Komatsu PC75UU-2 Hydraulic Excavator Shop Manual SEBM001302 PDF
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Komatsu PC75UU-2 Hydraulic Excavator Shop Manual SEBM001302 – PDF DOWNLOAD
- MACHINE MODEL SERIAL No.
PC75UU-2 5001 and up
Description
Komatsu PC75UU-2 Hydraulic Excavator Shop Manual SEBM001302 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PC75UU-2 Hydraulic Excavator Shop Manual SEBM001302 – PDF DOWNLOAD
Language : English
Pages : 391
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu PC75UU-2 Hydraulic Excavator Shop Manual SEBM001302 – PDF DOWNLOAD
- MACHINE MODEL SERIAL No.
PC75UU-2 5001 and up
COVER 1
CONTENTS 2
01 GENERAL 25
GENERAL ASSEMBLY DRAWING 26
SPECIFICATIONS 30
WEIGHT TABLE 34
LIST OF LUBRICANT AND WATER 36
10 STRUCTURE AND FUNCTION 38
HYDRAULIC PIPING DIAGRAM 39
HYDRULIC CIRCUIT DIAGRAM 40
ELECTRIC WIRING DIAGRAM 41
ELECTRIC CIRCUIT DIAGRAM 43
20 TESTING AND ADJUSTING 45
TABLE OF JUDGEMENT STANDARD VALUE 46
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 54
TOOLS FOR TESTING ,ADJUSTING,AND TROUBLESHOOTING 59
MEASURING ENGINE SPEED 60
MEASURING ENGINE OIL PRESSURE 60
MEASURING COMPRESSION PRESSURE 61
MEASURING BLOW-BY 62
ADJUSTING VALVE CLEARANCE 63
TESTING AND ADJUSTING FUEL INJECTION TIMING 64
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION 65
ADJUSTING FUEL CONTROL LEVER 66
TESTING AND ADJUSTING TRACK SHOE TENSION 68
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 69
TESTING CONTROL CIRCUIT PRESSURE 72
MEASURING OUTPUT PRESSURE OF PPC VALVE 74
ADJUSTING PPC VALVE 75
MEASURING OUTLET PORT PRESSURE OF SOLENOID VALVE,EPC VALVE 76
MEASURING OIL LEAKAGE INSIDE CYLINDER 77
MEASURING OIL LEAKAGE FROM SWING,TRAVEL MOTOR 78
BLEEDING AIR FROM HYDRAULIC CIRCUIT 79
RELEASING REMAINING FROM HYDRAULIC CIRCUIT 81
ADJUSTING BLADE CONTROL LEVER 82
ADJUSTING TRAVEL CONTROL LEVER 83
PROCEDURE FOR RESETTING ELECTRICAL SYSTEM INPUT/OUTPUT SIGNALS AND CHECKING OPERATION 84
PROCEDURE FOR REPLACING POTENTIOMETER 95
PROCDURE FOR CHECKING DIODE 96
TROUBLESHOOTING 97
POINTS TO REMEMBER WHEN TROUBLESHOOTING 98
SEQUENCE OF EVENTS IN TROUBLESHOOTING 99
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 100
CHECKS BEFORE TROUBLESHOOTING 107
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM 108
CONNECTOR ARRANGEMENT DRAWING 112
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 116
HANDING CONNECTORS 123
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM 124
DISPLAY METHOD FOR MONITOR PANEL,CONTROLLER 128
ACTION TAKEN BY SELF DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE 133
METHOD OF USING JUDGEMENT TABLE 134
METHOD OF USING TROUBLESHOOTING CHARTS 135
TROUBLESHOOTING OF CONTROLLER,ELECTRICAL SYSTEM (E MODE) 137
JUDGEMENT TABLE FOR CONTROLLER,ELECTRICAL,HYDRAULIC AND MECHANICAL SYSTEMS 138
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM 139
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS 142
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) 143
a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM 143
b) ABNORMALITY IN COMMUNICATIONS SYSTEM 144
E-2 ERROR CODE [21] (ABNORMALITY IN MODEL SELECTION SYSTEM) 145
E-3 ERROR CODE [22] (ABNORMALITY IN WORK EQUIPMENT SELECTION SYSTEM) 146
E-4 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTIOMETER SYSTEM) 147
E-5 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM) 148
E-6 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM) 149
E-7 ERROR CODE [41] (ABNORMALITY IN PPC LOCK SOLENOID SYSTEM) 150
E-8 ERROR CODE [42] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM) 151
E-9 ERROR CODE [44] (ABNORMALITY IN BOOM LOWER STOP SOLENIOD SYSTEM) 152
E-10 ERROR CODE [51] (ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM) 153
E-11 ERROR CODE [52] (ABNORMALITY IN ARM IN STOP SOLENOID SYSTEM) 154
E-12 WORK EQUIPMENT DOES NOT WORK EVEN WHEN EQUIPMENT LOCK LEVER IS RELEASED 155
E-13 DEPTH MODE,HEIGHT MODE,OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHING SET POSITION) 156
E-14 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE,DEPTH MODE,HEIGHT MODE,OFFSET MODE 157
E-15 CANCLE SWITCH IS NOT TURNED ON,BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRIC SYSTEM CAUTION LAMP FLASHES 158
E-16 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE,ARM IN,LEFT OFFSET (WHEN ERROR CODE [61] IS NOT DISPLAYED) 159
E-17 WORK EQUIPMENT LOCK LEVER IS AT LOCK POSITION BUT WORK EQUIPMENT MOVES 160
E-18 ENGINE DOES NOT START WHEN STARTING SWITCH IS TURNED TO START 161
E-19 EVEN WHEN STARTING SWITCH IS TURNED OFF,ENGINE DOES NOT STOP 163
E-20 UPPER STRUCTURE DOES NOT SWING (WHEN SWING LEVER IS OPERATED,AND NO ELECTRICITY FLOWS TO SWING BRAKE SOLENOID) 164
E-21 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN ELECTRIC CURRENT FLOWS TO SWING BRAKE SOLENIOD BOTH WHEN SWING LEVER IS OPERATED AND AT NEUTRAL) 166
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE) 168
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW 169
a) SPEEDS OF ALL WORK EQUIPMENT AND SWING ARE SLOW (WHEN BLADE AND TRAVEL SPEEDS ARE NORMAL) 169
b) SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE ALL SLOW 171
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS 172
H-3 NO WORK EQUIPMENT,SWING,TRAVEL MOVE 173
a) NONE OF WORK EQUIPMENT AND SWING MOVE 173
b) NONE OF WORK EQUIPMENT, SWING, TRAVEL MOVE 173
H-4 ALL WORK EQUIPMENT,SWING,TRAVEL LACK POWER 174
H-5 ABNORMAL NOISE GENERATED FROM AROUND PUMP 174
H-6 WORK EQUIPMENT SPEED IS SLOW (ONE OF BOOM,ARM,BUCKET,OFFSET IS SLOW) 175
H-7 WORK EQUIPMENT LACKS POWER (ONE OF BOOM,ARM,BUCKET,OFFSET LACKS POWER) 176
H-8 WORK EQUIPMENT DOES NOT MOVE (ONE OF BOOM,ARM,BUCKET,OFFSET DOES NOT MOVE) 176
H-9 EXCESSIVE HYDRAULIC DRIFT 177
H-10 EXCESSIVE TIME LAG 177
H-11 WHEN MACHINE IS TRAVELING,IT DEVIATES NATURALLY TO ONE SIDE 178
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE 178
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE 180
H-12 EXCESSIVE DEVIATION WHEN STARTING 181
H-13 TRAVEL LACKS POWER (OR SPEED IS SLOW) 181
H-14 TRACK DOES NOT MOVE (ONE SIDE ONLY) 182
H-15 TRAVEL LEVER IS HEAVY 182
H-16 DOES NOT SWING 183
H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR 183
H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING 184
H-19 EXCESSIVE SHOCK WHEN STOPPING SWING 185
H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 185
H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING 186
H-22 ERROR CODE [61] IS DISPLAYED ON MONITOR PANEL,AND JUST BEFORE INTERFERENCE,BOOM RAISE,ARM IN,AND LEFT OFFSET ALL STOP 187
H-23 BOOM RAISE,ARM IN,AND LEFT OFFSET DO NOT AUTOMATICALLY STOP AND THERE IS INTERFERENCE 188
TABLE OF FAILURE MODES AND CAUSES 189
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 190
M-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS) 191
M-2 WHEN STARTING SWITCH IS TURNED ON,LAMPS LIGHT UP FOR 3 SECONDS,BUT THEN DO NOT GO OUT 191
M-3 WHEN STARTING SWITCH IS TURNED ON,SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS 192
a) NO GAUGE LAMPS LIGHT UP PREHEATING PILOT DOES NOT LIGHT UP 192
b) BATTERY ELECTROLYTE LEVEL CAUTION LAMP DOES NOT LIGHT UP ,ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP 192
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP 192
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 192
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP 193
M-5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 193
M-6 DURING PREHEATING,PREHEATING PILOT LAMP DOES NOT LIGHT UP 194
M-7 WHEN STARTING SWITCH IS ON (ENGINE STOPPED),BATTERY ELECTROLYTE LEVEL CAUTION LAMP LIGHTS UP (BATTERY ELECTROLYTE IS AT SPECIFIED LEVEL) 194
M-8 WHEN ENGINE IS RUNNNG,ENGINE OIL PESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL) 195
M-9 WHEN ENGINE IS RNNING,CHARGE CAUTION LAMP LIGHTS UP 195
M-10 ABNORMALITY DISPLAY ON COOLANT TEMPERATURE GAUGE 196
a) AFTER ENGINE IS STARTED,LEVEL STAYS AT BOTTOM AND DOES NOT MOVE 196
b) AFTER ENGINE IS STARTED,LEVEL IMMEDIATELY RISES, ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE 196
M-11 ABNORMALITY DISPLAY ON FUEL GAUGE 197
a) ALL FUEL GAUGE SEGMENTS GO OUT 197
b) EVEN WHEN FUEL LEVEL GOES DOWN,FUEL GAUGE CONTINUES TO SHOW FULL 197
c) EVEN WHEN TANK IS FILLED,FUEL GAUGE DOES NOT SHOW FULL 198
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 199
a) BUZZER DOES NOT SOUND 199
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 199
M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE 200
a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP 200
b) WHEN CHARGE CAUTION LAMP LIGHTS UP 200
M-14 NIGHT LINGHTING DOES NOT LIGHT UP 201
a) LIGHTING OF COOLANT TEMPERATURE GAUGE,FUEL GAUGE,DEPTH DISPLAY DOES NOT LIGHT UP 201
b) LIGHTING OF SERVICE METER DOES NOT LIGHT UP 201
M-15 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP,AND DOES NOT GO OUT (NO ABNORMALITY DISPLAY ON CONTROLLER,OPERATION IS NORMAL) 202
30 DISASSEMBLY AND ASSEMBLY 203
METHOD OF USING MANUAL 205
PRECAUTIONS WHEN CARRYING OUT OPERATION 206
SPECIAL TOOLS LIST 208
SCHEMATIC DRAWING OF SPECIAL TOOL 212
STARTING MOTOR 218
REMOVAL AND INSTALLATION 218
ALTERNATOR 220
REMOVAL AND INSTALLATION 220
FUEL INJECTION PUMP 221
REMOVAL AND INSTALLATION 221
WATER PUMP 224
REMOVAL 224
INSTALLATION 225
NOZZLE HOLDER 226
REMOVAL AND INSTALLTION 226
THERMOSTAT 227
REMOVAL AND INSTALLATION 227
ENGINE FRONT SEAL 228
REMOVAL AND INSTALLATION 228
ENGINE REAR SEAL 229
REMOVAL AND INSTALLATION 229
CYLINDER HEAD 230
REMOVAL 230
INSTALLATION 234
HYDRAULIC OIL COOLER 236
REMOVAL AND INSTALLATION 236
RADIATOR 237
REMOVAL AND INSTALLATION 237
ENGINE AND MAIN PUMP 238
REMOVAL 238
INSTALLATION 241
DAMPER 245
REMOVAL AND INSTALLATION 245
CENTER SWIVEL JOINT 246
REMOVAL AND INSTALLATION 246
DISASSEMBLY AND ASSEMBLY 248
TRAVEL MOTOR 249
REMOVAL AND INSTALLATION 249
SPROCKET 250
REMOVAL AND INSTALLATION 250
SWING MOTOR AND SWING MACHINERY 251
REMOVAL AND INSTALLATION 251
SWING MOTOR 252
DISASSEMBLY 252
ASSEMBLY 256
SWING MACHINERY 262
DISASSEMBLY 262
ASSEMBLY 269
REVOLVING FRAME 276
REMOVAL 276
INSTALLATION 277
SWING CIRCLE 278
REMOVAL AND INSTALLATION 278
IDLER AND RECOIL SPRING 279
REMOVAL AND INSTALLATION 279
IDLER 280
DISASSEMBLY 280
ASSEMBLY 281
RECOIL SPRING 283
DISASSEMBLY 283
ASSEMBLY 284
TRACK ROLLER 285
REMOVAL AND INSTALLATION 285
DISASSEMBLY 286
ASSEMBLY 289
RUBBER SHOE 296
REMOVAL AND INSTALLATION 296
STEEL SHOE AND ROAD LINER 297
EXPANSION AND INSTALLATION 297
PPC PUMP 298
REMOVAL AND INSTALLATION 298
MAIN PUMP 299
REMOVAL AND INSTALLATION 299
DISASSEMBLY 300
ASSEMBLY 307
3-SPOOL CONTROL VALVE 315
REMOVAL 315
INSTALLATION 316
DISASSEMBLY 319
ASSEMBLY 321
4-SPOOL CONTROL VALVE 323
REMOVAL 323
INSTALLATION 324
MAIN RELIEF VALVE 325
REMOVAL AND INSTALLATION 325
DISASSEMBLY AND ASSEMBLY 326
PPC VALVE ASSEMBLY ON LEFT SIDE OF WORK EQUIPMENT 327
REMOVAL AND INSTALLATION 327
PPC VALVE ON RIGHT SIDE OF WORK EQUIPMENT 328
REMOVAL AND INSTALLATION 328
WORK EQUIPMENT PPC VALVE 329
DISASSEMBLY 329
ASSEMBLY 331
PPC VALVE FOR OFFSET OPERATION 334
REMOVAL AND INSTALLATION 334
ARM CYLINDER 335
REMOVAL 335
INSTALLATION 336
BUCKERT CYLINDER 337
REMOVAL 337
INSTALLATION 338
BOOM CYLINDER 339
REMOVAL 339
INSTALLATION 340
OFFSET CYLINDER 341
REMOVAL 341
INSTALLATION 342
BLADE CYLINDER 343
REMOVAL 343
INSTALLATION 344
HYDRAULIC CYLINDER 345
DISASSSEMBLY 345
ASSEMBLY 347
WORK EQUIPMENT 349
REMOVAL 349
INSTALLATION 350
BUCKET 351
REMOVAL AND INSTALLATION 351
ARM 352
REMOVAL 352
INSTALLATION 353
2ND BOOM 354
REMOVAL 354
INSTALLATION 356
BUCKET AND ARM 357
REMOVAL 357
INSTALLATION 358
1ST BOOM 359
REMOVAL 359
INSTALLATION 360
BLADE 361
REMOVAL AND INSTALLATION 361
OPERATOR’S CAB 362
REMOVAL AND INSTALLATION 362
FLOOR FRAME 363
REMOVAL 363
INSTALLATION 364
FUEL TANK 365
REMOVAL AND INSTALLATION 365
CONTROLLER 366
REMOVAL AND INSTALLATION 366
MONITOR 367
REMOVAL AND INSTALLATION 367
COUNTERWEIGHT 368
REMOVAL AND INSTALLATION 368
40 MAINTENANCE STANDARD 369
SWING MACHINERY 370
SWING CIRCLE 371
TRACK FRAME,RECOIL SPRING 372
IDLER 373
TRACK ROLLER 374
CARRIER ROLLER 375
SPROCKET 377
TRACK SHOE 378
HYDRAULIC PUMP 379
3-SPOOL CONTROL VALVE(FOR FRONT PUMP) 380
3-SPOOL CONTROL VALVE(FOR CENTER PUMP) 382
4-SPOOL CONTROL VALVE 384
SWING MOTOR 385
CENTER SWIVEL JOINT 386
PPC VALVE 387
HYDRAULIC CYLINDER 389
WORK EQUIPMENT 390
DESCRIPTION:
Komatsu PC75UU-2 Hydraulic Excavator Shop Manual SEBM001302 – PDF DOWNLOAD
- MACHINE MODEL SERIAL No.
PC75UU-2 5001 and up
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
G.B 18/12/24
