Komatsu Hydraulic Excavators PC750, PC800 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC750-6, PC800-6, PC750-7, PC800-7, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC750-6, PC800-6, PC750-7, PC800-7 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: 2,901 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM025305 - Hydraulic Excavator PC750-6, PC800-6 Shop Manual.pdf
SEBM008707 - Hydraulic Excavator PC750-6, PC800-6 Shop Manual.pdf
SEBM031308 - Hydraulic Excavator PC750-7, PC800-7 Shop Manual.pdf
SEAM010900 - Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6 Operation & Maintenance Manual.pdf
SEAWD00800 - Hydraulic Excavator PC750-6, PC800-6 Field Assembly Instruction.pdf
MAIN SECTIONS
SEAM010900 - Hydraulic Excavator PC750-6, PC750LC-6, PC750SE-6 Operation & Maintenance Manual.....2
COVER.....2
INTRODUCTION.....5
1. Foreword.....5
2. Safety information.....6
3. Introduction.....7
4. Location of plates, table to enter serial No. and distributor.....8
5. Contents.....9
SAFETY.....12
6. General precautions.....13
7. Precautions during operation.....20
7.1 Before starting engine.....20
7.2 After starting engine.....22
7.3 Transportation.....29
7.4 Battery.....30
7.5 Towing.....32
7.6 Lifting operations.....32
8. Precautions for maintenance.....33
8.1 Before carrying out maintenance.....33
8.2 During maintenance.....37
9. Position for attaching safety labels.....42
OPERATION.....46
10. General view.....47
10.1 General view of machine.....47
10.2 General view of controls and gauges.....48
11. Explanation of components.....49
11.1 Machine monitor.....49
11.2 Switches.....60
11.3 Control levers, pedals.....65
11.4 Ceiling window.....68
11.5 Front window.....69
11.6 Door lock.....71
11.7 Cap, cover with lock.....72
11.8 Hot and cool box.....73
11.9 Luggage box.....73
11.10 Ashtray.....73
11.11 Handling air conditioner.....74
11.12 Car radio.....77
11.13 Power supply socket.....81
11.14 Fuse.....82
11.15 Fusible link.....83
11.16 Controllers.....83
11.17 Tool holder (cloth bag).....83
11.18 Handling grease pump.....83
11.19 Handling accumulator.....86
12. Operation.....88
12.1 Check before starting engine.....88
12.2 Starting engine.....98
12.3 Operations and checks after starting engine.....101
12.4 Moving machine off.....107
12.5 Steering machine.....110
12.6 Stopping machine.....112
12.7 Swinging.....113
12.8 Operation of work equipment.....114
12.9 Handling working mode.....115
12.10 Prohibitions for operation.....116
12.11 Precautions for operation.....118
12.12 Precautions when traveling up or down hills.....119
12.13 How to escape from mud.....121
12.14 Work possible using hydraulic excavator.....122
12.15 Replacement of bucket.....123
12.16 Parking machine.....124
12.17 Check after finishing work.....125
12.18 Stopping engine.....126
12.19 Check after stopping engine.....127
12.20 Locking.....127
13. Transportation.....128
13.1 Loading, unloading work.....128
13.2 Precautions for loading.....130
13.3 Precautions for transportation.....130
13.4 Transportation posture.....131
13.5 Procedure for increasing or reducing track frame gauge.....136
14. Cold weather operation.....138
14.1 Precautions for low temperature.....138
14.2 Precautions after completion of work.....140
14.3 After cold weather.....140
15. Long-term storage.....141
15.1 Before storage.....141
15.2 During storage.....142
15.3 After storage.....142
15.4 Starting machine after long-term storage.....142
16. Troubleshooting.....143
16.1 Phenomena that are not failures.....143
16.2 Method of towing machine.....143
16.3 Precautions on particular jobsites.....143
16.4 If battery is discharged.....144
16.5 Other trouble.....148
MAINTENANCE.....153
17. Guides to maintenance.....154
18. Outlines of service.....157
18.1 Outline of oil, fuel, coolant.....157
18.2 Outline of electric system.....160
18.3 Outline of hydraulic system.....161
18.4 Releasing pressure.....162
18.5 Bleeding air from circuit.....163
19. Wear parts list.....166
20. Use of fuel, coolant and lubricants according to ambient temperature.....167
21. Standard tightening torques for bolts and nuts.....171
21.1 Introduction of necessary tools.....171
21.2 Torque list.....172
22. Periodic replacement of safety critical parts.....173
23. Maintenance schedule chart.....178
23.1 Maintenance schedule chart.....178
24. Service Procedure.....182
24.1 Initial 100 hours service.....182
24.2 Initial 250 hours service.....182
24.3 When required.....183
24.4 Check before starting.....199
24.5 Every 10 hours service.....204
24.6 Every 100 hours service.....206
24.7 Every 250 hours service.....207
24.8 Every 500 hours service.....216
24.9 Every 1000 hours service.....225
24.10 Every 2000 hours service.....230
24.11 Every 4000 hours service.....234
SPECIFICATIONS.....235
25. Specifications.....236
OPTIONS, ATTACHMENTS.....247
26. General precautions.....248
26.1 Precautions related to safety.....248
26.2 Precautions when installing attachments.....249
27. Using seat belt.....250
27.1 Seat belt.....250
28. Introduction of optional parts, attachments.....252
28.1 Combinations of work equipment.....252
28.2 Selection of track shoes.....254
SEAWD00800 - Hydraulic Excavator PC750-6, PC800-6 Field Assembly Instruction.....256
COVER.....256
CONTENTS .....257
Points Regarding Local Assembly.....259
Assembling Procedures, Applicable Equipment and Schedule.....260
Packing Style for Transportation .....262
List of Tools for Field Assembling .....267
Field Assembling .....268
Related Laws and Regulations .....269
Fitting of Left and Right Track Frames.....273
Arrangement of Travel Pipe.....275
Installation of FOPS.....278
Setting of Radiator Cover .....281
Fitting of Rearview Mirror.....282
Installation of Handrail .....284
Prevention of Natural Closing of Ceiling Window .....285
Installation of Step .....286
Installation of Left Side Step .....287
Setting of Muffler Tail Tube .....288
Sticking of Sheet (to Counterweight) .....289
Installation of Counterweight.....290
Installation of Radio Antenna.....291
Installation of Cab Top Light .....293
Fitting of Stopper (on Hydraulic Tank) .....297
Extension of Track Frame Gauge (Only when 3-split packages are transported) (l/3) .....298
Setting of Travel Pipe Cover.....301
Adjustment of Track Tension.....303
Inspection of Oil Amount and Water Amount .....305
Boom Foot Pin and Boom Cylinder Foot Pin .....306
Boom Assembly .....307
Relieving Remaining Pressure from Hydraulic Circuit .....308
Installation of Boom Cylinder Foot .....309
Arrangement of Boom Cylinder Hose .....310
Boom Cylinder .....311
Arm Cylinder .....312
Arrangement of Arm Cylinder Hose .....313
Installation of Arm Assembly.....314
Arrangement of Bucket Cylinder Hose between Boom and Bucket Cylinder .....316
Bucket Cylinder Hose between Boom and Bucket Cylinder .....317
Lubrication Piping to Work Equipment .....318
Air Bleeding from Cylinder .....319
Wiring of Work Equipment .....320
Inspection of Oil Level in Hvdraulic Tank and Refill .....321
Replacement of Return Filter (Standard Filter to Flushing Filter) (l/Z) .....323
Flushing of Hydraulic Circuit.....326
APPENDIX.....328
FIELD ASSEMBLY INSPECTION REPORT.....328
SEBM008707 - Hydraulic Excavator PC750-6, PC800-6 Shop Manual.....354
COVER.....354
CONTENTS.....355
01 GENERAL.....381
Specification drawings.....382
Specifications.....388
Weight table.....404
Fuel, coolant and lubricants.....414
10 STRUCTURE AND FUNCTION.....417
PTO.....418
PTO lubrication system.....419
Radiator, oil cooler, aftercooler.....420
Power train.....422
Swing machinery.....424
Swing circle.....425
Final drive.....426
Track frame.....427
Track shoe.....428
Air piping diagram.....429
Air circuit diagram.....430
Air governor.....431
Air tank.....431
Safety valve.....432
Horn valve.....432
Grease pump.....433
Hydraulic piping drawing.....434
Hydraulic circuit drawing.....437
Hydraulic tank.....439
Hydraulic pump.....440
Line oil filter.....482
Pilot oil filter.....482
Return oil filter.....483
Drain oil filter.....483
L.H. 5-spool control valve.....484
R.H. 4-spool control valve.....486
Swing motor.....492
Center swivel joint.....496
Travel motor.....497
PPC control relief valve.....508
Safety lock valve.....509
Accumulator.....510
Valve control.....511
Work equipment, swing PPC valve.....512
Travel PPC valve.....516
Solenoid valve assembly.....520
Work equipment.....521
Air conditioner.....524
Actual electric wiring diagram.....526
Electric circuit diagram.....530
Engine control.....534
Electronic control system.....542
Machine monitor system.....565
20 TESTING AND ADJUSTING.....575
Standard value table for engine related parts.....576
Standard value table for chassis related parts.....577
Standard value table for electrical parts.....596
Tools for testing, adjusting, and troubleshooting.....606
Measuring engine speed.....607
Measuring air supply pressure (boost pressure).....608
Measuring exhaust temperature.....609
Measuring exhaust color.....610
Adjusting valve clearance.....611
Measuring compression pressure.....612
Measuring blow-by pressure.....613
Testing and adjusting fuel injection timing.....614
Measuring engine oil pressure.....615
Testing and adjusting alternator belt tension.....616
Testing and adjusting fan belt tension.....616
Testing and adjusting belt tension for air conditioner compressor.....617
Testing and adjusting governor motor lever stroke.....618
Adjusting engine speed sensor.....619
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit.....620
Testing and adjusting control pump circuit oil pressure.....623
Testing and adjusting piston pump control pressure.....626
Measuring servo piston stroke .....639
Measuring PPC valve output pressure and testing PPC shuttle valve.....640
Testing solenoid valve output pressure.....641
Adjusting work equipment swing PPC valve.....642
Testing travel deviation.....643
Testing locations causing hydraulic drift of work equipment.....648
Measuring oil leakage.....649
Testing clearance of swing circle bearing.....654
Testing and adjusting track shoe tension.....656
Bleeding air.....657
TROUBLESHOOTING.....663
Points to remember when troubleshooting.....664
Sequence of events in troubleshooting.....665
Points to remember when carrying out maintenance.....666
Checks before troubleshooting.....674
Connector types and mounting locations.....676
Connection table for connector pin numbers.....680
Explanation of control mechanism of electrical system.....691
Display method and special functions of monitor panel.....693
Method of using judgement table.....709
Method of using troubleshooting charts.....711
Details of troubleshooting and troubleshooting procedure.....713
Service code table.....718
Troubleshooting of communication abnormality system (N mode).....719
N-1 [E218] Communication abnormality.....720
Troubleshooting of governor, pump controller [governor control system] (E mode).....723
Points to remember when carrying out troubleshooting of governor, pump controller system.....724
Action taken by controller and condition of machine when abnormality occurs.....726
Judgement table for governor, pump controller (governor control system) and engine related parts.....730
Electrical circuit diagram of governor, pump controller (governor control system).....732
E- 1 Abnormality in governor, pump controller power source (controller LED is OFF).....734
E- 2 [E308] Abnormality in fuel control dial input value is displayed.....735
E- 3 [E317] Abnormality (disconnection) in governor motor drive system is displayed.....736
E- 4 [E318] Abnormality (short circuit) in governor motor drive system is displayed.....737
E- 5 [E306] Abnormality in feedback potentiometer system is displayed.....738
E- 6 [E315] Abnormality (short circuit) in battery relay output system is displayed.....739
E- 7 [E316] Abnormality (step-out) in motor is displayed.....740
E- 8 Engine does not start.....742
E- 9 Engine speed is irregular.....744
a) Idling speed is irregular.....744
b) There is hunting.....746
E-10 Lack of output (engine high idling speed is too low).....748
E-11 Engine does not stop.....750
E-12 Defective operation of battery relay system (engine does not stop).....752
Troubleshooting of engine (S mode).....755
Method of using troubleshooting charts.....756
S- 1 Starting performance is poor (starting always takes time).....760
S- 2 Engine does not start.....761
1 Engine does not turn.....761
2 Engine turns but exhaust gas does not comes out (fuel is not being injected).....762
3 Exhaust gas comes out but engine does not start (fuel is being injected).....763
S- 3 Engine does not pick up smoothly (follow-up is poor).....764
S- 4 Engine stops during operation.....765
S- 5 Engine does not rotate smoothly (hunting).....766
S- 6 Engine lacks output (no power).....767
S- 7 Exhaust gas is black (incomplete combustion).....768
S- 8 Oil consumption is excessive (or exhaust gas is blue).....769
S- 9 Oil becomes contaminated quickly.....770
S-10 Fuel consumption is excessive.....771
S-11 Oil is in cooling water, or spurts back, or water level goes down.....772
S-12 Oil pressure caution lamp lights up (drop in oil pressure).....773
S-13 Oil level rises (water mixed with fuel).....774
S-14 Water temperature becomes too high (overheating).....775
S-15 Abnormal noise is made.....776
S-16 Vibration is excessive.....777
Troubleshooting of governor, pump controller system [pump control system] (C mode).....779
Judgement table for governor, pump controller and hydraulic related parts.....780
Points to remember when troubleshooting pump controller system.....782
Action taken by controller when abnormality occurs and problems on machine .....784
Electrical circuit diagram for C mode.....790
C- 1 Abnormality in controller power source system (controller LED is OFF).....792
C- 2 [E232] Short circuit in front pump TVC solenoid system is displayed.....793
C- 3 [E233] Disconnection in front pump TVC solenoid system is displayed.....795
C- 4 [E203] Short circuit in rear pump TVC solenoid system is displayed.....797
C- 5 [E213] Disconnection in swing holding brake solenoid system is displayed.....799
C- 6 [E201] Short circuit in CO cancel solenoid system is displayed.....801
C- 7 [E211] Disconnection in CO cancel solenoid system is displayed.....802
C- 8 [E202] Short circuit in straight travel solenoid system is displayed.....803
C- 9 [E212] Disconnection in straight travel solenoid system is displayed.....804
C-10 [E204] Short circuit in 2-stage relief solenoid system is displayed.....805
C-11 [E214] Disconnection in 2-stage relief solenoid system is displayed.....806
C-12 [E205] Short circuit in swing priority solenoid system is displayed.....807
C-13 [E215] Disconnection in swing priority solenoid system is displayed.....808
C-14 [E206] Short circuit in travel speed solenoid system is displayed.....809
C-15 [E216] Disconnection in travel speed solenoid system is displayed.....810
C-16 [E226] Abnormality in swing speed sensor power source system is displayed.....811
C-17 [E207] Short circuit in swing overrun prevention solenoid system is displayed.....812
C-18 [E208] Disconnection in swing overrun prevention solenoid system is displayed.....813
C-19 [E217] Model selection input error is displayed.....814
C-20 [E227] Abnormality in engine speed sensor system is displayed.....816
C-21 Abnormality in machine push-up solenoid system (no service code displayed).....817
C-22 Abnormality in shockless boom solenoid system (no service code displayed).....820
Troubleshooting of engine throttle, pump controller [input signal system] (F mode).....823
Electrical circuit diagram for F mode.....824
F- 1 Bit pattern 20-(1) Swing oil pressure switch does not light up.....826
F- 2 Bit pattern 20-(2) R.H. travel oil pressure switch does not light up.....827
F- 3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up.....828
F- 4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up.....829
F- 5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up.....830
F- 6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up.....831
F- 7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up.....832
F- 8 Bit pattern 21-(2) Bucket DUMP, service oil pressure switch does not light up.....833
F- 9 Bit pattern 21-(5) L.H. travel oil pressure switch does not light up.....834
F-10 Bit pattern 21-(3) Swing lock switch does not light up.....835
F-11 Bit pattern 25-(4) Swing speed sensor does not light up.....836
Troubleshooting of hydraulic, mechanical system (H mode).....837
Table of failure modes and causes.....838
Before carrying out troubleshooting of hydraulic system (H mode).....840
All work equipment, travel, swing.....844
H-1 Speeds of all work equipment, swing, travel are slow or lack power.....844
H-2 There is excessive drop in engine speed, or engine stalls.....845
H-3 No work equipment, travel, swing move.....847
H-4 Abnormal noise generated (around pump).....848
H-5 Auto-deceleration does not work.....848
Work equipment.....849
H-6 Work equipment speed is slow (boom, arm, bucket).....849
H-7 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal).....850
H-8 Excessive hydraulic drift.....850
H-9 Excessive time lag.....851
H-10 Excessive shock when boom is stopped.....851
H-11 Defective actuation of machine push-up function.....851
H-12 In compound operations, work equipment is slow.....852
Travel system.....853
H-13 Travel deviation is excessive during compound operations.....853
H-14 Machine deviates naturally to one side during travel operations.....855
H-15 Deviation is excessive when srtarting.....859
H-16 Travel speed is slow.....861
H-17 Travel speed does not switch.....862
H-18 Travel does not move (one side only).....862
Swing system.....863
H-19 Does not swing.....863
H-20 Swing speed is slow or swing acceleration is poor.....864
H-21 Swing speed is slow during compound operations.....865
H-22 Excessive overrun when stopping swing.....865
H-23 Excessive shock when stopping swing.....866
H-24 Excessive abnormal noise when stopping swing.....866
H-25 Excessive hydraulic drift of swing.....867
H-26 Swing speed is faster than specified swing speed.....868
Troubleshooting of monitor panel system (M mode).....870
Action taken by monitor panel when abnormality occurs and problems on machine.....873
Electrical circuit diagram for M mode system.....875
M-1 [E101] Abnormality in error data is displayed [E102] Error in clock data is displayed.....877
M-2 [E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed.....878
M-3 [E104] Air cleaner clogging detected is displayed.....879
M-4 [E106] Drop in engine oil pressure Hi detected is displayed.....879
M-5 [E108] Engine water temperature 105 detected is displayed.....880
M-6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds.....881
M-7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out.....883
M-8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine (model).....883
M-9 When starting switch is turned ON (engine stopped), basic check items flash.....884
M-10 Preheating is not being used but preheating monitor lights up.....887
M-11 When starting switch is turned ON and engine is started, basic check items flash.....888
M-12 When starting switch is turned ON (engine stopped), caution items, emergency stop items flash.....890
M-13 When starting switch is turned ON and engine is started, caution items, emergency stop items flash.....892
M-14 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second Caution item flashes but buzzer does not sound.....896
M-15 No abnormality is displayed on monitor but buzzer sounds.....896
M-16 Night lighting on monitor panel does not light up (liquid crystal display is normal).....897
M-17 Coolant temperature gauge does not rise.....898
M-18 Coolant temperature gauge does not give any display.....898
M-19 Fuel level gauge always displays FULL.....899
M-20 Fuel level gauge does not give any display.....899
M-21 Swing lock switch is turned ON (LOCK) but swing lock monitor does not light up.....900
M-22 Swing prolix switch is turned ON (prolix), but swing lock monitor does not flash.....900
M-23 Service meter does not advance while engine is running.....901
M-24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed.....901
M-25 Defective fuel level sensor system.....902
M-26 Defective coolant temperature sensor system.....903
M-27 Defective engine oil level sensor system.....904
M-28 Defective coolant level sensor system.....905
M-29 Defective hydraulic oil level sensor system.....906
M-30 Wiper does not work or switch is not being used but wiper is actuated.....907
30 DISASSEMBLY AND ASSEMBLY.....912
METHOD OF USING MANUAL.....914
PRECAUTIONS WHEN CARRYING OUT OPERATION.....917
SPECIAL TOOL LIST .....919
SKETCHES OF SPECIAL TOOLS .....928
STARTING MOTOR ASSEMBLY Removal, Installation.....932
ALTERNATOR ASSEMBLY Removal, Installation.....933
NOZZLE HOLDER ASSEMBLY Removal, Installation.....934
ENGINE OIL COOLER ASSEMBLY Removal, Installation.....936
FUEL INJECTION PUMP ASSEMBLY Removal, Installation.....937
WATER PUMP ASSEMBLY Removal, Installation.....938
TURBOCHARGER ASSEMBLY Removal, Installation.....939
THERMOSTAT ASSEMBLY Removal, Installation.....940
AIR COMPRESSOR ASSEMBLY Removal, Installation.....941
ENGINE FRONT SEAL Removal, Installation.....942
ENGINE REAR SEAL Removal, Installation.....943
GOVERNOR MOTOR ASSEMBLY Removal, Installation.....948
CYLINDER HEAD ASSEMBLY Removal, Installation.....949
AFTERCOOLER CORE Removal, Installation.....956
FAN GUARD, RADIATOR, HYDRAULIC COOLER ASSEMBLY Removal, Installation.....957
HYDRAULIC COOLER, AFTERCOOLER ASSEMBLY Removal, Installation.....960
ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY Removal, Installation .....962
PTO ASSEMBLY Removal, Installation.....970
PTO ASSEMBLY Disassembly, Assembly.....974
FINAL DRIVE ASSEMBLY Removal, Installation.....982
FINAL DRIVE ASSEMBLY Disassembly, Assembly.....983
REVOLVING FRAME ASSEMBLY Removal, Installation.....996
SWING MACHINERY ASSEMBLY Removal, Installation.....998
SWING MACHINERY ASSEMBLY Disassembly, Assembly.....999
SWING CIRCLE ASSEMBLY Removal, Installation.....1009
TRACK SHOE ASSEMBLY Removal, Installation.....1010
ONE LINK IN FIELD Disassembly, Assembly.....1012
SPROCKET Removal, Installation.....1016
IDLER ASSEMBLY Removal, Installation.....1017
IDLER ASSEMBLY Disassembly, Assembly.....1018
IDLER ADJUSTMENT CYLINDER ASSEMBLY Disassembly, Assembly.....1022
RECOIL SPRING ASSEMBLY Removal, Installation.....1023
RECOIL SPRING ASSEMBLY Disassembly, Assembly.....1024
CARRIER ROLLER ASSEMBLY Removal, Installation.....1027
CARRIER ROLLER ASSEMBLY Disassembly, Assembly.....1028
TRACK ROLLER ASSEMBLY Removal, Installation.....1031
TRACK ROLLER ASSEMBLY Disassembly, Assembly.....1032
TVC VALVE ASSEMBLY Removal, Installation.....1035
CO, NC VALVE ASSEMBLY Removal, Installation.....1036
SERVO VALVE ASSEMBLY Removal, Installation.....1038
NO. 1 PUMP ASSEMBLY Removal, Installation.....1039
DISASSEMBLY AND ASSEMBLY.....1043
NO. 2 PUMP ASSEMBLY Removal, Installation.....1071
DISASSEMBLY AND ASSEMBLY.....1075
MAIN PUMP INPUT SHAFT OIL SEAL Removal, Installation.....1101
CONTROL, PTO LUBRICATION PUMP ASSEMBLY Removal, Installation.....1102
MAIN RELIEF VALVE ASSEMBLY Removal, Installation.....1104
MAIN RELIEF VALVE ASSEMBLY Disassembly, Assembly.....1105
CONTROL PUMP RELIEF VALVE ASSEMBLY Removal, Installation.....1106
LEFT 5-SPOOL CONTROL VALVE ASSEMBLY Removal, Installation.....1107
RIGHT 4-SPOOL CONTROL VALVE ASSEMBLY Removal, Installation.....1108
CONTROL VALVE ASSEMBLY Disassembly, Assembly.....1112
SWING MOTOR ASSEMBLY Removal, Installation.....1116
DISASSEMBLY AND ASSEMBLY.....1117
CENTER SWIVEL JOINT ASSEMBLY Removal, Installation.....1127
CENTER SWIVEL JOINT ASSEMBLY Disassembly, Assembly.....1128
TRAVEL MOTOR ASSEMBLY Removal, Installation.....1129
DISASSEMBLY AND ASSEMBLY.....1130
WORK EQUIPMENT PPC VALVE ASSEMBLY Removal, Installation.....1161
WORK EQUIPMENT PPC VALVE ASSEMBLY Disassembly, Assembly.....1162
TRAVEL PPC VALVE ASSEMBLY Removal, Installation.....1164
TRAVEL PPC VALVE ASSEMBLY Disassembly, Assembly.....1165
BUCKET CYLINDER ASSEMBLY Removal, Installation.....1168
ARM CYLINDER ASSEMBLY Removal, Installation.....1172
BOOM CYLINDER ASSEMBLY Removal, Installation.....1176
BOTTOM DUMP CYLINDER ASSEMBLY Removal, Installation.....1180
HYDRAULIC CYLINDER ASSEMBLY Disassembly, Assembly.....1183
BUCKET ASSEMBLY Removal, Installation.....1188
ARM ASSEMBLY Removal, Installation.....1192
BOOM ASSEMBLY Removal, Installation.....1196
BUCKET, ARM ASSEMBLY Removal, Installation.....1200
WORK EQUIPMENT ASSEMBLY Removal, Installation.....1202
OPERATOR'S CAB ASSEMBLY Removal, Installation.....1206
COUNTERWEIGHT ASSEMBLY Removal, Installation.....1208
AIR CONDITIONER COMPRESSOR ASSEMBLY Removal, Installation.....1209
AIR CONDITIONER UNIT ASSEMBLY Removal, Installation.....1210
GOVERNOR, PUMP CONTROLLER ASSEMBLY Removal, Installation.....1212
MONITOR PANEL ASSEMBLY Removal, Installation.....1213
CONTROL STAND CASE Removal, Installation.....1214
40 MAINTENANCE STANDARD.....1217
Engine mount .....1219
PTO .....1220
Swing circle.....1222
Swing machinery .....1223
Final drive .....1225
Track frame .....1228
Idler .....1229
Carrier roller .....1231
Track roller .....1232
Track shoe.....1233
Hydraulic pump .....1238
Charging and PTO lubrication pump .....1240
L.H. 5-spool control valve .....1243
R.H. 4-spool control valve .....1245
Swing motor.....1248
Travel motor.....1249
Center swivel joint.....1251
PPC control relief valve.....1252
PPC valve .....1253
Hydraulic cylinder .....1255
Work equipment .....1261
Dimensions of work equipment .....1267
90 OTHERS.....1272
Hydraulic piping drawing (Back hoe).....1273
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10001-10238 - PC800,PC800SE-6 SERIAL NO.: 30001-30174.....1273
Hydraulic piping drawing (Back hoe).....1275
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10239 AND UP - PC800,PC800SE-6 SERIAL NO.: 30175 AND UP.....1275
Hydraulic piping drawing (Loading shovel).....1276
Hydraulic circuit drawing (Back hoe).....1277
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10001-10238 - PC800,PC800SE-6 SERIAL NO.: 30001-30174.....1277
Hydraulic circuit drawing (Loading shovel).....1278
PC750-6 - SERIAL NO.: 10001-10238.....1278
Hydraulic piping drawing (Back hoe).....1279
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10239 AND UP - PC800,PC800SE-6 SERIAL NO.: 30175 AND UP.....1279
Hydraulic circuit drawing (Loading shovel).....1284
PC750-6 - SERIAL NO.: 10239 AND UP.....1284
Actual electric wiring diagram (1/2) (Back hoe).....1289
Actual electric wiring diagram (2/2) (Back hoe).....1290
Actual electric wiring diagram (1/2) (Loading shovel).....1291
Actual electric wiring diagram (2/2) (Loading shovel).....1292
Electric circuit diagram (1/3) (Back hoe).....1293
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10001-10238 - PC800,PC800SE-6 SERIAL NO.: 30001-30174.....1293
Electric circuit diagram (2/3) (Back hoe).....1295
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10001-10238 - PC800,PC800SE-6 SERIAL NO.: 30001-30174.....1295
Electric circuit diagram (3/3) (Back hoe).....1297
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10001-10238 - PC800,PC800SE-6 SERIAL NO.: 30001-30174.....1297
Electric circuit diagram (1/3) (Loading shovel) .....1299
PC750-6 - SERIAL NO.: 10238 AND UP.....1299
Electric circuit diagram (2/3) (Loading shovel).....1300
PC750-6 - SERIAL NO.: 10238 AND UP.....1300
Electric circuit diagram (3/3) (Loading shovel).....1301
PC750-6 - SERIAL NO.: 10238 AND UP.....1301
Electric circuit diagram (1/3) (Back hoe).....1302
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10239 AND UP - PC800,PC800SE-6 SERIAL NO.: 30175 AND UP.....1302
Electric circuit diagram (2/3) (Back hoe).....1307
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10239 AND UP - PC800,PC800SE-6 SERIAL NO.: 30175 AND UP.....1307
Electric circuit diagram (3/3) (Back hoe).....1312
PC750,PC750SE,PC750LC-6 SERIAL NO.: 10239 AND UP - PC800,PC800SE-6 SERIAL NO.: 30175 AND UP.....1312
Electric circuit diagram (1/3) (Loading shovel).....1317
PC750-6 - SERIAL NO.: 10239 AND UP.....1317
Electric circuit diagram (2/3) (Loading shovel).....1322
PC750-6 - SERIAL NO.: 10239 AND UP.....1322
Electric circuit diagram (3/3) (Loading shovel).....1327
PC750-6 - SERIAL NO.: 10239 AND UP.....1327
Machine control system diagram .....1332
Connector arrangement diagram (1/2).....1333
Connector arrangement diagram (2/2).....1334
SEBM025305 - Hydraulic Excavator PC750-6, PC800-6 Shop Manual.....1335
COVER.....1335
CONTENTS.....1336
01 GENERAL.....1362
SPECIFICATION DRAWINGS.....1363
SPECIFICATIONS.....1367
WEIGHT TABLE.....1375
FUEL, COOLANT AND LUBRICANTS.....1379
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.....1380
PTO.....1381
PTO LUBRICATION SYSTEM.....1382
POWER TRAIN.....1383
SWING MACHINERY.....1385
SWING CIRCLE.....1387
FINAL DRIVE.....1388
TRACK FRAME AND RECOIL SPRING.....1390
IDLER.....1392
CARRIER ROLLER.....1394
TRACK ROLLER.....1395
TRACK SHOE.....1396
MOTOR GREASE PUMP.....1401
HYDRAULIC TANK.....1402
HYDRAULIC PUMP.....1403
LINE OIL FILTER.....1432
PILOT OIL FILTER.....1432
DRAIN OIL FILTER.....1433
L.H. 5-SPOOL CONTROL VALVE.....1434
R.H. 4-SPOOL CONTROL VALVE.....1439
STRAIGHT-TRAVEL VALVE.....1444
SWING MOTOR.....1447
CENTER SWIVEL JOINT.....1452
TRAVEL MOTOR.....1453
PPC CONTROL RELIEF VALVE.....1463
SAFETY LOCK VALVE.....1464
PPC ACCUMULATOR.....1465
VALVE CONTROL.....1466
WORK EQUIPMENT, SWING PPC VALVE.....1467
TRAVEL PPC VALVE.....1472
SOLENOID VALVE.....1476
HYDRAULIC CYLINDER.....1481
WORK EQUIPMENT.....1489
DIMENSIONS OF WORK EQUIPMENT.....1497
AIR CONDITIONER.....1501
ENGINE CONTROL.....1502
MACHINE CONTROL SYSTEM.....1507
MONITOR SYSTEM.....1535
SENSORS.....1542
20 TESTING AND ADJUSTING.....1545
STANDARD VALUE TABLE FOR ENGINE.....1546
STANDARD VALUE TABLE FOR CHASSIS.....1547
STANDARD VALUE TABLE FOR ELECTRICAL PARTS.....1556
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....1569
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).....1571
MEASURING EXHAUST TEMPERATURE.....1572
MEASURING EXHAUST COLOR.....1573
ADJUSTING VALVE CLEARANCE.....1574
MEASURING BLOW-BY PRESSURE.....1575
MEASURING COMPRESSION PRESSURE.....1575
MEASURING ENGINE OIL PRESSURE.....1576
HANDLING EQUIPMENT IN FUEL CIRCUIT.....1577
RELEASING REMAINING PRESSURE IN FUEL SYSTEM.....1577
MEASURING FUEL PRESSURE.....1578
REDUCED CYLINDER MODE OPERATION FOR ENGINE.....1579
BLEEDING AIR FROM FUEL CIRCUIT.....1581
CHECKING FOR LEAKAGE IN FUEL CIRCUIT.....1583
TESTING AND ADJUSTING ALTERNATOR BELT TENSION.....1584
TESTING AND ADJUSTING FAN BELT TENSION.....1585
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION.....1586
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT.....1587
ADJUSTING ENGINE SPEED SENSOR.....1588
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT.....1589
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE.....1592
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE.....1594
MEASURING SERVO PISTON STROKE.....1600
MEASURING PPC VALVE OUTPUT PRESSURE.....1601
TESTING SOLENOID VALVE OUTPUT PRESSURE.....1602
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.....1603
TESTING TRAVEL DEVIATION.....1604
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....1607
MEASURING OIL LEAKAGE.....1608
TESTING CLEARANCE OF SWING CIRCLE BEARING.....1613
TESTING AND ADJUSTING TRACK SHOE TENSION.....1614
BLEEDING AIR.....1615
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.....1617
PROCEDURE FOR CHECKING DIODE.....1618
TROUBLESHOOTING.....1619
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....1620
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....1621
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....1622
CHECKS BEFORE TROUBLESHOOTING.....1630
CONNECTOR TYPES AND MOUNTING LOCATIONS.....1631
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....1638
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM.....1661
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.....1662
METHOD OF USING JUDGEMENT TABLE.....1677
METHOD OF USING TROUBLESHOOTING CHARTS.....1679
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE.....1680
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE).....1684
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....1685
ELECTRICAL CIRCUIT DIAGRAM FOR N MODE SYSTEM.....1687
N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY.....1688
N-2 [E117, E218 OCCUR AT SAME TIME] ENGINE CONTROLLER COMMUNICATION ABNORMALITY.....1690
N-3 [E118, E955 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY.....1692
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE).....1694
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED.....1695
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS.....1703
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM.....1705
E-1 [E91b] (ABNORMALITY IN ENGINE SPEED NE SENSOR SYSTEM) IS DISPLAYED.....1707
E-2 [E91C] (ABNORMALITY IN ENGINE G ROTATION SENSOR SYSTEM) IS DISPLAYED.....1708
E-3 [E920] (ABNORMALITY IN MODEL SELECTION SYSTEM) IS DISPLAYED.....1709
E-4 [E922] (ENGINE OVERRUN) IS DISPLAYED.....1710
E-5 [E924] (DROP IN ENGINE OIL PRESSURE) IS DISPLAYED.....1711
E-6 [E931] (ABNORMALITY IN FUEL CONTROL DIAL SENSOR SYSTEM) IS DISPLAYED.....1712
E-7 [E934] (ABNORMALITY IN ENGINE WATER HIGH-TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.....1713
E-8 [E936] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED.....1714
E-9 [E93C] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED.....1716
E-10 [E93d] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.....1717
E-11 [E954] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED.....1718
E-12 [E955] (ABNORMALITY IN NETWORK SYSTEM) IS DISPLAYED.....1718
E-13 [E956] (POWER SOURCE SYSTEM ABNORMALITY 1) IS DISPLAYED.....1719
E-14 [E957] (POWER SOURCE SYSTEM ABNORMALITY 2) IS DISPLAYED.....1721
E-15 [E95A] (ABNORMALITY IN FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL) IS DISPLAYED.....1721
E-16 [E96A] (ABNORMALITY IN ENGINE WATER LOW-TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.....1722
E-17 [E970] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED.....1723
E-18 [E971] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED.....1724
E-19 [E974] (DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED.....1725
E-20 [E975] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED.....1726
E-21 [E977] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED.....1727
E-22 [E979] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1) IS DISPLAYED, [E97A] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2) IS DISPLAYED.....1728
E-23 [E97b] (FUEL SUPPLY PUMP NON-FORCE FEED 1) IS DISPLAYED, [E97C] (FUEL SUPPLY PUMP NON-FORCE FEED 2) IS DISPLAYED.....1729
E-24 [E97d] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE) IS DISPLAYED.....1731
E-25 [E980] (DEFECTIVE ENGINE CONTROLLER) IS DISPLAYED.....1731
E-26 [E981] (DISCONNECTION IN NO. 1 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1732
E-27 [E982] (DISCONNECTION IN NO. 2 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1733
E-28 [E983] (DISCONNECTION IN NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1734
E-29 [E984] (DISCONNECTION IN NO. 4 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1735
E-30 [E985] (DISCONNECTION IN NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1736
E-31 [E986] (DISCONNECTION IN NO. 6 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1737
E-32 [E98A] (SHORT CIRCUIT IN NO. 1, NO. 2, NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1738
E-33 [E98b] (SHORT CIRCUIT IN NO. 3, NO. 4, NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED.....1742
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE).....1746
POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM.....1747
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....1748
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS.....1756
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM.....1758
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF).....1760
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....1761
C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....1763
C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED.....1765
C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED.....1767
C-6 [E201] SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED.....1769
C-7 [E211] DISCONNECTION IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED.....1770
C-8 [E202] SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED.....1771
C-9 [E212] DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED.....1772
C-10 [E204] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.....1773
C-11 [E214] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.....1774
C-12 [E205] SHORT CIRCUIT IN SWING PRIORITY SELECTOR SOLENOID SYSTEM IS DISPLAYED.....1775
C-13 [E211] DISCONNECTION IN SWING PRIORITY SELECTOR SOLENOID SYSTEM IS DISPLAYED.....1776
C-14 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED.....1777
C-15 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED.....1778
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED.....1779
C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED.....1781
C-18 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED).....1782
C-19 ABNORMALITY IN SHOCKLESS BOOM SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED).....1784
C-20 [E207] SHORT CIRCUIT IN FLASH LIGHT RELAY DRIVE SYSTEM IS DISPLAYED.....1787
C-21 FLASH LIGHT RELAY DOES NOT WORK.....1788
C-22 [E231] ABNORMALITY (SHORT CIRCUIT) IN POWER SOURCE HOLDING RELAY OUTPUT SYSTEM FOR STEP LIGHT IS DISPLAYED.....1789
C-23 STEP LIGHT SWITCH DOES NOT WORK.....1790
C-24 [E302] SHORT CIRCUIT IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED.....1791
C-25 [303] DISCONNECTION IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED.....1792
C-26 STEP LIGHT DOES NOT LIGHT UP.....1793
C-27 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED.....1794
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).....1795
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM.....1796
F-1 [BIT PATTERN 20-(1)] SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1798
F-2 [BIT PATTERN 20-(2)] R.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1799
F-3 [BIT PATTERN 20-(3)] BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1800
F-4 [BIT PATTERN 20-(4)] BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1801
F-5 [BIT PATTERN 20-(5)] ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1802
F-6 [BIT PATTERN 20-(6)] ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1803
F-7 [BIT PATTERN 21-(1)] BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1804
F-8 [BIT PATTERN 21-(2)] BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1805
F-9 [BIT PATTERN 20-(5)] L.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1806
F-10 [BIT PATTERN 21-(4)] SERVICE OIL PRESSURE SWITCH DOES NOT LIGHT UP.....1807
F-11 [BIT PATTERN 21-(3)] SWING LOCK SWITCH DOES NOT LIGHT UP.....1808
F-12 [BIT PATTERN 24-(1)] WHEN STEP LIGHT SWITCH IS ON, IT DOES NOT GO OUT.....1809
F-13 [BIT PATTERN 24-(2)] WHEN HORN SWITCH IS ON, IT DOES NOT GO OUT.....1810
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).....1811
TABLE OF FAILURE MODES AND CAUSES.....1812
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE).....1814
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER.....1817
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.....1818
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE.....1820
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).....1821
H-5 AUTO-DECELERATION DOES NOT WORK.....1821
H-6 WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET).....1822
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).....1824
H-8 EXCESSIVE HYDRAULIC DRIFT.....1824
H-9 EXCESSIVE TIME LAG.....1825
H-10 EXCESSIVE SHOCK WHEN BOOM IS STOPPED.....1825
H-11 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION.....1825
H-12 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS.....1826
H-13 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS.....1827
H-14 DEVIATION IS EXCESSIVE WHEN STARTING.....1829
H-15 TRAVEL SPEED IS SLOW.....1830
H-16 TRAVEL SPEED DOES NOT SWITCH.....1831
H-17 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).....1831
H-18 DOES NOT SWING.....1832
H-19 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR.....1834
H-20 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR DURING COMPOUND OPERATIONS WITH ARM, BUCKET.....1835
H-21 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR DURING COMPOUND OPERATIONS WITH BOOM RAISE WHEN SWING PRIORITY IS ON.....1836
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING.....1837
H-23 EXCESSIVE SHOCK WHEN STOPPING SWING.....1838
H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING.....1839
H-25 EXCESSIVE HYDRAULIC DRIFT OF SWING.....1840
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).....1841
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....1842
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM.....1844
M-1 [E101] (ABNORMALITY IN ERROR DATA) OR [E102] (ABNORMALITY IN CLOCK DATA) IS DISPLAYED.....1846
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM) IS DISPLAYED.....1847
M-3 [E104] (AIR CLEANER CLOGGING DETECTION) IS DISPLAYED.....1848
M-4 [E108] (ENGINE WATER TEMPERATURE 105) IS DISPLAYED.....1848
M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS.....1849
M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT.....1851
M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE.....1851
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH.....1852
M-9 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY MOTOR LAMP LIGHTS UP.....1855
M-10 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH.....1856
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH.....1857
M-12 WHEN ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH.....1858
M-13 OPERATION OF ALARM BUZZER IS NOT NORMAL.....1862
M-14 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP.....1864
M-15 ENGINE WATER TEMPERATURE DISPLAY IS NOT NORMAL.....1865
M-16 FUEL LEVEL GAUGE DISPLAY IS NOT NORMAL.....1866
M-17 SWING LOCK SWITCH IS TURNED ON BUT SWING LOCK MONITOR LAMP DOES NOT LIGHT UP.....1868
M-18 WHEN SWING BRAKE RELEASE SWITCH IS SET TO RELEASE (EMERGENCY), SWING LOCK MONITOR LAMP DOES NOT FLASH.....1869
M-19 SERVICE METER DOES NOT GIVE NORMAL DISPLAY.....1870
M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.....1871
M-21 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM.....1872
M-22 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.....1873
M-23 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM.....1874
M-24 WIPER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WIPER IS ACTUATED WHEN WIPER SWITCH IS NOT OPERATED.....1875
M-25 WINDOW WASHER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WINDOW WASHER IS ACTUATED WHEN SWITCH IS NOT OPERATED.....1880
M-26 ELECTRIC GREASE GUN DOES NOT WORK (MACHINES EQUIPPED WITH ELECTRIC GREASE GUN).....1883
30 DISASSEMBLY AND ASSEMBLY.....1884
METHOD OF USING MANUAL.....1886
PRECAUTIONS WHEN CARRYING OUT OPERATION.....1889
SPECIAL TOOL LIST.....1891
SKETCHES OF SPECIAL TOOLS.....1898
FUEL SUPPLY PUMP.....1901
REMOVAL.....1901
INSTALLATION.....1903
FUEL INJECTOR.....1904
REMOVAL.....1904
INSTALLATION.....1906
NOZZLE TIP.....1908
REMOVAL.....1908
INSTALLATION.....1909
ENGINE FRONT SEAL.....1911
REMOVAL AND INSTALLATION.....1911
ENGINE REAR SEAL.....1913
REMOVAL.....1913
INSTALLATION.....1914
CYLINDER HEAD ASSEMBLY.....1918
REMOVAL.....1918
INSTALLATION.....1921
AFTERCOOLER CORE.....1925
REMOVAL, INSTALLATION.....1925
FAN GUARD, RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY.....1926
REMOVAL.....1926
INSTALLATION.....1928
FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY.....1929
REMOVAL, INSTALLATION.....1929
FUEL TANK ASSEMBLY.....1930
REMOVAL.....1930
INSTALLATION.....1931
ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY.....1932
REMOVAL.....1932
INSTALLATION.....1936
PTO ASSEMBLY.....1937
REMOVAL.....1937
INSTALLATION.....1938
PTO ASSEMBLY.....1939
DISASSEMBLY.....1939
ASSEMBLY.....1940
FINAL DRIVE ASSEMBLY.....1943
DISASSEMBLY.....1943
ASSEMBLY.....1948
REVOLVING FRAME ASSEMBLY.....1956
REMOVAL.....1956
INSTALLATION.....1957
SWING MACHINERY ASSEMBLY.....1958
REMOVAL, INSTALLATION.....1958
SWING MACHINERY ASSEMBLY.....1959
DISASSEMBLY.....1959
ASSEMBLY.....1963
SWING CIRCLE ASSEMBLY.....1968
REMOVAL, INSTALLATION.....1968
TRACK SHOE ASSEMBLY.....1969
REMOVAL.....1969
INSTALLATION.....1970
ONE LINK IN FIELD.....1971
DISASSEMBLY.....1971
ASSEMBLY.....1973
IDLER ASSEMBLY.....1975
REMOVAL, INSTALLATION.....1975
IDLER ASSEMBLY.....1976
DISASSEMBLY.....1976
ASSEMBLY.....1978
IDLER ADJUSTMENT CYLINDER ASSEMBLY.....1980
DISASSEMBLY, ASSEMBLY.....1980
RECOIL SPRING ASSEMBLY.....1981
REMOVAL, INSTALLATION.....1981
RECOIL SPRING ASSEMBLY.....1983
DISASSEMBLY.....1983
ASSEMBLY.....1984
CARRIER ROLLER ASSEMBLY.....1985
REMOVAL, INSTALLATION.....1985
CARRIER ROLLER ASSEMBLY.....1986
DISASSEMBLY.....1986
ASSEMBLY.....1987
TRACK ROLLER ASSEMBLY.....1988
REMOVAL, INSTALLATION.....1988
TRACK ROLLER ASSEMBLY.....1989
DISASSEMBLY.....1989
ASSEMBLY.....1990
HYDRAULIC TANK ASSEMBLY.....1992
REMOVAL.....1992
INSTALLATION.....1994
MAIN PUMP (NO. 1 PUMP) ASSEMBLY.....1995
REMOVAL.....1995
INSTALLATION.....1996
MAIN PUMP (NO. 2 PUMP) ASSEMBLY.....1997
REMOVAL.....1997
INSTALLATION.....1998
MAIN PUMP INPUT SHAFT OIL SEAL.....1999
REMOVAL, INSTALLATION.....1999
CONTROLPTO LUBRICATION PUMP ASSEMBLY.....2000
REMOVAL, INSTALLATION.....2000
MAIN RELIEF VALVE ASSEMBLY.....2001
DISASSEMBLY, ASSEMBLY.....2001
CONTROL VALVE ASSEMBLY.....2002
REMOVAL.....2002
INSTALLATION.....2004
DISASSEMBLY.....2005
ASSEMBLY.....2007
SOLENOID VALVE ASSEMBLY.....2009
REMOVAL.....2009
INSTALLATION.....2010
BOOM DAMPING VALVE ASSEMBLY.....2011
REMOVAL, INSTALLATION.....2011
SWING MOTOR ASSEMBLY.....2012
REMOVAL, INSTALLATION.....2012
CENTER SWIVEL JOINT ASSEMBLY.....2013
REMOVAL, INSTALLATION.....2013
CENTER SWIVEL JOINT ASSEMBLY.....2014
DISASSEMBLY, ASSEMBLY.....2014
TRAVEL MOTOR ASSEMBLY.....2015
REMOVAL, INSTALLATION.....2015
WORK EQUIPMENT PPC VALVE ASSEMBLY.....2016
DISASSEMBLY.....2016
ASSEMBLY.....2017
TRAVEL PPC VAVEL ASSEMBLY.....2018
DISASSEMBLY.....2018
ASSEMBLY.....2019
BUCKET CYLINDER ASSEMBLY.....2020
REMOVAL.....2020
INSTALLATION.....2022
ARM CYLINDER ASSEMBLY.....2024
REMOVAL.....2024
INSTALLATION.....2026
BOOM CYLINDER ASSEMBLY.....2028
REMOVAL.....2028
INSTALLATION.....2030
BOTTOM DUMP CYLINDER ASSEMBLY.....2032
REMOVAL.....2032
INSTALLATION.....2033
HYDRAULIC CYLINDER ASSEMBLY.....2034
DISASSEMBLY.....2034
ASSEMBLY.....2036
BUCKET ASSEMBLY.....2039
REMOVAL.....2039
INSTALLATION.....2041
ARM ASSEMBLY.....2043
REMOVAL.....2043
INSTALLATION.....2045
BOOM ASSEMBLY.....2047
REMOVAL.....2047
INSTALLATION.....2049
WORK EQUIPMENT ASSEMBLY.....2051
REMOVAL.....2051
INSTALLATION.....2053
OPERATOR'S CAB ASSEMBLY.....2055
REMOVAL.....2055
INSTALLATION.....2056
COUNTERWEIGHT ASSEMBLY.....2057
REMOVAL, INSTALLATION.....2057
90 OTHERS.....2058
HYDRAULIC CIRCUIT DRAWING (BACKHOE SPECIFICATION).....2059
HYDRAULIC CIRCUIT DRAWING (LOADING SHOVEL SPECIFICATION).....2060
ELECTRIC CIRCUIT DIAGRAM (1/4).....2061
ELECTRIC CIRCUIT DIAGRAM (2/4).....2062
ELECTRIC CIRCUIT DIAGRAM (3/4).....2063
ELECTRIC CIRCUIT DIAGRAM (4/4).....2064
SEBM031308 - Hydraulic Excavator PC750-7, PC800-7 Shop Manual.....2065
COVER.....2065
CONTENTS.....2066
01 GENERAL.....2093
SPECIFICATION DRAWINGS.....2094
SPECIFICATIONS.....2098
WEIGHT TABLE.....2106
FUEL, COOLANT AND LUBRICANTS.....2110
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.....2111
PTO.....2112
PTO LUBRICATION SYSTEM.....2113
POWER TRAIN.....2114
SWING MACHINERY.....2116
SWING CIRCLE.....2118
FINAL DRIVE.....2119
SPROCKET.....2121
TRACK FRAME AND RECOIL SPRING.....2123
IDLER.....2125
CARRIER ROLLER.....2127
TRACK ROLLER.....2128
TRACK SHOE.....2129
MOTOR GREASE PUMP.....2134
HYDRAULIC TANK.....2135
HYDRAULIC PUMP.....2136
RETURN OIL FILTER.....2165
LINE OIL FILTER.....2166
DRAIN OIL FILTER.....2167
L.H. 5-SPOOL CONTROL VALVE.....2168
R.H. 4-SPOOL CONTROL VALVE.....2173
STRAIGHT-TRAVEL VALVE.....2178
SWING MOTOR.....2181
CENTER SWIVEL JOINT.....2186
TRAVEL MOTOR.....2187
PPC CONTROL RELIEF VALVE.....2197
PPC ACCUMULATOR.....2198
VALVE CONTROL.....2199
WORK EQUIPMENT, SWING PPC VALVE.....2200
TRAVEL PPC VALVE.....2205
SOLENOID VALVE.....2209
HYDRAULIC CYLINDER.....2215
WORK EQUIPMENT.....2221
DIMENSIONS OF WORK EQUIPMENT.....2227
AIR CONDITIONER.....2231
ENGINE CONTROL.....2232
MACHINE CONTROL SYSTEM.....2238
MONITOR SYSTEM.....2267
SENSORS.....2282
20 TESTING AND ADJUSTING.....2286
STANDARD VALUE TABLE FOR ENGINE.....2287
STANDARD VALUE TABLE FOR CHASSIS.....2288
TESTING AND ADJUSTING.....2297
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.....2298
MEASURING ENGINE SPEED.....2300
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).....2301
MEASUREMENT OF EXHAUST GAS TEMPERATURE.....2302
MEASUREMENT OF EXHAUST GAS COLOR.....2303
ADJUSTING VALVE CLEARANCE.....2304
MEASURING COMPRESSION PRESSURE.....2305
MEASURING BLOW-BY PRESSURE.....2307
MEASURING ENGINE OIL PRESSURE.....2308
HANDLING OF FUEL SYSTEM EQUIPMENT.....2309
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT.....2309
MEASUREMENT OF FUEL PRESSURE.....2310
TESTING LEAKAGE THROUGH PRESSURE LIMITER AND RETURN RATE FROM INJECTOR.....2311
AIR BLEEDING FROM FUEL CIRCUIT.....2314
INSPECTION OF LEAKAGE FROM FUEL SYSTEM.....2316
ADJUSTING ENGINE SPEED SENSOR.....2317
TESTING AND ADJUSTING FAN BELT TENSION.....2318
TESTING AND ADJUSTING ALTERNATOR BELT TENSION.....2319
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT.....2320
INSPECTION OF SWING CIRCLE BEARING CLEARANCE.....2321
TESTING AND ADJUSTING TRACK SHOE TENSION.....2322
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES.....2323
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE.....2328
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE.....2329
INSPECTION OF SERVO PISTON STROKE.....2335
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE.....2336
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE.....2339
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.....2344
TESTING AND ADJUSTING TRAVEL DEVIATION.....2345
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT.....2347
MEASURING OIL LEAKAGE .....2348
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT.....2352
BLEEDING AIR FROM EACH PART.....2353
INSPECTION PROCEDURES FOR DIODE.....2356
SPECIAL FUNCTION OF MONITOR PANEL.....2357
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT.....2384
PREPARATION WORK.....2385
PM-CLINIC SERVICE.....2387
UNDERCARRIAGE INSPECTION.....2394
TROUBLESHOOTING.....2395
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....2396
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....2397
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....2398
CHECKS BEFORE TROUBLESHOOTING.....2406
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.....2407
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.....2411
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....2428
T-BRANCH BOX AND T-BRANCH TABLE.....2451
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED.....2453
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE.....2455
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.....2457
ERROR CODE IN ELECTRICAL SYSTEM E112 (WIPER DRIVE (FOR) S/C).....2459
ERROR CODE IN ELECTRICAL SYSTEM E113 (WIPER DRIVE (REV) S/C).....2463
ERROR CODE IN ELECTRICAL SYSTEM E114 (WASHER DRIVE S/C).....2465
ERROR CODE IN ELECTRICAL SYSTEM E115 (WIPER WORKING ABNORMALITY).....2467
ERROR CODE IN ELECTRICAL SYSTEM E116 (WIPER PARKING ABNORMALITY).....2469
ERROR CODE IN ELECTRICAL SYSTEM E117 (ENG. CONTROLLER S-NET COMM ERR.).....2473
ERROR CODE IN ELECTRICAL SYSTEM E118 (PUMP CONTROLLER S-NET COMM ERR.).....2475
ERROR CODE IN ELECTRICAL SYSTEM E128 (MONITOR COMM. ABNORMALITY).....2477
ERROR CODE IN ELECTRICAL SYSTEM E201 (CO CANCEL SOL. S/C).....2479
ERROR CODE IN ELECTRICAL SYSTEM E202 (TRAVEL JUNCTION SOL. S/C).....2481
ERROR CODE IN ELECTRICAL SYSTEM E203 (SWING BRAKE SOL. S/C).....2483
ERROR CODE IN ELECTRICAL SYSTEM E204 (2-STAGE RELIEF SOL. S/C).....2485
ERROR CODE IN ELECTRICAL SYSTEM E205 (SWING PRIORITY SOL. S/C).....2487
ERROR CODE IN ELECTRICAL SYSTEM E206 (TRAVEL SPEED SOL. S/C).....2489
ERROR CODE IN ELECTRICAL SYSTEM E207 (FLASH LIGHT RELAY S/C).....2491
ERROR CODE IN ELECTRICAL SYSTEM E211 (CO CANCEL SOL. DISC.).....2493
ERROR CODE IN ELECTRICAL SYSTEM E212 (TRAVEL JUNCTION SOL. DISC.).....2495
ERROR CODE IN ELECTRICAL SYSTEM E213 (SWING BRAKE SOL. DISC.).....2497
ERROR CODE IN ELECTRICAL SYSTEM E214 (2-STAGE RELIEF SOL. DISC.).....2499
ERROR CODE IN ELECTRICAL SYSTEM E215 (SWING PRIORITY SOL. DISC.).....2501
ERROR CODE IN ELECTRICAL SYSTEM E216 (TRAVEL SPEED SOL. DISC.).....2503
ERROR CODE IN ELECTRICAL SYSTEM E217 (MODEL SELECTION ABNORMALITY).....2505
ERROR CODE IN ELECTRICAL SYSTEM E218 (S-NET COMM. DISC.).....2507
ERROR CODE IN ELECTRICAL SYSTEM E221 (TRAVEL ALARM S/C).....2509
ERROR CODE IN ELECTRICAL SYSTEM E224 (F PUMP P. SENSOR ABNORMALITY).....2511
ERROR CODE IN ELECTRICAL SYSTEM E225 (R PUMP P. SENSOR ABNORMALITY).....2513
ERROR CODE IN ELECTRICAL SYSTEM E226 (PRESS. SENSOR POWER ABNORMALITY).....2515
ERROR CODE IN ELECTRICAL SYSTEM E227 (ENGINE SPEED SENSOR ABNORMALITY).....2517
ERROR CODE IN ELECTRICAL SYSTEM E232 (TVC SOL. S/C).....2519
ERROR CODE IN ELECTRICAL SYSTEM E233 (TVC SOL. DISC.).....2521
ERROR CODE IN ELECTRICAL SYSTEM E257 (PUMP COMM. ABNORMALITY).....2523
ERROR CODE IN ELECTRICAL SYSTEM E302 (STEP LIGHT RELAY S/C).....2525
ERROR CODE IN ELECTRICAL SYSTEM E304 (STEP LIGHT POWER HOLD RELAY S/C).....2527
ERROR CODE IN ELECTRICAL SYSTEM E315 (BATTERY RELAY DRIVE S/C).....2529
ERROR CODE IN ELECTRICAL SYSTEM E91B (ENGINE NE SENSOR PROBLEM).....2531
ERROR CODE IN ELECTRICAL SYSTEM E91C (ENGINE G SENSOR PROBLEM).....2532
ERROR CODE IN ELECTRICAL SYSTEM E920 (ENGINE TYPE SELECTION ERROR).....2533
ERROR CODE IN ELECTRICAL SYSTEM E921 (ENGINE TYPE MISMATCH).....2535
ERROR CODE IN ELECTRICAL SYSTEM E931 (FUEL DIAL SYS. ERROR).....2536
ERROR CODE IN ELECTRICAL SYSTEM E934 (ENGINE COOLANT SENSOR HI ERROR).....2538
ERROR CODE IN ELECTRICAL SYSTEM E936 (ENGINE OIL PRESS. SW. ERROR).....2540
ERROR CODE IN ELECTRICAL SYSTEM E93C (ENGINE BOOST SENSOR ERROR).....2542
ERROR CODE IN ELECTRICAL SYSTEM E93D (ENGINE FUEL TEMP. SENSOR ERROR).....2544
ERROR CODE IN ELECTRICAL SYSTEM E953 (ENGINE COMM. ABNORMALITY).....2546
ERROR CODE IN ELECTRICAL SYSTEM E954 (SHORT ENGINE STARTER SW.).....2548
ERROR CODE IN ELECTRICAL SYSTEM E955 (ENGINE S-NET ERROR).....2550
ERROR CODE IN ELECTRICAL SYSTEM E956 (ENGINE POWER FAILURE (1)).....2552
ERROR CODE IN ELECTRICAL SYSTEM E957 (ENGINE POWER FAILURE (2)).....2554
ERROR CODE IN ELECTRICAL SYSTEM E95A (ENGINE Q-ADJ. SW. SIGNAL ERROR).....2556
ERROR CODE IN ELECTRICAL SYSTEM E96A (ENGINE COOLANT SENSOR LO ERROR).....2557
ERROR CODE IN ELECTRICAL SYSTEM E970 (PCV1 OVER CURRENT).....2559
ERROR CODE IN ELECTRICAL SYSTEM E971 (PCV2 OVER CURRENT).....2561
ERROR CODE IN ELECTRICAL SYSTEM E974 (PCV1 LINE CUT).....2563
ERROR CODE IN ELECTRICAL SYSTEM E975 (PCV2 LINE CUT).....2565
ERROR CODE IN ELECTRICAL SYSTEM E977 (RAIL PRESS. SENSOR ERROR).....2567
ERROR CODE IN ELECTRICAL SYSTEM E979 (RAIL PRESS. HIGH).....2569
ERROR CODE IN ELECTRICAL SYSTEM E97A (RAIL PRESS. ABNORMAL).....2569
ERROR CODE IN ELECTRICAL SYSTEM E97B (RAIL PRESS. LOW).....2570
ERROR CODE IN ELECTRICAL SYSTEM E97C (RAIL PRESS. TOO LOW).....2573
ERROR CODE IN ELECTRICAL SYSTEM E97D (RAIL PRESS. OUT OF CONTROL).....2573
ERROR CODE IN ELECTRICAL SYSTEM E980 (ENG. CONTROLLER ABNORMALITY).....2574
ERROR CODE IN ELECTRICAL SYSTEM E981 (FUEL INJECTOR 1 DISC.).....2576
ERROR CODE IN ELECTRICAL SYSTEM E982 (FUEL INJECTOR 2 DISC.).....2577
ERROR CODE IN ELECTRICAL SYSTEM E983 (FUEL INJECTOR 3 DISC.).....2578
ERROR CODE IN ELECTRICAL SYSTEM E984 (FUEL INJECTOR 4 DISC.).....2579
ERROR CODE IN ELECTRICAL SYSTEM E985 (FUEL INJECTOR 5 DISC.).....2580
ERROR CODE IN ELECTRICAL SYSTEM E986 (FUEL INJECTOR 6 DISC.).....2581
ERROR CODE IN ELECTRICAL SYSTEM E98A (FUEL INJECTOR 1-3 S/C).....2582
ERROR CODE IN ELECTRICAL SYSTEM E98B (FUEL INJECTOR 4-6 S/C).....2584
FAILURE CODE IN MECHANICAL SYSTEM A000N1 (ENG. HI OUT OF STD).....2586
FAILURE CODE IN MECHANICAL SYSTEM AA10NX (AIRCLEANER CLOGGING).....2587
FAILURE CODE IN MECHANICAL SYSTEM AB00KE (CHARGE VOLTAGE LOW).....2589
FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ENG. OIL PRESS. LOW).....2591
FAILURE CODE IN MECHANICAL SYSTEM B@BAZK (ENG. OIL LEVEL LOW).....2593
FAILURE CODE IN MECHANICAL SYSTEM B@BCNS (ENG. COOLANT OVERHEAT).....2594
FAILURE CODE IN MECHANICAL SYSTEM B@BCZK (ENG. COOLANT LVL LOW).....2595
FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDR. OIL OVERHEAT).....2597
FAILURE CODE IN MECHANICAL SYSTEM DA80MA (AUTO. LUB ABNORMAL).....2599
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....2600
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE).....2601
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.....2603
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE).....2604
E-2 PREHEATER DOES NOT OPERATE.....2607
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK.....2609
E-4 AUTO-DECELERATOR DOES NOT OPERATE.....2610
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE.....2611
E-6 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY.....2613
E-7 BOOM SHOCKLESS FUNCTION DOES NOT OPERATE NORMALLY.....2615
E-8 ANY ITEM IS NOT DISPLAYED ON MONITOR PANEL.....2617
E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING.....2618
E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL.....2618
E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING.....2619
E-12 ENGINE COOLANT THERMOMETER DOES NOT DISPLAY NORMALLY.....2620
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.....2622
E-14 FUEL GAUGE DOES NOT DISPLAY CORRECTLY.....2623
E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY.....2624
E-16 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED.....2626
E-17 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK.....2628
E-18 ALARMING BUZZER CANNOT BE CANCELLED.....2635
E-19 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2636
E-20 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2637
E-21 "ARM IN" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2638
E-22 "ARM OUT" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2639
E-23 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2640
E-24 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2641
E-25 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2642
E-26 "LEFT TRAVEL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.....2644
E-27 "RIGHT TRAVEL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.....2646
E-28 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....2648
E-29 AIR CONDITIONER DOES NOT WORK.....2650
E-30 STEP LIGHT DOES NOT LIGHT UP OR GO OFF.....2651
E-31 ELECTRIC GREASE GUN DOES NOT OPERATE.....2655
E-32 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING.....2657
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).....2659
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).....2660
INFORMATION IN TROUBLESHOOTING TABLE.....2665
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW.....2666
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS.....2668
H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK.....2669
H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP.....2670
H-5 BOOM SPEED OR POWER IS LOW.....2671
H-6 SPEED OR POWER OF ARM IS LOW.....2673
H-7 SPEED OR POWER OF BUCKET IS LOW.....2674
H-8 BOOM DOES NOT MOVE.....2675
H-9 ARM DOES NOT MOVE.....2675
H-10 BUCKET DOES NOT MOVE.....2675
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE.....2676
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE.....2678
H-13 HEAVY LIFT FUNCTION DOES NOT OPERATE OR STOP.....2679
H-14 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE OR STOP.....2679
H-15 BOOM SHOCKLESS FUNCTION CANNOT BE TURNED ON OR OFF.....2679
H-16 MACHINE DEVIATES IN ONE DIRECTION.....2680
H-17 MACHINE DEVIATES LARGELY AT START.....2682
H-18 MACHINE DEVIATES LARGELY DURING COMPOUND OPERATION.....2683
H-19 TRAVEL SPEED OR POWER IS LOW.....2683
H-20 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK).....2684
H-21 TRAVEL SPEED DOES NOT CHANGE.....2685
H-22 UPPER STRUCTURE DOES NOT SWING.....2686
H-23 SWING SPEED OR ACCELERATION IS LOW.....2687
H-24 SWING SPEED OR ACCELERATION IS LOW DURING COMPOUND OPERATION OF SWING AND WORK EQUIPMENT.....2688
H-25 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING.....2690
H-26 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING .....2691
H-27 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING.....2692
H-28 HYDRAULIC DRIFT OF SWING IS LARGE.....2693
TROUBLESHOOTING OF ENGINE (S MODE).....2694
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....2695
METHOD OF USING TROUBLESHOOTING CHARTS.....2696
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).....2699
S-2 ENGINE DOES NOT START.....2700
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).....2703
S-4 ENGINE STOPS DURING OPERATIONS.....2704
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).....2705
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).....2706
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).....2707
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).....2708
S-9 OIL BECOMES CONTAMINATED QUICKLY.....2709
S-10 FUEL CONSUMPTION IS EXCESSIVE.....2710
S-11 OIL IS IN COOLING (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN).....2711
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).....2712
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL).....2713
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....2714
S-15 ABNORMAL NOISE IS MADE.....2715
S-16 VIBRATION IS EXCESSIVE.....2716
30 DISASSEMBLY AND ASSEMBLY.....2717
METHOD OF USING MANUAL.....2719
PRECAUTIONS WHEN CARRYING OUT OPERATION.....2721
SPECIAL TOOL LIST.....2723
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY.....2733
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY.....2736
REMOVAL AND INSTALLATION OF NOZZLE TIP.....2739
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.....2741
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL.....2743
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.....2748
REMOVAL AND INSTALLATION OF AFTERCOOLER CORE.....2754
REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY.....2755
REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY.....2758
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY.....2759
REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY.....2760
REMOVAL AND INSTALLATION OF PTO ASSEMBLY.....2764
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY.....2766
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY.....2769
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY.....2780
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY.....2781
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY.....2782
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY.....2789
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY.....2790
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD.....2792
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY.....2796
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY.....2797
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY.....2800
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY.....2801
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY.....2803
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.....2805
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.....2806
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY.....2809
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.....2810
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.....2813
REMOVAL AND INSTALLATION OF MAIN PUMP (NO.1 PUMP) ASSEMBLY.....2815
REMOVAL AND INSTALLATION OF MAIN PUMP (NO.2 PUMP).....2817
REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL.....2819
REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRICATION PUMP ASSEMBLY.....2820
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY.....2821
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY.....2822
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (WORK EQUIPMENT).....2825
REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY.....2828
REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY.....2830
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY.....2831
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT.....2833
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY.....2834
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY.....2836
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.....2837
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY.....2839
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (BACK HOE).....2841
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL).....2843
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (BACK HOE).....2845
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (LOADING SHOVEL).....2847
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (BACK HOE).....2849
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (LOADING SHOVEL).....2851
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL).....2853
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.....2854
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (BACK HOE).....2860
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (LOADING SHOVEL).....2861
REMOVAL AND INSTALLATION OF ARM ASSEMBLY (BACK HOE).....2862
REMOVAL AND INSTALLATION OF ARM ASSEMBLY (LOADING SHOVEL).....2864
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (BACK HOE).....2866
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (LOADING SHOVEL).....2868
REMOVAL AND INSTALLATION OF WORK EQUIPMENT (BACK HOE).....2870
REMOVAL AND INSTALLATION OF WORK EQUIPMENT (LOADING SHOVEL).....2872
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....2874
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).....2876
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.....2886
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY.....2892
90 OTHERS.....2893
HYDRAULIC CIRCUIT DIAGRAM (PC750-7, PC750SE-7, PC800-7, PC800SE-7).....2894
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL SPECIFICATION, PC750-7, PC750SE-7).....2895
ELECTRICAL CIRCUIT DIAGRAM (1/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7).....2896
ELECTRICAL CIRCUIT DIAGRAM (2/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7).....2897
ELECTRICAL CIRCUIT DIAGRAM (3/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7).....2898
ELECTRICAL CIRCUIT DIAGRAM (4/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7).....2899
ELECTRICAL CIRCUIT DIAGRAM (5/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7).....2900
ELECTRICAL CIRCUIT DIAGRAM (6/6) (LOADING SHOVEL SPECIFICATION, PC750-7, PC750SE-7).....2901
