Komatsu PC750-7 PC800-7 Hydraulic Excavator Shop Manual SEBM031314 – PDF DOWNLOAD

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Komatsu PC750-7 PC800-7 Hydraulic Excavator Shop Manual SEBM031314 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu PC750-7 PC800-7 Hydraulic Excavator Shop Manual SEBM031314 – PDF DOWNLOAD

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

FOREWORD:
GENERAL:

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 PC800-7 Hydraulic Excavator Shop Manual SEBM031314 – PDF DOWNLOAD

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

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