PC78MR-6
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION

TESTING TRAVEL DEVIATION

1. Measuring when traveling
1) Set the machine in the travel posture.
a For the travel posture, extend the bucket
and arm cylinder rods fully, and hold the
boom angle at 45Y.
2) Travel for 10 m, then measure deviation a
when traveling for the next 20 m.
a Measure with the engine at full throttle.
a Install a hydraulic pressure gauge and
measure the pump discharge pressure a
the same time.

PC78MR-6 20-129
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION

Adjusting 2. Insert hexagonal wrench (1) (Width across flats:

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

If the adjustment plug is loosened more than

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

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.

1. Check the position of each adjustment plug of

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

6. Check for travel deviation again. If the machine

still deviates, adjust again according to the
above procedure.
a Do not loosen the adjustment plugs more
than the adjustable range (2 turns / 720
degrees).

20-130 PC78MR-6