Komatsu Hydraulic Excavator PC75UU Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC75UU-1, PC75UU-2, PC75UU-3, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC75UU workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,805 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM000401 - Hydraulic Excavator PC75UU-1 Shop Manual.pdf
SEBM001302 - Hydraulic Excavator PC75UU-2 Shop Manual.pdf
SEBM016404 - Hydraulic Excavator PC75UU-3 Shop Manual.pdf
SEAM021W0100 - Hydraulic Excavator PC75UU-1 Operation & Maintenance Manual.pdf
SEAM005600 - Hydraulic Excavator PC75UU-2 Operation & Maintenance Manual.pdf
SEAM023201T - Hydraulic Excavator PC75UU-3 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
CONTENTS...2
01 GENERAL...26
GENERAL ASSEMBLY DRAWING...27
WORK EQUIPMENT RANGE DRAWING...32
SPECIFICATIONS...35
WEIGHT TABLE ...41
LIST OF LUBRICANT AND WATER...45
10 STRUCTURE AND FUNCTION...48
RADIATOR,OIL COOER...49
PTO (COUPLING)...51
POWER TRAIN...53
SWING MACHINERY...54
SWING CIRCLE...55
TRACK FRAME...56
HYDRAULIC EQUIPMENT LAYOUT...57
HYDRAULIC TANK...59
HYDRAULIC PUMP...60
CONTROL VALVE...86
SELF-PRESSURE REDUCING VALVE...97
CLSS...101
SWING MOTOR...119
CENTER SWIVEL JOINT...130
TRAVEL MOTOR...134
VALVE CONTROL...140
PPC VALVE...141
SOLENOID VALVE...152
SOLENOID VALVE,EPC VALVE...154
WORK EQUIPMENT...158
AIR CONDITIONER PIPING...159
ELECTRIC WIRING DIAGRAM...160
ENGINE CONTROL...163
FOUR SYSTEM (4 SYSTEM)...171
ELECTRICAL CONTROL SYSTEM...189
MONITOR SYSTEM...196
20 TESTING AND ADJUSTING...202
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...203
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...204
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS...211
TESTING AND ADJUSTING...219
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...220
MEASURING ENGINE SPEED...221
MEASURING EXHAUST COLOR...222
ADJUSTING VALVE CLEARANCE...223
MEASURING COMPRESSION PRESSURE...224
MEASURING BLOW-BY PRESSURE...225
TESTING AND ADJUSTING FUEL INJECTION TIMING...226
MEASURING ENGINE OIL PRESSURE...227
ADJUSTING ENGINE STOP SOLENOID LINKAGE TESTING...228
ADTUSTING FUEL CONTROL LINKAGE...229
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...230
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE...232
ADJUSTING PC VALVE...233
MEASURING CONTROL CIRCUIT OIL PRESSURE (REDUCED PUMP DISCHARGE SELF-PRESSURE)...234
MEASURING PPC VALVE OUTPUT PRESSURE...235
TESTING SOLENOID VALVE OUTPUT PRESSURE...236
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...238
TESTING TRAVEL DEVIATION...239
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...240
MEASURING SWING, TRAVEL MOTOR OIL LEAKAGE...241
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...241
TESTING CLEARANCE OF SWING CIRCLE BEARING...242
TESTING WEAR OF SPROCKET...243
TESTING AND ADJUSTING TRACK SHOE TENSION...244
BLEEDING AIR...245
PROCEDURE FOR RESETTING ELECTRICAL SYSTEM INPUT/ OUTPUT SIGNALS AND CHECKING OPERATION...247
PROCEDURE FOR ADJUSTMENT WHEN INSTALLING LONG ARM, SLIDE ARM (TELESCOPIC ARM)...259
PROCEDURE FOR REPLACING POTENTIOMETER...260
PROCEDURE FOR CHECKING DIODE...261
TROUBLESHOOTING...262
POINTS TO REMEMBER WHEN TROUBLESHOOTING...263
SEQUENCE OF EVENTS IN TROUBLESHOOTING...264
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...265
CHECKS BEFORE TROUBLESHOOTING...273
CONNECTOR TYPES AND MOUNTING LOCATIONS...274
CONNECTOR ARRANGEMENT DIAGRAM...276
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...279
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM...289
DISPLAY METHOD FOR MONITOR PANEL,CONTROLLER...293
METHOD OF USING JUDGEMENT TABLE...297
METHOD OF USING TROUBLESHOOTING CHARTS...298
TROUBLESHOOTING OF ENGINE (S MODE)...300
METHOD OF USING TROUBLESHOOTING CHART...301
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...305
S-2 ENGINE DOSE NOT START...307
(1) ENGINE DOSE NOT TURN...307
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...308
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOSE NOT START(FUEL IS BEING INJECTED)...309
S-3 ENGINE DOSE NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...310
S-4 ENGINE STOPS DURING OPERATIONS...311
S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)...312
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...313
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...314
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...315
S-9 OIL BECOMES CONTAMINATED QUICKLY...316
S-10 FUEL CONSUMPTION IS EXCESSIVE...317
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...318
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...319
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...320
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...321
S-15 ABNORMAL NOISE IS MADE...322
S-16 VIBRATION IS EXCESSIVE...323
TROUBLESHOOTING OF CONTROLLER,ELECTRICAL SYSTEM(E MODE)...324
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE...326
JUDGEMENT TABLE FOR 4 SYSTEM...332
JUDGEMENT TABLE FOR CHASSIS RELATED PARTS...334
ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM...336
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM...341
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS...344
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM)...345
a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM...345
b) ABNORMALITY IN COMMUNICATIONS SYSTEM...346
E-2 ERROR CODE [21] (ABNORMALITY IN MODEL SELECTION SYSTEM)...347
E-3 ERROR CODE [22] (ABNORMALITY IN WORK EQUIPMENT SELECTION SYSTEM)...348
E-4 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTLOMETER SYSTEM)...349
E-5 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM)...350
E-6 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM)...351
E-7 ERROR CODE [37] (ABNORMALITY IN POTENTIOMETER POWER SOURCE SYSTEM) IS DISPLAYED...352
E-8 ERROR CODE [38] (ABNORMALITY IN SLIDE ARM LENGTH SENSOR SYSTEM) IS DISPLAYED...353
E-9 ERROR CODE [41] (ABNORMALITY IN PPC LOCK SOLENOID SYSTEM)...354
E-10 ERROR CODE [42] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID STSTEM)...355
E-11 ERROR CODE [44] (ABNORMALITY IN BOOM LOWER STOP SOLENOID SYSTEM)...356
E-12 ERROR CODE [51] (ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM)...357
E-13 ERROR CODE [52] (ABNORMALITY IN ARM IN STOP EPC SOLENOID SYSTEM) IS DISPLAYED...358
E-14 ERROR CODE [61] (VALVE OPEN) IS DISPLAYED...358
E-15 DEPTH MODE, HEIGHT MODE,OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHING SET POSITION)...359
E-16 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE,DEPTH MODE,HEIGHTMODE,OFFSET MODE...361
E-17 CANCEL SWITCH IS NOT TURNED ON,BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRIC SYSTEM CAUTION LAMP FLASHES...362
E-18 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE,ARM IN,LEFT OFFSET(WHEN ERROR CODE [61] IS NOT DISPLAYED)...363
a) ALL OPERATIONS STOP IMMEDIATELY BOFORE INTERFERENCE...363
b) THERE IS INTERFERENCE...363
E-19 WHEN TELESCOPIC ARM IS EXTENDED (MORE THAN 200 MM) AUTOMATIC STOP DISTANCE IS NEAR...364
E-20 WHEN SLIDE ARM IS RETRACTED (LESS THAN 200 MM) AUTOMATIC STOP DISTANCE IS FAR ...365
E-21 WORK EQUIPMENT DOSE MOVE WHEN WORK EQUIPMENT LOCK LEVER IS SET TO FREE POSITION...366
E-22 WORK EQUIPMENT DOSE MOVE WHEN WORK EQUIPMENT LOCK LEVER IS SET TO FREE POSITION...367
E-23 DOSE NOT SWING...368
E-24 EXCESSIVE HYDRAULIC DRIFT OF SWING (SWING BRAKE HAS NO EFFECT)...371
E-25 EVEN WHEN TRAVEL BOOST PEDAL IS OPERATED (DEPRESSED),SPEED DOSE NOT INCREASE...374
E-26 TRAVEL BOOST PEDAL IS NOT BEING OPERATED (NOT DEPRESSED) BUT SPEED REMAINS BOOSTED...375
E-27 POWER MODE DOSE NOT SWITCH...376
a) WHEN ENGINE SPEED IS AT MID-RANGE SPEED OR ABOVE (LIMIT SWITCH ON) BUT WORK EQUIPMENT SPEED SLOW...376
b) EXCESSIVE DROP IN ENGINE SPEED WHEN ENGINE SPEED IS BELOW MID-RANGE SPEED (LIMIT SWITCH ON)...377
E-28 WIPER DOSE NOT WORK...378
E-29 ENGINE DOSE NOT START ...379
a) STARTING MOTOR DOSE NOT TURN...379
b) ENGINE STOP SOLENOID DOSE NOT WORK (STARTING MOTOR TURNS)...382
E-30 ENGINE DOSE NOT STOP...383
E-31 DEFECTIVE ENGINE CONTROL...384
a) DOSE NOT WORK,OR WORKS AND THEN STOPS WORKING...384
b) WORKS,BUT DOSE NOT WORKS SMOOTHLY (CABLE WORK ABNORMAL OR INSUFFICIENT STROKE)...386
c) SWIFT SLOW-DOWN DOSE NOT WORK...388
d) WORKS AT NEAR IDLING BUT DOSE NOT WORK UP TO FULL (LOAD BECOMES LARGER)...389
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)...390
TABLE OF FAILURE MODES AND CAUSES...391
H-1 SPEEDS OF ALL WORK EQUIPMENT,TRAVEL,AND SWING ARE SLOW OR LACK POWER...393
a) SPEEDS OF ALL WORK EQUIPMENT,TRAVEL,AND SWING ARE ALL SLOW OR LACK POWER...393
b) SPEEDS OF SWING AND BLADE ARE ALL SLOW OR LACK POWER (BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE NORMAL)...393
c) SPEEDS OF BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE ALL SLOW OR LACK POWER (SWING AND BLADE ARE NORMAL)...394
d) SPEEDS OF ALL WORK EQUIPMENT (BOOM,ARM,BUCKET,OFFSET) ARE ALL SLOW OR LACK POWER (TRAVEL AND AWING ARE NORMAL)...396
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS...397
H-3 NONE OF WORK EQUIPMENT,TRAVEL,OR SWING MOVE...398
a) NONE OF WORK EQUIPMENT,TRAVEL,OR SWING MOVE...398
b) NONE OF BOOM,ARM,BUCKET,OFFSET,OR TRAVEL MOVE (SWING AND BLADE ARE NORMAL)...398
c) SWING AND BLADE DO NOT MOVE (BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE NORMAL)...398
H-4 ABNORMAL NOISE GENERATED FROM AROUND PUMP...399
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR (BOOM,ARM,BUCKET,OFFSET)...399
H-6 BOOM IS SLOW OR LACKS POWER...400
H-7 ARM IS SLOW OR LACKS POWER ...402
H-8 BUCKET IS SLOW OR LACKS POWER...404
H-9 BLADE IS SLOW OR LACKS POWER...404
H-10 WORK EQUIPMENT DOSE NOT MOVE (ONE OF BOOM,ARM,BUCKET,OFFSET,BLADE DOSE NOT MOVE)...405
H-11 EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT...406
a) EXCESSIVE HYDRAULIC DRIFT OF BOOM,ARM,BUCKET...406
b) EXCESSIVE HYDRAULIC DRIFT OF BLADE...406
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...407
H-13 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS SLOW...407
H-14 IN SWING + BOOM RAISE,BOOM RAISE IS SLOW...408
H-15 IN TRAVEL + BOOM RAISE,TRAVEL SPEED DROPS EXCESSIVELY...408
