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Komatsu PC750-7, PC750SE-7, PC750LC-7, PC800-7, PC800SE-7 Excavator Service Repair Manual SEBM031308 – PDF DOWNLOAD
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- Komatsu PC750-7, PC750SE-7, PC750LC-7, PC800-7, PC800SE-7 Excavator Service Repair Manual
- PUBLICATION NUMBER:SEBM031308
- MACHINE MODEL SERIAL NUMBER
PC750-7 20001 and up
PC750SE-7 20001 and up
PC750LC-7 20001 and up
PC800-7 40001 and up
PC800SE-7 40001 and up
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Description
Komatsu PC750-7, PC750SE-7, PC750LC-7, PC800-7, PC800SE-7 Excavator Service Repair Manual SEBM031308
KOMATSU PC750-7, PC750SE-7, PC750LC-7, PC800-7, PC800SE-7 EXCAVATOR SERVICE REPAIR MANUAL SEBM031308 – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
Komatsu PC750-7, PC750SE-7, PC750LC-7, PC800-7, PC800SE-7 Excavator Service Repair Manual SEBM031308
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu PC750-7, PC750SE-7, PC750LC-7, PC800-7, PC800SE-7 Excavator Service Repair Manual SEBM031308
COVER............................................................................................................... 1 CONTENTS............................................................................................................ 2 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..................................................................................................... 55 SPROCKET........................................................................................................ 57 TRACK FRAME AND RECOIL SPRING................................................................................... 59 IDLER........................................................................................................... 61 CARRIER ROLLER.................................................................................................. 63 TRACK ROLLER.................................................................................................... 64 TRACK SHOE...................................................................................................... 65 MOTOR GREASE PUMP............................................................................................... 70 HYDRAULIC TANK.................................................................................................. 71 HYDRAULIC PUMP.................................................................................................. 72 RETURN OIL FILTER...............................................................................................101 LINE OIL FILTER.................................................................................................102 DRAIN OIL FILTER................................................................................................103 L.H. 5-SPOOL CONTROL VALVE......................................................................................104 R.H. 4-SPOOL CONTROL VALVE......................................................................................109 STRAIGHT-TRAVEL VALVE...........................................................................................114 SWING MOTOR.....................................................................................................117 CENTER SWIVEL JOINT.............................................................................................122 TRAVEL MOTOR....................................................................................................123 PPC CONTROL RELIEF VALVE........................................................................................133 PPC ACCUMULATOR.................................................................................................134 VALVE CONTROL...................................................................................................135 WORK EQUIPMENT, SWING PPC VALVE.................................................................................136 TRAVEL PPC VALVE................................................................................................141 SOLENOID VALVE..................................................................................................145 HYDRAULIC CYLINDER..............................................................................................151 WORK EQUIPMENT..................................................................................................157 DIMENSIONS OF WORK EQUIPMENT....................................................................................163 AIR CONDITIONER.................................................................................................167 ENGINE CONTROL..................................................................................................168 MACHINE CONTROL SYSTEM..........................................................................................174 MONITOR SYSTEM..................................................................................................203 SENSORS.........................................................................................................218 20 TESTING AND ADJUSTING............................................................................................222 STANDARD VALUE TABLE FOR ENGINE.................................................................................223 STANDARD VALUE TABLE FOR CHASSIS................................................................................224 TESTING AND ADJUSTING...........................................................................................233 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING............................................................234 MEASURING ENGINE SPEED......................................................................................236 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)..............................................................237 MEASUREMENT OF EXHAUST GAS TEMPERATURE......................................................................238 MEASUREMENT OF EXHAUST GAS COLOR............................................................................239 ADJUSTING VALVE CLEARANCE...................................................................................240 MEASURING COMPRESSION PRESSURE..............................................................................241 MEASURING BLOW-BY PRESSURE..................................................................................243 MEASURING ENGINE OIL PRESSURE...............................................................................244 HANDLING OF FUEL SYSTEM EQUIPMENT...........................................................................245 REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT........................................................245 MEASUREMENT OF FUEL PRESSURE................................................................................246 TESTING LEAKAGE THROUGH PRESSURE LIMITER AND RETURN RATE FROM INJECTOR......................................247 AIR BLEEDING FROM FUEL CIRCUIT..............................................................................250 INSPECTION OF LEAKAGE FROM FUEL SYSTEM......................................................................252 ADJUSTING ENGINE SPEED SENSOR...............................................................................253 TESTING AND ADJUSTING FAN BELT TENSION......................................................................254 TESTING AND ADJUSTING ALTERNATOR BELT TENSION...............................................................255 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT.......................................................256 INSPECTION OF SWING CIRCLE BEARING CLEARANCE................................................................257 TESTING AND ADJUSTING TRACK SHOE TENSION....................................................................258 TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES...............................259 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE..........................................................264 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE..........................................................265 INSPECTION OF SERVO PISTON STROKE...........................................................................271 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE....................................................................272 MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTOR VALVE....275 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...................................................................280 TESTING AND ADJUSTING TRAVEL DEVIATION......................................................................281 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................................283 MEASURING OIL LEAKAGE ......................................................................................284 RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT.........................................................288 BLEEDING AIR FROM EACH PART.................................................................................289 INSPECTION PROCEDURES FOR DIODE.............................................................................292 SPECIAL FUNCTION OF MONITOR PANEL...........................................................................293 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT.............................................................320 PREPARATION WORK............................................................................................321 PM-CLINIC SERVICE...........................................................................................323 UNDERCARRIAGE INSPECTION....................................................................................330 TROUBLESHOOTING.................................................................................................331 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................332 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................333 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................334 CHECKS BEFORE TROUBLESHOOTING...............................................................................342 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING................................................................343 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...........................................347 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................364 T-BRANCH BOX AND T-BRANCH TABLE.............................................................................387 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISPLAYED......389 BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE...................................................391 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................393 ERROR CODE IN ELECTRICAL SYSTEM E112 (WIPER DRIVE (FOR) S/C)............................................395 ERROR CODE IN ELECTRICAL SYSTEM E113 (WIPER DRIVE (REV) S/C)............................................399 ERROR CODE IN ELECTRICAL SYSTEM E114 (WASHER DRIVE S/C).................................................401 ERROR CODE IN ELECTRICAL SYSTEM E115 (WIPER WORKING ABNORMALITY)........................................403 ERROR CODE IN ELECTRICAL SYSTEM E116 (WIPER PARKING ABNORMALITY)........................................405 ERROR CODE IN ELECTRICAL SYSTEM E117 (ENG. CONTROLLER S-NET COMM ERR.)..................................409 ERROR CODE IN ELECTRICAL SYSTEM E118 (PUMP CONTROLLER S-NET COMM ERR.)..................................411 ERROR CODE IN ELECTRICAL SYSTEM E128 (MONITOR COMM. ABNORMALITY)........................................413 ERROR CODE IN ELECTRICAL SYSTEM E201 (CO CANCEL SOL. S/C)...............................................415 ERROR CODE IN ELECTRICAL SYSTEM E202 (TRAVEL JUNCTION SOL. S/C).........................................417 ERROR CODE IN ELECTRICAL SYSTEM E203 (SWING BRAKE SOL. S/C).............................................419 ERROR CODE IN ELECTRICAL SYSTEM E204 (2-STAGE RELIEF SOL. S/C)..........................................421 ERROR CODE IN ELECTRICAL SYSTEM E205 (SWING PRIORITY SOL. S/C)..........................................423 ERROR CODE IN ELECTRICAL SYSTEM E206 (TRAVEL SPEED SOL. S/C)............................................425 ERROR CODE IN ELECTRICAL SYSTEM E207 (FLASH LIGHT RELAY S/C)............................................427 ERROR CODE IN ELECTRICAL SYSTEM E211 (CO CANCEL SOL. DISC.).............................................429 ERROR CODE IN ELECTRICAL SYSTEM E212 (TRAVEL JUNCTION SOL. DISC.).......................................431 ERROR CODE IN ELECTRICAL SYSTEM E213 (SWING BRAKE SOL. DISC.)...........................................433 ERROR CODE IN ELECTRICAL SYSTEM E214 (2-STAGE RELIEF SOL. DISC.)........................................435 ERROR CODE IN ELECTRICAL SYSTEM E215 (SWING PRIORITY SOL. DISC.)........................................437 ERROR CODE IN ELECTRICAL SYSTEM E216 (TRAVEL SPEED SOL. DISC.)..........................................439 ERROR CODE IN ELECTRICAL SYSTEM E217 (MODEL SELECTION ABNORMALITY)......................................441 ERROR CODE IN ELECTRICAL SYSTEM E218 (S-NET COMM. DISC.)................................................443 ERROR CODE IN ELECTRICAL SYSTEM E221 (TRAVEL ALARM S/C).................................................445 ERROR CODE IN ELECTRICAL SYSTEM E224 (F PUMP P. SENSOR ABNORMALITY).....................................447 ERROR CODE IN ELECTRICAL SYSTEM E225 (R PUMP P. SENSOR ABNORMALITY).....................................449 ERROR CODE IN ELECTRICAL SYSTEM E226 (PRESS. SENSOR POWER ABNORMALITY)..................................451 ERROR CODE IN ELECTRICAL SYSTEM E227 (ENGINE SPEED SENSOR ABNORMALITY)..................................453 ERROR CODE IN ELECTRICAL SYSTEM E232 (TVC SOL. S/C).....................................................455 ERROR CODE IN ELECTRICAL SYSTEM E233 (TVC SOL. DISC.)...................................................457 ERROR CODE IN ELECTRICAL SYSTEM E257 (PUMP COMM. ABNORMALITY)...........................................459 ERROR CODE IN ELECTRICAL SYSTEM E302 (STEP LIGHT RELAY S/C).............................................461 ERROR CODE IN ELECTRICAL SYSTEM E304 (STEP LIGHT POWER HOLD RELAY S/C)..................................463 ERROR CODE IN ELECTRICAL SYSTEM E315 (BATTERY RELAY DRIVE S/C)..........................................465 ERROR CODE IN ELECTRICAL SYSTEM E91B (ENGINE NE SENSOR PROBLEM).........................................467 ERROR CODE IN ELECTRICAL SYSTEM E91C (ENGINE G SENSOR PROBLEM)..........................................468 ERROR CODE IN ELECTRICAL SYSTEM E920 (ENGINE TYPE SELECTION ERROR)......................................469 ERROR CODE IN ELECTRICAL SYSTEM E921 (ENGINE TYPE MISMATCH).............................................471 ERROR CODE IN ELECTRICAL SYSTEM E931 (FUEL DIAL SYS. ERROR).............................................472 ERROR CODE IN ELECTRICAL SYSTEM E934 (ENGINE COOLANT SENSOR HI ERROR)...................................474 ERROR CODE IN ELECTRICAL SYSTEM E936 (ENGINE OIL PRESS. SW. ERROR)......................................476 ERROR CODE IN ELECTRICAL SYSTEM E93C (ENGINE BOOST SENSOR ERROR)........................................478 ERROR CODE IN ELECTRICAL SYSTEM E93D (ENGINE FUEL TEMP. SENSOR ERROR)...................................480 ERROR CODE IN ELECTRICAL SYSTEM E953 (ENGINE COMM. ABNORMALITY).........................................482 ERROR CODE IN ELECTRICAL SYSTEM E954 (SHORT ENGINE STARTER SW.).........................................484 ERROR CODE IN ELECTRICAL SYSTEM E955 (ENGINE S-NET ERROR)...............................................486 ERROR CODE IN ELECTRICAL SYSTEM E956 (ENGINE POWER FAILURE (1)).........................................488 ERROR CODE IN ELECTRICAL SYSTEM E957 (ENGINE POWER FAILURE (2)).........................................490 ERROR CODE IN ELECTRICAL SYSTEM E95A (ENGINE Q-ADJ. SW. SIGNAL ERROR)...................................492 ERROR CODE IN ELECTRICAL SYSTEM E96A (ENGINE COOLANT SENSOR LO ERROR)...................................493 ERROR CODE IN ELECTRICAL SYSTEM E970 (PCV1 OVER CURRENT)................................................495 ERROR CODE IN ELECTRICAL SYSTEM E971 (PCV2 OVER CURRENT)................................................497 ERROR CODE IN ELECTRICAL SYSTEM E974 (PCV1 LINE CUT)....................................................499 ERROR CODE IN ELECTRICAL SYSTEM E975 (PCV2 LINE CUT)....................................................501 ERROR CODE IN ELECTRICAL SYSTEM E977 (RAIL PRESS. SENSOR ERROR).........................................503 ERROR CODE IN ELECTRICAL SYSTEM E979 (RAIL PRESS. HIGH).................................................505 ERROR CODE IN ELECTRICAL SYSTEM E97A (RAIL PRESS. ABNORMAL).............................................505 ERROR CODE IN ELECTRICAL SYSTEM E97B (RAIL PRESS. LOW)..................................................506 ERROR CODE IN ELECTRICAL SYSTEM E97C (RAIL PRESS. TOO LOW)..............................................509 ERROR CODE IN ELECTRICAL SYSTEM E97D (RAIL PRESS. OUT OF CONTROL).......................................509 ERROR CODE IN ELECTRICAL SYSTEM E980 (ENG. CONTROLLER ABNORMALITY)......................................510 ERROR CODE IN ELECTRICAL SYSTEM E981 (FUEL INJECTOR 1 DISC.)............................................512 ERROR CODE IN ELECTRICAL SYSTEM E982 (FUEL INJECTOR 2 DISC.)............................................513 ERROR CODE IN ELECTRICAL SYSTEM E983 (FUEL INJECTOR 3 DISC.)............................................514 ERROR CODE IN ELECTRICAL SYSTEM E984 (FUEL INJECTOR 4 DISC.)............................................515 ERROR CODE IN ELECTRICAL SYSTEM E985 (FUEL INJECTOR 5 DISC.)............................................516 ERROR CODE IN ELECTRICAL SYSTEM E986 (FUEL INJECTOR 6 DISC.)............................................517 ERROR CODE IN ELECTRICAL SYSTEM E98A (FUEL INJECTOR 1-3 S/C)............................................518 ERROR CODE IN ELECTRICAL SYSTEM E98B (FUEL INJECTOR 4-6 S/C)............................................520 FAILURE CODE IN MECHANICAL SYSTEM A000N1 (ENG. HI OUT OF STD)...........................................522 FAILURE CODE IN MECHANICAL SYSTEM AA10NX (AIRCLEANER CLOGGING)..........................................523 FAILURE CODE IN MECHANICAL SYSTEM AB00KE (CHARGE VOLTAGE LOW)...........................................525 FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ENG. OIL PRESS. LOW)..........................................527 FAILURE CODE IN MECHANICAL SYSTEM B@BAZK (ENG. OIL LEVEL LOW)...........................................529 FAILURE CODE IN MECHANICAL SYSTEM B@BCNS (ENG. COOLANT OVERHEAT)........................................530 FAILURE CODE IN MECHANICAL SYSTEM B@BCZK (ENG. COOLANT LVL LOW).........................................531 FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDR. OIL OVERHEAT)...........................................533 FAILURE CODE IN MECHANICAL SYSTEM DA80MA (AUTO. LUB ABNORMAL)...........................................535 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...............................................................536 BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)............................................................537 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................539 E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)......................................................540 E-2 PREHEATER DOES NOT OPERATE..........................................................................543 E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK............................................................545 E-4 AUTO-DECELERATOR DOES NOT OPERATE...................................................................546 E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE....................................................547 E-6 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY..................................................549 E-7 BOOM SHOCKLESS FUNCTION DOES NOT OPERATE NORMALLY...................................................551 E-8 ANY ITEM IS NOT DISPLAYED ON MONITOR PANEL..........................................................553 E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING.........................................................554 E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL............................................554 E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING......................................555 E-12 ENGINE COOLANT THERMOMETER DOES NOT DISPLAY NORMALLY...............................................556 E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.........................................558 E-14 FUEL GAUGE DOES NOT DISPLAY CORRECTLY..............................................................559 E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY......................................................560 E-16 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED..............................................562 E-17 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK.....................................................564 E-18 ALARMING BUZZER CANNOT BE CANCELLED................................................................571 E-19 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................572 E-20 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................573 E-21 "ARM IN" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION............................................574 E-22 "ARM OUT" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................575 E-23 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................576 E-24 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................577 E-25 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.............................................578 E-26 "LEFT TRAVEL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.....................................580 E-27 "RIGHT TRAVEL" IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION....................................582 E-28 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................584 E-29 AIR CONDITIONER DOES NOT WORK......................................................................586 E-30 STEP LIGHT DOES NOT LIGHT UP OR GO OFF.............................................................587 E-31 ELECTRIC GREASE GUN DOES NOT OPERATE...............................................................591 E-32 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING..............................................593 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).................................................595 BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....................................596 INFORMATION IN TROUBLESHOOTING TABLE....................................................................601 H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW......................................602 H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS.....................................................604 H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK...........................................605 H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP............................................................606 H-5 BOOM SPEED OR POWER IS LOW..........................................................................607 H-6 SPEED OR POWER OF ARM IS LOW........................................................................609 H-7 SPEED OR POWER OF BUCKET IS LOW.....................................................................610 H-8 BOOM DOES NOT MOVE..................................................................................611 H-9 ARM DOES NOT MOVE...................................................................................611 H-10 BUCKET DOES NOT MOVE...............................................................................611 H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE.........................................................612 H-12 TIME LAG OF WORK EQUIPMENT IS LARGE................................................................614 H-13 HEAVY LIFT FUNCTION DOES NOT OPERATE OR STOP.......................................................615 H-14 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE OR STOP..................................................615 H-15 BOOM SHOCKLESS FUNCTION CANNOT BE TURNED ON OR OFF.................................................615 H-16 MACHINE DEVIATES IN ONE DIRECTION..................................................................616 H-17 MACHINE DEVIATES LARGELY AT START..................................................................618 H-18 MACHINE DEVIATES LARGELY DURING COMPOUND OPERATION.................................................619 H-19 TRAVEL SPEED OR POWER IS LOW.......................................................................619 H-20 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)...........................................................620 H-21 TRAVEL SPEED DOES NOT CHANGE.......................................................................621 H-22 UPPER STRUCTURE DOES NOT SWING.....................................................................622 H-23 SWING SPEED OR ACCELERATION IS LOW.................................................................623 H-24 SWING SPEED OR ACCELERATION IS LOW DURING COMPOUND OPERATION OF SWING AND WORK EQUIPMENT...........624 H-25 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING........................................626 H-26 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING ...........................................627 H-27 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING...................................628 H-28 HYDRAULIC DRIFT OF SWING IS LARGE..................................................................629 TROUBLESHOOTING OF ENGINE (S MODE)..........................................................................630 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................631 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................632 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...........................................635 S-2 ENGINE DOES NOT START...............................................................................636 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................639 S-4 ENGINE STOPS DURING OPERATIONS......................................................................640 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................641 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................642 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................643 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................644 S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................645 S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................646 S-11 OIL IS IN COOLING (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN).............................647 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).........................................648 S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL).............................................................649 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................650 S-15 ABNORMAL NOISE IS MADE.............................................................................651 S-16 VIBRATION IS EXCESSIVE.............................................................................652 30 DISASSEMBLY AND ASSEMBLY.........................................................................................653 METHOD OF USING MANUAL..........................................................................................655 PRECAUTIONS WHEN CARRYING OUT OPERATION.........................................................................657 SPECIAL TOOL LIST...............................................................................................659 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY...........................................................669 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY..............................................................672 REMOVAL AND INSTALLATION OF NOZZLE TIP..........................................................................675 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...................................................................677 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL....................................................................679 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY..............................................................684 REMOVAL AND INSTALLATION OF AFTERCOOLER CORE....................................................................690 REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY...............................691 REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY..................................694 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY..................................................................695 REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY.............................................696 REMOVAL AND INSTALLATION OF PTO ASSEMBLY........................................................................700 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY........................................................................702 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY................................................................705 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY............................................................716 REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY............................................................717 DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY............................................................718 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...............................................................725 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY.................................................................726 DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD...................................................................728 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY......................................................................732 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY......................................................................733 DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY..................................................736 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY..............................................................737 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY..............................................................739 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.............................................................741 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.............................................................742 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY...............................................................745 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...............................................................746 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.............................................................749 REMOVAL AND INSTALLATION OF MAIN PUMP (NO.1 PUMP) ASSEMBLY......................................................751 REMOVAL AND INSTALLATION OF MAIN PUMP (NO.2 PUMP)...............................................................753 REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL......................................................755 REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRICATION PUMP ASSEMBLY...........................................756 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY..........................................................757 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY..............................................................758 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (WORK EQUIPMENT).............................................761 REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY.............................................................764 REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY.........................................................766 REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY................................................................767 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT.................................................................769 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY........................................................770 REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY...............................................................772 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY...................................................773 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...........................................................775 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (BACK HOE).................................................777 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL)...........................................779 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (BACK HOE)....................................................781 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (LOADING SHOVEL)..............................................783 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (BACK HOE)...................................................785 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (LOADING SHOVEL).............................................787 REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)......................................789 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.........................................................790 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (BACK HOE)..........................................................796 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (LOADING SHOVEL)....................................................797 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (BACK HOE).............................................................798 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (LOADING SHOVEL).......................................................800 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (BACK HOE)............................................................802 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (LOADING SHOVEL)......................................................804 REMOVAL AND INSTALLATION OF WORK EQUIPMENT (BACK HOE)...........................................................806 REMOVAL AND INSTALLATION OF WORK EQUIPMENT (LOADING SHOVEL).....................................................808 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.............................................................810 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)..................................................812 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...............................................................822 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY..............................................................828 90 OTHERS...........................................................................................................829 HYDRAULIC CIRCUIT DIAGRAM (PC750-7, PC750SE-7, PC800-7, PC800SE-7)..............................................830 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL SPECIFICATION, PC750-7, PC750SE-7)....................................831 ELECTRICAL CIRCUIT DIAGRAM (1/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)......................................832 ELECTRICAL CIRCUIT DIAGRAM (2/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)......................................833 ELECTRICAL CIRCUIT DIAGRAM (3/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)......................................834 ELECTRICAL CIRCUIT DIAGRAM (4/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)......................................835 ELECTRICAL CIRCUIT DIAGRAM (5/6) (PC750-7, PC750SE-7, PC800-7, PC800SE-7)......................................836 ELECTRICAL CIRCUIT DIAGRAM (6/6) (LOADING SHOVEL SPECIFICATION, PC750-7, PC750SE-7)............................837
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