Komatsu PC750-7 PC800-7 Shop Manual – PDF DOWNLOAD

Komatsu PC750-7 PC800-7 Shop Manual – PDF DOWNLOAD

DESCRIPTION:

Komatsu PC750-7 PC800-7 Shop Manual – PDF DOWNLOAD

MACHINE MODEL
PC750-7
PC750SE-7
PC750LC-7
PC800-7
PC800SE-7
SERIAL NUMBER
20001 and up
20001 and up
20001 and up
40001 and up
40001 and up

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 dangerous
situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully
BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator’s
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling.
In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide
safe footing.
TABLE OF CONTENTS:

Komatsu PC750-7 PC800-7 Shop Manual – PDF DOWNLOAD

COVER………………………………………………………………………………………………… 1
CONTENTS……………………………………………………………………………………………… 2
LIST OF REVISED PAGES………………………………………………………………………………….. 3
SAFETY……………………………………………………………………………………………….. 9
SAFETY NOTICE……………………………………………………………………………………… 9
FOREWORD……………………………………………………………………………………………… 11
GENERAL…………………………………………………………………………………………… 11
HOW TO READ THE SHOP MANUAL…………………………………………………………………………. 12
HOISTING INSTRUCTIONS………………………………………………………………………………. 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER……………………………………………… 14
COATING MATERIALS………………………………………………………………………………….. 16
STANDARD TIGHTENING TORQUE………………………………………………………………………….. 18
ELECTRIC WIRE CODE…………………………………………………………………………………. 21
CONVERSION TABLE…………………………………………………………………………………… 22
UNITS…………………………………………………………………………………………….. 28
01 GENERAL……………………………………………………………………………………………. 29
SPECIFICATION DRAWINGS……………………………………………………………………………… 30
SPECIFICATIONS…………………………………………………………………………………….. 34
WEIGHT TABLE………………………………………………………………………………………. 42
FUEL, COOLANT AND LUBRICANTS………………………………………………………………………… 46
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…………………………………………………………… 47
PTO………………………………………………………………………………………………. 48
PTO LUBRICATION SYSTEM……………………………………………………………………………… 49
POWER TRAIN……………………………………………………………………………………….. 50
SWING MACHINERY……………………………………………………………………………………. 52
SWING CIRCLE………………………………………………………………………………………. 54
FINAL DRIVE……………………………………………………………………………………….. 56
SPROCKET………………………………………………………………………………………….. 58
TRACK FRAME AND RECOIL SPRING……………………………………………………………………….. 60
IDLER…………………………………………………………………………………………….. 62
CARRIER ROLLER…………………………………………………………………………………….. 64
TRACK ROLLER………………………………………………………………………………………. 65
TRACK SHOE………………………………………………………………………………………… 66
MOTOR GREASE PUMP………………………………………………………………………………….. 71
HYDRAULIC TANK…………………………………………………………………………………….. 72
HYDRAULIC PUMP…………………………………………………………………………………….. 74
RETURN OIL FILTER…………………………………………………………………………………..104
LINE OIL FILTER…………………………………………………………………………………….105
PILOT OIL FILTER……………………………………………………………………………………105
DRAIN OIL FILTER……………………………………………………………………………………106
L.H. 5-SPOOL CONTROL VALVE…………………………………………………………………………..108
R.H. 4-SPOOL CONTROL VALVE…………………………………………………………………………..114
STRAIGHT-TRAVEL VALVE……………………………………………………………………………….120
SWING MOTOR………………………………………………………………………………………..123
CENTER SWIVEL JOINT…………………………………………………………………………………128
TRAVEL MOTOR……………………………………………………………………………………….129
PPC CONTROL RELIEF VALVE…………………………………………………………………………….139
PPC ACCUMULATOR…………………………………………………………………………………….140
VALVE CONTROL………………………………………………………………………………………141
WORK EQUIPMENT, SWING PPC VALVE………………………………………………………………………142
TRAVEL PPC VALVE……………………………………………………………………………………148
SOLENOID VALVE……………………………………………………………………………………..152
HYDRAULIC CYLINDER………………………………………………………………………………….158
WORK EQUIPMENT……………………………………………………………………………………..164
DIMENSIONS OF WORK EQUIPMENT…………………………………………………………………………170
AIR CONDITIONER…………………………………………………………………………………….174
ENGINE CONTROL……………………………………………………………………………………..175
MACHINE CONTROL SYSTEM………………………………………………………………………………181
MONITOR SYSTEM……………………………………………………………………………………..210
SENSORS……………………………………………………………………………………………225
20 TESTING AND ADJUSTING………………………………………………………………………………..229
STANDARD VALUE TABLE FOR ENGINE………………………………………………………………………230
STANDARD VALUE TABLE FOR CHASSIS……………………………………………………………………..231
TESTING AND ADJUSTING……………………………………………………………………………….241
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING……………………………………………………242
MEASURING ENGINE SPEED…………………………………………………………………………..244
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)……………………………………………………..245
MEASUREMENT OF EXHAUST GAS TEMPERATURE…………………………………………………………….246
MEASUREMENT OF EXHAUST GAS COLOR………………………………………………………………….247
ADJUSTING VALVE CLEARANCE………………………………………………………………………..248
MEASURING COMPRESSION PRESSURE……………………………………………………………………249
MEASURING BLOW-BY PRESSURE……………………………………………………………………….251
MEASURING ENGINE OIL PRESSURE…………………………………………………………………….252
HANDLING OF FUEL SYSTEM EQUIPMENT…………………………………………………………………253
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT………………………………………………..253
MEASUREMENT OF FUEL PRESSURE……………………………………………………………………..254
TESTING LEAKAGE THROUGH PRESSURE LIMITER AND RETURN RATE FROM INJECTOR………………………………..255
AIR BLEEDING FROM FUEL CIRCUIT……………………………………………………………………259
INSPECTION OF LEAKAGE FROM FUEL SYSTEM…………………………………………………………….261
ADJUSTING ENGINE SPEED SENSOR…………………………………………………………………….262
TESTING AND ADJUSTING FAN BELT TENSION…………………………………………………………….263
TESTING AND ADJUSTING ALTERNATOR BELT TENSION………………………………………………………264
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT……………………………………………….265
INSPECTION OF SWING CIRCLE BEARING CLEARANCE……………………………………………………….266
TESTING AND ADJUSTING TRACK SHOE TENSION…………………………………………………………..267
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES………………………….268
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE………………………………………………….273
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE………………………………………………….274
INSPECTION OF SERVO PISTON STROKE…………………………………………………………………280
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE…………………………………………………………..281
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE….284
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE………………………………………………………….289
TESTING AND ADJUSTING TRAVEL DEVIATION…………………………………………………………….290
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT…………………………………………292
MEASURING OIL LEAKAGE …………………………………………………………………………..293
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…………………………………………………297
BLEEDING AIR FROM EACH PART………………………………………………………………………298
INSPECTION PROCEDURES FOR DIODE…………………………………………………………………..301
ADJUSTING MIRRORS……………………………………………………………………………….302
SPECIAL FUNCTION OF MONITOR PANEL…………………………………………………………………304
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT…………………………………………………….331
PREPARATION WORK………………………………………………………………………………..332
PM-CLINIC SERVICE……………………………………………………………………………….335
UNDERCARRIAGE INSPECTION…………………………………………………………………………342
TROUBLESHOOTING…………………………………………………………………………………….343
POINTS TO REMEMBER WHEN TROUBLESHOOTING……………………………………………………………344
SEQUENCE OF EVENTS IN TROUBLESHOOTING……………………………………………………………..345
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE……………………………………………………346
CHECKS BEFORE TROUBLESHOOTING…………………………………………………………………….354
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING……………………………………………………….355
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM…………………………………….359
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…………………………………………………………376
T-BRANCH BOX AND T-BRANCH TABLE…………………………………………………………………..399
TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED……401
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE……………………………………………404
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE………………………………………………….406
ERROR CODE IN ELECTRICAL SYSTEM E112 (WIPER DRIVE (FOR) S/C)……………………………………..408
ERROR CODE IN ELECTRICAL SYSTEM E113 (WIPER DRIVE (REV) S/C)……………………………………..412
ERROR CODE IN ELECTRICAL SYSTEM E114 (WASHER DRIVE S/C)………………………………………….414
ERROR CODE IN ELECTRICAL SYSTEM E115 (WIPER WORKING ABNORMALITY)………………………………….416
ERROR CODE IN ELECTRICAL SYSTEM E116 (WIPER PARKING ABNORMALITY)………………………………….418
ERROR CODE IN ELECTRICAL SYSTEM E117 (ENG. CONTROLLER S-NET COMM ERR.)…………………………….422
ERROR CODE IN ELECTRICAL SYSTEM E118 (PUMP CONTROLLER S-NET COMM ERR.)…………………………….424
ERROR CODE IN ELECTRICAL SYSTEM E128 (MONITOR COMM. ABNORMALITY)………………………………….426
ERROR CODE IN ELECTRICAL SYSTEM E201 (CO CANCEL SOL. S/C)………………………………………..428
ERROR CODE IN ELECTRICAL SYSTEM E202 (TRAVEL JUNCTION SOL. S/C)…………………………………..430
ERROR CODE IN ELECTRICAL SYSTEM E203 (SWING BRAKE SOL. S/C)………………………………………432
ERROR CODE IN ELECTRICAL SYSTEM E204 (2-STAGE RELIEF SOL. S/C)……………………………………434
ERROR CODE IN ELECTRICAL SYSTEM E205 (SWING PRIORITY SOL. S/C)……………………………………436
ERROR CODE IN ELECTRICAL SYSTEM E206 (TRAVEL SPEED SOL. S/C)……………………………………..438
ERROR CODE IN ELECTRICAL SYSTEM E207 (FLASH LIGHT RELAY S/C)……………………………………..440
ERROR CODE IN ELECTRICAL SYSTEM E211 (CO CANCEL SOL. DISC.)………………………………………442
ERROR CODE IN ELECTRICAL SYSTEM E212 (TRAVEL JUNCTION SOL. DISC.)…………………………………444
ERROR CODE IN ELECTRICAL SYSTEM E213 (SWING BRAKE SOL. DISC.)…………………………………….446
ERROR CODE IN ELECTRICAL SYSTEM E214 (2-STAGE RELIEF SOL. DISC.)………………………………….448
ERROR CODE IN ELECTRICAL SYSTEM E215 (SWING PRIORITY SOL. DISC.)………………………………….450
ERROR CODE IN ELECTRICAL SYSTEM E216 (TRAVEL SPEED SOL. DISC.)……………………………………452
ERROR CODE IN ELECTRICAL SYSTEM E217 (MODEL SELECTION ABNORMALITY)………………………………..454
ERROR CODE IN ELECTRICAL SYSTEM E218 (S-NET COMM. DISC.)…………………………………………456
ERROR CODE IN ELECTRICAL SYSTEM E221 (TRAVEL ALARM S/C)………………………………………….458
ERROR CODE IN ELECTRICAL SYSTEM E224 (F PUMP P. SENSOR ABNORMALITY)……………………………….460
ERROR CODE IN ELECTRICAL SYSTEM E225 (R PUMP P. SENSOR ABNORMALITY)……………………………….462
ERROR CODE IN ELECTRICAL SYSTEM E226 (PRESS. SENSOR POWER ABNORMALITY)…………………………….464
ERROR CODE IN ELECTRICAL SYSTEM E227 (ENGINE SPEED SENSOR ABNORMALITY)…………………………….466
ERROR CODE IN ELECTRICAL SYSTEM E232 (TVC SOL. S/C)……………………………………………..468
ERROR CODE IN ELECTRICAL SYSTEM E233 (TVC SOL. DISC.)……………………………………………470
ERROR CODE IN ELECTRICAL SYSTEM E257 (PUMP COMM. ABNORMALITY)…………………………………….472
ERROR CODE IN ELECTRICAL SYSTEM E302 (STEP LIGHT RELAY S/C)………………………………………474
ERROR CODE IN ELECTRICAL SYSTEM E304 (STEP LIGHT POWER HOLD RELAY S/C)…………………………….476
ERROR CODE IN ELECTRICAL SYSTEM E315 (BATTERY RELAY DRIVE S/C)……………………………………478
ERROR CODE IN ELECTRICAL SYSTEM E91B (ENGINE NE SENSOR PROBLEM)…………………………………..480
ERROR CODE IN ELECTRICAL SYSTEM E91C (ENGINE G SENSOR PROBLEM)……………………………………481
ERROR CODE IN ELECTRICAL SYSTEM E920 (ENGINE TYPE SELECTION ERROR)………………………………..482
ERROR CODE IN ELECTRICAL SYSTEM E921 (ENGINE TYPE MISMATCH)………………………………………484
ERROR CODE IN ELECTRICAL SYSTEM E931 (FUEL DIAL SYS. ERROR)………………………………………486
ERROR CODE IN ELECTRICAL SYSTEM E934 (ENGINE COOLANT SENSOR HI ERROR)……………………………..488
ERROR CODE IN ELECTRICAL SYSTEM E936 (ENGINE OIL PRESS. SW. ERROR)………………………………..490
ERROR CODE IN ELECTRICAL SYSTEM E93C (ENGINE BOOST SENSOR ERROR)………………………………….492
ERROR CODE IN ELECTRICAL SYSTEM E93D (ENGINE FUEL TEMP. SENSOR ERROR)……………………………..494
ERROR CODE IN ELECTRICAL SYSTEM E953 (ENGINE COMM. ABNORMALITY)…………………………………..496
ERROR CODE IN ELECTRICAL SYSTEM E954 (SHORT ENGINE STARTER SW.)…………………………………..498
ERROR CODE IN ELECTRICAL SYSTEM E955 (ENGINE S-NET ERROR)………………………………………..500
ERROR CODE IN ELECTRICAL SYSTEM E956 (ENGINE POWER FAILURE (1))…………………………………..502
ERROR CODE IN ELECTRICAL SYSTEM E957 (ENGINE POWER FAILURE (2))…………………………………..504
ERROR CODE IN ELECTRICAL SYSTEM E95A (ENGINE Q-ADJ. SW. SIGNAL ERROR)……………………………..506
ERROR CODE IN ELECTRICAL SYSTEM E96A (ENGINE COOLANT SENSOR LO ERROR)……………………………..508
ERROR CODE IN ELECTRICAL SYSTEM E970 (PCV1 OVER CURRENT)…………………………………………510
ERROR CODE IN ELECTRICAL SYSTEM E971 (PCV2 OVER CURRENT)…………………………………………512
ERROR CODE IN ELECTRICAL SYSTEM E974 (PCV1 LINE CUT)…………………………………………….514
ERROR CODE IN ELECTRICAL SYSTEM E975 (PCV2 LINE CUT)…………………………………………….516
ERROR CODE IN ELECTRICAL SYSTEM E977 (RAIL PRESS. SENSOR ERROR)…………………………………..518
ERROR CODE IN ELECTRICAL SYSTEM E979 (RAIL PRESS. HIGH)………………………………………….520
ERROR CODE IN ELECTRICAL SYSTEM E97A (RAIL PRESS. ABNORMAL)………………………………………520
ERROR CODE IN ELECTRICAL SYSTEM E97B (RAIL PRESS. LOW)…………………………………………..521
ERROR CODE IN ELECTRICAL SYSTEM E97C (RAIL PRESS. TOO LOW)……………………………………….525
ERROR CODE IN ELECTRICAL SYSTEM E97D (RAIL PRESS. OUT OF CONTROL)…………………………………525
ERROR CODE IN ELECTRICAL SYSTEM E980 (ENG. CONTROLLER ABNORMALITY)………………………………..526
ERROR CODE IN ELECTRICAL SYSTEM E981 (FUEL INJECTOR 1 DISC.)……………………………………..528
ERROR CODE IN ELECTRICAL SYSTEM E982 (FUEL INJECTOR 2 DISC.)……………………………………..529
ERROR CODE IN ELECTRICAL SYSTEM E983 (FUEL INJECTOR 3 DISC.)……………………………………..530
ERROR CODE IN ELECTRICAL SYSTEM E984 (FUEL INJECTOR 4 DISC.)……………………………………..531
ERROR CODE IN ELECTRICAL SYSTEM E985 (FUEL INJECTOR 5 DISC.)……………………………………..532
ERROR CODE IN ELECTRICAL SYSTEM E986 (FUEL INJECTOR 6 DISC.)……………………………………..533
ERROR CODE IN ELECTRICAL SYSTEM E98A (FUEL INJECTOR 1-3 S/C)……………………………………..534
ERROR CODE IN ELECTRICAL SYSTEM E98B (FUEL INJECTOR 4-6 S/C)……………………………………..536
FAILURE CODE IN MECHANICAL SYSTEM A000N1 (ENG. HI OUT OF STD)…………………………………….539
FAILURE CODE IN MECHANICAL SYSTEM AA10NX (AIRCLEANER CLOGGING)……………………………………540
FAILURE CODE IN MECHANICAL SYSTEM AB00KE (CHARGE VOLTAGE LOW)…………………………………….542
FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ENG. OIL PRESS. LOW)……………………………………544
FAILURE CODE IN MECHANICAL SYSTEM B@BAZK (ENG. OIL LEVEL LOW)…………………………………….546
FAILURE CODE IN MECHANICAL SYSTEM B@BCNS (ENG. COOLANT OVERHEAT)………………………………….547
FAILURE CODE IN MECHANICAL SYSTEM B@BCZK (ENG. COOLANT LVL LOW)…………………………………..548
FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDR. OIL OVERHEAT)…………………………………….550
FAILURE CODE IN MECHANICAL SYSTEM DA80MA (AUTO. LUB ABNORMAL)…………………………………….552
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)………………………………………………………553
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)……………………………………………………554
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE………………………………………………….556
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)………………………………………………557
E-2 PREHEATER DOES NOT OPERATE………………………………………………………………..560
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK……………………………………………………562
E-4 AUTO-DECELERATOR DOES NOT OPERATE………………………………………………………….563
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE…………………………………………….564
E-6 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY…………………………………………..566
E-7 BOOM SHOCKLESS FUNCTION DOES NOT OPERATE NORMALLY……………………………………………568
E-8 ANY ITEM IS NOT DISPLAYED ON MONITOR PANEL………………………………………………….570
E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING…………………………………………………571
E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL……………………………………..571
E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING………………………………..572
E-12 ENGINE COOLANT THERMOMETER DOES NOT DISPLAY NORMALLY………………………………………..574
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…………………………………..576
E-14 FUEL GAUGE DOES NOT DISPLAY CORRECTLY……………………………………………………..577
E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY………………………………………………578
E-16 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED……………………………………….580
E-17 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK……………………………………………..582
E-18 ALARMING BUZZER CANNOT BE CANCELLED……………………………………………………….590
E-19 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION………………………………….591
E-20 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION………………………………….592
E-21 “ARM IN” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION……………………………………..593
E-22 “ARM OUT” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…………………………………….594
E-23 “BUCKET CURL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…………………………………595
E-24 “BUCKET DUMP” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…………………………………596
E-25 “SWING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION………………………………………597
E-26 “LEFT TRAVEL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION……………………………….600
E-27 “RIGHT TRAVEL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION………………………………602
E-28 “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION…………………………………….604
E-29 AIR CONDITIONER DOES NOT WORK…………………………………………………………….606
E-30 STEP LIGHT DOES NOT LIGHT UP OR GO OFF…………………………………………………….607
E-31 ELECTRIC GREASE GUN DOES NOT OPERATE………………………………………………………612
E-32 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING……………………………………….614
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)………………………………………….617
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)………………………………618
INFORMATION IN TROUBLESHOOTING TABLE…………………………………………………………..623
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW………………………………..624
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS……………………………………………..626
H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK…………………………………….627
H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP……………………………………………………628
H-5 BOOM SPEED OR POWER IS LOW………………………………………………………………..629
H-6 SPEED OR POWER OF ARM IS LOW………………………………………………………………631
H-7 SPEED OR POWER OF BUCKET IS LOW……………………………………………………………632
H-8 BOOM DOES NOT MOVE……………………………………………………………………….633
H-9 ARM DOES NOT MOVE………………………………………………………………………..633
H-10 BUCKET DOES NOT MOVE…………………………………………………………………….633
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE…………………………………………………634
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE……………………………………………………….636
H-13 HEAVY LIFT FUNCTION DOES NOT OPERATE OR STOP……………………………………………….637
H-14 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE OR STOP…………………………………………..637
H-15 BOOM SHOCKLESS FUNCTION CANNOT BE TURNED ON OR OFF………………………………………….637
H-16 MACHINE DEVIATES IN ONE DIRECTION…………………………………………………………638
H-17 MACHINE DEVIATES LARGELY AT START…………………………………………………………640
H-18 MACHINE DEVIATES LARGELY DURING COMPOUND OPERATION………………………………………….641
H-19 TRAVEL SPEED OR POWER IS LOW……………………………………………………………..641
H-20 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)…………………………………………………..642
H-21 TRAVEL SPEED DOES NOT CHANGE……………………………………………………………..643
H-22 UPPER STRUCTURE DOES NOT SWING……………………………………………………………644
H-23 SWING SPEED OR ACCELERATION IS LOW………………………………………………………..645
H-24 SWING SPEED OR ACCELERATION IS LOW DURING COMPOUND OPERATION OF SWING AND WORK EQUIPMENT………..646
H-25 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING………………………………….648
H-26 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING …………………………………….649
H-27 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING……………………………..650
H-28 HYDRAULIC DRIFT OF SWING IS LARGE…………………………………………………………651
TROUBLESHOOTING OF ENGINE (S MODE)………………………………………………………………..653
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………………………..654
METHOD OF USING TROUBLESHOOTING CHARTS…………………………………………………………655
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…………………………………….658
S-2 ENGINE DOES NOT START…………………………………………………………………….659
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…………………………………………662
S-4 ENGINE STOPS DURING OPERATIONS…………………………………………………………….663
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…………………………………………………..664
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)……………………………………………………….665
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)………………………………………………666
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)………………………………………667
S-9 OIL BECOMES CONTAMINATED QUICKLY…………………………………………………………..668
S-10 FUEL CONSUMPTION IS EXCESSIVE…………………………………………………………….669
S-11 OIL IS IN COOLING (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)………………………..670
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…………………………………..671
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL)…………………………………………………….672
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)………………………………………….673
S-15 ABNORMAL NOISE IS MADE…………………………………………………………………..674
S-16 VIBRATION IS EXCESSIVE…………………………………………………………………..675
30 DISASSEMBLY AND ASSEMBLY……………………………………………………………………………..677
METHOD OF USING MANUAL………………………………………………………………………………679
PRECAUTIONS WHEN CARRYING OUT OPERATION……………………………………………………………….681
SPECIAL TOOL LIST…………………………………………………………………………………..683
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…………………………………………………..693
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY……………………………………………………..696
REMOVAL AND INSTALLATION OF NOZZLE TIP………………………………………………………………..699
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL………………………………………………………….701
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…………………………………………………………..703
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY……………………………………………………..708
REMOVAL AND INSTALLATION OF AFTERCOOLER CORE…………………………………………………………..714
REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY………………………….715
REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY…………………………….718
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY…………………………………………………………719
REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY………………………………………720
REMOVAL AND INSTALLATION OF PTO ASSEMBLY………………………………………………………………724
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY………………………………………………………………726
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY……………………………………………………….729
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY……………………………………………………740
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY……………………………………………………741
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY……………………………………………………742
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY………………………………………………………749
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY………………………………………………………..750
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD………………………………………………………….752
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY…………………………………………………………….756
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…………………………………………………………….757
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY…………………………………………..760
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY……………………………………………………..761
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY……………………………………………………..763
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY…………………………………………………….765
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY…………………………………………………….766
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY………………………………………………………769
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY………………………………………………………770
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…………………………………………………….773
REMOVAL AND INSTALLATION OF MAIN PUMP (NO.1 PUMP) ASSEMBLY………………………………………………775
REMOVAL AND INSTALLATION OF MAIN PUMP (NO.2 PUMP)………………………………………………………777
REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL………………………………………………779
REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRICATION PUMP ASSEMBLY…………………………………….780
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY………………………………………………….781
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY……………………………………………………..782
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (WORK EQUIPMENT)………………………………………785
REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY…………………………………………………….788
REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY…………………………………………………790
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY……………………………………………………….791
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT………………………………………………………..793
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY………………………………………………..794
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY………………………………………………………796
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY……………………………………………797
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY…………………………………………………..799
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (BACK HOE)………………………………………….801
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL)…………………………………….803
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (BACK HOE)…………………………………………….805
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (LOADING SHOVEL)……………………………………….807
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (BACK HOE)……………………………………………809
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (LOADING SHOVEL)………………………………………811
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)………………………………..813
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…………………………………………………814
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (BACK HOE)………………………………………………….820
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (LOADING SHOVEL)…………………………………………….821
REMOVAL AND INSTALLATION OF ARM ASSEMBLY (BACK HOE)…………………………………………………….822
REMOVAL AND INSTALLATION OF ARM ASSEMBLY (LOADING SHOVEL)……………………………………………….824
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (BACK HOE)……………………………………………………826
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (LOADING SHOVEL)………………………………………………828
REMOVAL AND INSTALLATION OF WORK EQUIPMENT (BACK HOE)…………………………………………………..830
REMOVAL AND INSTALLATION OF WORK EQUIPMENT (LOADING SHOVEL)……………………………………………..832
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY…………………………………………………….834
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)…………………………………………..836
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY………………………………………………………846
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY……………………………………………………..852
90 OTHERS……………………………………………………………………………………………..853
HYDRAULIC CIRCUIT DIAGRAM (PC750-7, PC750SE-7, PC800-7, PC800SE-7)……………………………………….855
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL SPECIFICATION, PC750-7, PC750SE-7)………………………………857
ELECTRICAL CIRCUIT DIAGRAM (1/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)………………………………..859
ELECTRICAL CIRCUIT DIAGRAM (2/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)………………………………..861
ELECTRICAL CIRCUIT DIAGRAM (3/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)………………………………..863
ELECTRICAL CIRCUIT DIAGRAM (4/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)………………………………..865
ELECTRICAL CIRCUIT DIAGRAM (5/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)………………………………..867
ELECTRICAL CIRCUIT DIAGRAM (6/6) (LOADING SHOVEL SPECIFICATION, PC750-7, PC750SE-7)……………………….869
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