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Komatsu Hydraulic Excavators PC750SE-6K, PC750LC-6K Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC750SE-6K, PC750LC-6K, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC750SE-6K, PC750LC-6K 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.

EEAM008708 – Hydraulic Excavator PC750SE-6K, PC750LC-6K Operation & Maintenance Manual.pdf
UEAM002901 – Hydraulic Excavator PC750LC-7K, PC750SE-7K Operation & Maintenance Manual.pdf
UEBM001801 – Hydraulic Excavator PC750SE-6K, PC750LC-6K Shop Manual.pdf
UEBM002400 – Hydraulic Excavator PC750SE-7K, PC750LC-7K Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 2,034 pages
File Format: PDF
Language: English

EEAM008708 – Hydraulic Excavator PC750SE-6K, PC750LC-6K Operation & Maintenance Manual….2
FOREWORD….4
FOREWORD….5
SAFETY INFORMATION….7
NOISE….8
VIBRATION….8
INTRODUCTION….9
INTENDED USE….9
FEATURES….9
RUNNING IN THE MACHINE….9
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….11
MACHINE SERIAL NO. PLATE POSITION….11
ENGINE SERIAL NO. PLATE POSITION….11
SERVICE METER POSITION….12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….12
MACHINE SERIAL PLATE….13
SAFETY….20
GENERAL PRECAUTIONS….21
PRECAUTIONS DURING OPERATION….29
BEFORE STARTING THE ENGINE….29
AFTER STARTING ENGINE….31
TRANSPORTATION….38
BATTERY….39
TOWING….41
LIFTING OPERATIONS….42
PRECAUTIONS FOR MAINTENANCE….43
BEFORE CARRYING OUT MAINTENANCE….43
DURING MAINTENANCE….47
POSITION FOR ATTACHING SAFETY LABELS….55
OPERATION….62
GENERAL VIEW….63
GENERAL VIEW OF MACHINE….63
EXPLANATION OF COMPONENTS….64
MACHINE MONITOR….65
BASIC CHECK ITEMS (A)….67
CAUTION ITEMS (B)….69
EMERGENCY STOP ITEMS (C)….70
METER DISPLAY PORTION (D)….71
SWITCHES (E)….75
SWITCHES….77
CONTROL LEVERS, PEDALS….84
CEILING WINDOW….86
FRONT WINDOW….87
DOOR LOCK….91
LOCKABLE COMPARTMENTS AND FUEL CAP….91
OPENING AND CLOSING CAP WITH LOCK (for the fuel tank filler port)….92
OPENING AND CLOSING LOCKABLE COMPARTMENTS….92
LUGGAGE BOX….92
ASHTRAY….93
HANDLING AIR CONDITIONER….93
GENERAL LOCATIONS ON CONTROL PANEL….93
PRECAUTIONS WHEN USING AIR CONDITIONER….95
RADIO-CASSETTE (OPTION)….96
PRECAUTION DURING USE….96
FUSE….96
Fuse Capacities and Circuit Names….97
FUSIBLE LINK….97
CIRCUIT BREAKER….98
CONTROLLERS….99
TOOLKIT HOLDER (CLOTH BAG)….99
GREASE PUMP….99
Method of Use….100
Precautions when Using….101
Supplying Grease….101
ACCUMULATOR HANDLING….103
RELEASING PRESSURE IN THE CONTROL CIRCUIT ON MACHINES EQUIPPED WITH AN ACCUMULATOR….103
OPERATION….105
CHECKS BEFORE STARTING ENGINE….105
WALK-AROUND CHECK….105
CHECK BEFORE STARTING….106
ADJUST OPERATORS SEAT….113
Rearview Mirrors….115
Seat Belt….115
OPERATIONS AND CHECKS BEFORE STARTING ENGINE….117
STARTING ENGINE….118
NORMAL STARTING….118
STARTING IN COLD WEATHER….119
OPERATIONS AND CHECKS AFTER STARTING ENGINE….121
WHEN NORMAL….121
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)….123
TRAVELLING….126
TRAVELLING FORWARD….126
TRAVELLING BACKWARD….128
CHANGING DIRECTION….129
STOPPING MACHINE….132
SWINGING….133
OPERATION OF WORK EQUIPMENT….134
WORKING MODE OPERATION….135
PROHIBITIONS FOR OPERATION….136
PRECAUTIONS FOR OPERATION….138
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS….139
HOW TO ESCAPE FROM MUD….140
WHEN ONE SIDE IS STUCK….141
WHEN BOTH SIDES ARE STUCK….141
WORK POSSIBLE USING HYDRAULIC EXCAVATORS….141
BACKHOE WORK….141
DITCHING WORK….142
LOADING WORK….142
REPLACEMENT OF BUCKET….142
REPLACEMENT….142
PARKING MACHINE….144
CHECK AFTER FINISHING WORK….145
STOPPING ENGINE….145
CHECK AFTER STOPPING ENGINE….146
LOCKING….147
TRANSPORTATION….148
LOADING, UNLOADING WORK….148
PRECAUTIONS FOR LOADING….150
PRECAUTIONS FOR TRANSPORTATION….150
TRANSPORTATION POSTURE….151
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….156
COLD WEATHER OPERATION….158
PRECAUTIONS FOR LOW TEMPERATURE….158
FUEL AND LUBRICANTS….158
COOLANT….158
BATTERY….159
PRECAUTIONS AFTER COMPLETION OF WORK….159
AFTER COLD WEATHER….160
LONG-TERM STORAGE….161
BEFORE STORAGE….161
DURING STORAGE….161
AFTER STORAGE….162
STARTING MACHINE AFTER LONG-TERM STORAGE….162
TROUBLESHOOTING….163
WHEN MACHINE RUNS OUT OF FUEL….163
PHENOMENA THAT ARE NOT FAILURES….163
METHOD OF TOWING MACHINE….163
PRECAUTIONS ON PARTICULAR JOBSITES….164
IF BATTERY IS DISCHARGED….164
REMOVAL AND INSTALLATION OF BATTERY….164
STARTING ENGINE WITH BOOSTER CABLE….165
OTHER TROUBLE….167
ELECTRICAL SYSTEM….167
CHASSIS….168
Engine….169
Electronic Control System….171
MAINTENANCE….172
GUIDES TO MAINTENANCE….173
OUTLINES OF SERVICE….176
OUTLINE OF OIL, FUEL, COOLANT….176
OIL….176
USE OF BIO-DEGRADEABLE OIL….177
FUEL….177
COOLANT….178
GREASE….178
STORING OIL AND FUEL….179
FILTERS….179
OUTLINE OF ELECTRICAL SYSTEM….179
OUTLINE OF HYDRAULIC SYSTEM….180
RELEASING PRESSURE….181
RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT….181
BLEEDING AIR FROM CIRCUIT….181
Procedure for bleeding air….182
WEAR PARTS….184
WEAR PARTS LIST….184
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….186
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….186
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS….190
LIST OF NECESSARY TOOLS….190
TIGHTENING TORQUE LIST….191
SAFETY CRITICAL PARTS….192
SAFETY CRITICAL PARTS LIST….193
MAINTENANCE SCHEDULE….194
MAINTENANCE SCHEDULE CHART….194
SERVICE PROCEDURE….196
INITIAL 100 HOURS SERVICE….196
INITIAL 250 HOURS SERVICE….196
WHEN REQUIRED….196
Air Cleaner Element – Check/Clean/Replace….196
Checking….197
Air Cleaner Element – Install….199
Air Cleaner Inner Element – Replace….200
Cooling System Coolant – Clean/Change….202
CHECK AND TIGHTEN TRACK SHOE BOLTS….205
CHECK AND ADJUST TRACK TENSION….206
CHECK ELECTRICAL INTAKE AIR HEATER….208
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….208
ADJUST BUCKET CLEARANCE….209
Replacement of Fan Belt and Adjustment of Auto Tensioner….211
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….212
AIR CONDITIONER CHECK AND MAINTENANCE….213
Clean Line Filter, Remove Dirt….214
CHECK BEFORE STARTING….215
CHECK COOLANT LEVEL….215
CHECK OIL LEVEL IN ENGINE OIL PAN….215
CHECK FUEL LEVEL….215
CHECK OIL LEVEL IN HYDRAULIC TANK….215
CHECK FOR CLOGGING OF AIR CLEANER….215
CHECK ELECTRICAL WIRING….215
CHECK FUNCTION OF HORN….215
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL….216
CHECK OIL LEVEL IN P.T.O. CASE, ADD OIL….216
EVERY 10 HOURS SERVICE….217
LUBRICATING….217
DRAIN FUEL – WATER SEPARATOR….219
EVERY 100 HOURS MAINTENANCE….220
Swing Circle – Lubricate (4 points)….220
Fuel Tank – Drain….220
EVERY 250 HOURS MAINTENANCE….220
Final Drive Case Oil Level – Check/Add….220
Battery Electrolyte Level – Check….221
Fuel tank Strainer – Check/Clean….222
Track Frame and Axle Connecting Bolts – Check/ Tighten….223
Alternator Belt Tension – Inspect/Adjust….223
Air Conditioner Compressor Belt Tension – Inspect/Adjust….225
EVERY 500 HOURS MAINTENANCE….226
Fuel Filter Cartridge – Replace….226
Swing Pinion Gear Oil Level – Check/Add….228
Hydraulic Tank Strainer – Clean….229
Hydraulic Oil Filter Element – Replace….230
Radiator Fins, Oil Cooler Fins, After Cooler Fins, Fuel Filter Fins and Condenser Fins (Only for …..231
Air Conditioner FRESH/RECIRC Air Filters (Only for Machines Equipped with Air Conditioner) – Clean….232
Pilot Filter Element – Replace….233
P.T.O Case Oil Strainer – Clean….234
Fan Belt – Inspect….234
Drain Filter Cartridge – Replace….235
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge….235
EVERY 1000 HOURS MAINTENANCE….238
Swing Machinery Case Oil – Change….238
P.T.O Case Oil – Change….239
Turbocharger Fastening Parts – Inspect/Tighten….240
Turbocharger Rotor Play – Inspect….240
Corrosion Resister Cartridge – Replace….240
Fan Pulley Assembly and Tension Pulley Assembly – Lubricate….241
Hydraulic Tank Breather Filter Element – Replace….242
Welded Structure – Check….243
EVERY 2000 HOURS MAINTENANCE….246
Final Drive Case Oil – Change….246
Injector – Check….246
Engine Crankcase Breather – Clean….247
Turbocharger – Inspect….247
Alternator and Starting Motor – Inspect….247
Engine Valve Clearances – Inspect….248
EVERY 4000 HOURS MAINTENANCE….248
Water Pump – Inspect….248
Vibration Damper – Inspect….248
Fan Pulley and Tension Pulley – Check….248
Checking for Looseness of High-pressure Clamp, Hardening of Rubber….249
Injector Nozzle Assembly – Replace….250
Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber….250
EVERY 5000 HOURS MAINTENANCE….251
EVERY 8000 HOURS MAINTENANCE….253
High-pressure Piping Clamp – Replace….253
Fuel Spray Prevention Cap – Replace….253
SPECIFICATIONS….256
SPECIFICATIONS….257
MEMO….259
OPTIONS AND ATTACHMENTS….260
GENERAL PRECAUTIONS….261
PRECAUTIONS RELATED TO SAFETY….261
PRECAUTIONS WHEN INSTALLING ATTACHMENTS….262
OPTIONAL PARTS AND ATTACHMENTS….263
WORK EQUIPMENT COMBINATIONS….263
SELECTION OF TRACK SHOES….264
MEMO….267
LOADING SHOVEL….268
GENERAL LOCATIONS….269
INSTRUMENTS AND CONTROLS….270
SWITCHES….270
OPERATION OF WORK EQUIPMENT….271
PRECAUTIONS FOR MACHINE OPERATION….274
PRECAUTONS DURING OPERATION….274
PRECAUTIONS WHEN DISASSEMBLING MACHINE….278
RELEASING PRESSURE….278
RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT….278
RELEASING PRESSURE IN ACCUMULATOR CIRCUIT….278
MAINTENANCE….279
CHECK BEFORE STARTING….279
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….279
EVERY 10 HOURS SERVICE….280
LUBRICATING….281
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….281
EXCAVATOR WORK….284
TRANSPORTATION….285
PARTS FOR TRANSPORT….285
CONSUMABLE PARTS LIST….287
SPECIFICATIONS….288
COMBINATIONS OF WORK EQUIPMENT….289
COMBINATIONS OF WORK EQUIPMENT….289
UEAM002901 – Hydraulic Excavator PC750LC-7K, PC750SE-7K Operation & Maintenance Manual….290
COVER….290
FOREWORD….292
FOREWORD….293
SAFETY INFORMATION….294
NOISE….296
VIBRATION….296
BREAKING-IN THE NEW MACHINE….297
INTRODUCTION….298
DIRECTIONS OF MACHINE….298
PRODUCT INFORMATION….299
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….299
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….299
SERVICE METER LOCATION….300
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR….300
MACHINE SERIAL PLATE….301
FOREWORD….302
SAFETY….302
OPERATION….303
MAINTENANCE….306
SPECIFICATIONS….308
ATTACHMENTS AND OPTIONS….308
LOADING SHOVEL….308
INDEX….309
COLOPHON….309
SAFETY….310
SAFETY INFORMATION….311
SAFETY LABELS….313
LOCATION OF SAFETY LABELS….314
SAFETY LABELS….315
SAFETY INFORMATION….322
SAFETY MACHINE OPERATION….332
STARTING ENGINE….332
OPERATION….334
TRANSPORTATION….341
BATTERY….342
TOWING….344
LIFTING OBJECTS WITH BUCKET….345
SAFETY MAINTENANCE INFORMATION….346
OPERATION….354
MACHINE VIEW ILLUSTRATIONS….356
OVERALL MACHINE VIEW….356
CONTROLS AND GAUGES….357
DETAILED CONTROLS AND GAUGES….359
MONITORING SYSTEM….359
Basic Operation Of Machine Monitor….360
Basic Check Monitors….362
Caution Monitors….364
Emergency Monitors….366
Meter Display Portion….368
Monitor Switches Portion….372
SWITCHES….382
CONTROL LEVERS AND PEDALS….389
SUN ROOF….393
Opening….393
Closing….393
WINDSHIELD….394
EMERGENCY EXIT FROM OPERATOR'S CAB….399
DOOR LOCK….399
CAP WITH LOCK….400
HOT AND COOL BOX….401
MAGAZINE BOX….401
ASHTRAY….402
AIR CONDITIONER CONTROLS….403
Air Conditioner Control Panel….403
Method Of Operation….408
Use Air Conditioner With Care….414
Air Conditioner Maintenance….414
Other Functions….415
CAB RADIO….416
Use Radio With Care….416
AUXILIARY ELECTRIC POWER….417
24V power source….417
12V power source….417
FUSE….418
CIRCUIT BREAKER….419
CONTROLLERS….420
TOOL BOX….420
GREASE PUMP….420
Method of Use….421
Precautions when Using….422
Supplying Grease….423
ACCUMULATOR….424
Releasing Hydraulic Pressure With Accumulator….424
MACHINE OPERATIONS AND CONTROLS….425
BEFORE STARTING ENGINE….425
Walk-Around Checks….425
Checks Before Starting….426
Adjustment….437
Seat Belt….439
Operations Before Starting Engine….440
STARTING ENGINE….443
Normal Starting….443
Starting Engine In Cold Weather….445
AFTER STARTING ENGINE….448
Warming-Up Operation….448
In Cold Weather Areas….452
STOPPING THE ENGINE….457
MACHINE OPERATION….458
Preparations For Moving The Machine Off….458
Moving Machine Forward….459
Moving Machine Backward….460
Stopping Machine….461
STEERING THE MACHINE….462
Steering….462
SWINGING….464
WORK EQUIPMENT CONTROLS AND OPERATIONS….465
WORKING MODE….467
PROHIBITED OPERATIONS….468
GENERAL OPERATION INFORMATION….470
TRAVELING ON SLOPES….472
ESCAPE FROM MUD….474
Stuck One Side Of Track….474
Stuck Both Sides Of Tracks….474
RECOMMENDED APPLICATIONS….475
Backhoe Work….475
Ditching Work….475
Loading Work….475
BUCKET REPLACEMENT….476
Replacement….476
PARKING MACHINE….478
CHECK AFTER SHUT OFF ENGINE….479
LOCKING….480
TRANSPORTATION….481
PRECAUTIONS FOR TRANSPORTATION….481
LIFTING MACHINE….481
SHIPPING MACHINE INFORMATION….483
TRANSPORTATION POSTURE….484
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….489
COLD WEATHER OPERATION….491
COLD WEATHER OPERATION INFORMATION….491
Fuel And Lubricants….491
AFTER DAILY WORK COMPLETION….493
AFTER COLD WEATHER SEASON….493
LONG TERM STORAGE….494
BEFORE STORAGE….494
DURING STORAGE….494
AFTER STORAGE….495
STARTING MACHINE AFTER LONG-TERM STORAGE….495
TROUBLES AND ACTIONS….496
RUNNING OUT OF FUEL….496
PHENOMENA THAT ARE NOT FAILURES….498
TOWING THE MACHINE….499
SEVERE JOB CONDITION….499
DISCHARGED BATTERY….500
Battery Removal And Installation….500
Battery Charges….501
Starting Engine With Booster Cables….502
OTHER TROUBLE….504
Electrical System….504
Chassis….505
Engine….506
Electronic Control System….508
Point Of Contact To Telephone When Error Occurs….509
MAINTENANCE….510
MAINTENANCE INFORMATION….511
LUBRICANTS, COOLANT AND FILTERS….513
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….513
Oil….513
Fuel….513
Cooling System Coolant….514
Grease….514
Carrying out KOWA (Komatsu Oil Wear Analysis)….515
Oil And Fuel Storage….516
Filters….516
ELECTRIC SYSTEM MAINTENANCE….516
WEAR PARTS….517
WEAR PARTS LIST….518
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….519
PROPER SELECTION….519
TIGHTENING TORQUE SPECIFICATIONS….523
TIGHTENING TORQUE LIST….523
SAFETY CRITICAL PARTS….524
SAFETY CRITICAL PARTS LIST….525
MAINTENANCE SCHEDULE….526
MAINTENANCE SCHEDULE CHART….526
MAINTENANCE PROCEDURE….528
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)….528
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….528
WHEN REQUIRED….529
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….529
CLEAN INSIDE OF COOLING SYSTEM….534
CHECK AND TIGHTEN TRACK SHOE BOLTS….538
CHECK AND ADJUST TRACK TENSION….539
CHECK ELECTRICAL INTAKE AIR HEATER….541
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….541
ADJUST BUCKET CLEARANCE….542
REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER….543
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….544
CHECK AND ADJUST AIR CONDITIONER….545
CLEAN LINE FILTER, REMOVE DIRT….546
BLEEDING AIR FROM HYDRAULIC SYSTEM….547
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….550
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit)….551
CHECK BEFORE STARTING….552
EVERY 10 HOURS MAINTENANCE….553
LUBRICATING….553
EVERY 100 HOURS MAINTENANCE….556
LUBRICATING SWING CIRCLE….556
EVERY 250 HOURS MAINTENANCE….557
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….557
CHECK LEVEL OF BATTERY ELECTROLYTE….558
CHECK, CLEAN FUEL TANK STRAINER….561
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS….561
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST….562
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….563
EVERY 500 HOURS MAINTENANCE….564
REPLACE FUEL FILTER CARTRIDGE….564
REPLACEMENT OF ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED)….565
CHECK SWING PINION GREASE LEVEL, ADD GREASE….567
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)….568
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)….569
REPLACE PILOT FILTER ELEMENT….571
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER….572
CHECK FAN BELT….572
REPLACE DRAIN FILTER CARTRIDGE….573
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….574
EVERY 1000 HOURS MAINTENANCE….576
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….576
REPLACE HYDRAULIC OIL FILTER ELEMENT….577
CHANGE OIL IN SWING MACHINERY CASE….579
CHANGE OIL IN P.T.O CASE….581
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….581
CHECK PLAY TURBOCHARGER ROTOR….581
REPLACE CORROSION RESISTOR CARTRIDGE….582
LUBRICATING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY….582
CHECK WELDED STRUCTURE….583
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)….585
EVERY 2000 HOURS MAINTENANCE….586
CHANGE OIL IN FINAL DRIVE CASE….586
CHECK INJECTOR….586
CLEAN HYDRAULIC TANK STRAINER….587
CLEAN ENGINE BREATHER….588
CLEAN, CHECK TURBOCHARGER….588
CHECK ALTERNATOR, STARTING MOTOR….588
CHECK ENGINE VALVE CLEARANCE, ADJUST….588
EVERY 4000 HOURS MAINTENENCE….589
CHECK WATER PUMP….589
CHECK VIBRATION DAMPER….589
CHECK FAN PULLEY AND TENSION PULLEY….589
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….589
REPLACE INJECTOR NOZZLE ASSEMBLY….590
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….591
EVERY 5000 HOURS MAINTENANCE….592
CHANGE OIL IN HYDRAULIC TANK….592
EVERY 8000 HOURS MAINTENANCE….593
REPLACE HIGH-PRESSURE PIPING CLAMP….593
REPLACE FUEL SPRAY PREVENTION CAP….593
SPECIFICATIONS….594
SPECIFICATIONS….595
ATTACHMENTS AND OPTIONS….598
GENERAL PRECAUTIONS FOR SAFETY….599
PRECAUTIONS WHEN SELECTING….599
READ THE INSTRUCTION MANUAL THOROUGHLY….599
PRECAUTIONS WHEN REMOVING OR INSTALLING….599
PRECAUTIONS WHEN USING….600
ATTACHMENT GUIDE….601
COMBINATIONS OF WORK EQUIPMENT….601
Working Range Diagram….603
LOADING SHOVEL….604
GENERAL LOCATIONS….605
INSTRUMENTS AND CONTROLS….606
SWITCHES….606
OPERATION OF WORK EQUIPMENT….607
PRECAUTIONS FOR MACHINE OPERATION….609
PRECAUTONS DURING OPERATION….609
Phenomena that do not indicate failure….612
PRECAUTIONS WHEN DISASSEMBLING MACHINE….613
RELEASING PRESSURE….613
RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT….613
RELEASING PRESSURE IN ACCUMULATOR CIRCUIT….613
MAINTENANCE….614
CHECK BEFORE STARTING….614
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL….614
EVERY 10 HOURS SERVICE….616
LUBRICATING….616
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….617
EXCAVATOR WORK….619
TRANSPORTATION….620
PARTS FOR TRANSPORT….620
CONSUMABLE PARTS LIST….621
SPECIFICATIONS….622
COMBINATIONS OF WORK EQUIPMENT….623
COMBINATIONS OF WORK EQUIPMENT….623
INDEX….624
<A>….626
<B>….626
<C>….626
<D>….626
<E>….626
<F>….626
<G>….626
<H>….626
<L>….626
<M>….626
<O>….626
<P>….626
<R>….627
<S>….627
<T>….627
<W>….627
<Y>….627
COLOPHON….628
UEBM001801 – Hydraulic Excavator PC750SE-6K, PC750LC-6K Shop Manual….630
GENERAL ….658
SPECIFICATION DRAWINGS ….659
FUEL, COOLANT AND LUBRICANTS ….667
PTO ….669
PTO LUBRICATION SYSTEM ….670
POWER TRAIN SWING MACHINERY SWING CIRCLE ….675
FINAL DRIVE ….677
TRACK FRAME AND RECOIL SPRING ….679
IDLER CARRIER ROLLER ….683
TRACK ROLLER ….684
TRACK SHOE ( 1/ 2) ….685
( 2/ 2) ….687
MOTOR GREASE PUMP ….690
HYDRAULIC TANK ….691
HYDRAULIC PUMP ….693
LINE OIL FILTER ….723
PILOT OIL FILTER ….723
DRAIN OIL FILTER ….724
L. H. 5- SPOOL CONTROL VALVE ….725
R. H. 4- SPOOL CONTROL VALVE ….731
STRAIGHT- TRAVEL VALVE ….737
SWING MOTOR ….740
CENTER SWIVEL JOINT ….745
TRAVEL MOTOR ….746
PPC CONTROL RELIEF VALVE ….756
SAFETY LOCK VALVE ….757
PPC ACCUMULATOR ….758
VALVE CONTROL ….759
WORK EQUIPMENT, SWING PPC VALVE ….760
TRAVEL PPC VALVE ….765
SOLENOID VALVE ….769
HYDRAULIC CYLINDER ….775
WORK EQUIPMENT ….779
DIMENSIONS OF WORK EQUIPMENT ….783
AIR CONDITIONER ….787
ENGINE CONTROL ….788
MACHINE CONTROL SYSTEM ….793
MONITOR SYSTEM ….821
SENSORS ….828
TESTING AND ADJUSTING ….832
STANDARD VALUE TABLE FOR ENGINE ….833
STANDARD VALUE TABLE FOR CHASSIS ….834
STANDARD VALUE TABLE FOR ELECTRICAL PARTS ….843
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ….856
MEASURING AIR SUPPLY PRESSURE ( BOOST PRESSURE) ….859
MEASURING EXHAUST TEMPERATURE ….860
MEASURING EXHAUST COLOR ….861
ADJUSTING VALVE CLEARANCE ….862
MEASURING BLOW- BY PRESSURE ….863
MEASURING COMPRESSION PRESSURE ….863
MEASURING ENGINE OIL PRESSURE ….864
HANDLING EQUIPMENT IN FUEL CIRCUIT ….865
RELEASING REMAINING PRESSURE IN FUEL SYSTEM ….865
MEASURING FUEL PRESSURE ….866
REDUCED CYLINDER MODE OPERATION FOR ENGINE ….867
BLEEDING AIR FROM FUEL CIRCUIT ….869
CHECKING FOR LEAKAGE IN FUEL CIRCUIT ….871
TESTING AND ADJUSTING ALTERNATOR BELT TENSION ….872
TESTING AND ADJUSTING FAN BELT TENSION ….873
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION ….874
HANDLING ENGINE CONTROL- LER HIGH VOLTAGE CIRCUIT ….875
ADJUSTING ENGINE SPEED SENSOR ….876
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT ….877
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE ….880
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE ….882
MEASURING SERVO PISTON STROKE ….888
MEASURING PPC VALVE OUT- PUT PRESSURE ….889
TESTING SOLENOID VALVE OUTPUT PRESSURE ….890
ADJUSTING WORK EQUIP- MENT, SWING PPC VALVE ….891
TESTING TRAVEL DEVIATION ….892
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ….895
MEASURING OIL LEAKAGE ….896
TESTING CLEARANCE OF SWING CIRCLE BEARING ….901
TESTING AND ADJUSTING TRACK SHOE TENSION ….902
BLEEDING AIR ….903
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ….905
PROCEDURE FOR CHECKING DIODE ….906
POINTS TO REMEMBER WHEN TROUBLESHOOTING ….909
SEQUENCE OF EVENTS IN TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE CHECKS BEFORE TROUBLESHOOTING ….919
CONNECTOR TYPES AND MOUNTING LOCATIONS ….920
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ….927
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM ….950
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL ….951
METHOD OF USING JUDGEMENT TABLE ….966
METHOD OF USING TROUBLESHOOTING CHARTS ….968
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE ….969
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ….975
N- 1 [ E117, E118 occur at same time ] Monitor panel communication abnormality ….978
N- 2 [ E117, E218 occur at same time ] Engine controller communication abnormality ….980
N- 3 [ E118, E955 occur at same time ] Pump controller communication abnormality ….982
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED ….985
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED ….985
E- 1 [ E91b ] ( Abnormality in engine speed Ne sensor system) is displayed ….997
E- 2 [ E91C ] ( Abnormality in engine G rotation sensor system) is displayed ….998
E- 3 [ E920 ] ( Abnormality in model selection system) is displayed ….999
E- 4 [ E922 ] ( Engine overrun) is displayed ….1000
E- 5 [ E924 ] ( Drop in engine oil pressure) is displayed ….1001
E- 6 [ E931 ] ( Abnormality in fuel control dial sensor system) is displayed ….1002
E- 7 [ E934 ] ( Abnormality in engine water high- temperature sensor system) is displayed ….1003
E- 8 [ E936 ] ( Abnormality in engine oil pressure switch system) is displayed ….1004
E- 9 [ E93C ] ( Abnormality in boost pressure sensor system) is displayed ….1006
E- 10 [ E93d ] ( Abnormality in fuel temperature sensor system) is displayed ….1007
E- 11 [ E954 ] ( Short circuit in starting switch C system) is displayed ….1008
12 [ E955 ] ( Abnormality in network system) is displayed ….1008
E- 13 [ E956 ] ( Power source system abnormality 1) is displayed ….1009
E- 14 [ E957 ] ( Power source system abnormality 2) is displayed ….1011
15 [ E95A ] ( Abnormality in fuel injection amount adjustment switch signal) is displayed ….1011
E- 16 [ E96A ] ( Abnormality in engine water low- temperature sensor system) is displayed ….1012
E- 17 [ E970 ] ( Excess current in fuel supply pump PCV1 system) is displayed ….1013
E- 18 [ E971 ] ( Excess current in fuel supply pump PCV2 system) is displayed ….1014
E- 19 [ E974 ] ( Disconnection in fuel supply pump PCV1 system) is displayed ….1015
E- 20 [ E975 ] ( Disconnection in fuel supply pump PCV2 system) is displayed ….1016
E- 21 [ E977 ] ( Abnormality in common rail fuel pressure sensor system) is displayed ….1017
E- 22 [ E979 ] ( Common rail fuel high pressure abnormality 1) is displayed [ E97A ] ( Common rail fuel high pressure abnormality 2) is displayed ….1018
E- 23 [ E97b ] ( Fuel supply pump non- force feed 1) is displayed [ E97C ] ( Fuel supply pump non- force feed 2) is displayed ….1019
E- 24 [ E97d ] ( Abnormality in common rail fuel pressure) is displayed ….1021
E- 25 [ E980 ] ( Defective engine controller) is displayed ….1021
E- 26 [ E981 ] ( Disconnection in No. 1 fuel injector system) is displayed ….1022
E- 27 [ E982 ] ( Disconnection in No. 2 fuel injector system) is displayed ….1023
E- 28 [ E983 ] ( Disconnection in No. 3 fuel injector system) is displayed ….1024
E- 29 [ E984 ] ( Disconnection in No. 4 fuel injector system) is displayed ….1025
E- 30 [ E985 ] ( Disconnection in No. 5 fuel injector system) is displayed ….1026
E- 31 [ E986 ] ( Disconnection in No. 6 fuel injector system) is displayed ….1027
E- 32 [ E98A ] ( Short circuit in No. 1, No. 2, No. 3 fuel injector system) is displayed ….1028
E- 33 [ E98b ] ( Short circuit in No. 3, No. 4, No. 5 fuel injector system) is displayed ….1032
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM ( C MODE) ….1036
POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM ….1037
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ….1039
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS ….1047
POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM ….1037
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ….1039
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS ….1047
C- 1 Abnormality in controller power source system ( controller LED is OFF) ….1051
C- 1 Related electrical circuit diagram ….1051
TROUBLESHOOTING C- 2 ….1052
C- 2 [ E232 ] Short circuit in pump TVC solenoid system is displayed ….1052
TROUBLESHOOTING C- 2 C- 2 Related electrical circuit diagram TROUBLESHOOTING C- 3 ….1054
C- 3 [ E233 ] Disconnection in pump TVC solenoid system is displayed ….1054
TROUBLESHOOTING C- 3 C- 3 Related electrical circuit diagram TROUBLESHOOTING C- 4 ….1056
C- 4 [ E203 ] Short circuit in swing holding brake solenoid system is displayed ….1056
TROUBLESHOOTING C- 4 C- 4 Related electrical circuit diagram TROUBLESHOOTING C- 5 ….1058
C- 5 [ E213 ] Disconnection in swing holding brake solenoid system is displayed ….1058
TROUBLESHOOTING C- 5 C- 5 Related electrical circuit diagram TROUBLESHOOTING C- 6 ….1060
C- 6 [ E201 ] Short circuit in CO cancel solenoid system is displayed ….1060
C- 6 Related electrical circuit diagram ….1060
TROUBLESHOOTING C- 7 ….1061
C- 7 [ E211 ] Disconnection in CO cancel solenoid system is displayed ….1061
C- 7 Related electrical circuit diagram ….1061
TROUBLESHOOTING C- 8 ….1062
C- 8 [ E202 ] Short circuit in straight- travel solenoid system is displayed ….1062
C- 8 Related electrical circuit diagram ….1062
TROUBLESHOOTING C- 9 ….1063
C- 9 [ E212 ] Disconnection in straight- travel solenoid system is displayed ….1063
C- 9 Related electrical circuit diagram ….1063
TROUBLESHOOTING C- 10 ….1064
C- 10 [ E204 ] Short circuit in 2- stage relief solenoid system is displayed ….1064
C- 10 Related electrical circuit diagram ….1064
TROUBLESHOOTING C- 11 ….1065
C- 11 [ E214 ] Disconnection in 2- stage relief solenoid system is displayed ….1065
C- 11 Related electrical circuit diagram ….1065
TROUBLESHOOTING C- 12 ….1066
C- 12 [ E205 ] Short circuit in swing priority selector solenoid system is displayed ….1066
C- 12 Related electrical circuit diagram ….1066
TROUBLESHOOTING C- 13 ….1067
C- 13 [ E211 ] Disconnection in swing priority selector solenoid system is displayed ….1067
C- 13 Related electrical circuit diagram ….1067
TROUBLESHOOTING C- 14 ….1068
C- 14 [ E206 ] Short circuit in travel speed solenoid system is displayed ….1068
C- 14 Related electrical circuit diagram ….1068
TROUBLESHOOTING C- 15 ….1069
C- 15 [ E216 ] Disconnection in travel speed solenoid system is displayed ….1069
C- 15 Related electric circuit diagram ….1069
TROUBLESHOOTING C- 16 ….1070
C- 16 [ E217 ] Model selection input error is displayed ….1070
TROUBLESHOOTING C- 16 C- 16 Related electrical circuit diagram TROUBLESHOOTING C- 17 ….1072
C- 17 [ E227 ] Abnormality in engine speed sensor system is displayed ….1072
C- 17 Related electrical circuit diagram ….1072
TROUBLESHOOTING C- 18 ….1073
C- 18 Abnormality in machine push- up solenoid system ( no service code displayed) ….1073
a) Even when machine push- up switch is set to low pressure, solenoid is not switched ON ….1073
C- 19 Related electrical circuit diagram ….1073
TROUBLESHOOTING C- 18 b) Even when machine push- up switch is set to high pressure, solenoid is not switched OFF ….1074
C- 18 Related electrical circuit diagram ….1074
TROUBLESHOOTING C- 19 ….1075
C- 19 Abnormality in shockless boom solenoid system ( no service code displayed) ….1075
a) Shockless mode cannot be canceled ( solenoid is not switched ON) ….1075
TROUBLESHOOTING C- 19 C- 19 Related electrical circuit diagram ….1076
TROUBLESHOOTING C- 19 ….1077
b) Shockless mode is not actuated ….1077
C- 19 Related electric circuit diagram TROUBLESHOOTING C- 20 C- 20 Related electrical circuit diagram ….1078
C- 20 [ E207 ] Short circuit in flash light relay drive system is displayed ….1078
TROUBLESHOOTING C- 21 ….1079
C- 21 Flash light relay does not work ….1079
C- 21 Related electrical circuit diagram ….1079
TROUBLESHOOTING C- 22 ….1080
C- 22 [ E231 ] Abnormality ( short circuit) in power source holding relay output system for step light is displayed ….1080
C- 22 Related electrical circuit diagram ….1080
TROUBLESHOOTING C- 23 ….1081
C- 23 Step light switch does not work ….1081
C- 23 Related electrical circuit diagram ….1081
TROUBLESHOOTING C- 24 ….1082
C- 24 [ E302 ] Short circuit in step light relay drive system is displayed ….1082
C- 24 Related electrical circuit diagram ….1082
TROUBLESHOOTING C- 25 ….1083
C- 25 [ 303 ] Disconnection in step light relay drive system is displayed ….1083
C- 25 Related electrical circuit diagram ….1083
TROUBLESHOOTING C- 26 ….1084
C- 26 Step light does not light up ….1084
C- 26 Related electrical circuit diagram ….1084
TROUBLESHOOTING C- 27 ….1085
C- 27 [ E228 ] Abnormality in auto- deceleration output system is displayed ….1085
C- 27 Related electrical circuit diagram ….1085
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER ( INPUT SIGNAL SYSTEM) ( F MODE) ….1086
F- 1 [ Bit pattern 20- ( 1) ] Swing oil pressure switch does not light up ….1089
TROUBLESHOOTING F- 2 F- 2 Related electrical circuit diagram ….1090
F- 2 [ Bit pattern 20- ( 2) ] R. H. travel oil pressure switch does not light up ….1090
F- 3 Related electrical circuit diagram TROUBLESHOOTING F- 3 ….1091
F- 3 [ Bit pattern 20- ( 3) ] Boom LOWER oil pressure switch does not light up ….1091
TROUBLESHOOTING F- 4 F- 4 Related electrical circuit diagram ….1092
F- 4 [ Bit pattern 20- ( 4) ] Boom RAISE oil pressure switch does not light up ….1092
F- 5 Related electrical circuit diagram TROUBLESHOOTING F- 5 ….1093
F- 5 [ Bit pattern 20- ( 5) ] Arm IN oil pressure switch does not light up ….1093
TROUBLESHOOTING F- 6 F- 6 Related electrical circuit diagram ….1094
F- 6 [ Bit pattern 20- ( 6) ] Arm OUT oil pressure switch does not light up ….1094
F- 7 Related electrical circuit diagram TROUBLESHOOTING F- 7 ….1095
F- 7 [ Bit pattern 21- ( 1) ] Bucket CURL oil pressure switch does not light up ….1095
TROUBLESHOOTING F- 8 F- 8 Related electrical circuit diagram ….1096
F- 8 [ Bit pattern 21- ( 2) ] Bucket DUMP oil pressure switch does not light up ….1096
F- 9 Related electrical circuit diagram TROUBLESHOOTING F- 9 ….1097
F- 9 [ Bit pattern 20- ( 5) ] L. H. travel oil pressure switch does not light up ….1097
TROUBLESHOOTING F- 10 F- 10 Related electrical circuit diagram ….1098
F- 10 [ Bit pattern 21- ( 4) ] Service oil pressure switch does not light up ….1098
F- 11 Related electrical circuit diagram TROUBLESHOOTING F- 11 ….1099
F- 11 [ Bit pattern 21- ( 3) ] Swing lock switch does not light up ….1099
TROUBLESHOOTING F- 12 F- 12 Related electrical circuit diagram ….1100
F- 12 [ Bit pattern 24- ( 1) ] When step light switch is ON, it does not go out ….1100
F- 13 Related electrical circuit diagram TROUBLESHOOTING F- 13 ….1101
F- 13 [ Bit pattern 24- ( 2) ] When horn switch is ON, it does not go out ….1101
TABLE OF FAILURE MODES AND CAUSES ….1103
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES ….1104
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) ….1105
1. Actuation and combination of main pumps ….1105
2. Judgement procedure ….1105
BEFORE CARRYING OUT TROUBLESHOOTING TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) ….1105
BEFORE CARRYING OUT TROUBLESHOOTING TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) Hydraulic circuit diagram after interchanging hoses Method of interchanging hoses TROUBLESHOOTING ….1108
TROUBLESHOOTING H- 2 ….1109
TROUBLESHOOTING H- 2 ….1110
TROUBLESHOOTING H- 3 ….1111
H- 3 Related circuit diagram ….1111
TROUBLESHOOTING H- 4, H- 5 ….1112
TROUBLESHOOTING H- 6 ….1113
a) If work equipment speed ( boom, arm, bucket) is slow or lacks power in normal mode ….1113
TROUBLESHOOTING H- 6 b) If boom RAISE speed is slow or lacks power in heavy lift mode ….1114
c) If boom LOWER speed is slow or lacks power when machine push- up is ON TROUBLESHOOTING H- 7, H- 8 ….1115
TROUBLESHOOTING H- 9, H- 10, H- 11 ….1116
TROUBLESHOOTING H- 12 ….1117
TROUBLESHOOTING H- 13 ….1118
a) Direction of deviation is same in FORWARD and REVERSE ….1118
TROUBLESHOOTING H- 13 b) Direction of deviation is different in FORWARD and REVERSE ….1119
TROUBLESHOOTING H- 14 ….1120
TROUBLESHOOTING H- 14, H- 15 ….1121
TROUBLESHOOTING H- 16, H- 17 ….1122
TROUBLESHOOTING H- 18 ….1123
TROUBLESHOOTING H- 18 ….1124
TROUBLESHOOTING H- 19 ….1125
TROUBLESHOOTING H- 19, H- 20 ….1126
TROUBLESHOOTING H- 21 ….1127
TROUBLESHOOTING H- 22 ….1128
TROUBLESHOOTING H- 23 ….1129
TROUBLESHOOTING H- 24 ….1130
TROUBLESHOOTING H- 25 ….1131
a) When swing holding brake is released ….1131
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ….1133
M- 1 [ E101 ] ( Abnormality in error data) or [ E102 ] ( Abnormality in clock data) is displayed ….1137
M- 2 [ E103 ] ( Short circuit in buzzer output system) is displayed ….1138
M- 3 [ E104 ] ( Air cleaner clogging detection) is displayed ….1139
M- 4 [ E108 ] ( Engine water temperature 105 ….1139
C) is displayed ….1139
M- 5 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds ….1140
M- 6 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out ….1142
M- 7 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine ….1142
M- 8 When starting switch is turned ON ( engine stopped) , basic check items flash ….1143
M- 9 Preheating is not being used but preheating display motor lamp lights up ….1146
M- 10 When engine is started, basic check items flash ….1147
M- 11 When starting switch is turned ON ( engine stopped) , CAUTION items and EMERGENCY STOP items flash ….1148
M- 12 When engine is started, CAUTION items and EMERGENCY STOP items flash ….1149
M- 13 Operation of alarm buzzer is not normal ….1153
M- 14 Night lighting on monitor panel does not light up ….1155
M- 15 Engine water temperature display is not normal ….1156
M- 16 Fuel level gauge display is not normal ….1157
M- 17 Swing lock switch is turned ON but swing lock monitor lamp does not light up ….1159
M- 18 When swing brake release switch is set to RELEASE ( EMERGENCY) , swing lock monitor lamp does not flash ….1160
M- 19 Service meter does not give normal display ….1161
M- 20 Defective fuel level sensor system ….1162
M- 21 Defective engine oil level sensor system ….1163
M- 22 Defective coolant level sensor system ….1164
M- 23 Defective hydraulic oil level sensor system ….1165
M- 24 Wiper is not actuated when wiper switch is operated or wiper is actuated when wiper switch is not operated ….1166
M- 25 Window washer is not actuated when wiper switch is operated or window washer is actuated when switch is not operated ….1171
M- 26 Electric grease gun does not work ( machines equipped with electric grease gun) ….1174
METHOD OF USING MANUAL ….1177
1. When removing or installing unit assemblies ….1177
2. ….1177
3. Listing of special tools ….1177
A1 ….1177
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL ….1178
6. Tightening torque of split flange bolts ….1178
5. Tightening torque of hose nuts ….1178
4. Standard tightening torques of bolts and nuts DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL ….1179
7. Tightening torque of O- ring boss connector ….1179
8. Tightening torque of O- ring boss connector ….1179
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION ….1180
PRECAUTIONS WHEN CARRYING OUT OPERATION ….1180
1. Precautions when carrying out removal work ….1180
SPECIAL TOOL LIST ….1182
SKETCHES OF SPECIAL TOOLS ….1189
REMOVAL OF AFTERCOOLER CORE ….1191
INSTALLATION OF AFTERCOOLER CORE ….1191
REMOVAL OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY ….1192
INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY ….1194
Water Filling ….1194
Filling ( Hydraulic Tank) with Oil ….1194
Filling of Air Conditioner Gas ….1194
Alignment of Engine Pulley and Fan Pulley ….1194
Filling ( Fuel Tank) with Diesel Fuel ….1194
REMOVAL OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY ….1195
INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY ….1195
REMOVAL OF FUEL TANK ASSEMBLY ….1196
INSTALLATION OF FUEL TANK ASSEMBLY ….1197
REMOVAL OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY ….1198
INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY ….1202
Water Filling ….1202
Air Bleeding ….1202
REMOVAL OF PTO ASSEMBLY ….1203
INSTALLATION OF PTO ASSEMBLY ….1204
DISASSEMBLY OF PTO ASSEMBLY ….1205
1. Cover ….1205
2. Gear assembly ….1205
3. Removal of bearing ….1205
ASSEMBLY OF PTO ASSEMBLY ….1206
1. Bearings ….1206
2. Outer race at case end ….1206
3. Nipples, plug ….1206
4. Gears ….1206
DISASSEMBLY OF FINAL DRIVE ASSEMBLY ….1209
ASSEMBLY OF FINAL DRIVE ASSEMBLY ….1214
REMOVAL OF REVOLVING FRAME ASSEMBLY ….1222
INSTALLATION OF REVOLVING FRAME ASSEMBLY ….1223
REMOVAL OF SWING MACHINERY ASSEMBLY ….1224
INSTALLATION OF SWING MACHINERY ASSEMBLY ….1224
DISASSEMBLY OF SWING MACHINERY ASSEMBLY ….1225
ASSEMBLY OF SWING MACHINERY ASSEMBLY ….1229
REMOVAL OF SWING CIRCLE ASSEMBLY ….1234
INSTALLATION OF SWING CIRCLE ASSEMBLY ….1234
REMOVAL OF TRACK SHOE ASSEMBLY ….1235
INSTALLATION OF TRACK SHOE ASSEMBLY ….1236
DISASSEMBLY OF ONE LINK IN FIELD ….1237
FIELD ASSEMBLY OF ONE LINK ….1239
REMOVAL OF IDLER ASSEMBLY ….1241
INSTALLATION OF IDLER ASSEMBLY ….1241
DISASSEMBLY OF IDLER ASSEMBLY ….1242
ASSEMBLY OF IDLER ASSEMBLY ….1244
DISASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY ….1246
ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY ….1246
REMOVAL OF RECOIL SPRING ASSEMBLY ….1247
INSTALLATION OF RECOIL SPRING ASSEMBLY ….1247
DISASSEMBLY OF RECOIL SPRING ASSEMBLY ….1249
ASSEMBLY OF RECOIL SPRING ASSEMBLY ….1250
REMOVAL OF CARRIER ROLLER ASSEMBLY ….1251
INSTALLATION OF CARRIER ROLLER ASSEMBLY ….1251
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY ….1252
ASSEMBLY OF CARRIER ROLLER ASSEMBLY ….1253
REMOVAL OF TRACK ROLLER ASSEMBLY ….1254
INSTALLATION OF TRACK ROLLER ASSEMBLY ….1254
DISASSEMBLY OF TRACK ROLLER ASSEMBLY ….1255
ASSEMBLY OF TRACK ROLLER ASSEMBLY ….1256
REMOVAL OF HYDRAULIC TANK ASSEMBLY ….1258
INSTALLATION OF HYDRAULIC TANK ASSEMBLY ….1260
REMOVAL OF MAIN PUMP ( NO. 1 PUMP) ASSEMBLY ….1261
INSTALLATION OF MAIN PUMP ( NO. 1 PUMP) ASSEMBLY ….1262
REMOVAL OF MAIN PUMP ( NO. 2 PUMP) ….1263
INSTALLATION OF MAIN PUMP ( NO. 2 PUMP) ASSEMBLY ….1264
REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL ….1265
INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL ….1265
REMOVAL OF CONTROL PTO LUBRICATION PUMP ASSEMBLY ….1266
INSTALLATION OF CONTROL PTO LUBRICATION PUMP ASSEMBLY ….1266
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ….1267
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ….1267
REMOVAL OF CONTROL VALVE ASSEMBLY ….1268
INSTALLATION OF CONTROL VALVE ASSEMBLY ….1270
DISASSEMBLY OF CONTROL VALVE ASSEMBLY ( WORK EQUIPMENT) ….1272
ASSEMBLY OF CONTROL VALVE ASSEMBLY ( WORK EQUIPMENT) ….1274
REMOVAL OF SOLENOID VALVE ASSEMBLY ….1276
INSTALLATION OF SOLENOID VALVE ASSEMBLY ….1277
REMOVAL OF BOOM DAMPING VALVE ASSEMBLY ….1278
INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY ….1278
REMOVAL OF SWING MOTOR ASSEMBLY ….1279
INSTALLATION OF SWING MOTOR ASSEMBLY ….1279
REMOVAL OF CENTER SWIVEL JOINT ….1280
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY ….1280
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ….1281
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ….1281
REMOVAL OF TRAVEL MOTOR ASSEMBLY ….1282
INSTALLATION OF TRAVEL MOTOR ASSEMBLY ….1282
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY ….1283
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY ….1284
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY ….1285
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY ….1286
REMOVAL OF BUCKET CYLINDER ASSEMBLY ….1287
INSTALLATION OF BUCKET CYLINDER ASSEMBLY ….1289
REMOVAL OF ARM CYLINDER ASSEMBLY ….1291
INSTALLATION OF ARM CYLINDER ASSEMBLY ….1293
REMOVAL OF BOOM CYLINDER ASSEMBLY ….1295
INSTALLATION OF BOOM CYLINDER ASSEMBLY ….1297
REMOVAL OF BOTTOM DUMP CYLINDER ASSEMBLY ….1299
INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY ….1300
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ….1301
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ….1303
REMOVAL OF BUCKET ASSEMBLY ….1306
INSTALLATION OF BUCKET ASSEMBLY ….1308
REMOVAL OF ARM ASSEMBLY ….1310
INSTALLATION OF ARM ASSEMBLY ….1312
REMOVAL OF BOOM ASSEMBLY ….1314
INSTALLATION OF BOOM ASSEMBLY ….1316
REMOVAL OF WORK EQUIPMENT ….1318
INSTALLATION OF WORK EQUIPMENT ASSEMBLY ….1320
REMOVAL OF OPERATOR S CAB ASSEMBLY ….1322
INSTALLATION OF OPERATOR S CAB ASSEMBLY ….1323
REMOVAL OF COUNTERWEIGHT ASSEMBLY ….1324
INSTALLATION OF COUNTERWEIGHT ASSEMBLY ….1324
UEBM002400 – Hydraulic Excavator PC750SE-7K, PC750LC-7K Shop Manual….1331
Foreword.pdf….0
SAFETY….1333
SAFETY NOTICE….1333
IMPORTANT SAFETY NOTICE….1333
GENERAL PRECAUTIONS….1333
PREPARATIONS FOR WORK….1333
PRECAUTIONS DURING WORK….1334
FOREWORD….1335
GENERAL….1335
STRUCTURE AND FUNCTION….1335
TESTING AND ADJUSTING….1335
DISASSEMBLY AND ASSEMBLY….1335
MAINTENANCE STANDARD….1335
OTHERS….1335
HOW TO READ THE SHOP MANUAL….1336
VOLUMES….1336
DISTRIBUTION AND UPDATING….1336
FILING METHOD….1336
REVISED EDITION MARK….1336
REVISIONS….1336
SYMBOLS….1336
HOISTING INSTRUCTIONS….1337
HOISTING….1337
WIRE ROPES….1337
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER….1338
Disconnection….1338
Connection….1338
COATING MATERIALS….1340
STANDARD TIGHTENING TORQUE….1342
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)….1342
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS….1342
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS….1343
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS….1343
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS….1343
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)….1344
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)….1344
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)….1344
ELECTRIC WIRE CODE….1345
CLASSIFICATION BY THICKNESS….1345
CLASSIFICATION BY COLOR AND CODE….1345
CONVERSION TABLE….1346
METHOD OF USING THE CONVERSION TABLE….1346
EXAMPLE….1346
Millimeters to inches….1346
Millimeters to Inches….1347
Kilogram to Pound….1347
Liter to U.S. Gallon….1348
Liter to U.K. Gallon….1348
kgm to ft. lb….1349
kg/cm2 to lb/in2….1350
Temperature….1351
UNITS….1352
Example:….1352
01.pdf….0
01 GENERAL….1353
SPECIFICATION DRAWINGS….1354
SPECIFICATIONS….1356
WEIGHT TABLE….1361
FUEL, COOLANT AND LUBRICANTS….1363
10.pdf….0
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….1365
PTO….1366
PTO LUBRICATION SYSTEM….1367
POWER TRAIN….1368
SWING MACHINERY….1370
SWING CIRCLE….1372
FINAL DRIVE….1374
TRACK FRAME AND RECOIL SPRING….1376
IDLER….1378
CARRIER ROLLER….1380
TRACK ROLLER….1381
TRACK SHOE….1382
MOTOR GREASE PUMP….1387
HYDRAULIC TANK….1388
HYDRAULIC PUMP….1390
RETURN OIL FILTER….1420
LINE OIL FILTER….1421
PILOT OIL FILTER….1421
DRAIN OIL FILTER….1422
L.H. 5-SPOOL CONTROL VALVE….1424
R.H. 4-SPOOL CONTROL VALVE….1430
STRAIGHT-TRAVEL VALVE….1436
SWING MOTOR….1439
CENTER SWIVEL JOINT….1444
TRAVEL MOTOR….1445
PPC CONTROL RELIEF VALVE….1455
PPC ACCUMULATOR….1456
VALVE CONTROL….1457
WORK EQUIPMENT, SWING PPC VALVE….1458
TRAVEL PPC VALVE….1464
SOLENOID VALVE….1468
HYDRAULIC CYLINDER….1474
WORK EQUIPMENT….1476
DIMENSIONS OF WORK EQUIPMENT….1478
AIR CONDITIONER….1480
ENGINE CONTROL….1481
MACHINE CONTROL SYSTEM….1487
MONITOR SYSTEM….1516
SENSORS….1531
20.pdf….0
20 TESTING AND ADJUSTING….1535
STANDARD VALUE TABLE FOR ENGINE….1534
STANDARD VALUE TABLE FOR CHASSIS….1537
20_101.pdf….0
TESTING AND ADJUSTING….1547
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING….1366
MEASURING ENGINE SPEED….1550
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)….1551
MEASUREMENT OF EXHAUST GAS TEMPERATURE….1552
MEASUREMENT OF EXHAUST GAS COLOR….1553
ADJUSTING VALVE CLEARANCE….1554
MEASURING COMPRESSION PRESSURE….1534
MEASURING BLOW-BY PRESSURE….1557
MEASURING ENGINE OIL PRESSURE….1558
HANDLING OF FUEL SYSTEM EQUIPMENT….1559
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT….1559
MEASUREMENT OF FUEL PRESSURE….1560
AIR BLEEDING FROM FUEL CIRCUIT….1561
INSPECTION OF LEAKAGE FROM FUEL SYSTEM….1563
ADJUSTING ENGINE SPEED SENSOR….1544
TESTING AND ADJUSTING FAN BELT TENSION….1565
TESTING AND ADJUSTING ALTERNATOR BELT TENSION….1566
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT….1567
INSPECTION OF SWING CIRCLE BEARING CLEARANCE….1568
TESTING AND ADJUSTING TRACK SHOE TENSION….1569
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES….1570
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE….1575
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE….1543
INSPECTION OF SERVO PISTON STROKE….1582
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE….1583
MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTO…..1586
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE….1591
TESTING AND ADJUSTING TRAVEL DEVIATION….1592
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT….1594
MEASURING OIL LEAKAGE….1595
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT….1599
BLEEDING AIR FROM EACH PART….1600
INSPECTION PROCEDURES FOR DIODE….1603
SPECIAL FUNCTION OF MONITOR PANEL….1604
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT….1631
PREPARATION WORK….1632
20_101A.pdf….0
Pm-CLINIC SERVICE….1634
Positions to install measuring devices (Related to engine and PTO)….1548
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)….1637
Pm-CLINIC SERVICE PC750 (LC, SE)….1640
Arm….1640
1. Arm cylinder bracket….1640
2. Arm foot….1640
3. Arm top boss….1640
Boom….1640
4. Boom top bracket….1640
5. Boom cylinder bracket….1640
6. Arm cylinder bracket….1640
7. Boom lower plate….1640
8. Boom foot….1640
Revolving frame….1640
9. Boom bracket….1640
Track frame….1640
10. Circle bracket….1640
11. Track frame mounting section….1640
Visual check of welded structures (For PC750SE-7)….1641
Arm….1641
1. Arm cylinder bracket….1641
2. Arm foot….1641
3. Arm top boss….1641
Boom….1641
4. Boom top bracket….1641
5. Boom cylinder bracket….1641
6. Arm cylinder bracket….1641
7. Boom lower plate….1641
8. Boom foot….1641
Revolving frame….1641
9. Boom bracket….1641
Track frame….1641
10. Circle bracket….1641
11. Track frame mounting section….1641
UNDERCARRIAGE INSPECTION….1642
(Program form No.: ***************)….1642
20_201.pdf….0
TROUBLESHOOTING….1547
POINTS TO REMEMBER WHEN TROUBLESHOOTING….1644
SEQUENCE OF EVENTS IN TROUBLESHOOTING….1640
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….1646
CHECKS BEFORE TROUBLESHOOTING….1654
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING….1655
Classification of troubleshooting….1611
Steps for troubleshooting….1611
Failure-looking Phenomenon and Troubleshooting No….1656
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM….1659
Connector table….1659
Connector Location Stereogram….1664
Monitor Panel System Circuit Diagram (M Circuit)….1670
Engine Control System Circuit Diagram (E Ciruit)….1672
Pump Controller System Circuit Diagram (P Circuit)….1674
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….1676
T-BRANCH BOX AND T-BRANCH TABLE….1698
20_301.pdf….0
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISP…..1701
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE….1617
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….1706
Error Code in Electrical System E112 (Wiper Drive (For) S/C)….1708
Error Code in Electrical System E113 (Wiper Drive (Rev) S/C)….1712
Error Code in Electrical System E114 (Washer Drive S/C)….1714
Error Code in Electrical System E115 (Wiper Working Abnormality)….1716
Error Code in Electrical System E116 (Wiper Parking Abnormality)….1718
Error Code in Electrical System E117 (Eng. Controller S-NET Comm Err.)….1722
Error Code in Electrical System E118 (Pump Controller S-NET Comm Err.)….1724
Error Code in Electrical System E128 (Monitor Comm. Abnormality)….1726
Error Code in Electrical System E201 (CO Cancel Sol. S/C)….1728
Error Code in Electrical System E202 (Travel Junction Sol. S/C)….1730
Error Code in Electrical System E203 (Swing Brake Sol. S/C)….1732
Error Code in Electrical System E204 (2-stage Relief Sol. S/C)….1734
Error Code in Electrical System E205 (Swing Priority Sol. S/C)….1736
Error Code in Electrical System E206 (Travel Speed Sol. S/C)….1738
Error Code in Electrical System E207 (Flash Light Relay S/C)….1740
Error Code in Electrical System E211 (CO Cancel Sol. Disc.)….1742
Error Code in Electrical System E212 (Travel Junction Sol. Disc.)….1744
Error Code in Electrical System E213 (Swing Brake Sol. Disc.)….1746
Error Code in Electrical System E214 (2-stage Relief Sol. Disc.)….1748
Error Code in Electrical System E215 (Swing Priority Sol. Disc.)….1750
Error Code in Electrical System E216 (Travel Speed Sol. Disc.)….1752
Error Code in Electrical System E217 (Model selection Abnormality)….1754
Error Code in Electrical System E218 (S-Net Comm. Disc.)….1756
Error Code in Electrical System E221 (Travel Alarm S/C)….1758
Error Code in Electrical System E224 (F Pump P. Sensor Abnormality)….1760
Error Code in Electrical System E225 (R Pump P. Sensor Abnormality)….1762
Error Code in Electrical System E226 (Press. Sensor Power Abnormality)….1764
Error Code in Electrical System E227 (Engine Speed Sensor Abnormality)….1766
Error Code in Electrical System E232 (TVC Sol. S/C)….1768
Error Code in Electrical System E233 (TVC Sol. Disc.)….1770
Error Code in Electrical System E257 (Pump Comm. Abnormality)….1772
Error Code in Electrical System E302 (Step Light Relay S/C)….1774
Error Code in Electrical System E304 (Step Light Power Hold Relay S/C)….1776
Error Code in Electrical System E315 (Battery Relay Drive S/C)….1778
Error Code in Electrical System E91B (Engine Ne sensor problem)….1780
Error Code in Electrical System E91C (Engine G sensor problem)….1781
Error Code in Electrical System E920 (Engine type selection error)….1782
Error Code in Electrical System E921 (Engine type mismatch)….1784
Error Code in Electrical System E931 (Fuel dial sys. error)….1786
Error Code in Electrical System E934 (Engine coolant sensor Hi error)….1788
Error Code in Electrical System E936 (Engine oil press. sw. error)….1790
Error Code in Electrical System E93C (Engine boost sensor error)….1792
Error Code in Electrical System E93D (Engine fuel temp. sensor error)….1794
Error Code in Electrical System E953 (Engine Comm. Abnormality)….1796
Error Code in Electrical System E954 (Short engine starter sw.)….1798
Error Code in Electrical System E955 (Engine S-NET error)….1800
Error Code in Electrical System E956 (Engine power failure (1))….1802
Error Code in Electrical System E957 (Engine power failure (2))….1804
Error Code in Electrical System E95A (Engine Q-adj. sw. signal error)….1806
Error Code in Electrical System E96A (Engine coolant sensor Lo error)….1808
Error Code in Electrical System E970 (PCV1 over current)….1810
Error Code in Electrical System E971 (PCV2 over current)….1812
Error Code in Electrical System E974 (PCV1 line cut)….1814
Error Code in Electrical System E975 (PCV2 line cut)….1816
Error Code in Electrical System E977 (Rail press. sensor error)….1818
Error Code in Electrical System E979 (Rail press. high)….1820
Error Code in Electrical System E97A (Rail press. abnormal)….1820
Error Code in Electrical System E97B (Rail press. low)….1821
Error Code in Electrical System E97C (Rail press. too low)….1823
Error Code in Electrical System E97D (Rail press. out of control)….1823
Error Code in Electrical System E980 (Eng. Controller Abnormality)….1824
Error Code in Electrical System E981 (Fuel Injector 1 Disc.)….1826
Error Code in Electrical System E982 (Fuel Injector 2 Disc.)….1827
Error Code in Electrical System E983 (Fuel Injector 3 Disc.)….1828
Error Code in Electrical System E984 (Fuel Injector 4 Disc.)….1829
Error Code in Electrical System E985 (Fuel Injector 5 Disc.)….1830
Error Code in Electrical System E986 (Fuel Injector 6 Disc.)….1831
Error Code in Electrical System E98A (Fuel Injector 1 3 S/C)….1832
Error Code in Electrical System E98B (Fuel Injector 4 6 S/C)….1834
Failure Code in Mechanical System A000N1 (Eng. Hi Out of Std)….1837
Failure Code in Mechanical System AA10NX (Aircleaner Clogging)….1838
Failure Code in Mechanical System AB00KE (Charge Voltage Low)….1840
Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low)….1842
Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low)….1844
Failure Code in Mechanical System B@BCNS (Eng. Water Overheat)….1845
Failure Code in Mechanical System B@BCZK (Eng. Water Lvl Low)….1846
Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat)….1848
Failure Code in Mechanical System DA80MA (Auto. Lub Abnormal.)….1850
20_501.pdf….0
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….1701
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)….1617
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….1854
E-1 Engine does not start (Engine does not rotate)….1708
E-2 Preheater does not operate….1858
E-3 Auto engine warm-up device does not work….1860
E-4 Auto-decelerator does not operate….1861
E-5 All work equipment, swing and travel do not move….1862
E-6 Machine push-up function does not operate normally….1864
E-7 Boom shockless function does not operate normally….1866
E-8 Any item is not displayed on monitor panel….1868
E-9 Part of display on monitor panel is missing….1869
E-10 Monitor panel displays contents irrelevant to the model….1869
E-11 Fuel level monitor red lamp lights up while engine is running….1870
E-12 Engine water thermometer does not display normally….1872
E-13 Hydraulic oil temperature gauge does not display correctly….1874
E-14 Fuel gauge does not display correctly….1875
E-15 Swing lock monitor does not display correctly….1876
E-16 When monitor switch is operated, nothing is displayed….1878
E-17 Windshield wiper and window washer do not work….1880
E-18 Alarming buzzer cannot be cancelled….1888
E-19 "Boom RAISE" is not correctly displayed in monitor function….1889
E-20 "Boom LOWER" is not correctly displayed in monitor function….1890
E-21 "Arm IN" is not correctly displayed in monitor function….1891
E-22 "Arm OUT" is not correctly displayed in monitor function….1892
E-23 "Bucket CURL" is not correctly displayed in monitor function….1893
E-24 "Bucket DUMP" is not correctly displayed in monitor function….1894
E-25 "SWING" is not correctly displayed in monitor function….1896
E-26 "Left travel" is not displayed normally in monitoring function….1898
E-27 "Right travel" is not displayed normally in monitoring function….1900
E-28 "Service" is not correctly displayed in monitor function….1902
E-29 Air conditioner does not work….1904
E-30 Step light does not light up or go off….1905
E-31 Electric grease gun does not operate….1910
E-32 Travel alarm does not sound or does not stop sounding….1912
20_601.pdf….0
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….1701
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)….1916
INFORMATION IN TROUBLESHOOTING TABLE….1921
H-1 Speed or power of all work equipment, travel, and swing is low….1708
H-2 Engine speed lowers remarkably or engine stalls….1924
H-3 All work equipment, travel, and swing systems do not work….1860
H-4 Abnormal sound is heard from around pump….1926
H-5 Boom speed or power is low….1861
H-6 Speed or power of arm is low….1929
H-7 Speed or power of bucket is low….1930
H-8 Boom does not move….1931
H-9 Arm does not move….1931
H-10 Bucket does not move….1931
H-11 Hydraulic drift of work equipment is large….1932
H-12 Time lag of work equipment is large….1934
H-13 Heavy lift function does not operate or stop….1935
H-14 Machine push-up function does not operate or stop….1935
H-15 Boom shockless function cannot be turned ON or OFF….1935
H-16 Machine deviates in one direction….1936
H-17 Machine deviates largely at start….1938
H-18 Machine deviates largely during compound operation….1939
H-19 Travel speed or power is low….1939
H-20 Machine does not travel (only one track)….1940
H-21 Travel speed does not change….1941
H-22 Upper structure does not swing….1942
H-23 Swing speed or acceleration is low….1943
H-24 Swing speed or acceleration is low during compound operation of swing and work equipment….1944
H-25 Upper structure overruns excessively when it stops swinging….1946
H-26 Large shock is made when upper structure stops swinging….1947
H-27 Large abnormal sound is made when upper structure stops swinging….1948
H-28 Hydraulic drift of swing is large….1949
20_701.pdf….0
TROUBLESHOOTING OF ENGINE (S MODE)….1701
POINTS TO REMEMBER WHEN TROUBLESHOOTING….1952
METHOD OF USING TROUBLESHOOTING CHARTS….1953
S-1 Starting performance is poor (starting always takes time)….1956
S-2 Engine does not start….1957
S-3 Engine does not pick up smoothly (follow-up is poor)….1960
S-4 Engine stops during operations….1961
S-5 Engine does not rotate smoothly (hunting)….1962
S-6 Engine lacks output (or lacks power)….1963
S-7 Exhaust smoke is black (incomplete combustion)….1964
S-8 Oil consumption is excessive (or exhaust smoke is blue)….1965
S-9 Oil becomes contaminated quickly….1966
S-10 Fuel consumption is excessive….1967
S-11 Oil is in cooling water (or water spurts back, or water level goes down)….1968
S-12 Oil pressure caution lamp lights up (drop in oil pressure)….1969
S-13 Oil level rises (water, fuel in oil)….1970
S-14 Water temperature becomes too high (overheating)….1971
S-15 Abnormal noise is made….1972
S-16 Vibration is excessive….1973
30.pdf….0
30 DISASSEMBLY AND ASSEMBLY….1975
METHOD OF USING MANUAL….1977
PRECAUTIONS WHEN CARRYING OUT OPERATION….1979
SPECIAL TOOL LIST….1981
REMOVAL AND INSTALLATION OF AFTERCOOLER CORE….1988
REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY….1989
REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY….1992
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY….1993
REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY….1994
REMOVAL AND INSTALLATION OF PTO ASSEMBLY….1998
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY….2000
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY….2003
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY….2014
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY….2015
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY….2016
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY….2023
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY….2024
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD….2026
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY….2030
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY….2031
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY….2034
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY….2035
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY….2037
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY….2039
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY….2040
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY….2043
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY….2044
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY….2047
REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 1 PUMP) ASSEMBLY….2049
REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 2 PUMP)….2051
REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL….2053
REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRICATION PUMP ASSEMBLY….2054
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY….2055
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY….2056
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (WORK EQUIPMENT)….2059
REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY….2062
REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY….2064
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY….2065
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT….2067
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY….2068
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY….2070
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY….2071
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY….2073
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY….2075
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY….2077
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY….2079
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY….2081
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY….2083
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY….2085
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY….2087
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….2088
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY….2094
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY….2095
REMOVAL AND INSTALLATION OF ARM ASSEMBLY….2096
REMOVAL AND INSTALLATION OF ARM ASSEMBLY….2098
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY….2100
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY….2102
REMOVAL AND INSTALLATION OF WORK EQUIPMENT….2104
REMOVAL AND INSTALLATION OF WORK EQUIPMENT….2106
REMOVAL AND INSTALLATION OF OPERATORS CAB ASSEMBLY….2108
REMOVAL AND INSTALLATION OF OPERATORS CAB GLASS (STUCK GLASS)….2110
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY….2120
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY….2126
90.pdf….0
90 OTHERS….1353
90-01.pdf….0
HYDRAULIC CIRCUIT DIAGRAM….2131
ELECTRICAL CIRCUIT DIAGRAM (1/5)….2133
ELECTRICAL CIRCUIT DIAGRAM (2/5)….2135
ELECTRICAL CIRCUIT DIAGRAM (3/5)….2137
ELECTRICAL CIRCUIT DIAGRAM (4/5)….2139
ELECTRICAL CIRCUIT DIAGRAM (5/5)….2141

Komatsu Hydraulic Excavators PC750SE-6K, PC750LC-6K Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 9, 2025 by admin

Komatsu Hydraulic Excavators PC750, PC800 Repair Service Manuals

INSTANT DOWNLOAD

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, and 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: 2,654 pages
File Format: PDF
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

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
CONTROL・PTO 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

Komatsu Hydraulic Excavators PC750, PC800 Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 9, 2025 by admin

Komatsu Hydraulic Excavators PC650, PC650LC, PC650SE, PC710 Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC650-1, PC650-3, PC650-5, PC650LC-3, PC650SE-3, PC710-5, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC650-1, PC650-3, PC650-5, PC650LC-3, PC650SE-3, PC710-5 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: 2,321 pages
File Format: PDF
Language: English

SEBM0209A04 – Hydraulic Excavator PC650-1 Shop Manual.pdf
SEBM000607 – Hydraulic Excavator PC650-5, PC710-5 Shop Manual.pdf
SEBM02090307 – Hydraulic Excavator PC650-3, PC650LC-3, PC650SE-3 Shop Manual.pdf
SEAM000604 – Hydraulic Excavator PC650-5, PC650LC-5, PC650SE-5, PC710-5, PC710SE-5 Operation & Maintenance Manual.pdf
SEAM02090303 – Hydraulic Excavator PC650-3 Operation & Maintenance Manual.pdf
SEAM02090306 – Hydraulic Excavator PC650-3, PC650LC-3, PC650SE-3 Operation & Maintenance Manual.pdf

SEAM000604 – Hydraulic Excavator PC650-5, PC650LC-5, PC650SE-5, PC710-5, PC710SE-5 Operation & Maintenance Manual…2
COVER…2
1.FOREWORD…3
2.SAFETY INFORMATION…4
3.INTRODUCTION…5
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…6
5.CONTENTS…7
SAFETY…11
6.GENERAL PRECAUTIONS…12
7.PRECAUTIONS DURING OPERATION…18
7.1 BEFORE STARTING ENGINE…18
7.2 OPERATING MACHINE…20
7.3 TRANSPORTATION…25
7.4 BATTERY…26
7.5 BUCKET WITH HOOK…27
8.PRECAUTIONS FOR MAINTENANCE…30
8.1 BEFORE CARRYING OUT MAINTENANCE…30
8.2 DURING MAINTENANCE…33
9.POSITION FOR ATTACHING SAFETY LABELS…37
OPERATION…40
10.GENERAL VIEW…41
10.1 GENERAL VIEW OF MACHINE…41
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…42
11.EXPLANATION OF COMPONENTS…43
11.1 MACHINE MONITOR…43
11.2 LAMP…53
11.3 SWITCHES…54
11.4 CONTROL LEVERS, PEDALS…58
11.5 CEILING WINDOW…61
11.6 FRONT WINDOW…62
11.7 DOOR LOCK…64
11.8 EMERGENCY ENGINE STOP LEVER…64
11.9 DUST INDICATOR…65
11.10 AIR CONDITIONER…66
11.11 RADIO…71
11.12 FUSE …75
11.13 CONTROLLERS…76
11.14 TOOL BOX…76
11.15 GREASE PUMP…76
11.16 HANDLING GREASE PUMP…77
11.17 HANDLING ACCUMULATOR…79
12.OPERATION…81
12.1 CHECK BEFORE STARTING ENGINE…81
12.2 STARTING ENGINE…90
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…93
12.4 MOVING MACHINE OFF…95
12.5 STEERING MACHINE…99
12.6 STOPPING MACHINE…101
12.7 SWINGING…102
12.8 OPERATION OF WORK EQUIPMENT…103
12.9 WORKING MODE SELECTION…104
12.10 PROHIBITIONS FOR OPERATION…105
12.11 PRECAUTIONS FOR OPERATION…107
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…108
12.13 HOW TO ESCAPE FROM MUD…110
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…111
12.15 REPLACEMENT OF BUCKET…112
12.16 PARKING MACHINE…113
12.17 CHECK AFTER FINISHING WORK…114
12.18 STOPPING ENGINE…115
12.19 CHECK AFTER STOPPING ENGINE…116
12.20 LOCKING…116
13.TRANSPORTATION…117
13.1 LOADING,UNLOADING WORK…117
13.2 PRECAUTIONS FOR LOADING…119
13.3 PRECAUTIONS FOR TRANSPORTATION…120
13.4 PARTS FOR TRANSPORT…121
13.5 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…127
14.COLD WEATHER OPERATION…129
14.1 PRECAUTIONS FOR LOW TEMPERATURE…129
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…131
14.3 AFTER COLD WEATHER…131
15.LONG-TERM STORAGE…132
15.1 BEFORE STORAGE…132
15.2 DURING STORAGE…133
15.3 AFTER STORAGE…133
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…133
16.TROUBLESHOOTING…134
16.1 PHENOMENA THAT ARE NOT FAILURES…134
16.2 PRECAUTIONS ON PARTICULAR JOBSITES…134
16.3 IF BATTERY IS DISCHARGED…135
16.4 OTHER TROUBLE…139
MAINTENANCE …144
17.GUIDES TO MAINTENANCE…145
18.OUTLINES OF SERVICE…149
18.1 OUTLINE OF OIL,FUEL,COOLANT…149
18.2 OUTLINE OF ELECTRIC SYSTEM…152
18.3 OUTLINE OF HYDRAULIC SYSTEM…153
18.4 RELEASING PRESSURE…154
18.5 BLEEDING AIR FROM CIRCUIT…155
18.6 OIL FILTER AND LEVEL GAUGE POSITIONS…156
19.CONSUMABLE PARTS LIST…157
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…158
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…162
21.1 INTRODUCTION OF NECESSARY TOOLS…162
21.2 TORQUE LIST…163
22.PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS…164
23.MAINTENANCE SCHEDULE CHART…166
23.1 MAINTENANCE SCHEDULE CHART…166
24.SERVICE PROCEDURE…170
24.1 INITIAL 100 HOURS SERVICE…170
24.2 INITIAL 250 HOURS SERVICE…170
24.3 WHEN REQUIRED…171
24.4 CHECK BEFORE STARTING…192
24.5 EVERY 10 HOURS SERVICE…197
24.6 EVERY 100 HOURS SERVICE…199
24.7 EVERY 250 HOURS SERVICE…200
24.8 EVERY 500 HOURS SERVICE…207
24.9 EVERY 1000 HOURS SERVICE…210
24.10 EVERY 2000 HOURS SERVICE…214
24.11 EVERY 4000 HOURS SERVICE…219
SPECIFICATIONS…220
25.SPECIFICATIONS…221
OPTIONS,ATTACHMENTS…230
26.GENERAL PRECAUTIONS…231
26.1 PRECAUTIONS RELATED TO SAFETY…231
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…232
27.HANDLING BUCKET WITH HOOK…233
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…233
27.2 PROHIBITED OPERATIONS…233
27.3 PRECAUTIONS DURING OPERATIONS…233
28.USING SEAT BELT…234
28.1 SEAT BELT…234
29.INTRODUCTION OF ATTACHMENTS…236
29.1 SPECIFICATION,USE…236
29.2 ATTACHMENT INSTALLATION COMBINATION TABLE…237
30.OPERATING RADIO…238
30.1 EXPLANATION OF COMPONENTS…238
30.2 OPERATION METHOD…240
30.3 PRECAUTIONS FOR USE…241
30.4 SPECIFICATIONS…241
LOADING SHOVEL…242
31.GENERAL LOCATIONS…243
32.INSTRUMENTS AND CONTROLS…244
32.1 SWITCH…244
32.2 CONTROL LEVERS…246
32.3 CONTORL BOX…248
32.4 FUSE BOX…249
33.OPERATIONS…250
33.1 OPERATION OF WORK EQUIPMENT…250
34.PRECAUTIONS FOR MACHINE OPERATION…252
34.1 PRECAUTIONS DURING OPERATION…252
35.PRECAUTIONS WHEN DISASSEMBLING MACHINE…255
36.MAINTENANCE…256
36.1 CHECK BEFORE STARTING…256
36.2 EVERY 10 HOURS SERVICE…257
37.EXCAVATOR WORK…259
38.TRANSPORTATION…260
39.TROUBLESHOOTING…261
40.CONSUMABLE PARTS LIST…263
41.SPECIFICATIONS…264
SEAM02090303 – Hydraulic Excavator PC650-3 Operation & Maintenance Manual…267
COVER…267
FOREWORD…268
BREAKING IN YOUR NEW MACHINE…269
CONTENTS…270
SAFETY HINTS…271
GENERAL LOCATIONS AND SPECIFICATIONS…280
INSTRUMENTS AND CONTROLS…281
OPERATING THE AIR CONDITIONER…315
USING ACCUMULATORS…321
USING GREASE GUN…322
CHECK BEFORE STARTING…324
OPERATING YOUR MACHINE…331
HANDLING OF BATTERY…346
TRANSPORTATION…349
COLD WEATHER OPERATION…353
PERIODIC MAINTENANCE…358
PRECAUTIONS FOR MAINTENANCE…359
PRECAUTIONS WHEN DISASSEMBLING MACHINE…364
BLEEDING AIR FORM CIRCUIT…366
MAINTENANCE TABLE…370
OIL FILLER AND LEVEL GAUGE POSITIONS…374
CHECK BEFORE STARTING…375
INITIAL 100 HOURS SERVICE…375
EVERY 100 HOURS SERVICE…376
INITIAL 250 HOURS SERVICE…378
EVERY 250 HOURS SERVICE…378
EVERY 500 HOURS SERVICE…386
EVERY 1000 HOURS SERVICE…390
EVERY 2000 HOURS SERVICE…393
EVERY 4000 HOURS SERVICE…398
WHEN REQUIRED…399
ADJUSTMENT…411
TROUBLE SHOOTING GUIDE…413
STORAGE…417
SERVICE METER…419
MACHINE AND ENGINE SERIAL NUMBERS…420
FUEL,COOLANT AND LUBRICANTS…421
LOADING SHOVEL…425
GENERAL LOCATIONS AND SPECIFICATIONS…426
TRANSPORTATION…437
PRECAUTIONS WHEN DISASSEMBLING MACHINE…440
MAINTENANCE TABLE…442
OIL FILLER AND LEVEL GAUGE POSITIONS…445
EVERY 100 HOURS SERVICE…446
EVERY 200 HOURS SERVICE…449
SEAM02090306 – Hydraulic Excavator PC650-3, PC650LC-3, PC650SE-3 Operation & Maintenance Manual…452
COVER…452
FOREWORD…453
BREAKING IN YOUR NEW MACHINE…454
CONTENTS…455
SAFETY HINTS…456
GENERAL LOCATIONS AND SPECIFICATIONS…465
INSTRUMENTS AND CONTROLS…466
OPERATING THE AIR CONDITIONER…500
USING ACCUMULATORS…506
USING GREASE GUN…507
CHECK BEFORE STARTING…509
OPERATING YOUR MACHINE…516
HANDLING OF BATTERY…531
TRANSPORTATION…534
COLD WEATHER OPERATION…538
PERIODIC MAINTENANCE…543
PRECAUTIONS FOR MAINTENANCE…544
PRECAUTIONS WHEN DISASSEMBLING MACHINE…549
BLEEDING AIR FORM CIRCUIT…551
MAINTENANCE TABLE…555
OIL FILLER AND LEVEL GAUGE POSITIONS…559
CHECK BEFORE STARTING…560
INITIAL 100 HOURS SERVICE…560
EVERY 100 HOURS SERVICE…561
INITIAL 250 HOURS SERVICE…563
EVERY 250 HOURS SERVICE…563
EVERY 500 HOURS SERVICE…571
EVERY 1000 HOURS SERVICE…575
EVERY 2000 HOURS SERVICE…578
EVERY 4000 HOURS SERVICE…583
WHEN REQUIRED…584
ADJUSTMENT…596
TROUBLE SHOOTING GUIDE…598
STORAGE…602
SERVICE METER…604
MACHINE AND ENGINE SERIAL NUMBERS…605
FUEL,COOLANT AND LUBRICANTS…606
LOADING SHOVEL…610
GENERAL LOCATIONS AND SPECIFICATIONS…611
TRANSPORTATION…622
PRECAUTIONS WHEN DISASSEMBLING MACHINE…625
MAINTENANCE TABLE…627
OIL FILLER AND LEVEL GAUGE POSITIONS…630
EVERY 100 HOURS SERVICE…631
EVERY 200 HOURS SERVICE…634
SEBM000607 – Hydraulic Excavator PC650-5, PC710-5 Shop Manual…637
COVER…637
CONTENTS…638
01 GENERAL…659
ASSEMBLY DRAWING…660
SPECIFICATIONS…666
WEIGHT TABLE…672
LIST OF LUBRICANT AND WATER…678
10 STRUCTURE AND FUNCTION…679
PTO (POWER TAKE-OFF)…680
PTO LUBRICATION SYSTEM…681
RADIATOR AND OIL COOLER…682
POWER TRAIN…683
SWING MACHINERY…684
SWING CIRCLE…685
FINAL DRIVE…686
TRACK FRAME…687
IDLER CUSHION…689
IDLER…689
TRACK ROLLER…690
CARRIER ROLLER…690
TRACK SHOE…691
AIR PIPING…692
AIR CIRCUIT DIAGRAM…693
AIR COMPRESSOR…693
AIR GOVERNOR…694
AIR TANK…694
SAFETY VALVE…695
HORN VALVE…695
GREASE PUMP…696
HYDRAULIC UNIT LOCATION…697
HYDRAULIC CIRCUIT DIAGRAM…699
HYDRAULIC TANK…702
NO.1 PUMP…703
NO.2 PUMP…722
SWING PUMP…727
CHARGING AND PTO LUBRICATING PUMP…732
LINE OIL FILTER…733
PILOT OIL FILTER…733
RETURN OIL FILTER…734
DRAIN OIL FILTER…734
L.H. 5-SPOOL CONTROL VALVE…735
R.H. 4-SPOOL CONTROL VALVE…739
SWING CONTROL VALVE…744
SWING MOTOR…747
CENTER SWIVEL JOINT…751
TRAVEL MOTOR…752
CONTROL RELIEF VALVE…759
SAFETY LOCK VALVE…760
ACCUMULATOR…762
PPC VALVE…763
SOLENOID VALVE ASSEMBLY…767
EPC VALVE…772
AUTO-DECELERATION CYLINDER…774
PPC SHUTTLE VALVE…775
HYDRAULIC CYLINDER…776
WORK EQUIPMENT…780
ELECTRICAL WIRING DIAGRAM…783
ELECTRICAL CIRCUIT DIAGRAM…789
ENGINE CONTROL…805
MACHINE CONTROL SYSTEM…807
WORK EQUIPMENT CONTROL SYSTEM…837
MACHINE MONITORING SYSTEM…842
20 TESTING AND ADJUSTING…863
TABLE OF JUDGEMENT STANDARD VALUE…864
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…881
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…890
MEASURING ENGINE SPEED…891
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…892
MEASURING EXHAUST GAS TEMPERATURE…893
MEASURING EXHAUST GAS COLOR…894
ADJUSTING VALVE CLEARANCE…895
MEASURING COMPRESSION PRESSURE…896
MEASURING BLOW-BY PRESSURE…897
TESTING AND ADJUSTING FUEL INJECTION TIMING…898
MEASURING ENGINE OIL PRESSURE…900
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…901
TESTING AND ADJUSTING FAN BELT TENSION…901
ADJUSTING FUEL CONTROL LINKAGE…902
ADJUSTING ENGINE SPEED SENSOR…907
CHECKING SWING CIRCLE BEARING CLEARANCE…908
TESTING AND ADJUSTING TRACK SHOE TENSION…909
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT PRESSURE…910
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE…913
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE…915
MEASURING STROKE OF SERVO PISTON…921
TESTING AND ADJUSTING TRAVEL DEVIATION…922
MEASURING OIL LEAKAGE…924
CHECKING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…928
MEASURING PPC VALVE OUTPUT PRESSURE…929
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…930
MEASURING SOLENOID VALVE OUTLET PRESSURE…931
BLEEDING AIR…932
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…934
TROUBLESHOOTING…935
POINTS TO REMEMBER WHEN TROUBLESHOOTING…936
SEQUENCE OF EVENTS IN TROUBLESHOOTING…937
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…938
CHECKS BEFORE TROUBLESHOOTING…946
ELECTRICAL CIRCUIT DIAGRAM…947
POSITION OF CONNECTORS FOR TROUBLESHOOTING…972
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…976
SELF-DIAGNOSTIC DISPLAY OF CONTROLLERS…986
METHOD OF USING JUDGEMENT TABLE…987
METHOD OF USING TROUBLESHOOTING CHART…989
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…991
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM OR HYDRAULIC, MECHANICAL SYSTEM…992
E-1. EXCESSIVE DEVIATION WHEN TRAVEL (CONSTANT DEVIATION)…994
E-2. SPEED OF WORK EQUIPMENT, SWING, TRAVEL IS EXTREMELY SLOW OR LACKS POWER…997
E-3. ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS…1001
E-4. EVEN WHEN MODE SELECTOR SWITCH IS SWITCHED, OUTPUT DOES NOT CHANGE…1004
E-5. AUTO-DECELERATION FUNCTION DOES NOT WORK PROPERLY (THERE IS NO DECELERATION, OR DECELERATION STAYS ON)…1011
E-6. UPPER STRUCTURE DOES NOT SWING…1019
E-7. EXCESSIVE HYDRAULIC DRIFT OF SWING…1024
E-8. TRAVEL SPEED DOES NOT CHANGE…1028
E-9. EXCESSIVE TRAVEL DEVIATION DURING COMPOUND OPERATIONS (BUT ONLY FOR COMBINATION OF TRAVEL AND WORK EQUIPMENT)…1030
E-10. DEFECTIVE OPERATION OF HEAVY LIFT FUNCTION…1041
E-11. MACHINE PUSH UP FUNCTION IS NOT ACTUATED…1049
E-12. ENGINE DOES NOT START…1056
E-13. ENGINE DOES NOT STOP…1059
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…1061
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTME (H MODE)…1062
H-1. EXCESSIVE TRAVEL DEVIATION (GOES OUTSIDE STANDARD ONLY DURING TRAVEL OPERATIONS, WHEN TRAVEL LEVER IS OPERATED TO END OF STROKE)…1065
H-2. EXCESSIVE TRAVEL DEVIATION DURING COMPOUND OPERATIONS…1069
H-3. EXCESSIVE DEVIATION WHEN STARTING…1070
H-4. CONTROL LEVERS ARE EXTREMELY HEAVY…1072
H-5. WORK EQUIPMENT, TRAVEL, SWING START TO MOVE SUDDENLY (IN FINE CONTROL RANGE)…1073
H-6. SPEED OF WORK EQUIPMENT, SWING, TRAVEL IS EXTREMELY SLOW OR LACKS POWER …1074
H-7. ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATION…1078
H-8. OUTPUT DOES NOT CHANGE WHEN MODE SELECTOR SWITCH IS OPERATED…1079
H-9. AUTO-DECELERATION FUNCTION DOES NOT WORK PROPERLY (THERE IS NO DECELERATION OR DECELERATION STAYS ON )…1079
H-10. ABNORMAL NOISE COMES FROM AROUND PUMP…1080
H-11. SWING SPEED IS SLOW, OR THERE IS EXCESSIVE OVERRUN WHEN STOPPING SWING…1081
H-12. UPPER STRUCTURE DOES NOT SWING…1082
H-13. EXCESSIVE HYDRAULIC DRIFT OF SWING…1083
H-14. EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT…1083
H-15. EXCESSIVE TIME LAG OF WORK EQUIPMENT…1084
H-16. TRAVEL SPEED DOES ONT CHANGE…1085
H-17. DEFECTIVE ACTUATION OF HEAVY-LIFT FUNCTION (BOOM RAISE SET PRESSURE DOES NOT INCREASE, OR INCREASES BUT DOES NOT GO DOWN)…1086
H-18. DEFECTIVE ACTUATION OF MACHINE PUSH UP FUNCTION (BOOM LOWER SET PRESSURE DOES NOT INCREASE, OR INCRESES BUT DOES NOT GO DOWN)…1086
TABLE OF FAILURE MODES AND CAUSES…1087
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…1089
M-1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR…1090
M-2. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT…1090
M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH. (FLUID LEVEL OF CHECK ITEMS ARE CORRECT)…1091
M-4. WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH…1094
M-5. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH…1096
M-6. WHEN STARTING SWITCH IS TURNED ON AMD ENGINE IS STARTED, CAUTION ITEMS FLASH…1097
M-7. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 1 SECOND, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND…1102
M-8. NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS…1103
M-9. PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…1104
M-10. WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE, WHEN ENGINE IS STOPPED, SERVICE METER MOVES…1106
M-11. COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE…1108
M-12. COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY…1109
M-13. FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…1110
M-14. FUEL LEVEL GAUGE GIVES NO DISPLAY…1111
M-15. HEAD LAMP, WORKING LAMP DO NOT LIGHT UP…1112
M-16. WIPERS DO NOT WORK…1115
30 DISASSEMBLY AND ASSEMBLY…1117
METHOD OF USING MANUAL…1119
PRECAUTIONS WHEN CARRYING OUT OPERATION…1120
SPECIAL TOOL LIST…1122
STARTING MOTOR…1130
REMOVAL AND INSTALLATION…1130
ALTERNATOR…1131
REMOVAL AND INSTALLATION…1131
NOZZLE HOLDER…1132
REMOVAL…1132
INSTALLATION…1133
ENGINE OIL COOLER…1134
REMOVAL AND INSTALLATION…1134
FUEL INJECTION PUMP…1135
REMOVAL AND INSTALLATION…1135
WATER PUMP…1136
REMOVAL AND INSTALLATION…1136
TURBOCHARGER…1137
REMOVAL AND INSTALLATION…1137
HYRDAULIC COOLER…1138
REMOVAL AND INSTALLATION…1138
CYLINDER HEAD…1139
REMOVAL…1139
INSTALLATION…1142
RADIATOR…1144
REMOVAL AND INSTALLATION…1144
AFTER-COOLER CORE…1145
REMOVAL AND INSTALLATION…1145
ENGINE, PTO, HYDRAULIC PUMP…1146
REMOVAL…1146
INSTALLATION…1150
PTO…1151
REMOVAL…1151
INSTALLATION…1153
DISASSEMBLY…1154
ASSEMBLY…1155
FINAL DRIVE…1156
REMOVAL AND INSTALLATION…1156
DISASSEMBLY…1157
ASSEMBLY…1161
REVOLVING FRAME…1166
REMOVAL…1166
INSTALLATION…1167
SWING MACHINERY…1168
REMOVAL AND INSTALLATION…1168
DISASSEMBLY…1169
ASSEMBLY…1172
SWING CIRCLE…1176
REMOVAL AND INSTALLATION…1176
TRACK SHOE…1177
REMOVAL…1177
INSTALLATION…1178
ONE LINK…1179
FIELD DISASSEMBLY…1179
FIELD ASSEMBLY…1181
SPROCKET…1183
REMOVAL AND INSTALLATION…1183
IDLER…1184
REMOVAL AND INSTALLATION…1184
FRONT IDLER…1185
DISASSEMBLY…1185
ASSEMBLY…1187
IDLER ADJUSTMENT CYLINDER…1189
DISASSEMBLY AND ASSEMBLY…1189
RECOIL SPRING…1190
REMOVAL AND INSTALLATION…1190
DISASSEMBLY AND ASSEMBLY…1192
CARRIER ROLLER…1193
REMOVAL AND INSTALLATION…1193
DISASSEMBLY…1194
ASSEMBLY…1195
TRACK ROLLER…1197
REMOVAL AND INSTALLATION…1197
DISASSEMBLY…1198
ASSEMBLY…1199
NO.1 PUMP…1201
REMOVAL…1201
INSTALLATION…1202
HYDRAULIC PUMP…1203
DISASSEMBLY…1203
ASSEMBLY…1208
SERVO VALVE…1219
REMOVAL AND INSTALLATION…1219
TVC VALVE…1220
REMOVAL AND INSTALLATION…1220
CO・NC VALVE…1221
REMOVAL AND INSTALLATION…1221
NO.2 PUMP…1222
REMOVAL…1222
INSTALLATION…1223
SWING PUMP…1224
REMOVAL AND INSTALLATION…1224
DISASSEMBLY…1225
ASSEMBLY…1228
CHARGING, PTO LUBRICATION PUMP…1239
REMOVAL AND INSTALLATION…1239
MAIN RELIEF VALVE (FOR SWING CONTROL VALVE)…1240
REMOVAL AND INSTALLATION…1240
DISASSEMBLY AND ASSEMBLY…1241
MAIN CONTROL VALVE (FOR WORK EQUIPMENT,4-,5-SPOOL CONTROL VALVE)…1242
REMOVAL AND INSTALLATION…1242
DISASSEMBLY AND ASSEMBLY…1243
SWING CONTROL VALVE…1244
REMOVAL AND INSTALLATION…1244
DISASSEMBLY…1245
ASSEMBLY…1246
CONTROL VALVE (WORK EQUIPMENT)…1247
DISASSEMBLY…1247
ASSEMBLY…1249
SWING MOTOR…1251
REMOVAL AND INSTALLATION…1251
DISASSEMBLY…1252
ASSEMBLY…1255
CENTER SWIVEL JOINT…1260
REMOVAL AND INSTALLATION…1260
DISASSEMBLY…1261
ASSEMBLY…1262
TRAVEL MOTOR…1263
REMOVAL AND INSTALLATION…1263
DISASSEMBLY…1264
ASSEMBLY…1274
CHARGING PUMP RELIEF VALVE…1286
REMOVAL AND INSTALLATION…1286
DISASSEMBLY AND ASSEMBLY…1287
PPC VALVE (FOR TRAVEL)…1288
DISASSEMBLY AND ASSEMBLY…1288
PPC VALVE (FOR WORK EQUIPMENT, SWING)…1289
DISASSEMBLY AND ASSEMBLY…1289
AUTO-DECELERATION CYLINDER…1290
REMOVAL AND INSTALLATION…1290
BOOM CYLINDER (BACK HOE)…1291
REMOVAL…1291
INSTALLATION…1292
ARM CYLINDER (BACK HOE)…1293
REMOVAL AND INSTALLATION…1293
BUCKET CYLINDER (BACK HOE)…1294
REMOVAL…1294
INSTALLATION…1295
BOOM CYLINDER (LOADING SHOVEL)…1296
REMOVAL…1296
INSTALLATION…1297
ARM CYLINDER (LOADING SHOVEL)…1298
REMOVAL…1298
INSTALLATION…1299
BUCKET CYLINDER (LOADING SHOVEL)…1300
REMOVAL…1300
INSTALLATION…1301
BOTTOM, DUMP CYLINDER (LOADING SHOVEL)…1302
REMOVAL AND INSTALLATION…1302
HYDRAULIC CYLINDER…1303
DISASSEMBLY…1303
ASSEMBLY…1305
BUCKET (BACK HOE)…1308
REMOVAL AND INSTALLATION…1308
ARM (BACK HOE)…1309
REMOVAL…1309
INSTALLATION…1310
BOOM (BACK HOE)…1311
REMOVAL AND INSTALLATION…1311
BUCKET AND ARM (BACK HOE)…1312
REMOVAL AND INSTALLATION…1312
WORK EQUIPMENT (BACK HOE)…1313
REMOVAL…1313
INSTALLATION…1314
BUCKET (LOADING SHOVEL)…1315
REMOVAL AND INSTALLATION…1315
ARM (LOADING SHOVEL)…1316
REMOVAL…1316
INSTALLATION…1317
BOOM (LOADING SHOVEL)…1318
REMOVAL…1318
INSTALLATION…1319
WORK EQUIPMENT (LOADING SHOVEL)…1320
REMOVAL…1320
INSTALLATION…1321
OPERATOR'S CAB…1322
REMOVAL AND INSTALLATION…1322
COUNTERWEIGHT…1323
REMOVAL AND INSTALLATION…1323
MONITOR PANEL…1324
REMOVAL AND INSTALLATION…1324
AUTO-DECELERATION・OLSS CONTROLLER…1325
REMOVAL AND INSTALLATION…1325
40 MAINTENANCE STANDARD…1326
PTO…1327
SWING CIRCLE…1328
SWING MACHINERY…1329
FINAL DRIVE…1331
TRACK FRAME AND RECOIL SPRING…1333
TRACK ROLLER…1334
IDLER…1335
CARRIER ROLLER…1337
TRACK SHOE…1339
CHARGING AND PTO LUBRICATION PUMP…1340
L.H. 5-SPOOL CONTROL VALVE…1341
R.H. 4-SPOOL CONTROL VALVE…1345
SWING CONTROL VALVE…1348
SWING MOTOR…1350
CENTER SWIVEL JOINT…1351
PILOT RELIEF VALVE…1352
PPC VALVE…1353
HYDRAULIC CYLINDER…1355
WORK EQUIPMENT…1357
SEBM02090307 – Hydraulic Excavator PC650-3, PC650LC-3, PC650SE-3 Shop Manual…1371
COVER…1371
CONTENTS…1372
10 ENGINE…1397
11 STRUCTURE AND FUNCTION…1397
ENGINE RELATED PARTS…1398
PTO (POWER TAKE-OFF)…1399
PTO LUBRICATION SYSTEM…1400
RADIATOR AND OIL COOLER…1401
FUEL TANK AND PIPING…1402
ENGINE CONTROL SYSTEM…1403
AUTO-DECELERATION SYSTEM (IF EQUIPPED)…1404
12 TESTING AND ADJUSTING…1412
STANDARD FOR TESTING AND ADJUSTING…1413
TESTING AND ADJUSTING TOOL LIST…1413
ADJUSTING VALVE CLEARANCE…1414
MEASURING COMPRESSION PRESSURE…1415
ADJUSTING FUEL INJECTION TIMING…1416
MEASURING EXHAUST GAS COLOR…1417
MEASURING BLOW-BY PRESSURE…1418
TESTING AND ADJUSTING FAN BELT TENSION…1419
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…1419
ADJUSTING FUEL CONTROL LEVER…1420
ADJUSTING AUTO-DECELERATION SYSTEM…1423
13 DISASSEMBLY AND ASSEMBLY…1424
STARTING MOTOR…1425
REMOVAL…1425
INSTALLATION…1425
ALTERNATOR…1425
REMOVAL…1425
INSTALLATION…1425
ENGINE OIL COOLER…1425
REMOVAL…1425
INSTALLATION…1425
FUEL INJECTION PUMP…1427
REMOVAL…1427
INSTALLATION…1427
WATER PUMP…1427
REMOVAL…1427
INSTALLATION…1427
NOZZLE HOLDER…1429
REMOVAL…1429
INSTALLATION…1429
TURBOCHARGER…1429
REMOVAL…1429
INSTALLATION…1429
CYLINDER HEAD…1431
REMOVAL…1431
INSTALLATION…1435
HYDRAULIC OIL COOLER…1439
REMOVAL…1439
INSTALLATION…1439
RADIATOR…1439
REMOVAL…1439
INSTALLATION…1439
ENGINE, PTO AND HYDRAULIC PUMP…1441
REMOVAL…1441
INSTALLATION…1445
PTO…1449
REMOVAL…1449
INSTALLATION…1449
DISASSEMBLY…1451
ASSEMBLY…1451
DECELERATOR CYLINDER (IF EQUIPPED)…1455
REMOVAL…1455
INSTALLATION…1455
14 MAINTENANCE STANDARD…1457
PTO…1458
20 POWER TRAIN…1459
21 STRUCTURE AND FUNCTION…1459
POWER TRAIN …1460
TRAVEL AND BRAKE SYSTEM…1462
1. OUTLINE…1462
2. TRAVEL CONTROL CIRCUIT SCHEMATICS…1464
3. TRAVEL CONTROL CIRCUIT…1466
4. STRAIGHT-TRAVEL SYSTEM…1468
5. CENTER SWIVEL JOINT…1474
6. TRAVEL MOTOR (WITH PARKING BRAKE) ASSEMBLY…1475
7. TRAVEL BRAKE VALVE…1491
8. FINAL DRIVE…1494
SWING SYSTEM…1497
1. OUTLINE…1497
2. SWING HYDRAULIC CIRCUIT SCHEMATICS…1498
3. SWING HYDRAULIC CIRCUIT…1499
4. SWING PUMP…1500
5. SWING CONTROL VALVE…1503
6. SWING MOTOR (WITH MECHANICAL BRAKE) AND SAFETY VALVE ASSEMBLY…1507
7. SWING BRAKE (AUTOMATIC) AND SWING PARKING BRAKE (MANUAL)…1513
8. FREE SWING SYSTEM…1517
9. SWING MACHINERY…1522
10. SWING CIRCLE…1524
23 DISASSEMBLY AND ASSEMBLY…1525
CENTER SWIVEL JOINT…1526
REMOVAL…1526
INSTALLATION…1526
DISASSEMBLY…1528
ASSEMBLY…1528
TRAVEL MOTOR (WITH FOUR TRAVEL MOTORS)…1530
REMOVAL…1530
INSTALLATION…1530
DISASSEMBLY…1534
ASSEMBLY…1540
TRAVEL BRAKE VALVE (WITH FOUR TRAVEL MOTORS)…1530
REMOVAL…1530
INSTALLATION…1530
TRAVEL MOTOR (WITH TWO TRAVEL MOTORS)…1532
REMOVAL…1532
INSTALLATION…1532
DISASSEMBLY…1550
ASSEMBLY…1563
FINAL DRIVE…1579
REMOVAL (WITH FOUR TRAVEL MOTORS)…1579
INSTALLATION (WITH FOUR TRAVEL MOTORS)…1579
REMOVAL (WITH TWO TRAVEL MOTORS)…1581
INSTALLATION (WITH TWO TRAVEL MOTORS)…1581
DISASSEMBLY (WITH FOUR TRAVEL MOTORS)…1583
ASSEMBLY (WITH FOUR TRAVEL MOTORS)…1587
DISASSEMBLY (WITH TWO TRAVEL MOTORS)…1595
ASSEMBLY (WITH TWO TRAVEL MOTORS)…1599
SPROCKET…1607
REMOVAL…1607
INSTALLATION…1607
SWING PUMP…1609
REMOVAL…1609
INSTALLATION…1609
DISASSEMBLY…1611
ASSEMBLY…1615
CO・NC VALVE (FOR SWING PUMP)…1625
REMOVAL…1625
INSTALLATION…1625
SERVO VALVE (FOR SWING PUMP)…1625
REMOVAL…1625
INSTALLATION…1625
SWING CONTROL VALVE…1625
REMOVAL…1625
INSTALLATION…1625
DISASSEMBLY…1627
ASSEMBLY…1627
MAIN RELIEF VALVE (FOR SWING CONTROL VALVE)…1627
REMOVAL…1627
INSTALLATION…1627
SWING MOTOR…1629
REMOVAL…1629
INSTALLATION…1629
DISASSEMBLY…1631
ASSEMBLY…1635
REVOLVING FRAME…1639
REMOVAL…1639
INSTALLATION…1639
SWING CIRCLE…1641
REMOVAL…1641
INSTALLATION…1641
SWING MACHINERY…1643
REMOVAL…1643
INSTALLATION…1643
DISASSEMBLY…1645
ASSEMBLY…1649
24 MAINTENANCE STANDARD…1653
TRAVEL MOTOR…1654
TRAVEL SHUTTLE VALVE…1655
STRAIGHT-TRAVEL VALVE…1656
TRAVEL BRAKE VALVE…1657
FINAL DRIVE…1659
SWING CONTROL VALVE…1663
JET SENSOR…1665
SWING MOTOR…1666
SWING SHADOW VALVE (IF EQUIPPED)…1667
CONNECTION VALVE (IF EQUIPPED)…1668
SWING MACHINERY…1669
SWING CIRCLE…1671
30 UNDERCARRIAGE…1672
31 STRUCTURE AND FUNCTION…1672
TRACK FRAME…1673
IDLER CUSHION…1675
IDLER…1679
TRACK ROLLER…1680
CARRIER ROLLER…1681
TRACK SHOE…1682
33 DISASSEMBLY AND ASSEMBLY…1684
IDLER…1685
REMOVAL…1685
INSTALLATION…1685
IDLER CUSHION…1685
REMOVAL…1685
INSTALLATION…1685
DISASSEMBLY…1687
ASSEMBLY…1687
IDLER ADJUSTMENT CYLINDER…1687
DISASSEMBLY…1687
ASSEMBLY…1687
TRACK ROLLER…1689
REMOVAL…1689
INSTALLATION…1689
CARRIER ROLLER…1689
REMOVAL…1689
INSTALLATION…1689
TRACK SHOE…1691
REMOVAL…1691
INSTALLATION…1691
34 MAINTENANCE STANDARD…1693
TRACK FRAME…1694
TRACK SHOE…1695
IDLER…1697
TRACK ROLLER…1699
CARRIER ROLLER…1701
50 AIR SYSTEM…1702
51 STRUCTURE AND FUNCTION…1702
AIR PIPING…1703
AIR CIRCUIT DIAGRAM…1704
AIR GOVERNOR…1705
AIR TANK…1705
SAFETY VALVE…1706
HORN VALVE…1706
GREASE PUMP…1707
60 HYDRAULIC SYSTEM…1708
61 STRUCTURE AND FUNCTION…1708
HYDRAULIC PIPING…1709
HYDRAULIC CIRCUIT DIAGRAM…1713
WORK EQUIPMENT CONTROL…1717
ELECTRONIC AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)…1733
HYDRAULIC TANK…1742
MAIN PUMP…1743
HYDRAULIC OIL FILTER…1762
CHARGING AND PTO LUBRICATING PUMP…1766
2-STAGE AND 3-STAGE MODE SELECTOR OLSS (OPEN CENTER LOAD SENSING SYSTEM)…1767
HYDRAULIC CONTROL VALVE…1785
PPC VALVE…1792
PPC SHUTTLE VALVE…1798
ACCUMULATOR…1800
PILOT RELIEF VALVE…1801
SAFETY LOCK VALVE…1803
HYDRAULIC CYLINDER…1805
WORK EQUIPMENT…1812
62 TESTING AND ADJUSTING…1814
TABLE OF JUDGEMENT STANDARD VALUE…1815
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE…1824
TESTING AND ADJUSTING TOOL LIST…1838
TESTING TRAVEL AND OPERATING FORCE…1839
TESTING AND ADJUSTING MAIN RELIEF VALVE…1840
TESTING CONTROL CIRCUIT PRESSURE…1842
MEASURING DISCHARGE OF MAIN PISTON PUMP…1845
CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE…1846
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR…1849
TESTING OIL LEAKAGE FROM SWIVEL JOINT…1850
BLEEDING AIR…1852
CHARGING ACCUMULATOR WITH GAS…1855
TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK…1857
ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER…1858
ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX…1859
TROUBLESHOOTING…1864
ELECTRICAL CIRCUIT DIAGRAM…1865
POSITION OF CONNECTORS FOR TROUBLESHOOTING …1869
CONNECTION TABLE FOR CONNECTOR PINS…1879
TROUBLESHOOTING PROCEDURE…1883
CHECKS BEFORE TROUBLESHOOTING…1884
E.H MODE TROUBLESHOOTING…1887
ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY…1888
TROUBLESHOOTING (EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR)…1889
E-1 MACHINE DEVIATES EXCESSIVELY…1893
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1894
b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)…1896
E-2 WORK EQUIPMENT, SWING, TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER…1897
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1897
b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)…1899
E-3 ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS…1902
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1902
b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)…1904
E-4 NO CHANGE IN OUTPUT WHEN MODE SWITCH IS OPERATED…1905
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1906
b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)…1906
E-5 AUTO-DECELERATION DOES NOT WORK…1911
a) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1911
b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)…1915
E-6 SWING DOES NOT WORK…1917
E-7 EXCESSIVE HYDRAULIC DRIFT OF SWING …1919
E-8 TRAVEL SPEED DOES NOT SWITCH…1920
a) SPEED DOES NOT INCREASE WHEN PLACED IN HI (DOES NOT SWITCH TO HI)…1920
b) SPEED DOES NOT DECREASE WHEN PLACED IN LO…1920
H-1 MACHINE DEVIATES EXCESSIVELY (DEVIATES MORE THAN STANDARD WHEN ONLY TRAVEL SYSTEM IS USED, TRAVEL LEVER AT FULL POSITION)…1926
H-2 EXCESSIVE DEVIATION IN TRAVEL DURING SIMULTANEOUS OPERATIONS…1930
H-3 MACHINE DEVIATES EXCESSIVELY WHEN STARTING…1932
H-4 CONTROL LEVERS ARE EXTREMELY HEAVY…1934
a) IF TRAVEL LEVER IS HEAVY…1934
b) IF WORK EQUIPMENT LEVERS ARE HEAVY…1934
H-5 WORK EQUIPMENT, TRAVEL, AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS…1935
H-6 SPEEDS FOR WORK EQUIPMENT, SWING, AND TRAVEL ARE ALL EXTREMELY SLOW, OR THERE IS NO POWER…1936
a) MACHINE HARDLY MOVES…1936
b) ABNORMALITY IN SOME PART (ABNORMALITY ON ONE SIDE)…1938
H-7 ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATIONS…1940
H-8 NO CHANGE IN OUTPUT WHEN MODE SELECTOR SWITCH IS OPERATED…1941
H-9 AUTO-DECELERATION DOES NOT COME ON, OR DOES NOT GO OFF…1942
H-10 ABNORMAL NOISE COMES FROM AROUND PUMP…1942
H-11 SWING SPEED IS SLOW, OR OVERRUN WHEN STOPPING SWING IS EXCESSIVE…1943
H-12 UPPER STRUCTURE DOES NOT SWING…1945
H-13 EXCESSIVE HYDRAULIC DRIFT…1947
H-16 EXCESSIVE TIME LAG FOR WORK EQUIPMENT…1947
H-17 TRAVEL SPEED DOES NOT SWITCH…1948
a) SPEED DOES NOT INCREASE EVEN WHEN SELECTOR SWITCH IS PLACED IN HI…1948
b) SPEED DOES NOT DECREASE EVEN WHEN SELECTOR SWITCH IS PLACED IN LO…1948
FAILURE MODE AND COMPONENTS…1949
W.L MODE TROUBLESHOOTING …1950
ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY…1951
TROUBLESHOOTING…1952
W-1 IN ARC DIGGING MODE, WORK EQUIPMENT CARRIES OUT HORIZONTAL DIGGING, OR THERE IS BUCKET ANGLE COMPENSATION…1954
W-2 IN HORIZONTAL DIGGING MODE, WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING…1955
a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY…1955
b) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1957
W-3 IN HORIZONTAL DIGGING MODE, THERE IS BUCKET ANGLE COMPENSATION…1963
W-4 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, WORK EQUIPMENT CARRIES OUT HORIZONTAL DIGGING, BUT THERE IS NO BUCKET ANGLE COMPENSATION…1964
a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY…1964
b) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1966
W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, THERE IS BUCKET ANGLE COMPENSATION, BUT WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING…1968
a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY…1968
b) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1968
W-6 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING, AND THERE IS NO BUCKET ANGLE COMPENSATION…1970
a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY…1970
b) SELF-TESTING DISPLAY SHOWS ABNORMALITY…1971
L-1 WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION…1977
63 DISASSEMBLY AND ASSEMBLY…1978
CHARGING AND PTO LUBRICATION PUMP…1979
REMOVAL AND INSTALLATION…1979
NO.1 PUMP…1981
REMOVAL AND INSTALLATION…1981
NO.2 PUMP…1983
REMOVAL AND INSTALLATION…1983
MAIN PUMP…1985
DISASSEMBLY…1985
ASSEMBLY…1989
SERVO VALVE (FOR NO.1 FRONT PUMP)…2001
REMOVAL AND INSTALLATION…2001
SERVO VALVE (FOR NO.1 REAR PUMP)…2001
REMOVAL AND INSTALLATION…2001
SERVO VALVE (FOR NO.2 FRONT PUMP)…2001
REMOVAL AND INSTALLATION…2001
SERVO VALVE (FOR NO.2 REAR PUMP)…2001
REMOVAL AND INSTALLATION…2001
CO・NC VALVE (FOR NO.1 FRONT PUMP)…2003
REMOVAL AND INSTALLATION…2003
CO・NC VALVE (FOR NO.1 REAR PUMP)…2003
REMOVAL AND INSTALLATION…2003
TVC VALVE…2005
REMOVAL AND INSTALLATION…2005
L.H.5-SPOOL CONTROL VALVE…2007
REMOVAL…2007
INSTALLATION…2009
R.H.4-SPOOL CONTROL VALVE…2013
REMOVAL …2013
INSTALLATION…2015
CONTROL VALVE…2019
DISASSEMBLY AND ASSEMBLY…2019
MAIN RELIEF VALVE (FOR L.H.5-SPOOL,R.H.4-SPOOL VALVE)…2021
REMOVAL AND INSTALLATION…2021
PILOT RELIEF VALVE…2021
REMOVAL AND INSTALLATION…2021
PPC VALVE (FOR TRAVEL)…2023
REMOVAL AND INSTALLATION…2023
DISASSEMBLY AND ASSEMBLY…2025
PPC VALVE (FOR WORK EQUIPMENT AND SWING)…2025
DISASSEMBLY AND ASSEMBLY…2025
BOOM CYLINDER (BACK HOE)…2027
REMOVAL AND INSTALLATION…2027
ARM CYLINDER (BACK HOE)…2029
REMOVAL AND INSTALLATION…2029
BUCKET CYLINDER (BACK HOE)…2031
REMOVAL AND INSTALLATION…2031
BOOM CYLINDER (LOADING SHOVEL)…2033
REMOVAL AND INSTALLATION…2033
ARM CYLINDER (LOADING SHOVEL)…2035
REMOVAL AND INSTALLATION…2035
BUCKET CYLINDER (LOADING SHOVEL)…2037
REMOVAL AND INSTALLATION…2037
BOTTOM DUMP CYLINDER (LOADING SHOVEL)…2039
REMOVAL AND INSTALLATION…2039
HYDRAULIC CYLINDER…2041
DISASSEMBLY…2041
ASSEMBLY…2045
BUCKET (BACK HOE)…2049
REMOVAL AND INSTALLATION…2049
ARM (BACK HOE)…2051
REMOVAL AND INSTALLATION…2051
BOOM (BACK HOE)…2053
REMOVAL AND INSTALLATION…2053
BUCKET AND ARM (BACK HOE)…2055
REMOVAL AND INSTALLATION…2055
WORK EQUIPMENT (BACK HOE)…2057
REMOVAL AND INSTALLATION…2057
BUCKET (LOADING SHOVEL)…2059
REMOVAL AND INSTALLATION…2059
ARM (LOADING SHOVEL)…2061
REMOVAL AND INSTALLATION…2061
BOOM (LOADING SHOVEL)…2063
REMOVAL AND INSTALLATION…2063
WORK EQUIPMENT (LOADING SHOVEL)…2065
REMOVAL AND INSTALLATION…2065
POTENTIOMETER (LOADING SHOVEL)…2067
DISASSEMBLY AND ASSEMBLY…2067
COUNTERWEIGHT …2067
REMOVAL AND INSTALLATION…2067
64 MAINTENANCE STANDARD…2069
CHARGING AND PTO LUBRICATION PUMP…2070
PILOT RELIEF VALVE…2071
L.H. 5-SPOOL CONTROL VALVE…2072
R.H. 4-SPOOL CONTROL VALVE…2074
PPC VALVE…2076
PPC SHUTTLE VALVE…2077
HYDRAULIC CYLINDER…2078
WORK EQUIPMENT…2082
80 ELECTRIC AND ELECTRONIC SYSTEM…2086
81 STRUCTURE AND FUNCTION…2086
ELECTRICAL WIRING DIAGRAM…2087
ELECTRICAL CIRCUIT DIAGRAM…2089
ELECTRONIC COMPONENTS OF 3-STAGE MODE SELECTOR OLSS…2093
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM…2098
EVMS…2102
82 TESTING AND ADJUSTING…2110
ELECTRICAL CIRCUIT DIAGRAM…2111
POSITION OF CONNECTORS FOR TROUBLESHOOTING …2113
M MODE TROUBLESHOOTING…2123
SERIAL NO: 10501-10599…2125
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR…2125
a) NO DISPLAY APPEARS ON MONITOR PANEL (GAUGES AND MONITOR ITEMS)…2125
b) DISPLAY OF EITHER GAUGES OR MONITOR ITEMS DOES NOT APPEAR ON MONITOR PANEL…2125
c) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY…2126
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT GO OUT…2126
M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP…2127
a) (COOLANT LEVEL) FLASHES…2127
b) (ENGINE OIL LEVEL) FLASHES…2127
c) (HYDRAULIC OIL LEVEL) FLASHES…2128
d) (HEATER SIGNAL) FLASHES…2128
M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CHECK BEFORE STARTING ITEMS FLASH…2130
a) ALTERNATOR SYSTEM…2130
b) ENGINE OIL PRESSURE SYSTEM…2130
M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH…2132
M-6 WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS FLASH…2133
a) (ENGINE OIL PRESSURE) FLASHES…2133
b) (COOLANT LEVEL) FLASHES…2133
c) (COOLANT TEMPERATURE GAUGE) FLASHES…2134
d) (CHARGE LEVEL) FLASHES…2134
e) (HYDRAULIC OIL FILTER) FLASHES…2135
f) (HYDRAULIC OIL TEMPERATURE) FLASHES…2136
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 2 SECONDS, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND…2139
M-8 NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS…2141
M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP (INDICATION ON MONITOR PANEL IS CORRECT)…2142
a) NO LAMPS ON PANEL LIGHT UP…2142
b) SOME LAMPS ON PANEL DO NOT LIGHT UP…2143
M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES…2145
a) SERVICE METER DOES NOT MOVE…2145
b) SERVICE METER DOES NOT STOP MOVING …2146
M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED…2147
M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY…2147
M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK…2149
M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL…2149
SERIAL NO: 10600 AND UP…2151
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR…2151
a) NO DISPLAY APPEARS ON MONITOR PANEL (GAUGE AND MONITOR ITEMS)…2151
b) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY…2151
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT GO OUT…2151
M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP (FLUID LEVEL OF CHECK BEFORE STARTING ITEMS ARE CORRECT)…2152
a) (COOLANT LEVEL) FLASHES…2152
b) (ENGINE OIL LEVEL) FLASHES…2152
c) (HYDRAULIC OIL LEVEL) FLASHES…2153
M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CHECK BEFORE STARTING ITEMS FLASH…2155
a) ALTERNATOR SYSTEM…2155
b) ENGINE OIL PRESSURE SYSTEM…2155
M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH…2157
M-6 WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS FLASH…2158
a) (ENGINE OIL PRESSURE) FLASHES…2158
b) (COOLANT LEVEL) FLASHES…2158
c) (COOLANT TEMPERATURE GAUGE) FLASHES…2159
d) (CHARGE LEVEL) FLASHES…2159
e) (HYDRAULIC OIL FILTER) FLASHES…2160
f) (HYDRAULIC OIL TEMPERATURE) FLASHES…2160
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 1 SECOND, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND…2163
M-8 NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS…2163
M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP (INDICATION ON MONITOR PANEL IS CORRECT)…2165
M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES…2166
a) SERVICE METER DOES NOT MOVE, WHEN ENGINE IS STARTED…2166
b) SERVICE METER DOES NOT STOP MOVING, WHEN ENGINE IS STOPPED…2166
M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED…2168
M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY…2168
M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK…2170
M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL…2170
SEBM0209A04 – Hydraulic Excavator PC650-1 Shop Manual…2172

Komatsu Hydraulic Excavators PC650, PC650LC, PC650SE, PC710 Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 9, 2025 by admin

Komatsu Hydraulic Excavators PC600-6, PC600LC-6, PC600-7, PC600LC-7, PC600-8, PC600LC-8 Repair Service Manuals

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC600-6, PC600LC-6, PC600-7, PC600LC-7, PC600-8, PC600LC-8, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC600-6, PC600LC-6, PC600-7, PC600LC-7, PC600-8, PC600LC-8 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: 6,521 pages
File Format: PDF
Language: English

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SEAM046200 – Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual.pdf
SEAM022108T – Hydraulic Excavator PC600-6, PC600LC-6 Operation & Maintenance Manual.pdf
SEAM022100 – Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual.pdf
GEN00043-04 – Hydraulic Excavator PC600-8, PC600LC-8 Field Assembly Instruction.pdf
GEN00013-01 – Hydraulic Excavator PC600-7 Field Assembly Instruction.pdf

GEN00013-01 – Hydraulic Excavator PC600-7 Field Assembly Instruction….3
COVER….3
FOREWORD….4
CONTENTS….5
SPECIFICATIONS….6
FIELD ASSEMBLING….7
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE….8
TRANSPORTATION….10
PACKING STYLE FOR TRANSPORTATION….10
LIST OF TOOLS FOR FIELD ASSEMBLING….14
STANDARD TIGHTENING TORQUE….15
A. ASSEMBLY OF BASE MACHINE….19
A-1. INSTALLATION OF LEFT AND RIGHT TRACK FRAMES….20
A-2. INSTALLATION OF TRAVEL PIPE….23
A-3. INSTALLATION OF TOP GUARD….25
A-4. INSTALLATION OF REARVIEW MIRROR….26
A-5. INSTALLATION OF HANDRAIL….29
A-6. INSTALLATION OF STEP….32
A-7. INSTALLATION OF LEFT SIDE STEP….33
A-8. STICKING SEAT TO COUNTERWEIGHT….34
A-9. REMOVAL OF MUFFLER TAIL PIPE….35
A-10. INSTALLATION OF COUNTERWEIGHT….36
A-11. INSTALLATION OF MUFFLER TAIL PIPE….37
A-12. INSTALLATION OF ORBCOMM ANTENNA (IF EQUIPPED)….38
A-13. INSTALLATION OF STEP LIGHT….39
A-14. EXTENSION OF TRACK FRAME GAUGE….41
A-15. INSTALLATION OF TRAVEL PIPING COVER….45
A-16. TESTING TRACK SHOE TENSION….46
A-17. INSPECTION OF OIL AMOUNT AND WATER AMOUNT….49
A-18. PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY….51
B. ASSEMBLING OF WORK EQUIPMENT….52
B-1. ASSEMBLY OF BOOM FOOT PIN, BOOM CYLINDER FOOT PIN….53
B-2. ASSEMBLY OF BOOM ASSEMBLY….54
B-3. INSTALLATION OF BOOM CYLINDER FOOT….55
B-4. INSTALLATION OF BOOM CYLINDER HOSES….56
B-5. INSTALLATION OF HOSES FROM CHASSIS ALONG TOP OF BOOM….57
B-6. ASSEMBLY OF BOOM CYLINDER….58
B-7. ASSEMBLY OF ARM CYLINDER….59
B-8. INSTALLATION OF ARM CYLINDER HOSES….60
B-9. INSTALLATION OF ARM ASSEMBLY….61
B-10. INSTALLATION OF BUCKET CYLINDER HOSES BETWEEN BOOM AND BUCKET CYLINDER….63
B-11. INSTALLATION OF BUCKET….64
B-12. CONNECTION OF WORK EQUIPMENT GREASE PIPING….65
B-13. CONNECTION OF WORK EQUIPMENT WIRING….66
B-14. GREASING AFTER ASSEMBLING WORK EQUIPMENT….68
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY….69
M-1. INSPECTION OF OIL LEVEL IN HYDRAULIC TANK AND REFILL….70
M-2. REPLACEMENT OF RETURN FILTER (STANDARD FILTER TO FLUSHING FILTER)….72
M-3. FLUSHING OF HYDRAULIC CIRCUIT….75
FIELD ASSEMBLY INSPECTION REPORT (BACKHOE)….77
GEN00043-04 – Hydraulic Excavator PC600-8, PC600LC-8 Field Assembly Instruction….90
FOREWORD….90
CONTENTS….91
SPECIFICATIONS….94
PRECAUTIONS FOR FIELD ASSEMBLY….95
DISPOSAL OF REMOVED PARTS….96
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE….97
KIT LAYOUT DIAGRAM….98
TRANSPORTATION….99
LIST OF TOOLS FOR FIELD ASSEMBLING….104
TIGHTENING TORQUE….106
A. ASSEMBLY OF CHASSIS….112
A-1. Installation of Left and Right Track Frames….113
A-2. Installation of Travel Pipe….117
A-3. Installation of Operator Cab’s Left Handrail….119
A-4. Installation of Operator Cab’s Door Stopper and Striker….120
A-5. Installation of Rearview Mirror….122
A-6. Installation of Handrail….126
A-7. Installation of Step….129
A-8. Installation of Left Side Step….130
A-9. Sticking Sheet to Counterweight….131
A-10. Installation of Counterweight….132
A-11. Installation of Step Light….133
A-12. Installation of Travel Piping Cover….135
A-13. Testing Track Shoe Tension….139
A-14. Check Fuel, Coolant and Oil Levels….142
B. ASSEMBLING OF WORK EQUIPMENT….146
B-1. Assembly of Arm Cylinder….147
B-2. Connection of Arm Cylinder Hoses….148
B-3. Installation of Boom Cylinder….149
B-4. Installation of Boom Foot Dust Seal….150
B-5. Assembly of Boom Assembly….151
B-6. Installation of Boom Cylinder Hoses….152
B-7. Installation of Hoses from Chassis Along Top of Boom….153
B-8. Connection of Boom Cylinder Head….154
B-9. Installation of Arm Assembly….155
B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder….157
B-11. Installation of Bucket….158
B-12. Connection of Work Equipment Grease Piping….159
B-13. Connection of Work Equipment Wiring….160
B-14. Greasing after Assembling Work Equipment….162
B-15. Bleeding Air from Work Equipment Circuit….163
B-16. Parts to be Touched up After Field Assembly….164
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY….166
M-1. Inspection of Oil Level in Hydraulic Tank and Refill….167
M-2. Replacement of Return Filter (Standard Filter to Flushing Filter)….169
M-3. Flushing of Hydraulic Circuit….172
M-4. Error Code….174
M-5. Operating Method of Monitoring….179
D. ASSEMBLING OF COUNTERWEIGHT REMOVER….184
D-1. Sticking Sheet to Counterweight….185
D-2. Adjustment of Shims for Counterweight….186
D-3. Greasing….191
D-4. Installation of Counterweight Remover….192
D-5. Installation of Covers….193
D-6. Installation of Clamps….194
D-7. Installation of Hoses….197
D-8. Bleeding Air from Counterweight Remover Circuit….198
D-9. Installation of Counterweight….199
D-10. Check of Operation….201
Field Assembly Inspection Report (Backhoe)….202
SEAM022100 – Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual….228
SEAM022108T – Hydraulic Excavator PC600-6, PC600LC-6 Operation & Maintenance Manual….462
COVER….462
FOREWORD….463
FOREWORD….464
SAFETY INFORMATION….467
INTRODUCTION….469
DIRECTIONS OF MACHINE….469
BREAKING-IN THE NEW MACHINE….469
PRODUCT INFORMATION….470
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION….470
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….470
SERVICE METER LOCATION….471
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….471
CONTENTS….472
SAFETY….476
SAFETY INFORMATION….477
SAFETY LABELS….479
LOCATION OF SAFETY LABELS….480
SAFETY LABELS….481
SAFETY INFORMATION….486
SAFETY RULES….486
IF ABNORMALITIES ARE FOUND….486
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….486
FIRE EXTINGUISHER AND FIRST AID KIT….486
SAFETY EQUIPMENT….486
KEEP MACHINE CLEAN….487
KEEP OPERATOR'S COMPARTMENT CLEAN….487
LEAVING OPERATOR'S SEAT WITH LOCK….487
HANDRAILS AND STEPS….488
MOUNTING AND DISMOUNTING….488
NO PERSONS ON ATTACHMENTS….488
BURN PREVENTION….489
FIRE PREVENTION AND EXPLOSION PREVENTION….489
ACTION IF FIRE OCCURS….490
WINDSHIELD WASHER FLUID….490
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….490
ATTACHMENT INSTALLATION….491
ATTACHMENT COMBINATIONS….491
CAB WINDOW GLASSES….491
UNAUTHORIZED MODIFICATIONS….491
SAFETY AT JOBSITE….491
WORKING ON LOOSE GROUND….491
DISTANCE TO HIGH VOLTAGE CABLES….492
ENSURE GOOD VISIBILITY….492
VENTILATION FOR ENCLOSED AREA….493
SIGNALMAN'S SIGNAL AND SIGNS….493
EMERGENCY EXIT FROM OPERATOR'S CAB….493
ASBESTOS DUST HAZARD PREVENTION….493
SAFETY MACHINE OPERATION….494
STARTING ENGINE….494
CHECKS BEFORE STARTING ENGINE….494
SAFETY RULES FOR STARTING ENGINE….494
STARTING ENGINE IN COLD WEATHER….494
OPERATION….496
CHECKS BEFORE OPERATION….496
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….496
SAFETY RULES FOR TRAVELING….497
TRAVELING ON SLOPES….497
OPERATIONS ON SLOPES….498
PROHIBITED OPERATIONS….499
OPERATIONS ON SNOW….500
PARKING MACHINE….501
TRANSPORTATION….502
LOADING AND UNLOADING….502
SHIPPING THE MACHINE….502
BATTERY….503
BATTERY HAZARD PREVENTION….503
STARTING ENGINE WITH BOOSTER CABLES….504
TOWING….505
SAFETY RULES FOR TOWING….505
LIFTING OBJECTS WITH BUCKET….506
SAFETY RULES FOR LIFTING OBJECTS….506
SAFETY MAINTENANCE INFORMATION….507
WARNING TAG….507
KEEP WORK PLACE CLEAN AND TIDY….507
APPOINT LEADER WHEN WORKING WITH OTHERS….507
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….508
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….509
PROPER TOOLS….509
ACCUMULATOR….509
PERSONNEL….510
ATTACHMENTS….510
WORK UNDER THE MACHINE….510
NOISE….510
WHEN USING HAMMER….510
WELDING WORKS….511
REMOVING BATTERY TERMINALS….511
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….511
DO NOT DISASSEMBLE RECOIL SPRINGS….511
SAFETY RULES FOR HIGH-PRESSURE OIL….512
PRECAUTION FOR HIGH FUEL PRESSURE….512
SAFETY HANDLING HIGH-PRESSURE HOSES….512
PRECAUTION FOR HIGH VOLTAGE….512
WASTE MATERIALS….513
AIR CONDITIONER MAINTENANCE….513
COMPRESSED AIR….513
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….513
OPERATION….514
MACHINE VIEW ILLUSTRATIONS….515
OVERALL MACHINE VIEW….515
CONTROLS AND GAUGES….516
DETAILED CONTROLS AND GAUGES….517
MONITORING SYSTEM….517
SWITCHES….531
CONTROL LEVERS AND PEDALS….537
SUN ROOF….540
WINDSHIELD….541
EMERGENCY EXIT FROM OPERATOR'S CAB….544
DOOR LOCK….544
CAP WITH LOCK….545
HOT AND COOL BOX….546
LUGGAGE BOX….546
ASHTRAY….547
AIR CONDITIONER CONTROLS….548
RADIO….554
AUXILIARY ELECTRIC POWER….559
FUSE….559
CIRCUIT BREAKER….560
CONTROLLERS….561
TOOL BOX….561
GREASE PUMP….562
ACCUMULATOR….565
MACHINE OPERATIONS AND CONTROLS….566
BEFORE STARTING ENGINE….566
STARTING ENGINE….580
AFTER STARTING ENGINE….584
STOPPING THE ENGINE….590
MACHINE OPERATION….591
STEERING THE MACHINE….595
SWINGING….597
WORK EQUIPMENT CONTROLS AND OPERATIONS….598
WORKING MODE….599
PROHIBITED OPERATIONS….600
GENERAL OPERATION INFORMATION….602
TRAVELING ON SLOPES….603
ESCAPE FROM MUD….605
RECOMMENDED APPLICATIONS….606
BUCKET REPLACEMENT….607
PARKING MACHINE….609
CHECK AFTER SHUT OFF ENGINE….610
MACHINE INSPECTION AFTER DAILY WORK….610
LOCKING….611
TRANSPORTATION….612
PRECAUTIONS FOR TRANSPORTATION….612
LIFTING MACHINE….612
SHIPPING MACHINE INFORMATION….613
TRANSPORTATION POSTURE….614
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….619
COLD WEATHER OPERATION….621
COLD WEATHER OPERATION INFORMATION….621
AFTER DAILY WORK COMPLETION….623
AFTER COLD WEATHER SEASON….623
LONG TERM STORAGE….624
BEFORE STORAGE….624
DURING STORAGE….624
AFTER STORAGE….624
STARTING MACHINE AFTER LONG-TERM STORAGE….625
TROUBLES AND ACTIONS….626
RUNNING OUT OF FUEL….626
PHENOMENA THAT ARE NOT FAILURES….628
TOWING THE MACHINE….629
SEVERE JOB CONDITION….629
DISCHARGED BATTERY….630
OTHER TROUBLE….634
MAINTENANCE….639
MAINTENANCE INFORMATION….640
LUBRICANTS,COOLANT AND FILTERS….642
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….642
ELECTRIC SYSTEM MAINTENANCE….644
WEAR PARTS….645
WEAR PARTS LIST….645
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….646
PROPER SELECTION….646
TIGHTENING TORQUE SPECIFICATIONS….650
TIGHTENING TORQUE LIST….650
SAFETY CRITICAL PARTS….652
SAFETY CRITICAL PARTS LIST….652
MAINTENANCE SCHEDULE….653
MAINTENANCE SCHEDULE CHART….653
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….655
MAINTENANCE PROCEDURE….656
WHEN REQUIRED….656
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….656
CLEAN INSIDE OF COOLING SYSTEM….661
CHECK AND TIGHTEN TRACK SHOE BOLTS….663
CHECK AND ADJUST TRACK TENSION….664
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….666
ADJUST BUCKET CLEARANCE….667
REPLACE OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER….668
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….668
CHECK AND ADJUST AIR CONDITIONER….669
CLEAN LINE FILTER,REMOVE DIRT….670
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….671
BLEEDING AIR FROM HYDRAULIC SYSTEM….672
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….675
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)….676
CHECK BEFORE STARTING….677
EVERY 10 HOURS MAINTENANCE….678
LUBRICATING….678
EVERY 100 HOURS MAINTENANCE….681
SWING MACHINERY CASE OIL-CHECK/ADD….681
EVERY 250 HOURS MAINTENANCE….682
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….682
CHECK LEVEL OF BATTERY ELECTROLYTE….683
LUBRICATE SWING CIRCLE….685
CHANGE OIL LEVEL IN P.T.O CASE, ADD OIL….686
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS….686
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST….687
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….688
CHECK, CLEAN FUEL TANK STRAINER….689
EVERY 500 HOURS MAINTENANCE….690
REPLACE FUEL FILTER CARTRIDGE….690
CHECK SWING PINION GREASE LEVEL, ADD GREASE….691
REPLACE BREATHER FILTER ELEMENT IN HYDRAULIC TANK….692
CLEAN HYDRAULIC TANK STRAINER….693
REPLACE HYDRAULIC OIL FILTER ELEMENT….694
CLEAN, CHECK RADIATOR FIN, OIL COOLER FIN, FUEL COOLER FIN, CONDENSER FIN (MACHINES EQUIPMENT WITH AIR CONDITIONER)….695
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)….696
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER….697
CHECK FAN BELT….697
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….698
EVERY 1000 HOURS MAINTENANCE….700
CHANGE OIL IN SWING MACHINERY CASE….700
CHANGE OIL IN P.T.O CASE….701
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….701
CHECK PLAY TURBOCHARGER ROTOR….701
REPLACE CORROSION RESISTOR CARTRIDGE….702
CHECK WELDED STRUCTURE….702
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)….704
EVERY 2000 HOURS MAINTENANCE….705
CHANGE OIL IN FINAL DRIVE CASE….705
CHECK INJECTOR….705
CLEAN ENGINE BREATHER….706
CLEAN, CHECK TURBOCHARGER….706
CHECK ALTERNATOR, STARTING MOTOR….706
CHECK ENGINE VALVE CLEARANCE, ADJUST….706
EVERY 4000 HOURS MAINTENANCE….707
CHECK WATER PUMP….707
CHECK VIBRATION DAMPER….707
CHECK FAN PULLEY AND TENSION PULLEY….707
CHECK AIR COMPRESSOR, ADJUST….707
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….708
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….709
REPLACE INJECTOR NOZZLE ASSEMBLY….709
EVERY 5000 HOURS MAINTENANCE….710
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER….710
EVERY 8000 HOURS MAINTENANCE….712
REPLACE HIGH-PRESSURE PIPING CLAMP….712
REPLACE FUEL SPRAY PREVENTION CAP….712
SPECIFICATIONS….713
SPECIFICATIONS….714
ATTACHMENTS, OPTIONS….716
GENERAL PRECAUTIONS FOR SAFETY….717
PRECAUTIONS WHEN SELECTING….717
READ THE INSTRUCTION MANUAL THOROUGHLY….717
PRECAUTIONS WHEN REMOVING OR INSTALLING….717
PRECAUTIONS WHEN USING….717
BUCKET WITH HOOK….718
HOOK CANDMON….718
PROHIBITED OPERATIONS….718
ATTACHMENT GUIDE….719
COMBINATIONS OF WORK EQUIPMENT….719
TACK SHOES SELECTION….720
LOADING SHOVEL….721
EXPLANATION OF COMPONENTS….722
SWITCHES….722
OPERATIONS ….724
OPERATION OF WORK EQUIPMENT….724
PRECAUTIONS DURING OPERATION….726
EXCAVATOR WORK….730
PRECAUTIONS WHEN DISASSEMBLING MACHINE….731
RELEASING PRESSURE….731
TRANSPORTATION….732
MACHINE CONFIGURATION FOR TRANSPORT….732
WEAR PARTS….733
WEAR PARTS LIST….733
MAINTENANCE….734
CHECK BEFORE STARTING….734
EVERY 10 HOURS MAINTENANCE….736
EVERY 5000 HOURS MAINTENANCE….737
SPECIFICATION….739
COMBINATION OF WORK EQUIPMENT….740
COMBINATION OF WORK EQUIPMENT….740
INDEX….742
SEAM046200 – Hydraulic Excavator PC600-6, PC600LC-6 avance Operation & Maintenance Manual….745
SEAM053202T – Hydraulic Excavator GALEO PC600-7, PC600LC-7 Operation & Maintenance Manual….1007
SEAW001700 – Hydraulic Excavator PC600-6 Field Assembly Instruction….1306
SEAW002802 – Hydraulic Excavator PC600-6, PC600LC-6 Field Assembly Manual….1361
SEAW004900 – Hydraulic Excavator (Loading Shovel) PC600-6, PC600LC-6 Field Assembly Manual….1486
SEBM017111 – Hydraulic Excavator PC600-6, PC600LC-6 Shop Manual….1535
COVER PAGE….1535
CONTENTS….1536
LIST OF REVISED PAGES….1537
01 GENERAL ….1563
SPECIFICATIONS….1564
WEIGHT TABLE….1574
FUEL, COOLANT AND LUBRICANTS….1578
10 STRUCTURE AND FUNCTION….1579
PARTS RELATED TO ENGINE….1580
PTO….1582
RADIATOR, OIL COOLER….1583
POWER TRAIN….1584
FINAL DRIVE….1586
SWING CIRCLE….1587
SWING MACHINERY….1588
TRACK FRAME, RECOIL SPRING….1589
TRACK SHOE….1590
HYDRAULIC PIPING DRAWING….1592
HYDRAULIC TANK, HYDRAULIC FILTER….1594
HYDRAULIC PUMP (PISTON PUMP)….1597
SERVO VALVE….1600
TVC VALVE….1607
CO+NC VALVE….1613
SERVO VALVE (NO.2 FRONT)….1623
LINE OIL FILTER….1625
CONTROL VALVE….1626
TRAVEL SHUTTLE VALVE….1632
STRAIGHT-TRAVEL VALVE….1635
SWING PRIORITY VALVE….1637
ARM THROTTLE VALVE….1639
SWING MOTOR….1641
SWING BRAKE….1645
SAFETY VALVE….1646
REVERSE PREVENTION VALVE….1648
CENTRAL SWIVEL JOINT….1651
TRAVEL MOTOR….1652
PARKING BRAKE….1656
VALVE CONTROL….1662
WORK EQUIPMENT – SWING PPC VALVE….1664
TRAVEL PPC VALVE….1668
SERVICE PPC VALVE….1672
PPC SAFETY LOCK VALVE….1675
PPC ACCUMULATOR….1675
PPC SHUTTLE VALVE….1676
SOLENOID VALVE….1677
BUCKET CURL HI CANCEL….1679
BOOM HOLDING VALVE….1680
BOOM LOWER REGENERATION VALVE….1684
AIR CONDITIONER….1687
ACTUAL ELECTRIC WIRING DIAGRAM….1688
ENGINE CONTROL….1696
MACHINE CONTROL SYSTEM….1707
MACHINE CONTROL SYSTEM DIAGRAM….1708
MONITOR SYSTEM….1742
20 TESTING AND ADJUSTING….1759
STANDARD VALUE TABLE FOR ENGING….1760
STANDARD VALUE TABLE FOR CHASSIS….1763
STANDARD VALUE TABLE FOR ELECTRICAL PARTS….1773
TESTING AND ADJUSTING….1791
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING….1792
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)….1793
MEASURING EXHAUST TEMPERATURE….1794
MEASURING EXHAUST COLOR….1795
ADJUSTING VALVE CLEARANCE….1796
MEASURING COMPRESSION PRESSURE….1797
MEASURING BLOW-BY PRESSURE….1797
MEASURING ENGINE OIL PRESSURE….1798
HANDLING EQUIPMENT IN FUEL CIRCUIT….1799
RELEASING REMAINING PRESSURE IN FUEL SYSTEM….1799
MEASURING FUEL PRESSURE….1800
REDUCED CYLINDER OPERATION FOR ENGINE….1801
BLEEDING AIR FROM FUEL SYSTEM….1803
CHECK FOR LEAKAGE IN FUEL SYSTEM….1804
ADJUSTING ENGINE SPEED SENSORY….1805
TESTING AND ADJUSTING ALTERNATOR BELT TENSION….1806
TESTING AND ADJUSTING FAN BELT TENSION….1807
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT….1808
TESTING AND ADJUSTING AIR CONDITIONAL COMPRESSOR DRIVE BELT TENSION….1809
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE….1810
TESTING WEAR OF SPROCKET….1811
TESTING AND ADJUSTING TRACK SHOE TENSION….1812
TESTING CLEARANCE OF SWING CIRCLE BEARING….1813
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT….1814
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE….1817
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE….1819
MEASURING PPC VALVE OUTPUT PRESSUSRE….1825
TESTING SOLENOID VALVE OUTPUT PRESSURE….1826
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE….1827
TESTING TRAVEL DEVIATION….1828
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT….1829
MEASURING OIL LEAKAGE….1830
BLEEDING AIR….1833
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT….1835
PROCEDURE FOR CHECKING DIODE….1836
TROUBLESHOOTING….1837
POINTS TO REMEMBER WHEN TROUBLESHOOTING….1838
SEQUENCE OF EVENTS IN TROUBLESHOOTING….1839
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….1840
CHECKS BEFORE TROUBLESHOOTING….1848
CONNECTOR TYPES AND MOUNTING LOCATIONS….1850
CONNECTOR ARRANGEMENT DIAGRAM….1852
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….1864
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM….1888
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL….1891
TABLE OF MONITORING CODES….1896
TABLE OF SERVICE CODES….1909
TABLE 1 OF MONITORING CODES (ALL CODES)….1913
TABLE 2 OF MONITORING CODES (DETAILS OF BIT PATTERN CODE)….1914
METHOD OF USING JUDGEMENT TABLE….1921
METHOD OF USING TROUBLESHOOTING CHARTS….1925
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE….1929
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (n MODE)….1939
N-1(E218) COMMUNICATION ABNORMALITY….1940
TROUBLESHOOTING OF CUMMUNICATION ABNORMALITY SYSTEM (N MODE)….1943
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….1944
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM….1946
N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY….1947
N-2 [E117, E218 OCCUR AT SAME TIME] ENGINEER CONTROLLER COMMUNICATION ABNORMALITY….1949
N-3 [E118, E955 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY….1951
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM0, ENGING CONTROL SYSTEM (E MODE)….1953
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER SYSTEM….1954
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….1956
JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS….1960
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM….1962
E-1 ABNORMALITY IN ENGINE THROTTLE & PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)….1964
E-2 [E308] (ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE) IS DISPLAYED….1965
E-3 [E317] (ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM) IS DISPLAYED….1966
E-4 [E318] (ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED….1967
E-5 [E306] (ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM) IS DISPLAYED….1968
E-6 [E315] (ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM) IS DISPLAYED….1969
E-7 [E316] (ABNORMALITY (STEP-0UT) IN MOTOR) IS DISPLAYED….1970
E-8 ENGINE SPEED IS IRREGULAR….1972
E-9 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)….1976
E-10 ENGINE DOES NOT START….1978
E-11 ENGINE DOES NOT STOP (DEFECT IN ENGINE STOP SOLENOID SYSTEM)….1981
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (MONITOR PANEL, CONTROLLER DO NOT STOP)….1982
E-13 ENGINE DOES NOT STOP….1984
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)….1985
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED….1986
JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS….1994
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM….1996
E-1 [E91b] (ABNORMALITY IN ENGINE SPEED NE SENSOR SYSTEM) IS DISPLAYED….1998
E-2 [E91C] (ABNORMALITY IN ENGINE G ROTATION SENSOR SYSTEM) IS DISPLAYED….1999
E-3 [E920] (ABNORMALITY IN MODEL SELECTION SYSTEM) IS DISPLAYED….2000
E-4 [E922] (ENGINE OVERRUN) IS DISPLAYED….2001
E-5 [E924] (DROP IN ENGINE OIL PRESSURE IS DISPLAYED….2002
E-6 [E931] (ABNORMALITY IN FUEL CONTROL DIAL SENSOR SYSTEM) IS DISPLAYED….2003
E-7 [E934] (ABNORMALITY IN ENGINE WATER TEMPERATURE 9HIGH) SENSOR SYSTEM) IS DISPLAYED….2004
E-8 [E936] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED….2005
E-9 [E93C] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED….2006
E-10 [E93d] 9ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED….2007
E-11 [E954] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED….2008
E-12 [E955] (ABNORMALITY IN NETWORK SYSTEM) IS DISPLAYED….2008
E-13 [E956] (POWER SOURCE SYSTEM ABNORMALITY 1) IS DISPLAYED….2009
E-14 [E957] (POWER SOURCE SYSTEM ABNORMALITY 2) IS DISPLAYED….2010
E-15 [E95A] (ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL) IS DISPLAYED….2011
E-16 [E96A} (ABNORMALITY IN ENGINE WATER TEMPERATURE (LOW) SENSOR SYSTEM) IS DISPLAYED….2012
E-17 [E970] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED….2013
E-18 [E971] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED….2014
E-19 [E974] (DISCONNECTION IN FUEL SUPPLY PUMP PCV 1 SYSTEM) IS DISPLAYED….2015
E-20 [E975] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED….2016
E-21 [E977] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED….2017
E-22 [E979] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1) IS DISPLAYED….2018
E-22 [E97A] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2) IS DISPLAYED….2018
E-23 [E97b] (FUEL SUPPLY PUMP NON-FORCE FEED 1) IS DISPLAYED….2019
E-23 [E97C] (FUEL SUPPLY PUMP NON-FORCE FEED 2) IS DISPLAYED….2019
E-24 [E97d] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE) IS DISPLAYED….2021
E-25 [E980] (DEFECTIVE ENGINE CONTROLLER) IS DISPLAYED….2021
E-26 [E981] (DISCONNECTION IN NO. 1 FUEL INJECTOR SYSTEM) IS DISPLAYED….2022
E-27 [E982] (DISCONNECTION IN NO. 2 FUEL INJECTOR SYSTEM) IS DISPLAYED….2023
E-28 [E983] (DISCONNECTION IN NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED….2024
E-29 [E984] (DISCONNECTION IN NO. 4 FUEL INJECTOR SYSTEM) IS DISPLAYED….2025
E-30 [E985] (DISCONNECTION IN NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED….2026
E-31 [E986] (DISCONNECTION IN NO. 6 FUEL INJECTOR SYSTEM) IS DISPLAYED….2027
E-32 [E98A] (SHORT CIRCUIT IN NO. 1, NO. 2, NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED….2028
E-33 [E98b] (SHORT CIRCUIT IN NO. 3, NO. 4, NO. 5 FUEL INJECTOR SYSTEM,) IS DISPLAYED….2031
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROL SYSTEM) (C MODE)….2035
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM….2036
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….2038
JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS….2044
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE….2046
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)….2048
C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED….2049
C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED….2051
C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED….2053
C-5 [E213] (DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM) IS DISPLAYED….2055
C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED….2057
C-7 [E211] (DISCONNECTION IN C0 CANCEL SOLENOID SYSTEM) IS DISPLATED….2058
C-8 [E205] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED….2059
C-9 [E-215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED….2060
C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED….2061
C-11 [E216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED….2062
C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED….2063
C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED….2064
C-14 [E217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED….2065
C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED….2067
C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED….2068
C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED….2069
C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED….2070
C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)….2071
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)….2073
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM….2074
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….2076
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS….2084
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM….2086
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)….2088
C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED….2089
C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED….2091
C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED….2093
C-5 [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED….2095
C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED….2097
C-7 [E211] (DISCONNECTION IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED….2098
C-8 [E204] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED….2099
C-9 [E214] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED….2100
C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED….2101
C-11 [E-216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED….2102
C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCELSOLENOID SYTEM) IS DISPLAYED….2103
C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED….2104
C-14 [E-217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED….2105
C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED….2107
C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED….2108
C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED….2109
C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED….2110
C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)….2111
C-20 [E207] SHORT CIRCUIT IN FLASHING LIGHT RELAY DRIVE SYSTEM IS DISPLAYED….2113
C-21 FLASHING LIGHT RELAY DOES NOT WORK….2114
C-22 [E231] ABNORMALITY (SHORT CIRCUIT) IN STEP LIGHT POWER SOURCE RETENTION RELAY OUTPUT SYSTEM IS DISPLAYED….2115
C-23 STEP LIGHT SWITCH DOES NOT WORK….2116
C-24 [E302] SHORT CIRCUIT IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED….2117
C-25 STEP LIGHT DOES NOT LIGHT UP….2118
C-26 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED….2119
TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)….2121
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE….2122
F-1 BIT PATTERN 20-(1) (SWING OILS PRESSURE SWITCH) DOES NOT LIGHT UP….2124
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2125
F-3 BIT PATTERN 20-3 (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2126
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH ) DOES NOT LIGHT UP….2127
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2128
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2129
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2130
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2131
F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2132
F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP….2133
F-11 BIT PATTERN 22-(5) (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP….2134
F-12 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP….2135
TROUBLESHOOTING OF PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)….2137
ELECTRICAL CIRCUIT DIAGRAM FOR F MOD….2138
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2140
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2141
F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2142
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2143
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DIES NOT LIGHT UP….2144
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2145
F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP'….2146
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2147
F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP….2148
F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP….2149
F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP….2150
F-12 WHEN STEP LIGHT SWITCH IS ON, BIT PATTERN 24-(1) DOES NOT GO OUT….2151
F-13 WHEN HORN SWITCH IS ON, BIT PATTERN 24-(2) DOES NOT GO OUT….2152
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)….2153
TABLE OF FAILURE MODES AND CAUSES….2154
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)….2156
WORK EQUIPMENT IS SLOW OR LACKS POWER….2157
HYDRAULIC CIRCUIT DIAGRAM AFTER INTERCHANGING HOSES….2158
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER….2159
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS….2160
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE….2162
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)….2163
H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) IS SLOW OR LACKS PWOER….2164
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)….2165
H-8 EXCESSIVE HYDRULIC DRIFT….2165
H-9 EXCESSIVE TIME LAG….2166
H-10 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION….2166
H-11 IN COMPOUND OPERATIONS WITH SWING, WORK EQUIPMENT SPEED IS SLOW….2167
H-12 IN COMPOUND OPERATIONS WITH BUCKET CURL, SWING AND OTHER WORK EQUIPMENT SPEEDS ARE SLOW….2167
H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS….2167
H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRVELOPERATIONS….2168
H-15 DEVIATION IS EXCESSIVE WHEN STARTING….2172
H-16 TRAVEL SPEED IS SLOW….2174
H-17 TRAVEL SPEED DOES NOT SWITCH….2175
H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)….2175
H-19 DOES NOT SWING….2176
H-20 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR….2177
H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING….2178
H-22 EXCESSIVE SHOCK WHEN STOPPING SWING….2179
H-23 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING….2179
H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING….2180
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)….2181
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….2184
ELECTRICAL CIRCUIT DIGRAM FOR M MODE SYSTEM….2186
M-1 [E101] ABNORMALITY IN ERROR DATA) IS DISPLAYED….2188
M-1 [E-102] (ERROR IN CLOCK DATA) IS DISPLAYED….2188
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED….2189
M-3 [E-104] (AIR CLEANER CLOGGING DETECTED) IS DISPLAYED….2190
M-4 [E-106] (DROP IN ENGINE OIL PRESSURE DETECTED) IS DISPLAYED ….2190
M-5 [E-108] (ENGINE WATER TEMPERATURE 105 DEG. C DETECTED) IS DISPLAYED….2191
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS….2192
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT….2194
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)….2194
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH….2195
M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH….2198
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)….2200
M-12 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)….2202
M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND….2206
M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS….2206
M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)….2207
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE….2208
M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)….2208
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL….2209
M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY….2209
M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT graphic (SWING LOCK MONITOR) DOES NOT LIGHT UP….2210
M-21 SWING HOLDING BRAKE RELEASE SWITCH IS TURNED ON, BUT graphic (SWING LOCK MONITOR) DOES NOT FLASH….2210
M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING….2211
M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED….2211
M-24 DEFECTIVE FUEL LEVEL SENSOR SYSTEM….2212
M-25 DEFECTIVE COOLAND TEMPERATURE SENSOR SYSTEM….2213
M-26 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM….2214
M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM….2215
M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM….2216
M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)….2218
M-30 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114)….2223
M-31 ELECTRIC GREASE GUN DOES NOT WORK….2225
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)….2227
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE….2230
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM….2232
M-1 [E101] ABNORMALITY IN ERROR DATA ) OR [E102] (ABNORMALITY IN CLOCK DATA) IS DISPLAYED….2234
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM) IS DISPLAYED….2235
M-3 [E-104] (AIR CLEANER CLOGGING DETECTION) IS DISPLAYED….2236
M-4 [E108] (ENGINE WATER TEMPERATURE 105 DEG. C) IS DISPLAYED….2236
M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS….2237
M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT….2239
M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE….2239
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH….2240
M-9 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY MONITOR LAMP LIGHTS UP….2243
M-10 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH….2244
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH….2245
M-12 WHEN ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH….2246
M-13 OPERATION OF ALARM BUZZER IS NOT NORMAL….2250
M-14 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP….2252
M-15 ENGINE WATER TEMPERATURE DISPLAY IS NOT NORMAL….2253
M-16 FUEL LEVEL GAUGE DISPLAY IS NOT NORMAL….2254
M-17 SWING LOCK SWITCH IS TURNED ON BUT SWING LOCK MONITOR LAMP DOES NOT LIGHT UP….2256
M-18 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL (EMERGENCY), SWING LOCK MONITOR LAMP DOES NOT FLASH….2257
M-19 SERVICE METER DOES NOT GIVE NORMAL DISPLAY….2258
M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM….2259
M-21 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM….2260
M-22 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM….2261
M-23 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM….2262
M-24 WIPER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WIPER IS ACTUATED WHEN WIPER SWITCH IS NOT OPERATED….2263
M-25 WINDOW WASHER IS NOT ACTUATED WHEN SWITCH IS OPERATED OR WINDOW WASHER IS ACTUATED WHEN SWITCH IS NOT OPERATED….2268
M-26 ELECTRIC GREASE GUN DOES NOT WORK (MACHINES EQUIPPED WITH ELECTRIC GREASE GUN)….2271
30 DISASSEMBLY AND ASSEMBLY….2273
METHOD OF USING MANUAL….2276
PRECAUTIONS WHEN CARRYING OUT OPERATION….2279
SPECIAL TOOL LIST….2281
SKETCHES OF SPECIAL TOOLS….2291
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY….2300
REMOVAL OF FUEL SUPPLY PUMP ASSEMBLY….2301
INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY….2303
REMOVAL OF FUEL INJECTOR ASSEMBLY….2304
INSTALLATION OF FUEL INJECTOR ASSEMBLY….2306
REMOVAL OF NOZZLE TIP….2308
INSTALLATION OF NOZZLE TIP….2309
REMOVAL OF ENGINE FRONT SEAL….2309
INSTALLATION OF ENGINE FRONT SEAL….2311
REMOVAL OF ENGINE REAR SEAL….2313
INSTALLATION OF ENGINE REAR SEAL….2314
REMOVAL OF CYLINDER HEAD ASSEMBLY….2318
INSTALLATION OF CYLINDER HEAD ASSEMBLY….2321
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY….2325
INSTALLATION OF RADIATOR, HYDRUALIC COOLER ASSEMBLY….2326
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY….2327
INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY….2328
REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY….2330
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY….2333
REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY….2334
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY….2337
REMOVAL OF PTO ASSEMBLY….2338
INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY….2338
DISASSEMBLY OF PTO ASSEMBLY….2339
ASSEMBLY OF PTO ASSEMBLY….2341
REMOVAL OF FUEL TANK ASSEMBLY….2343
INSTALLATION OF FUEL TANK….2343
REMOVAL OF FUEL TANK ASSEMBLY….2344
INSTALLATION OF FUEL TANK….2344
DISASSEMBLY OF FINAL DRIVE ASSEMBLY….2346
ASSEMBLY OF FINAL DRIVE ASSEMBLY….2352
REMOVAL OF REVOLVING FRAME ASSEMBLY….2360
INSTALLATION OF REVOLVING FRAME ASSEMBLY….2361
REMOVAL OF SWING MOTOR ASSEMBLY….2362
INSTALLATION OF SWING MOTOR ASSEMBLY….2362
DISASSEMBLY OF SWING MOTOR ASSEMBLY….2363
ASSEMBLY OF SWING MOTOR ASSEMBLY….2367
REMOVAL OF SWING MACHINERY ASSEMBLY….2375
INSTALLATION OF SWING MACHINERY ASSEMBLY….2375
DISASSEMBLY OF SWING MACHINERY ASSEMBLY….2376
ASSEMBLY OF SWING MACHINERY ASSEMBLY….2380
REMOVAL OF SWING CIRCLE ASSEMBLY….2385
INSTALLATION OF SWING CIRCLE ASSEMBLY….2385
REMOVAL OF TRACK SHOE ASSEMBLY….2386
INSTALLATION OF TRACK SHOE ASSEMBLY….2387
DISASSEMBLY OF ONE LINK IN FIELD….2388
ASSEMBLY OF ONE LINK IN FIELD….2390
REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY….2392
INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY….2392
DISASSEMBLY OF IDLER ASSEMBLY….2393
ASSEMBLY OF IDLER ASSEMBLY….2395
DISASSEMBLY OF RECOIL SPRING ASSEMBLY….2397
ASSEMBLY OF RECOIL SPRING ASSEMBLY….2398
REMOVAL OF TRACK ROLLER ASSEMBLY….2399
INSTALLATION OF TRACK ROLLER ASSEMBLY….2399
DISASSEMBLY OF TRACK ROLLER ASSEMBLY….2400
ASSEMBLY OF TRACK ROLLER ASSEMBLY….2401
REMOVAL OF CARRIER ROLLER ASSEMBLY….2403
INSTALLATION OF CARRIER ROLLER ASSEMBLY….2403
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY….2404
ASSEMBLY OF CARRIER ROLLER ASSEMBLY….2405
REMOVAL OF HYDRAULIC TANK ASSEMBLY….2407
INSTALLATION OF HYDRAULIC TANK ASSEMBLY….2408
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY….2410
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY….2411
REMOVAL OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY….2412
INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY….2413
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY….2414
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY….2416
REMOVAL OF NO. 1 AND NO. 2 PUMP ASSEMBLY….2418
INSTALLATION OF NO. 1 AND NO. 2 PUMP ASSEMBLY….2419
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY….2420
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY….2430
REMOVAL OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY….2446
INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY….2446
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY….2447
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY….2447
DISASSEMBLY OF CENTER SWIVEL JOING ASSEMBLY….2448
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY….2448
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY….2449
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY….2450
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY….2451
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY….2452
REMOVAL OF BUCKET CYLINDER ASSEMBLY….2453
INSTALLATION OF BUCKET CYLINDER ASSEMBLY….2454
REMOVAL OF ARM CYLINDER ASSEMBLY….2455
INSTALLATION OF ARM CYLINDER ASSEMBLY….2456
REMOVAL OF BOOM CYLINDER ASSEMBLY….2457
INSTALLATION OF BOOM CYLINDER ASSEMBLY….2458
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….2459
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….2462
REMOVAL OF BUCKET ASSEMBLY….2466
INSTALLATION OF BUCKET ASSEMBLY….2467
REMOVAL OF ARM ASSEMBLY….2468
INSTALLATION OF ARM ASSEMBLY….2469
REMOVAL OF BOOM ASSEMBLY….2470
INSTALLATION OF BOOM ASSEMBLY….2471
REMOVAL OF OPERATOR'S CAB ASSEMBLY….2472
INSTALLATION OF OPERATOR'S CAB ASSEMBLY….2473
REMOVAL OF COUNTERWEIGHT ASSEMBLY….2474
INSTALLATION OF COUNTERWEIGHT ASSEMBLY….2474
40 MAINTENANCE STANDARD….2475
ENGINE MOUNT….2476
PTO….2477
SWING MACHINERY….2478
SWING CIRCLE….2480
FINAL DRIVE….2482
TRACK FRAME AND RECOIL SPRING….2484
IDLER….2486
CARRIER ROLLER….2488
TRACK ROLLER….2489
TRACK SHOE….2490
DOUBLE SHOE….2493
TRIPLE GROUSER SHOE….2494
HYDRAULIC PUMP….2495
CONTROL AND PTO LUBRICATION PUMP….2497
CONTROL VALVE….2498
SWING MOTOR….2505
TRAVEL MOTOR….2506
WORK EQUIPMENT – SWING PPC VALVE….2507
TRAVEL PPC VALVE….2508
SERVICE PPC VALVE….2509
SOLENOID VALVE….2510
CENTER SWIVEL JOINT….2511
BOOM HOLDING VALVE….2512
BOOM LOWER REGENERATION VALVE….2513
HYDRAULIC CYLINDER….2514
BACKHOE SPECIFICATION….2514
BOOM CYLINDER….2514
ARM CYLINDER….2514
BUCKET CYLINDER….2514
LOADING SHOVEL SPECIFICATION….2516
BOOM CYLINDER….2516
ARM CYLINDER….2516
BUCKET CYLINDER….2516
BOTTOM DUMP CYLINDER….2517
WORK EQUIPMENT….2518
BACKHOE SPECIFICATION….2518
LOADING SHOVEL SPECIFICATION….2520
DIMENSIONS OF WORK EQUIPMENT….2522
BACKHOE SPECIFICATION….2522
ARM….2522
BUCKET….2524
90 OTHERS….2527
HYDRAULIC CIRCUIT DIAGRAM (2/2)….2529
HYDRAULIC CIRCUIT DIAGRAM (1/2)….2534
HYDRAULIC CIRCUIT DIAGRAM (2/2)….2539
ELECTRIC CIRCUIT DIAGRAM (1/3)….2540
ELECTRIC CIRCUIT DIAGRAM (2/3)….2545
ELECTRIC CIRCUIT DIAGRAM (3/3)….2550
ELECTRIC CIRCUIT DIAGRAM (1/4)….2555
ELECTRIC CIRCUIT DIAGRAM (2/4)….2560
ELECTRIC CIRCUIT DIAGRAM (3/4)….2565
ELECTRIC CIRCUIT DIAGRAM (4/4)….2570
SEBM027100K – Hydraulic Excavator PC600LC-6 Shop Manual Supplement for Machines Built To Cold Weather Specifications (-50°C) (use with SEBM017100 & revisions)….2576
SEBM031206 – Hydraulic Excavator PC600-7, PC600LC-7 Shop Manual….3342
COVER….3342
CONTENTS….3343
01 GENERAL….3370
SPECIFICATION DRAWINGS….3371
SPECIFICATIONS….3373
WEIGHT TABLE….3377
FUEL, COOLANT AND LUBRICANTS….3379
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….3380
PARTS RELATED TO ENGINE….3381
PTO….3383
CONTROL AND PTO LUBRICATION PUMP….3385
RADIATOR, OIL COOLER….3386
POWER TRAIN….3387
FINAL DRIVE….3389
SPROCKET….3390
SWING CIRCLE….3394
SWING MACHINERY….3395
TRACK FRAME, RECOIL SPRING….3397
IDLER….3399
CARRIER ROLLER….3401
TRACK ROLLER….3402
TRACK SHOE….3403
HYDRAULIC PIPING DRAWING….3409
HYDRAULIC TANK, HYDRAULIC FILTER….3411
HYDRAULIC PUMP (PISTON PUMP)….3413
LINE OIL FILTER….3441
CONTROL VALVE….3442
SWING MOTOR….3461
CENTER SWIVEL JOINT….3470
TRAVEL MOTOR….3471
VALVE CONTROL….3482
WORK EQUIPMENT, SWING PPC VALVE….3483
TRAVEL PPC VALVE….3487
SERVICE PPC VALVE….3489
PPC ACCUMULATOR….3490
PPC SHUTTLE VALVE….3491
SOLENOID VALVE….3492
BOOM HOLDING VALVE….3497
BOOM LOWER REGENERATION VALVE….3501
HYDRAULIC CYLINDER….3504
WORK EQUIPMENT….3507
DIMENSIONS OF WORK EQUPMENT….3509
COUNTERWEIGHT REMOVER….3513
AIR CONDITIONER….3517
ENGINE CONTROL….3518
MACHINE CONTROL SYSTEM….3523
MONITOR SYSTEM….3548
SENSORS….3563
20 TESTING AND ADJUSTING….3567
STANDARD VALUE TABLE FOR ENGINE….3568
STANDARD VALUE TABLE FOR CHASSIS….3569
TESTING AND ADJUSTING….3578
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING….3579
MEASURING ENGINE SPEED….3581
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)….3582
MEASURING EXHAUST GAS TEMPERATURE….3583
MEASURING EXHAUST GAS COLOR….3584
ADJUSTING VALVE CLEARANCE….3585
MEASURING COMPRESSION PRESSURE….3586
MEASURING BLOW-BY PRESSURE….3588
MEASURING ENGINE OIL PRESSURE….3589
HANDLING EQUIPMENT IN FUEL CIRCUIT….3590
RELEASING REMAINING PRESSURE IN FUEL SYSTEM….3590
MEASURING FUEL PRESSURE….3591
BLEEDING AIR FROM FUEL CIRCUIT….3592
CHECK FOR LEAKAGE IN FUEL SYSTEM….3594
ADJUSTING ENGINE SPEED SENSOR….3595
TESTING AND ADJUSTING FAN BELT TENSION….3596
TESTING AND ADJUSTING ALTERNATOR BELT TENSION….3597
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION….3598
TESTING CLEARANCE OF SWING CIRCLE BEARING….3599
TESTING AND ADJUSTING TRACK SHOE TENSION….3600
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES….3601
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE….3606
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE….3608
TESTING SERVO PISTON STROKE….3614
MEASURING PPC VALVE OUTPUT PRESSURE….3615
MEASURING OUTLET PRESSURES OF SOLENOID VALVE AND PPC SHUTTLE VALVE….3619
ADJUSTING WORK EQUIPMENT・SWING PPC VALVE….3625
TESTING AND ADJUSTING TRAVEL DEVIATION….3626
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT….3628
MEASURING OIL LEAKAGE ….3629
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT….3633
BLEEDING AIR FROM EACH PART….3634
INSPECTION PROCEDURES FOR DIODE….3637
SPECIAL FUNCTION OF MONITOR PANEL….3638
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT….3665
PREPARATION WORK FOR TROUBLESHOOTING ELECTRICAL SYSTEM….3666
PM-CLINIC SERVICE….3668
UNDERCARRIAGE INSPECTION….3674
TROUBLESHOOTING….3675
POINTS TO REMEMBER WHEN TROUBLESHOOTING….3676
SEQUENCE OF EVENTS IN TROUBLESHOOTING….3677
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….3678
CHECKS BEFORE TROUBLESHOOTING….3686
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING….3687
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM….3691
TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (DISPLAYED CODE)….3732
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE….3734
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….3736
ERROR CODE IN ELECTRICAL SYSTEM E112 (WIPER DRIVE (FOR) S/C)….3738
ERROR CODE IN ELECTRICAL SYSTEM E113 (WIPER DRIVE (REV) S/C)….3742
ERROR CODE IN ELECTRICAL SYSTEM E114 (WASHER DRIVE S/C)….3744
ERROR CODE IN ELECTRICAL SYSTEM E115 (WIPER WORKING ABNORMALITY)….3746
ERROR CODE IN ELECTRICAL SYSTEM E116 (WIPER PARKING ABNORMALITY)….3748
ERROR CODE IN ELECTRICAL SYSTEM E117 (ENG. CONTROLLER S-NET COMM. ERR.)….3752
ERROR CODE IN ELECTRICAL SYSTEM E118 (PUMP CONTROLLER S-NET COMM. ERR.)….3754
ERROR CODE IN ELECTRICAL SYSTEM E128 (MONITOR COMM. ABNORMALITY)….3756
ERROR CODE IN ELECTRICAL SYSTEM E201 (CO CANCEL SOL. S/C)….3758
ERROR CODE IN ELECTRICAL SYSTEM E203 (SWING BRAKE SOL. S/C)….3760
ERROR CODE IN ELECTRICAL SYSTEM E204 (2-STAGE RELIEF SOL. S/C)….3762
ERROR CODE IN ELECTRICAL SYSTEM E206 (TRAVEL SPEED SOL. S/C)….3764
ERROR CODE IN ELECTRICAL SYSTEM E207 (FLASH LIGHT RELAY S/C)….3766
ERROR CODE IN ELECTRICAL SYSTEM E211 (CO CANCEL SOL. DISC.)….3768
ERROR CODE IN ELECTRICAL SYSTEM E213 (SWING BRAKE SOL. DISC.)….3770
ERROR CODE IN ELECTRICAL SYSTEM E214 (2-STAGE RELIEF SOL. DISC.)….3772
ERROR CODE IN ELECTRICAL SYSTEM E216 (TRAVEL SPEED SOL. DISC.)….3774
ERROR CODE IN ELECTRICAL SYSTEM E217 (MODEL SELECTION ABNORMALITY)….3776
ERROR CODE IN ELECTRICAL SYSTEM E218 (S-NET COMM. DISC.)….3778
ERROR CODE IN ELECTRICAL SYSTEM E221 (TRAVEL ALARM S/C)….3780
ERROR CODE IN ELECTRICAL SYSTEM E224 (F PUMP P. SENSOR ABNORMALITY)….3782
ERROR CODE IN ELECTRICAL SYSTEM E225 (R PUMP P. SENSOR ABNORMALITY)….3784
ERROR CODE IN ELECTRICAL SYSTEM E226 (PRESS. SENSOR POWER ABNORMALITY)….3786
ERROR CODE IN ELECTRICAL SYSTEM E227 (ENGINE SPEED SENSOR ABNORMALITY)….3788
ERROR CODE IN ELECTRICAL SYSTEM E232 (TVC SOL. S/C)….3790
ERROR CODE IN ELECTRICAL SYSTEM E233 (TVC SOL. DISC.)….3792
ERROR CODE IN ELECTRICAL SYSTEM E257 (PUMP COMM. ABNORMALITY)….3794
ERROR CODE IN ELECTRICAL SYSTEM E302 (STEP LIGHT RELAY S/C)….3796
ERROR CODE IN ELECTRICAL SYSTEM E304 (STEP LIGHT POWER HOLD RELAY S/C)….3798
ERROR CODE IN ELECTRICAL SYSTEM E311 (BUCKET CURL HI CANCEL SOL. S/C)….3800
ERROR CODE IN ELECTRICAL SYSTEM E312 (BUCKET CURL HI CANCEL SOL. DISC.)….3802
ERROR CODE IN ELECTRICAL SYSTEM E315 (BATTERY RELAY DRIVE S/C)….3804
ERROR CODE IN ELECTRICAL SYSTEM E91B (ENGINE NE SENSOR PROBLEM)….3806
ERROR CODE IN ELECTRICAL SYSTEM E91C (ENGINE G SENSOR PROBLEM)….3807
ERROR CODE IN ELECTRICAL SYSTEM E920 (ENGINE TYPE SELECTION ERROR)….3808
ERROR CODE IN ELECTRICAL SYSTEM E921 (ENGINE TYPE MISMATCH)….3810
ERROR CODE IN ELECTRICAL SYSTEM E931 (FUEL DIAL SYS. ERROR)….3811
ERROR CODE IN ELECTRICAL SYSTEM E934 (ENGINE COOLANT SENSOR HI ERROR)….3813
ERROR CODE IN ELECTRICAL SYSTEM E936 (ENGINE OIL PRESS. SW. ERROR)….3815
ERROR CODE IN ELECTRICAL SYSTEM E93C (ENGINE BOOST SENSOR ERROR)….3817
ERROR CODE IN ELECTRICAL SYSTEM E93D (ENGINE FUEL TEMP. SENSOR ERROR)….3819
ERROR CODE IN ELECTRICAL SYSTEM E953 (ENGINE COMM. ABNORMALITY)….3821
ERROR CODE IN ELECTRICAL SYSTEM E954 (SHORT ENGINE STARTER SW.)….3823
ERROR CODE IN ELECTRICAL SYSTEM E955 (ENGINE S-NET ERROR)….3825
ERROR CODE IN ELECTRICAL SYSTEM E956 (ENGINE POWER FAILURE (1))….3827
ERROR CODE IN ELECTRICAL SYSTEM E957 (ENGINE POWER FAILURE (2))….3829
ERROR CODE IN ELECTRICAL SYSTEM E95A (ENGINE Q-ADJ. SW. SIGNAL ERROR)….3831
ERROR CODE IN ELECTRICAL SYSTEM E96A (ENGINE COOLANT SENSOR LO ERROR)….3832
ERROR CODE IN ELECTRICAL SYSTEM E970 (PCV1 OVER CURRENT)….3834
ERROR CODE IN ELECTRICAL SYSTEM E971 (PCV2 OVER CURRENT)….3836
ERROR CODE IN ELECTRICAL SYSTEM E974 (PCV1 LINE CUT)….3838
ERROR CODE IN ELECTRICAL SYSTEM E975 (PCV2 LINE CUT)….3840
ERROR CODE IN ELECTRICAL SYSTEM E977 (RAIL PRESS. SENSOR ERROR)….3842
ERROR CODE IN ELECTRICAL SYSTEM E979 (RAIL PRESS. HIGH)….3844
ERROR CODE IN ELECTRICAL SYSTEM E97A (RAIL PRESS. ABNORMAL)….3844
ERROR CODE IN ELECTRICAL SYSTEM E97B (RAIL PRESS. LOW)….3845
ERROR CODE IN ELECTRICAL SYSTEM E97C (RAIL PRESS. TOO LOW)….3847
ERROR CODE IN ELECTRICAL SYSTEM E97D (RAIL PRESS. OUT OF CONTROL)….3847
ERROR CODE IN ELECTRICAL SYSTEM E980 (ENG. CONTROLLER ABNORMALITY)….3848
ERROR CODE IN ELECTRICAL SYSTEM E981 (FUEL INJECTOR 1 DISC.)….3850
ERROR CODE IN ELECTRICAL SYSTEM E982 (FUEL INJECTOR 2 DISC.)….3851
ERROR CODE IN ELECTRICAL SYSTEM E983 (FUEL INJECTOR 3 DISC.)….3852
ERROR CODE IN ELECTRICAL SYSTEM E984 (FUEL INJECTOR 4 DISC.)….3853
ERROR CODE IN ELECTRICAL SYSTEM E985 (FUEL INJECTOR 5 DISC.)….3854
ERROR CODE IN ELECTRICAL SYSTEM E986 (FUEL INJECTOR 6 DISC.)….3855
ERROR CODE IN ELECTRICAL SYSTEM E98A (FUEL INJECTOR 1-3 S/C)….3856
ERROR CODE IN ELECTRICAL SYSTEM E98B (FUEL INJECTOR 4-6 S/C)….3858
FAILURE CODE IN MECHANICAL SYSTEM A000N1 (ENG. HI OUT OF STD)….3860
FAILURE CODE IN MECHANICAL SYSTEM AA10NX (AIRCLEANER CLOGGING)….3861
FAILURE CODE IN MECHANICAL SYSTEM AB00KE (CHARGE VOLTAGE LOW)….3863
FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ENG. OIL PRESS. LOW)….3865
FAILURE CODE IN MECHANICAL SYSTEM B@BAZK (ENG. OIL LEVEL LOW)….3867
FAILURE CODE IN MECHANICAL SYSTEM B@BCNS (ENG. WATER OVERHEAT)….3868
FAILURE CODE IN MECHANICAL SYSTEM B@BCZK (ENG. WATER LVL LOW)….3869
FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDR. OIL OVERHEAT)….3871
FAILURE CODE IN MECHANICAL SYSTEM DA80MA (AUTO. LUB ABNORMAL)….3873
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….3874
BEFORE CARRYING OUT TROUBLESHOOTING E MODE….3875
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….3877
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)….3878
E-2 PREHEATER DOES NOT OPERATE….3881
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK….3883
E-4 AUTO-DECELERATOR DOES NOT OPERATE….3884
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE….3885
E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE….3887
E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY….3888
E-8 ANY ITEM IS NOT DISPLAYED ON MONITOR PANEL….3890
E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING….3891
E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL….3891
E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING….3892
E-12 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….3893
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….3895
E-14 FUEL GAUGE DOES NOT DISPLAY CORRECTLY….3896
E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY….3897
E-16 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED….3899
E-17 WIPER AND WINDOW WASHER DO NOT WORK….3901
E-18 ALARM BUZZER CANNOT BE CANCELLED….3908
E-19 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….3909
E-20 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….3910
E-21 "ARM CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….3911
E-22 "ARM DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….3912
E-23 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….3913
E-24 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….3914
E-25 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….3915
E-26 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….3917
E-27 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….3919
E-28 AIR CONDITIONER DOES NOT WORK….3921
E-29 STEP LIGHT DOES NOT LIGHT UP OR GO OFF….3922
E-30 ELECTRIC GREASE GUN DOES NOT OPERATE….3926
E-31 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING….3928
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….3930
BEFORE TROUBLESHOOTING H MODE….3931
INFORMATION IN TROUBLESHOOTING TABLE….3936
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW….3937
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS….3939
H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK….3940
H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP….3941
H-5 AUTO-DECELERATOR IS NOT RESET….3942
H-6 BOOM SPEED OR POWER IS LOW….3943
H-7 ARM SPEED OR POWER IS LOW….3945
H-8 BUCKET SPEED OR POWER IS LOW….3946
H-9 BOOM DOES NOT MOVE….3947
H-10 ARM DOES NOT MOVE….3947
H-11 BUCKET DOES NOT MOVE….3947
H-12 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE….3948
H-13 TIME LAG OF WORK EQUIPMENT IS LARGE….3950
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE OR STOP….3951
H-15 HEAVY LIFT FUNCTION DOES NOT OPERATE OR STOP….3951
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE OR STOP….3951
H-17 WHEN ARM AND BOOM・BUCKET ARE OPERATED SIMULTANEOUSLY, BOOM・BUCKET SPEED IS LOW….3952
H-18 WHEN BUCKET AND BOOM・ARM・SWING・TRAVEL ARE OPERATED SIMULTANEOUSLY, BOOM・ARM・SWING・TRAVEL SPEED IS LOW….3952
H-19 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, SWING SPEED IS LOW….3953
H-20 MACHINE DEVIATES IN ONE DIRECTION….3954
H-21 MACHINE DEVIATES LARGELY AT START….3956
H-22 TRAVEL DEVIATION IS LARGE DURING COMPOUND OPERATION….3957
H-23 TRAVEL SPEED OR POWER IS LOW….3958
H-24 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)….3959
H-25 TRAVEL SPEED DOES NOT CHANGE….3960
H-26 UPPER STRUCTURE DOES NOT SWING….3961
H-27 SWING SPEED OR ACCELERATION IS LOW….3962
H-28 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING….3963
H-29 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING ….3964
H-30 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING….3965
H-31 HYDRAULIC DRIFT OF SWING IS LARGE….3966
TROUBLESHOOTING OF ENGINE (S MODE)….3967
POINTS TO REMEMBER WHEN TROUBLESHOOTING….3968
METHOD OF USING TROUBLESHOOTING CHARTS….3969
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….3972
S-2 ENGINE DOES NOT START….3973
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)….3976
S-4 ENGINE STOPS DURING OPERATIONS….3977
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….3978
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)….3979
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….3980
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)….3981
S-9 OIL BECOMES CONTAMINATED QUICKLY….3982
S-10 FUEL CONSUMPTION IS EXCESSIVE….3983
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)….3984
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)….3985
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)….3986
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….3987
S-15 ABNORMAL NOISE IS MADE….3988
S-16 VIBRATION IS EXCESSIVE….3989
30 DISASSEMBLY AND ASSEMBLY….3990
METHOD OF USING MANUAL….3992
PRECAUTIONS WHEN CARRYING OUT OPERATION….3994
SPECIAL TOOL LIST….3996
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY….4013
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY….4016
REMOVAL AND INSTALLATION OF NOZZLE TIP….4020
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL….4022
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL….4024
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY….4029
REMOVAL AND INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY….4035
REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY….4037
REMOVAL AND INSTALLATION OF PTO ASSEMBLY….4040
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY….4041
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY….4043
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY….4044
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR ASSEMBLY….4056
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY….4071
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY….4072
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY….4073
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY….4084
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY….4085
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY….4093
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY….4094
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD….4096
REMOVAL AND INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY….4099
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY….4100
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY….4103
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY….4105
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY….4106
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY….4109
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY….4110
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY….4113
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY….4115
REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY….4117
DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY….4119
REMOVAL AND INSTALLATION OF NO.1 AND NO.2 PUMP ASSEMBLY….4123
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY….4125
REMOVAL AND INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY….4145
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY….4146
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY….4147
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY….4148
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY….4150
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY….4152
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY….4154
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY….4156
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….4158
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY….4163
REMOVAL AND INSTALLATION OF ARM ASSEMBLY….4165
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY….4167
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY….4170
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY….4171
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)….4172
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY….4181
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY….4187
90 OTHERS….4188
HYDRAULIC CIRCUIT DIAGRAM….4189
ELECTRICAL CIRCUIT DIAGRAM (1/5)….4190
ELECTRICAL CIRCUIT DIAGRAM (2/5)….4191
ELECTRICAL CIRCUIT DIAGRAM (3/5)….4192
ELECTRICAL CIRCUIT DIAGRAM (4/5)….4193
ELECTRICAL CIRCUIT DIAGRAM (5/5)….4194
ELECTRICAL CIRCUIT FOR AIR CONDITIONER….4195
SEBM031208 – Hydraulic Excavator PC600-7, PC600LC-7 Shop Manual….4196
COVER….4196
CONTENTS….4197
01 GENERAL….4224
SPECIFICATION DRAWINGS….4225
SPECIFICATIONS….4227
WEIGHT TABLE….4231
FUEL, COOLANT AND LUBRICANTS….4233
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD….4234
PARTS RELATED TO ENGINE….4235
PTO….4237
CONTROL AND PTO LUBRICATION PUMP….4239
RADIATOR, OIL COOLER….4240
POWER TRAIN….4241
FINAL DRIVE….4243
SPROCKET….4244
SWING CIRCLE….4249
SWING MACHINERY….4251
TRACK FRAME, RECOIL SPRING….4253
IDLER….4255
CARRIER ROLLER….4257
TRACK ROLLER….4258
TRACK SHOE….4259
HYDRAULIC PIPING DRAWING….4265
HYDRAULIC TANK, HYDRAULIC FILTER….4267
HYDRAULIC PUMP (PISTON PUMP)….4269
LINE OIL FILTER….4297
CONTROL VALVE….4299
SWING MOTOR….4318
CENTER SWIVEL JOINT….4327
TRAVEL MOTOR….4328
VALVE CONTROL….4339
WORK EQUIPMENT, SWING PPC VALVE….4341
TRAVEL PPC VALVE….4345
SERVICE PPC VALVE….4347
PPC ACCUMULATOR….4348
PPC SHUTTLE VALVE….4349
SOLENOID VALVE….4350
BOOM HOLDING VALVE….4355
BOOM LOWER REGENERATION VALVE….4359
HYDRAULIC CYLINDER….4363
WORK EQUIPMENT….4367
DIMENSIONS OF WORK EQUPMENT….4369
COUNTERWEIGHT REMOVER….4373
AIR CONDITIONER….4377
ENGINE CONTROL….4378
MACHINE CONTROL SYSTEM….4384
MONITOR SYSTEM….4410
SENSORS….4425
20 TESTING AND ADJUSTING….4430
STANDARD VALUE TABLE FOR ENGINE….4431
STANDARD VALUE TABLE FOR CHASSIS….4432
TESTING AND ADJUSTING….4442
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING….4443
MEASURING ENGINE SPEED….4445
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)….4446
MEASURING EXHAUST GAS TEMPERATURE….4447
MEASURING EXHAUST GAS COLOR….4448
ADJUSTING VALVE CLEARANCE….4449
MEASURING COMPRESSION PRESSURE….4450
MEASURING BLOW-BY PRESSURE….4452
MEASURING ENGINE OIL PRESSURE….4453
HANDLING EQUIPMENT IN FUEL CIRCUIT….4454
RELEASING REMAINING PRESSURE IN FUEL SYSTEM….4454
MEASURING FUEL PRESSURE….4455
BLEEDING AIR FROM FUEL CIRCUIT….4456
CHECK FOR LEAKAGE IN FUEL SYSTEM….4458
ADJUSTING ENGINE SPEED SENSOR….4459
TESTING AND ADJUSTING FAN BELT TENSION….4460
TESTING AND ADJUSTING ALTERNATOR BELT TENSION….4461
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION….4462
TESTING CLEARANCE OF SWING CIRCLE BEARING….4463
TESTING AND ADJUSTING TRACK SHOE TENSION….4464
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES….4465
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE….4470
TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE….4472
TESTING SERVO PISTON STROKE….4478
MEASURING PPC VALVE OUTPUT PRESSURE….4479
MEASURING OUTLET PRESSURES OF SOLENOID VALVE AND PPC SHUTTLE VALVE….4483
ADJUSTING WORK EQUIPMENT・SWING PPC VALVE….4489
TESTING AND ADJUSTING TRAVEL DEVIATION….4490
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT….4492
MEASURING OIL LEAKAGE ….4493
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT….4497
BLEEDING AIR FROM EACH PART….4498
INSPECTION PROCEDURES FOR DIODE….4501
SPECIAL FUNCTION OF MONITOR PANEL….4502
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT….4529
PREPARATION WORK FOR TROUBLESHOOTING ELECTRICAL SYSTEM….4530
PM-CLINIC SERVICE….4532
UNDERCARRIAGE INSPECTION….4538
TROUBLESHOOTING….4540
POINTS TO REMEMBER WHEN TROUBLESHOOTING….4541
SEQUENCE OF EVENTS IN TROUBLESHOOTING….4542
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….4543
CHECKS BEFORE TROUBLESHOOTING….4551
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING….4552
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM….4556
TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (DISPLAYED CODE)….4598
BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE….4601
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….4603
ERROR CODE IN ELECTRICAL SYSTEM E112 (WIPER DRIVE (FOR) S/C)….4605
ERROR CODE IN ELECTRICAL SYSTEM E113 (WIPER DRIVE (REV) S/C)….4609
ERROR CODE IN ELECTRICAL SYSTEM E114 (WASHER DRIVE S/C)….4611
ERROR CODE IN ELECTRICAL SYSTEM E115 (WIPER WORKING ABNORMALITY)….4613
ERROR CODE IN ELECTRICAL SYSTEM E116 (WIPER PARKING ABNORMALITY)….4615
ERROR CODE IN ELECTRICAL SYSTEM E117 (ENG. CONTROLLER S-NET COMM. ERR.)….4619
ERROR CODE IN ELECTRICAL SYSTEM E118 (PUMP CONTROLLER S-NET COMM. ERR.)….4621
ERROR CODE IN ELECTRICAL SYSTEM E128 (MONITOR COMM. ABNORMALITY)….4623
ERROR CODE IN ELECTRICAL SYSTEM E201 (CO CANCEL SOL. S/C)….4625
ERROR CODE IN ELECTRICAL SYSTEM E203 (SWING BRAKE SOL. S/C)….4627
ERROR CODE IN ELECTRICAL SYSTEM E204 (2-STAGE RELIEF SOL. S/C)….4629
ERROR CODE IN ELECTRICAL SYSTEM E206 (TRAVEL SPEED SOL. S/C)….4631
ERROR CODE IN ELECTRICAL SYSTEM E207 (FLASH LIGHT RELAY S/C)….4633
ERROR CODE IN ELECTRICAL SYSTEM E211 (CO CANCEL SOL. DISC.)….4635
ERROR CODE IN ELECTRICAL SYSTEM E213 (SWING BRAKE SOL. DISC.)….4637
ERROR CODE IN ELECTRICAL SYSTEM E214 (2-STAGE RELIEF SOL. DISC.)….4639
ERROR CODE IN ELECTRICAL SYSTEM E216 (TRAVEL SPEED SOL. DISC.)….4641
ERROR CODE IN ELECTRICAL SYSTEM E217 (MODEL SELECTION ABNORMALITY)….4643
ERROR CODE IN ELECTRICAL SYSTEM E218 (S-NET COMM. DISC.)….4645
ERROR CODE IN ELECTRICAL SYSTEM E221 (TRAVEL ALARM S/C)….4647
ERROR CODE IN ELECTRICAL SYSTEM E224 (F PUMP P. SENSOR ABNORMALITY)….4649
ERROR CODE IN ELECTRICAL SYSTEM E225 (R PUMP P. SENSOR ABNORMALITY)….4651
ERROR CODE IN ELECTRICAL SYSTEM E226 (PRESS. SENSOR POWER ABNORMALITY)….4653
ERROR CODE IN ELECTRICAL SYSTEM E227 (ENGINE SPEED SENSOR ABNORMALITY)….4655
ERROR CODE IN ELECTRICAL SYSTEM E232 (TVC SOL. S/C)….4657
ERROR CODE IN ELECTRICAL SYSTEM E233 (TVC SOL. DISC.)….4659
ERROR CODE IN ELECTRICAL SYSTEM E257 (PUMP COMM. ABNORMALITY)….4661
ERROR CODE IN ELECTRICAL SYSTEM E302 (STEP LIGHT RELAY S/C)….4663
ERROR CODE IN ELECTRICAL SYSTEM E304 (STEP LIGHT POWER HOLD RELAY S/C)….4665
ERROR CODE IN ELECTRICAL SYSTEM E311 (BUCKET CURL HI CANCEL SOL. S/C)….4667
ERROR CODE IN ELECTRICAL SYSTEM E312 (BUCKET CURL HI CANCEL SOL. DISC.)….4669
ERROR CODE IN ELECTRICAL SYSTEM E315 (BATTERY RELAY DRIVE S/C)….4671
ERROR CODE IN ELECTRICAL SYSTEM E91B (ENGINE NE SENSOR PROBLEM)….4673
ERROR CODE IN ELECTRICAL SYSTEM E91C (ENGINE G SENSOR PROBLEM)….4674
ERROR CODE IN ELECTRICAL SYSTEM E920 (ENGINE TYPE SELECTION ERROR)….4675
ERROR CODE IN ELECTRICAL SYSTEM E921 (ENGINE TYPE MISMATCH)….4677
ERROR CODE IN ELECTRICAL SYSTEM E931 (FUEL DIAL SYS. ERROR)….4679
ERROR CODE IN ELECTRICAL SYSTEM E934 (ENGINE COOLANT SENSOR HI ERROR)….4681
ERROR CODE IN ELECTRICAL SYSTEM E936 (ENGINE OIL PRESS. SW. ERROR)….4683
ERROR CODE IN ELECTRICAL SYSTEM E93C (ENGINE BOOST SENSOR ERROR)….4685
ERROR CODE IN ELECTRICAL SYSTEM E93D (ENGINE FUEL TEMP. SENSOR ERROR)….4687
ERROR CODE IN ELECTRICAL SYSTEM E953 (ENGINE COMM. ABNORMALITY)….4689
ERROR CODE IN ELECTRICAL SYSTEM E954 (SHORT ENGINE STARTER SW.)….4691
ERROR CODE IN ELECTRICAL SYSTEM E955 (ENGINE S-NET ERROR)….4693
ERROR CODE IN ELECTRICAL SYSTEM E956 (ENGINE POWER FAILURE (1))….4695
ERROR CODE IN ELECTRICAL SYSTEM E957 (ENGINE POWER FAILURE (2))….4697
ERROR CODE IN ELECTRICAL SYSTEM E95A (ENGINE Q-ADJ. SW. SIGNAL ERROR)….4699
ERROR CODE IN ELECTRICAL SYSTEM E96A (ENGINE COOLANT SENSOR LO ERROR)….4701
ERROR CODE IN ELECTRICAL SYSTEM E970 (PCV1 OVER CURRENT)….4703
ERROR CODE IN ELECTRICAL SYSTEM E971 (PCV2 OVER CURRENT)….4705
ERROR CODE IN ELECTRICAL SYSTEM E974 (PCV1 LINE CUT)….4707
ERROR CODE IN ELECTRICAL SYSTEM E975 (PCV2 LINE CUT)….4709
ERROR CODE IN ELECTRICAL SYSTEM E977 (RAIL PRESS. SENSOR ERROR)….4711
ERROR CODE IN ELECTRICAL SYSTEM E979 (RAIL PRESS. HIGH)….4713
ERROR CODE IN ELECTRICAL SYSTEM E97A (RAIL PRESS. ABNORMAL)….4713
ERROR CODE IN ELECTRICAL SYSTEM E97B (RAIL PRESS. LOW)….4714
ERROR CODE IN ELECTRICAL SYSTEM E97C (RAIL PRESS. TOO LOW)….4716
ERROR CODE IN ELECTRICAL SYSTEM E97D (RAIL PRESS. OUT OF CONTROL)….4716
ERROR CODE IN ELECTRICAL SYSTEM E980 (ENG. CONTROLLER ABNORMALITY)….4717
ERROR CODE IN ELECTRICAL SYSTEM E981 (FUEL INJECTOR 1 DISC.)….4719
ERROR CODE IN ELECTRICAL SYSTEM E982 (FUEL INJECTOR 2 DISC.)….4720
ERROR CODE IN ELECTRICAL SYSTEM E983 (FUEL INJECTOR 3 DISC.)….4721
ERROR CODE IN ELECTRICAL SYSTEM E984 (FUEL INJECTOR 4 DISC.)….4722
ERROR CODE IN ELECTRICAL SYSTEM E985 (FUEL INJECTOR 5 DISC.)….4723
ERROR CODE IN ELECTRICAL SYSTEM E986 (FUEL INJECTOR 6 DISC.)….4724
ERROR CODE IN ELECTRICAL SYSTEM E98A (FUEL INJECTOR 1-3 S/C)….4725
ERROR CODE IN ELECTRICAL SYSTEM E98B (FUEL INJECTOR 4-6 S/C)….4727
FAILURE CODE IN MECHANICAL SYSTEM A000N1 (ENG. HI OUT OF STD)….4730
FAILURE CODE IN MECHANICAL SYSTEM AA10NX (AIRCLEANER CLOGGING)….4731
FAILURE CODE IN MECHANICAL SYSTEM AB00KE (CHARGE VOLTAGE LOW)….4733
FAILURE CODE IN MECHANICAL SYSTEM B@BAZG (ENG. OIL PRESS. LOW)….4735
FAILURE CODE IN MECHANICAL SYSTEM B@BAZK (ENG. OIL LEVEL LOW)….4737
FAILURE CODE IN MECHANICAL SYSTEM B@BCNS (ENG. WATER OVERHEAT)….4738
FAILURE CODE IN MECHANICAL SYSTEM B@BCZK (ENG. WATER LVL LOW)….4739
FAILURE CODE IN MECHANICAL SYSTEM B@HANS (HYDR. OIL OVERHEAT)….4741
FAILURE CODE IN MECHANICAL SYSTEM DA80MA (AUTO. LUB ABNORMAL)….4743
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)….4744
BEFORE CARRYING OUT TROUBLESHOOTING E MODE….4745
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….4747
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)….4748
E-2 PREHEATER DOES NOT OPERATE….4751
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK….4753
E-4 AUTO-DECELERATOR DOES NOT OPERATE….4754
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE….4755
E-6 ONE-TOUCH POWER MAX, FUNCTION DOES NOT OPERATE….4757
E-7 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY….4758
E-8 ANY ITEM IS NOT DISPLAYED ON MONITOR PANEL….4760
E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING….4761
E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL….4761
E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING….4762
E-12 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….4763
E-13 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….4765
E-14 FUEL GAUGE DOES NOT DISPLAY CORRECTLY….4766
E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY….4767
E-16 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED….4769
E-17 WIPER AND WINDOW WASHER DO NOT WORK….4771
E-18 ALARM BUZZER CANNOT BE CANCELLED….4779
E-19 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….4780
E-20 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….4781
E-21 "ARM CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….4782
E-22 "ARM DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….4783
E-23 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….4784
E-24 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….4785
E-25 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….4787
E-26 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….4789
E-27 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITORING FUNCTION….4791
E-28 AIR CONDITIONER DOES NOT WORK….4793
E-29 STEP LIGHT DOES NOT LIGHT UP OR GO OFF….4795
E-30 ELECTRIC GREASE GUN DOES NOT OPERATE….4799
E-31 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING….4801
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)….4804
BEFORE TROUBLESHOOTING H MODE….4805
INFORMATION IN TROUBLESHOOTING TABLE….4810
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW….4811
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS….4813
H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK….4814
H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP….4815
H-5 AUTO-DECELERATOR IS NOT RESET….4816
H-6 BOOM SPEED OR POWER IS LOW….4817
H-7 ARM SPEED OR POWER IS LOW….4819
H-8 BUCKET SPEED OR POWER IS LOW….4820
H-9 BOOM DOES NOT MOVE….4821
H-10 ARM DOES NOT MOVE….4821
H-11 BUCKET DOES NOT MOVE….4821
H-12 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE….4822
H-13 TIME LAG OF WORK EQUIPMENT IS LARGE….4824
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE OR STOP….4825
H-15 HEAVY LIFT FUNCTION DOES NOT OPERATE OR STOP….4825
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE OR STOP….4825
H-17 WHEN ARM AND BOOM・BUCKET ARE OPERATED SIMULTANEOUSLY, BOOM・BUCKET SPEED IS LOW….4826
H-18 WHEN BUCKET AND BOOM・ARM・SWING・TRAVEL ARE OPERATED SIMULTANEOUSLY, BOOM・ARM・SWING・TRAVEL SPEED IS LOW….4826
H-19 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, SWING SPEED IS LOW….4827
H-20 MACHINE DEVIATES IN ONE DIRECTION….4829
H-21 MACHINE DEVIATES LARGELY AT START….4831
H-22 TRAVEL DEVIATION IS LARGE DURING COMPOUND OPERATION….4832
H-23 TRAVEL SPEED OR POWER IS LOW….4833
H-24 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)….4834
H-25 TRAVEL SPEED DOES NOT CHANGE….4835
H-26 UPPER STRUCTURE DOES NOT SWING….4836
H-27 SWING SPEED OR ACCELERATION IS LOW….4837
H-28 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING….4838
H-29 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING ….4839
H-30 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING….4840
H-31 HYDRAULIC DRIFT OF SWING IS LARGE….4841
TROUBLESHOOTING OF ENGINE (S MODE)….4842
POINTS TO REMEMBER WHEN TROUBLESHOOTING….4843
METHOD OF USING TROUBLESHOOTING CHARTS….4844
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….4847
S-2 ENGINE DOES NOT START….4848
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)….4851
S-4 ENGINE STOPS DURING OPERATIONS….4852
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….4853
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)….4854
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….4855
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)….4856
S-9 OIL BECOMES CONTAMINATED QUICKLY….4857
S-10 FUEL CONSUMPTION IS EXCESSIVE….4858
S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)….4859
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)….4860
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)….4861
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….4862
S-15 ABNORMAL NOISE IS MADE….4863
S-16 VIBRATION IS EXCESSIVE….4864
30 DISASSEMBLY AND ASSEMBLY….4866
METHOD OF USING MANUAL….4868
PRECAUTIONS WHEN CARRYING OUT OPERATION….4870
SPECIAL TOOL LIST….4872
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY….4890
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY….4893
REMOVAL AND INSTALLATION OF NOZZLE TIP….4897
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL….4899
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL….4901
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY….4906
REMOVAL AND INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY….4912
REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY….4914
REMOVAL AND INSTALLATION OF PTO ASSEMBLY….4917
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY….4918
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY….4920
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY….4921
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR ASSEMBLY….4933
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY….4948
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY….4949
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY….4950
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY….4961
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY….4962
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY….4970
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY….4971
DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD….4973
REMOVAL AND INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY….4976
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY….4977
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY….4980
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY….4982
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY….4983
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY….4986
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY….4987
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY….4990
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY….4993
REMOVAL AND INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY….4995
DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY….4997
REMOVAL AND INSTALLATION OF NO.1 AND NO.2 PUMP ASSEMBLY….5001
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY….5003
REMOVAL AND INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY….5023
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY….5024
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY….5025
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY….5026
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY….5028
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY….5030
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY….5032
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY….5034
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….5036
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY….5041
REMOVAL AND INSTALLATION OF ARM ASSEMBLY….5043
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY….5045
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY….5048
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY….5049
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)….5050
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY….5059
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY….5065
90 OTHERS….5066
HYDRAULIC CIRCUIT DIAGRAM….5068
ELECTRICAL CIRCUIT DIAGRAM (1/5)….5069
ELECTRICAL CIRCUIT DIAGRAM (2/5)….5070
ELECTRICAL CIRCUIT DIAGRAM (3/5)….5071
ELECTRICAL CIRCUIT DIAGRAM (4/5)….5072
ELECTRICAL CIRCUIT DIAGRAM (5/5)….5073
ELECTRICAL CIRCUIT FOR AIR CONDITIONER….5074
SEN00128-16 – Hydraulic Excavator PC600-8, PC600LC-8 Shop Manual….5075
COVER….5075
00 Index and foreword….0
Index….5077
Composition of shop manual….5078
Table of contents….5080
Foreword and general information….5089
Safety notice….5090
How to read the shop manual….5095
Explanation of terms for maintenance standard….5097
Handling of electric equipment and hydraulic component….5099
Handling of connectors newly used for engines….5108
How to read electric wire code….5111
Precautions when carrying out operation….5114
Method of disassembling and connecting push-pull type coupler….5117
Standard tightening torque table….5120
Conversion table….5124
01 Specification….0
Specification and technical data….5131
Specification and technical data….5132
Specification drawings….5132
Working range drawings….5134
Specifications….5136
Weight table….5144
Table of fuel, coolant and lubricants….5148
10 Structure, function and maintenance standard….0
Engine and cooling system….5151
Engine and cooling system….5152
Parts related to engine….5152
PTO….5154
Fan, control and PTO lubrication pump….5156
Radiator, oil cooler….5157
Power train….5159
Power train….5160
Power train….5160
Final drive….5163
Sprocket….5166
Swing circle….5168
Swing machinery….5170
Undercarriage and frame….5173
Undercarriage and frame….5174
Track frame, recoil spring….5174
Idler….5176
Carrier roller….5178
Track roller….5179
Track shoe….5180
Hydraulic system, Part 1….5187
Hydraulic system, Part 1….5188
Hydraulic piping drawing….5188
Hydraulic tank, hydraulic filter….5190
Hydraulic pump (piston pump)….5192
Line oil filter….5220
Cooling fan pump….5222
Cooling fan motor….5230
Hydraulic system, Part 2….5237
Hydraulic system, Part 2….5238
Control valve….5238
Swing motor….5257
Swing brake….5260
Safety valve….5261
Reverse prevention valve….5263
Center swivel joint….5266
Travel motor….5267
Parking brake….5272
Brake valve….5274
Set pressures varying mechanism….5277
Valve control….5278
Work equipment, swing PPC valve….5280
Travel PPC valve….5284
Service PPC valve….5286
PPC accumulator….5287
PPC shuttle valve….5288
Solenoid valve….5289
Boom holding valve….5294
Boom LOWER regeneration valve….5298
Quick return valve….5301
Hydraulic cylinder….5304
Work equipment….5309
Work equipment….5310
Work equipment….5310
Dimensions of work equipment….5314
Cab and its attachments….5319
Cab and its attachments….5320
Air conditioner piping….5320
Electrical system….5322
Engine control….5323
Machine control system diagram….5328
Monitor system….5352
Sensors….5367
KOMTRAX system….5371
20 Standard value table….0
Standard service value table….5374
Standard value table for engine….5375
Standard value table for chassis….5376
30 Testing and adjusting….0
Testing and adjusting, Part 1….5398
Tools for testing, adjusting and troubleshooting….5401
Measuring engine speed….5406
Measuring intake air pressure (boost pressure)….5407
Measuring exhaust gas temperature….5408
Measuring exhaust gas color….5409
Adjusting valve clearance….5410
Measuring compression pressure….5411
Measuring blow-by pressure….5413
Measuring engine oil pressure….5413
Testing EGR valve and bypass valve drive oil pressure….5414
Handling equipment in fuel circuit….5415
Releasing remaining pressure in fuel system….5415
Measuring fuel pressure….5416
Reduced cylinder mode operation….5417
No-injection cranking….5417
Testing leakage from pressure limiter and return rate from injector….5418
Bleeding air from fuel circuit….5420
Testing fuel system for leakage….5422
Testing and adjusting alternator belt tension….5423
Testing and adjusting air conditioner compressor belt tension….5424
Testing clearance of swing circle bearing….5425
Testing and adjusting track shoe tension….5426
Testing and adjusting work equipment, swing, and travel circuit oil pressures….5427
Testing and adjusting control circuit oil pressure….5432
Testing and adjusting piston pump control oil pressure….5434
Testing servo piston stroke….5440
Measuring PPC valve output pressure….5441
Measuring outlet pressures of solenoid valve and PPC shuttle valve….5445
Adjusting work equipment, swing PPC valve….5451
Testing and adjusting travel deviation….5452
Measuring fan speed….5454
Measuring fan circuit oil pressure….5454
Inspection of locations of hydraulic drift of work equipment….5455
Measuring oil leakage….5456
Releasing remaining pressure in hydraulic circuit….5460
Bleeding air from each part….5461
Inspection procedures for diode….5464
Testing and adjusting, Part 2….5466
Special function of machine monitor….5467
Handling controller voltage circuit….5501
Procedure for turning on KOMTRAX terminal….5502
KOMTRAX terminal lamp indications….5505
Preparation work for troubleshooting electrical system….5508
Adjusting mirrors….5510
Pm-clinic service….5511
Undercarriage inspection….5517
40 Troubleshooting….0
Failure code table and fuse locations….5520
Failure codes table….5521
Fuse locations….5525
General information on troubleshooting….5528
Points to remember when troubleshooting….5529
Sequence of events in troubleshooting….5530
Checks before troubleshooting….5531
Classification and procedures of troubleshooting….5532
Information contained in troubleshooting table….5533
Failure-looking phenomenon and troubleshooting No….5535
Connection table for connector pin numbers….5539
T- branch box and T- branch adapter table….5575
Troubleshooting by failure code (Display of code), Part 1….5580
Failure code [A000N1] Eng. Hi Out of Std….5582
Failure code [AA10NX] Aircleaner clogging….5583
Failure code [AB00KE] Charge Voltage Low….5585
Failure code [B@BAZG] Eng. Oil Press. Low….5587
Failure code [B@BAZK] Eng. Oil Level Low….5589
Failure code [B@BCNS] Eng. Water Overheat….5590
Failure code [B@BCZK] Eng. Water Lvl Low….5591
Failure code [B@HANS] Hydr. Oil Overheat….5593
Failure code [CA111] ECM Critical Internal Failure….5594
Failure code [CA115] Eng Ne and Bkup Speed Sens Error….5595
Failure code [CA122] Chg Air Press Sensor High Error….5597
Failure code [CA123] Chg Air Press Sensor Low Error….5599
Failure code [CA131] Throttle Sensor High Error….5601
Failure code [CA132] Throttle Sensor Low Error….5603
Failure code [CA135] Eng Oil Press Sensor High Error….5605
Failure code [CA141] Eng Oil Press Sensor Low Error….5607
Failure code [CA144] Coolant Temp Sens High Error….5609
Failure code [CA145] Coolant Temp Sens Low Error….5611
Failure code [CA153] Chg Air Temp Sensor High Error….5613
Failure code [CA154] Chg Air Temp Sensor Low Error….5615
Failure code [CA187] Sens Supply 2 Volt Low Error….5615
Failure code [CA221] Ambient Press Sens High Error….5617
Failure code [CA222] Ambient Press Sens Low Error….5619
Failure code [CA227] Sens Supply 2 Volt High Error….5621
Failure code [CA234] Eng Overspeed….5623
Failure code [CA238] Ne Speed Sens Supply Volt Error….5624
Failure code [CA263] Fuel Temp Sensor High Error….5625
Failure code [CA265] Fuel Temp Sensor Low Error….5627
Failure code [CA271] IMV/PCV1 Short Error….5628
Failure code [CA272] IMV/PCV1 Open Error….5629
Failure code [CA273] PCV2 Short Error….5630
Failure code [CA274] PCV2 Open Error….5631
Troubleshooting by failure code (Display of code), Part 2….5634
Failure code [CA322] Inj #1 (L#1) Open/Short Error….5637
Failure code [CA323] Inj #5 (L#5) Open/Short Error….5639
Failure code [CA324] Inj #3 (L#3) Open/Short Error….5641
Failure code [CA325] Inj #6 (L#6) Open/Short Error….5643
Failure code [CA331] Inj #2 (L#2) Open/Short Error….5645
Failure code [CA332] Inj #4 (L#4) Open/Short Error….5647
Failure code [CA342] Calibration Code Incompatibility….5649
Failure code [CA351] Injectors Drive Circuit Error….5650
Failure code [CA352] Sens Supply 1 Volt Low Error….5652
Failure code [CA386] Sens Supply 1 Volt High Error….5653
Failure code [CA441] Battery Voltage Low Error….5655
Failure code [CA442] Battery Voltage High Error….5655
Failure code [CA449] Rail Press Very High Error….5656
Failure code [CA451] Rail Press Sensor High Error….5657
Failure code [CA452] Rail Press Sensor Low Error….5659
Failure code [CA553] Rail Press High Error….5659
Failure code [CA554] Rail Press Sensor In Range Error….5660
Failure code [CA559] Rail Press Low Error….5661
Failure code [CA689] Eng Ne Speed Sensor Error….5665
Failure code [CA731] Eng Bkup Speed Sens Phase Error….5667
Failure code [CA757] All Persistent Data Lost Error….5668
Failure code [CA778] Engine Bkup Speed Sensor Error….5669
Failure code [CA1228] EGR Valve Servo Error 1….5671
Failure code [CA1625] EGR Valve Servo Error 2….5672
Failure code [CA1626] BP Valve Sol Current High Error….5673
Failure code [CA1627] BP Valve Sol Current Low Error….5675
Failure code [CA1628] Bypass Valve Servo Error 1….5676
Failure code [CA1629] Bypass Valve Servo Error 2….5677
Failure code [CA1631] BP Valve Pos Sens High Error….5678
Failure code [CA1632] BP Valve Pos Sens Low Error….5680
Failure code [CA1633] KOMNET Datalink Timeout Error….5681
Failure code [CA1642] EGR Inlet Press Sens Low Error….5684
Failure code [CA1653] EGR Inlet Press Sens High Error….5685
Failure code [CA2185] Throt Sens Sup Volt High Error….5687
Failure code [CA2186] Throt Sens Sup Volt Low Error….5689
Failure code [CA2249] Rail Press Very Low Error….5690
Failure code [CA2271] EGR Valve Pos Sens High Error….5691
Failure code [CA2272] EGR Valve Pos Sens Low Error….5693
Failure code [CA2351] EGR Valve Sol Current High Error….5695
Failure code [CA2352] EGR Valve Sol Current Low Error….5697
Failure code [CA2555] Grid Htr Relay Volt Low Error….5698
Failure code [CA2556] Grid Htr Relay Volt High Error….5699
Troubleshooting by failure code (Display of code), Part 3….5702
Failure code [D110KB] Battery Relay Drive S/C….5705
Failure code [D163KB] Flash Light Relay S/C….5707
Failure code [D195KB] Step Light Relay S/C….5709
Failure code [DA25KP] Press. Sensor Power Abnormality….5711
Failure code [DA2SKQ] Model Selection Abnormality….5713
Failure code [DA80MA] Auto. Lub Abnormal….5715
Failure code [DA2RMC] Pump Comm. Abnormality….5717
Failure code [DAFRMC] Monitor Comm. Abnormality….5719
Failure code [DGE5KY] Ambi. Temp. Sensor S/C….5721
Failure code [DGE5KY] Ambi. Temp. Sensor S/C….5723
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C….5724
Failure code [DHPAMA] F pump P. Sensor Abnormality….5725
Failure code [DHPBMA] R pump P. Sensor Abnormality….5727
Failure code [DV20KB] Travel Alarm S/C….5729
Failure code [DW43KA] Travel Speed Sol. Disc….5731
Failure code [DW43KB] Travel Speed Sol. S/C….5733
Failure code [DW45KA] Swing Brake Sol. Disc….5735
Failure code [DW45KB] Swing Brake Sol. S/C….5737
Failure code [DW48KA] CO Cancel Sol. Disc….5739
Failure code [DW48KB] CO Cancel Sol. S/C….5741
Failure code [DW7BKA] Fan Reverse Sol. Disc….5743
Failure code [DW7BKB] Fan Reverse Sol. S/C….5744
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc….5745
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C….5747
Failure code [DWK0KA] 2-stage Relief Sol. Disc….5749
Failure code [DWK0KB] 2-stage Relief Sol. S/C….5751
Failure code [DX16KA] Fan Pump EPC Sol. Disc….5753
Failure code [DX16KB] Fan Pump EPC Sol. S/C….5755
Failure code [DXA0KA] TVC Sol. Disc….5757
Failure code [DXA0KB] TVC Sol. S/C….5759
Failure code [DY20KA] Wiper Working Abnormality….5761
Failure code [DY20MA] Wiper Parking Abnormality….5763
Failure code [DY2CKB] Washer Drive S/C….5767
Failure code [DY2DKB] Wiper Drive (For) S/C….5769
Failure code [DY2EKB] Wiper Drive (Rev) S/C….5773
Troubleshooting of electrical system (E-mode)….5774
E-1 Engine does not start (Engine does not rotate)….5776
E-2 Preheater does not operate….5779
E-3 Auto engine warm-up device does not work….5781
E-4 Auto-decelerator does not operate….5782
E-5 All work equipment, swing and travel do not move….5783
E-6 Power max. function does not operate….5785
E-7 Machine push-up function does not operate normally….5786
E-8 Any item is not displayed on machine monitor….5788
E-9 Part of display on machine monitor is missing….5789
E-10 Machine monitor displays contents irrelevant to the model….5789
E-11 Fuel level monitor red lamp lights up while engine is running….5790
E-12 Engine coolant temperature gauge does not display correctly….5791
E-13 Hydraulic oil temperature gauge does not display correctly….5793
E-14 Fuel gauge does not display correctly….5794
E-15 Swing lock monitor does not display correctly….5795
E-16 When monitor switch is operated, nothing is displayed….5797
E-17 Wiper and window washer do not work….5799
E-18 "Boom Raise" is not correctly displayed in monitoring function….5807
E-19 "Boom Lower" is not correctly displayed in monitoring function….5809
E-20 "Arm IN" is not correctly displayed in monitoring function….5811
E-21 "Arm OUT" is not correctly displayed in monitoring function….5812
E-22 "Bucket CURL" is not correctly displayed in monitoring function….5813
E-23 "Bucket DUMP" is not correctly displayed in monitoring function….5814
E-24 "Swing" is not correctly displayed in monitoring function….5815
E-25 "Travel" is not correctly displayed in monitoring function….5817
E-26 Air conditioner does not work….5819
E-27 Step light does not light up or go off….5821
E-28 Electric grease gun does not operate….5825
E-29 Travel alarm does not sound or does not stop sounding….5827
E-30 Horn does not sound….5829
E-31 Bottom dump does not move….5831
Troubleshooting of hydraulic and mechanical system (H-mode)….5834
Before troubleshooting H-mode….5836
Information in troubleshooting table….5841
H-1 Speed or power of all work equipment, travel, and swing is low….5843
H-2 Engine speed lowers remarkably or engine stalls….5845
H-3 All work equipment, travel, and swing systems do not work….5847
H-4 Abnormal sound is heard from around pump….5849
H-5 Auto-decelerator is not reset….5850
H-6 Boom speed or power is low….5851
H-7 Arm speed or power is low….5853
H-8 Bucket speed or power is low….5854
H-9 Boom does not move….5855
H-10 Arm does not move….5855
H-11 Bucket does not move….5856
H-12 Bottom dump does not move….5856
H-13 Hydraulic drift of work equipment is large….5857
H-14 Time lag of work equipment is large….5858
H-15 Power max. function does not operate or stop….5859
H-16 Machine push-up function does not operate or stop….5859
H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low….5860
H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low….5860
H-19 When arm and swing are operated simultaneously, swing speed is low….5861
H-20 Machine deviates in one direction….5862
H-21 Machine deviates largely at start….5864
H-22 Travel deviation is large during compound operation….5865
H-23 Travel speed or power is low….5866
H-24 Machine does not travel (only one track)….5867
H-25 Travel speed does not change….5868
H-26 Upper structure does not swing….5869
H-27 Swing speed or acceleration is low….5870
H-28 Upper structure overruns excessively when it stops swinging….5871
H-29 Large shock is made when upper structure stops swinging….5872
H-30 Large abnormal sound is made when upper structure stops swinging….5873
H-31 Hydraulic drift of swing is large….5874
Troubleshooting of engine (S-mode)….5876
Method of using troubleshooting chart….5878
S-1 Starting performance is poor….5881
S-2 Engine does not start….5883
S-3 Engine does not pick up smoothly….5887
S-4 Engine stops during operations….5888
S-5 Engine does not rotate smoothly….5889
S-6 Engine lacks output (or lacks power)….5890
S-7 Exhaust smoke is black (incomplete combustion)….5891
S-8 Oil consumption is excessive (or exhaust smoke is blue)….5892
S-9 Oil becomes contaminated quickly….5893
S-10 Fuel consumption is excessive….5894
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)….5895
S-12 Oil pressure drops….5896
S-13 Oil level rises (Entry of coolant or fuel)….5897
S-14 Coolant temperature becomes too high (overheating)….5899
S-15 Abnormal noise is made….5900
S-16 Vibration is excessive….5901
50 Disassembly and assembly….0
General information on disassembly and assembly….5904
How to read this manual….5905
Coating materials list….5907
Special tools list….5910
Sketches of special tools….5916
Engine and cooling system, Part 1….5924
Removal and installation of fuel supply pump assembly….5925
Removal and installation of cylinder head assembly….5931
Removal and installation of fuel injector assembly….5947
Removal and installation of engine front seal….5950
Removal and installation of engine rear seal….5954
Engine and cooling system, Part 2….5960
Removal and installation of engine, PTO and hydraulic pump assembly….5961
Removal and installation of radiator assembly….5968
Removal and installation of hydraulic oil cooler assembly….5970
Removal and installation of aftercooler assembly….5972
Removal and installation of fan motor assembly….5974
Removal and installation of fuel tank assembly….5978
Power train….5980
Removal and installation of PTO assembly….5981
Disassembly and assembly of PTO assembly….5983
Removal and installation of swing motor and swing machinery assembly….5986
Disassembly and assembly of swing machinery assembly….5987
Removal and installation of swing circle assembly….5994
Disassembly and assembly of final drive assembly….5995
Undercarriage and frame….6006
Removal and installation of track shoe assembly….6007
Disassembly and assembly of 1 link in field….6009
Removal and installation of idler, recoil spring assembly….6013
Disassembly and assembly of idler assembly….6014
Disassembly and assembly of recoil spring assembly….6017
Removal and installation of track roller assembly….6019
Disassembly and assembly of track roller assembly….6020
Removal and installation of carrier roller assembly….6023
Disassembly and assembly of carrier roller assembly….6024
Removal and installation of revolving frame assembly….6027
Removal and installation of counterweight assembly….6029
Removal and installation of counterweight remover assembly….6030
Hydraulic system….6034
Removal and installation of hydraulic tank assembly….6035
Removal and installation of hydraulic pump assembly….6037
Removal and installation of control valve and solenoid valve assembly….6040
Disassembly and assembly of control valve assembly….6042
Disassembly and assembly of main control valve assembly….6043
Removal and installation of swing motor assembly….6047
Removal and installation of center swivel joint assembly….6048
Disassembly and assembly of center swivel joint assembly….6049
Disassembly and assembly of work equipment PPC valve assembly….6051
Disassembly and assembly of travel PPC valve assembly….6053
Disassembly and assembly of hydraulic cylinder assembly….6056
Disassembly and assembly of grease gun assembly….6062
Work equipment….6064
Removal and installation of bucket cylinder assembly (Backhoe specification)….6065
Removal and installation of bucket cylinder assembly (Loading shovel specification)….6067
Removal and installation of arm cylinder assembly (Backhoe specification)….6069
Removal and installation of arm cylinder assembly (Loading shovel specification)….6071
Removal and installation of boom cylinder assembly (Backhoe specification)….6073
Removal and installation of boom cylinder assembly (Loading shovel specification)….6075
Removal and installation of bottom dump cylinder assembly (Loading shovel specification)….6077
Removal and installation of bucket assembly (Backhoe specification)….6078
Removal and installation of bucket assembly (Loading shovel specification)….6080
Removal and installation of arm assembly (Backhoe specification)….6081
Removal and installation of arm assembly (Loading shovel specification)….6083
Removal and installation of boom assembly (Backhoe specification)….6084
Removal and installation of boom assembly (Loading shovel specification)….6086
Removal and installation of work equipment (Backhoe specification)….6088
Removal and installation of work equipment (Loading shovel specification)….6090
Cab and its attachments….6094
Removal and installation of operator’s cab….6095
Removal and installation of operator’s cab glass (stuck glass)….6098
Removal and installation of front window assembly….6108
Electrical system….6114
Removal and installation of air conditioner unit assembly….6115
Removal and installation of engine controller assembly….6117
Removal and Installation of KOMTRAX terminal assembly….6119
Removal and installation of pump controller assembly….6119
Removal and installation of monitor assembly….6120
90 Diagrams and drawings….0
Hydraulic diagrams and drawings….6122
Hydraulic circuit diagram (1/4) (Backhoe specification)….6124
Hydraulic circuit diagram (2/4) (ATT specification)….6125
Hydraulic circuit diagram (3/4) (Loading shovel specification)….6126
Hydraulic circuit diagram (4/4) (Loading shovel specification)….6127
Electrical diagrams and drawings….6130
Electrical circuit diagram (1/6)….6132
Electrical circuit diagram (2/6)….6133
Electrical circuit diagram (3/6)….6134
Electrical circuit diagram (4/6)….6135
Electrical circuit diagram (5/6)….6136
Electrical circuit diagram (6/6)….6137
Connector arrangement diagram….6138
Electrical circuit diagram for air conditioner….6139
TEN00037-02 – Hydraulic Excavator PC600-7, PC600LC-7 Operation & Maintenance Manual….6142
COVER….6142
FOREWORD….6143
FOREWORD….6144
SAFETY INFORMATION….6147
INTRODUCTION….6149
DIRECTIONS OF MACHINE….6149
BREAKING-IN THE NEW MACHINE….6149
PRODUCT INFORMATION….6150
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….6150
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….6150
SERVICE METER LOCATION….6151
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….6151
CONTENTS….6152
SAFETY….6155
SAFETY….6156
SAFETY LABELS….6158
LOCATION OF SAFETY LABELS….6159
SAFETY LABELS….6160
GENERAL PRECAUTIONS….6166
SAFETY MACHINE OPERATION….6174
STARTING ENGINE….6174
OPERATION….6176
TRANSPORTATION….6181
BATTERY….6183
TOWING….6185
LIFTING OBJECTS WITH BUCKET….6186
SAFETY MAINTENANCE INFORMATION….6187
OPERATION….6195
MACHINE VIEW ILLUSTRATIONS….6196
OVERALL MACHINE VIEW….6196
CONTROLS AND GAUGES….6197
DETAILED CONTROLS AND GAUGES….6199
MONITORING SYSTEM….6199
SWITCHES….6222
CONTROL LEVERS AND PEDALS….6229
SUN ROOF….6232
WINDSHIELD….6232
EMERGENCY EXIT FROM OPERATOR'S CAB….6237
DOOR LOCK….6237
CAP WITH LOCK….6238
HOT AND COOL BOX….6239
MAGAZINE BOX….6239
ASHTRAY….6240
AIR CONDITIONER CONTROLS….6241
RADIO….6255
AUXILIARY ELECTRIC POWER….6260
FUSE….6261
CIRCUIT BREAKER….6262
CONTROLLER….6262
TOOL BOX….6263
GREASE PUMP….6264
ACCUMULATOR….6267
MACHINE OPERATIONS AND CONTROLS….6269
BEFORE STARTING ENGINE….6269
STARTING ENGINE….6287
AFTER STARTING ENGINE….6292
STOPPING THE ENGINE….6300
MACHINE OPERATION….6301
STEERING THE MACHINE….6305
SWINGING….6307
WORK EQUIPMENT CONTROLS AND OPERATIONS….6308
WORKING MODE….6310
PROHIBITED OPERATIONS….6311
GENERAL OPERATION INFORMATION….6314
TRAVELING ON SLOPES….6316
ESCAPE FROM MUD….6318
RECOMMENDED APPLICATIONS….6319
BUCKET REPLACEMENT….6320
PARKING MACHINE….6322
CHECK AFTER SHUT OFF ENGINE….6323
LOCKING….6324
TRANSPORTATION….6325
PRECAUTIONS FOR TRANSPORTATION….6325
LIFTING MACHINE….6325
SHIPPING MACHINE INFORMATION….6327
TRANSPORTATION POSTURE….6328
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….6333
COLD WEATHER OPERATION….6335
COLD WEATHER OPERATION INFORMATION….6335
AFTER DAILY WORK COMPLETION….6338
AFTER COLD WEATHER SEASON….6338
LONG TERM STORAGE….6339
BEFORE STORAGE….6339
DURING STORAGE….6339
AFTER STORAGE….6339
STARTING MACHINE AFTER LONG-TERM STORAGE….6340
TROUBLES AND ACTIONS….6341
RUNNING OUT OF FUEL….6341
PHENOMENA THAT ARE NOT FAILURES….6342
TOWING THE MACHINE….6343
SEVERE JOB CONDITION….6343
DISCHARGED BATTERY….6344
OTHER TROUBLE….6348
MAINTENANCE….6355
MAINTENANCE INFORMATION….6356
OUTLINE OF SERVICE….6358
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….6358
ELECTRIC SYSTEM MAINTENANCE….6360
WEAR PARTS….6361
WEAR PARTS LIST….6361
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….6362
TIGHTENING TORQUE SPECIFICATIONS….6366
TIGHTENING TORQUE LIST….6366
SAFETY CRITICAL PARTS….6367
SAFETY CRITICAL PARTS LIST….6368
MAINTENANCE SCHEDULE….6369
MAINTENANCE SCHEDULE CHART….6369
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….6371
MAINTENANCE PROCEDURE….6372
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)….6372
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….6372
WHEN REQUIRED….6373
CHECK BEFORE STARTING….6396
EVERY 10 HOURS MAINTENANCE….6397
EVERY 100 HOURS MAINTENANCE….6400
EVERY 250 HOURS MAINTENANCE….6401
EVERY 500 HOURS MAINTENANCE….6408
EVERY 1000 HOURS MAINTENANCE….6420
EVERY 2000 HOURS MAINTENANCE….6429
EVERY 4000 HOURS MAINTENANCE….6432
EVERY 5000 HOURS MAINTENANCE….6435
EVERY 8000 HOURS MAINTENANCE….6437
SPECIFICATIONS….6439
SPECIFICATIONS….6440
ATTACHMENTS, OPTIONS….6443
GENERAL PRECAUTIONS FOR SAFETY….6444
PRECAUTIONS WHEN SELECTING….6444
READ THE INSTRUCTION MANUAL THOROUGHLY….6444
PRECAUTIONS WHEN REMOVING OR INSTALLING….6444
PRECAUTIONS WHEN USING….6444
ATTACHMENT GUIDE….6445
COMBINATIONS OF WORK EQUIPMENT….6445
TRACK SHOES SELECTION….6448
HANDLING COUNTERWEIGHT REMOVER….6449
INDEX….6459
TEN00118-07 – Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual….6463
COVER….6463
FOREWORD….6464
BEFORE READING THIS MANUAL….6465
SAFETY INFORMATION….6466
INTRODUCTION….6467
USE OF MACHINE….6467
DIRECTIONS OF MACHINE….6467
VISIBILITY FROM OPERATOR'S SEAT….6468
PRODUCT INFORMATION….6469
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….6469
EPA REGULATIONS, ENGINE NUMBER PLATE….6469
SERVICE METER LOCATION….6470
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….6470
CONTENTS….6471
SAFETY….6476
SAFETY….6477
SAFETY LABELS….6480
LOCATION OF SAFETY LABELS….6481
SAFETY LABELS….6482
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….6488
PRECAUTIONS BEFORE STARTING OPERATION….6488
PREPARATIONS FOR SAFE OPERATION….6488
FIRE PREVENTION….6490
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….6491
DO NOT GET CAUGHT IN WORK EQUIPMENT….6493
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….6493
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….6493
UNAUTHORIZED MODIFICATION….6494
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….6494
PRECAUTIONS RELATED TO CAB GLASS….6494
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….6494
PRECAUTIONS FOR OPERATION….6495
PRECAUTIONS FOR JOBSITE….6495
STARTING ENGINE….6497
OPERATION….6499
TRANSPORTATION….6506
TOWING….6507
LIFTING OBJECTS WITH BUCKET….6508
PRECAUTIONS FOR MAINTENANCE….6509
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….6509
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….6513
OPERATION….6520
MACHINE VIEW ILLUSTRATIONS….6521
OVERALL MACHINE VIEW….6521
CONTROLS AND GAUGES….6522
DETAILED CONTROLS AND GAUGES….6524
MONITORING SYSTEM….6524
SWITCHES….6553
CONTROL LEVERS AND PEDALS….6560
SUN ROOF….6563
WINDSHIELD….6563
EMERGENCY EXIT FROM OPERATOR'S CAB….6568
DOOR LOCK….6568
CAP WITH LOCK….6569
HOT AND COOL BOX….6570
MAGAZINE BOX….6571
ASHTRAY….6571
FIRE EXTINGUISHER….6572
AIR CONDITIONER CONTROLS….6573
RADIO….6587
AUXILIARY ELECTRIC POWER….6591
FUSE….6592
CIRCUIT BREAKER….6593
CONTROLLER….6594
TOOL BOX….6594
GREASE PUMP….6595
MACHINE OPERATIONS AND CONTROLS….6598
BEFORE STARTING ENGINE….6598
STARTING ENGINE….6617
AFTER STARTING ENGINE….6620
STOPPING THE ENGINE….6629
MACHINE OPERATION….6630
STEERING THE MACHINE….6634
SWINGING….6636
WORK EQUIPMENT CONTROLS AND OPERATIONS….6637
WORKING MODE….6639
PROHIBITED OPERATIONS….6640
GENERAL OPERATION INFORMATION….6645
TRAVELING ON SLOPES….6647
ESCAPE FROM MUD….6649
RECOMMENDED APPLICATIONS….6650
BUCKET REPLACEMENT….6651
PARKING MACHINE….6653
MACHINE INSPECTION AFTER DAILY WORK….6654
LOCKING….6655
TRANSPORTATION….6656
PRECAUTIONS FOR TRANSPORTATION….6656
LIFTING MACHINE….6656
SHIPPING MACHINE INFORMATION….6658
TRANSPORTATION POSTURE….6659
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….6664
COLD WEATHER OPERATION….6666
COLD WEATHER OPERATION INFORMATION….6666
AFTER DAILY WORK COMPLETION….6669
AFTER COLD WEATHER SEASON….6669
LONG TERM STORAGE….6670
BEFORE STORAGE….6670
DURING STORAGE….6670
AFTER STORAGE….6671
STARTING MACHINE AFTER LONG-TERM STORAGE….6671
TROUBLES AND ACTIONS….6672
RUNNING OUT OF FUEL….6672
PHENOMENA THAT ARE NOT FAILURES….6673
TOWING THE MACHINE….6674
SEVERE JOB CONDITION….6674
DISCHARGED BATTERY….6675
OTHER TROUBLE….6679
MAINTENANCE….6686
MAINTENANCE INFORMATION….6687
OUTLINE OF SERVICE….6689
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….6689
ELECTRIC SYSTEM MAINTENANCE….6692
WEAR PARTS….6693
WEAR PARTS LIST….6693
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….6694
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….6696
TIGHTENING TORQUE SPECIFICATIONS….6697
TIGHTENING TORQUE LIST….6697
SAFETY CRITICAL PARTS….6698
SAFETY CRITICAL PARTS LIST….6699
MAINTENANCE SCHEDULE….6700
MAINTENANCE SCHEDULE CHART….6700
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….6702
MAINTENANCE PROCEDURE….6703
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)….6703
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….6703
WHEN REQUIRED….6704
CHECK BEFORE STARTING….6728
EVERY 10 HOURS MAINTENANCE….6729
EVERY 100 HOURS MAINTENANCE….6731
EVERY 250 HOURS MAINTENANCE….6732
EVERY 500 HOURS MAINTENANCE….6738
EVERY 1000 HOURS MAINTENANCE….6748
EVERY 2000 HOURS MAINTENANCE….6760
EVERY 4000 HOURS MAINTENANCE….6766
EVERY 5000 HOURS MAINTENANCE….6769
EVERY 8000 HOURS MAINTENANCE….6770
SPECIFICATIONS….6772
SPECIFICATIONS….6773
ATTACHMENTS, OPTIONS….6776
GENERAL PRECAUTIONS FOR SAFETY….6777
PRECAUTIONS WHEN SELECTING….6777
READ THE INSTRUCTION MANUAL THOROUGHLY….6777
PRECAUTIONS WHEN REMOVING OR INSTALLING….6777
PRECAUTIONS WHEN USING….6777
ATTACHMENT GUIDE….6778
COMBINATIONS OF WORK EQUIPMENT….6778
TRACK SHOES SELECTION….6780
HANDLING COUNTERWEIGHT REMOVER….6781
HANDLING MACHINES EQUIPPED WITH KOMTRAX….6790
BASIC PRECAUTIONS….6790
LOADING SHOVEL….6792
EXPLANATION OF COMPONENTS….6793
SWITCHES….6793
FUSE….6796
OPERATIONS….6797
OPERATION OF WORK EQUIPMENT….6797
PRECAUTIONS DURING OPERATION….6799
PRECAUTIONS FOR JOBSITE….6802
EXCAVATOR WORK….6804
TRANSPORTATION….6805
MACHINE CONFIGURATION FOR TRANSPORT….6805
WEAR PARTS….6806
WEAR PARTS LIST….6806
MAINTENANCE….6807
CHECK BEFORE STARTING….6807
EVERY 10 HOURS MAINTENANCE….6809
EVERY 5000 HOURS MAINTENANCE….6810
SPECIFICATION….6811
COMBINATION OF WORK EQUIPMENT….6812
COMBINATION OF WORK EQUIPMENT….6812
INDEX….6814
TEN00346-02 – Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual….6818
COVER….6818
FOREWORD….6819
BEFORE READING THIS MANUAL….6820
SAFETY INFORMATION….6821
INTRODUCTION….6822
USE OF MACHINE….6822
DIRECTIONS OF MACHINE….6822
VISIBILITY FROM OPERATOR'S SEAT….6823
PRODUCT INFORMATION….6824
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….6824
EPA REGULATIONS, ENGINE NUMBER PLATE….6824
SERVICE METER LOCATION….6825
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….6825
CONTENTS….6826
SAFETY….6831
SAFETY….6832
SAFETY LABELS….6835
LOCATION OF SAFETY LABELS….6836
SAFETY LABELS….6837
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….6843
PRECAUTIONS BEFORE STARTING OPERATION….6843
PREPARATIONS FOR SAFE OPERATION….6843
FIRE PREVENTION….6845
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….6846
DO NOT GET CAUGHT IN WORK EQUIPMENT….6848
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….6848
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….6849
UNAUTHORIZED MODIFICATION….6850
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….6850
PRECAUTIONS RELATED TO CAB GLASS….6850
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….6850
PRECAUTIONS FOR OPERATION….6851
PRECAUTIONS FOR JOBSITE….6851
STARTING ENGINE….6853
OPERATION….6855
TRANSPORTATION….6862
TOWING….6863
LIFTING OBJECTS WITH BUCKET….6864
PRECAUTIONS FOR MAINTENANCE….6865
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….6865
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….6869
OPERATION….6875
MACHINE VIEW ILLUSTRATIONS….6876
OVERALL MACHINE VIEW….6876
CONTROLS AND GAUGES….6877
DETAILED CONTROLS AND GAUGES….6879
MONITORING SYSTEM….6879
SWITCHES….6908
CONTROL LEVERS AND PEDALS….6915
SUN ROOF….6918
WINDSHIELD….6918
EMERGENCY EXIT FROM OPERATOR'S CAB….6923
DOOR LOCK….6923
CAP WITH LOCK….6924
HOT AND COOL BOX….6925
MAGAZINE BOX….6926
ASHTRAY….6926
FIRE EXTINGUISHER….6927
AIR CONDITIONER CONTROLS….6928
RADIO….6942
AUXILIARY ELECTRIC POWER….6946
FUSE….6947
CIRCUIT BREAKER….6948
CONTROLLER….6949
TOOL BOX….6949
GREASE PUMP….6950
MACHINE OPERATIONS AND CONTROLS….6953
BEFORE STARTING ENGINE….6953
STARTING ENGINE….6972
AFTER STARTING ENGINE….6975
STOPPING THE ENGINE….6984
MACHINE OPERATION….6985
STEERING THE MACHINE….6989
SWINGING….6991
WORK EQUIPMENT CONTROLS AND OPERATIONS….6992
WORKING MODE….6994
PROHIBITED OPERATIONS….6995
GENERAL OPERATION INFORMATION….7000
TRAVELING ON SLOPES….7002
ESCAPE FROM MUD….7004
RECOMMENDED APPLICATIONS….7005
BUCKET REPLACEMENT….7006
PARKING MACHINE….7008
MACHINE INSPECTION AFTER DAILY WORK….7009
LOCKING….7010
TRANSPORTATION….7011
PRECAUTIONS FOR TRANSPORTATION….7011
LIFTING MACHINE….7011
SHIPPING MACHINE INFORMATION….7013
TRANSPORTATION POSTURE….7014
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….7019
COLD WEATHER OPERATION….7021
COLD WEATHER OPERATION INFORMATION….7021
AFTER DAILY WORK COMPLETION….7024
AFTER COLD WEATHER SEASON….7024
LONG TERM STORAGE….7025
BEFORE STORAGE….7025
DURING STORAGE….7025
AFTER STORAGE….7026
STARTING MACHINE AFTER LONG-TERM STORAGE….7026
TROUBLES AND ACTIONS….7027
RUNNING OUT OF FUEL….7027
PHENOMENA THAT ARE NOT FAILURES….7028
TOWING THE MACHINE….7029
SEVERE JOB CONDITION….7029
DISCHARGED BATTERY….7030
OTHER TROUBLE….7034
MAINTENANCE….7041
MAINTENANCE INFORMATION….7042
OUTLINE OF SERVICE….7044
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….7044
ELECTRIC SYSTEM MAINTENANCE….7047
WEAR PARTS….7048
WEAR PARTS LIST….7048
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….7049
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….7051
TIGHTENING TORQUE SPECIFICATIONS….7052
TIGHTENING TORQUE LIST….7052
SAFETY CRITICAL PARTS….7053
SAFETY CRITICAL PARTS LIST….7054
MAINTENANCE SCHEDULE….7055
MAINTENANCE SCHEDULE CHART….7055
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….7057
MAINTENANCE PROCEDURE….7058
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)….7058
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….7058
WHEN REQUIRED….7059
CHECK BEFORE STARTING….7082
EVERY 10 HOURS MAINTENANCE….7083
EVERY 100 HOURS MAINTENANCE….7085
EVERY 250 HOURS MAINTENANCE….7086
EVERY 500 HOURS MAINTENANCE….7092
EVERY 1000 HOURS MAINTENANCE….7102
EVERY 2000 HOURS MAINTENANCE….7113
EVERY 4000 HOURS MAINTENANCE….7119
EVERY 5000 HOURS MAINTENANCE….7122
EVERY 8000 HOURS MAINTENANCE….7123
SPECIFICATIONS….7125
SPECIFICATIONS….7126
ATTACHMENTS, OPTAIONS….7129
GENERAL PRECAUTIONS FOR SAFETY….7130
PRECAUTIONS WHEN SELECTING….7130
READ THE INSTRUCTION MANUAL THOROUGHLY….7130
PRECAUTIONS WHEN REMOVING OR INSTALLING….7130
PRECAUTIONS WHEN USING….7130
ATTACHMENT GUIDE….7131
COMBINATIONS OF WORK EQUIPMENT….7131
TRACK SHOES SELECTION….7133
HANDLING COUNTERWEIGHT REMOVER….7134
HANDLING MACHINES EQUIPPED WITH KOMTRAX….7143
BASIC PRECAUTIONS….7143
LOADING SHOVEL….7145
EXPLANATION OF COMPONENTS….7146
SWITCHES….7146
FUSE….7149
OPERATIONS….7150
OPERATION OF WORK EQUIPMENT….7150
PRECAUTIONS DURING OPERATION….7152
PRECAUTIONS FOR JOBSITE….7155
EXCAVATOR WORK….7157
TRANSPORTATION….7158
MACHINE CONFIGURATION FOR TRANSPORT….7158
WEAR PARTS….7159
WEAR PARTS LIST….7159
MAINTENANCE….7160
CHECK BEFORE STARTING….7160
EVERY 10 HOURS MAINTENANCE….7162
EVERY 5000 HOURS MAINTENANCE….7163
SPECIFICATION….7164
COMBINATION OF WORK EQUIPMENT….7165
COMBINATION OF WORK EQUIPMENT….7165
INDEX….7167
UEAM005000 – Hydraulic Excavator PC600-8, PC600LC-8 Operation & Maintenance Manual….7171
FOREWORD….7174
SAFETY INFORMATION….7175
Signal words….7175
Example of safety message using signal word….7175
Other signal words….7175
Example of safety label using words….7176
Safety labels using pictogram….7176
NOISE….7177
Vibration levels….7178
Operating condition:….7178
Guide to Reduce Vibration Levels on Machine….7178
INTRODUCTION….7180
DIRECTIONS OF MACHINE….7180
VISIBILITY FROM OPERATOR'S SEAT….7181
PROXIMITY VISIBILITY….7181
12M CIRCUMFERENCE VISIBILITY….7181
BREAKING-IN THE NEW MACHINE….7182
PRODUCT INFORMATION….7183
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….7183
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….7183
SERVICE METER LOCATION….7184
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….7184
MACHINE SERIAL PLATE….7185
FOREWORD….7186
SAFETY….7186
OPERATION….7187
MAINTENANCE….7189
SPECIFICATIONS….7191
ATTACHMENTS AND OPTIONS….7192
INDEX….7192
COLOPHON….7192
SAFETY INFORMATION….7194
SAFETY LABELS….7196
LOCATION OF SAFETY LABELS….7197
SAFETY LABELS….7198
SAFETY INFORMATION….7205
SAFETY RULES….7205
IF PROBLEMS ARE FOUND….7205
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….7205
FIRE EXTINGUISHER AND FIRST AID KIT….7205
SAFETY EQUIPMENT….7206
KEEP MACHINE CLEAN….7206
KEEP OPERATOR'S COMPARTMENT CLEAN….7206
LEAVING OPERATOR'S SEAT WITH LOCK….7206
HANDRAILS AND STEPS….7207
MOUNTING AND DISMOUNTING….7208
NO PERSONS ON ATTACHMENTS….7208
DO NOT GET CAUGHT IN ARTICULATED PORTION….7208
BURN PREVENTION….7208
FIRE PREVENTION AND EXPLOSION PREVENTION….7209
ACTION IF FIRE OCCURS….7210
WINDSHIELD WASHER FLUID….7210
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….7210
ATTACHMENT INSTALLATION….7210
ATTACHMENT COMBINATIONS….7210
CAB WINDOW GLASSES….7211
UNAUTHORIZED MODIFICATIONS….7211
SAFETY AT JOBSITE….7211
WORKING ON LOOSE GROUND….7211
DISTANCE TO HIGH VOLTAGE CABLES….7212
ENSURE GOOD VISIBILITY….7212
VENTILATION FOR ENCLOSED AREA….7213
SIGNALMAN'S SIGNAL AND SIGNS….7213
EMERGENCY EXIT FROM OPERATOR'S CAB….7213
ASBESTOS DUST HAZARD PREVENTION….7213
SAFETY MACHINE OPERATION….7214
STARTING ENGINE….7214
CHECKS BEFORE STARTING ENGINE….7214
SAFETY RULES FOR STARTING ENGINE….7215
STARTING ENGINE IN COLD WEATHER….7215
OPERATION….7216
CHECKS BEFORE OPERATION….7216
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….7216
SAFETY RULES FOR TRAVELING….7217
TRAVELING ON SLOPES….7217
OPERATIONS ON SLOPES….7218
PROHIBITED OPERATIONS….7218
OPERATIONS ON SNOW….7220
PARKING MACHINE….7221
TRANSPORTATION….7222
LOADING AND UNLOADING….7222
SHIPPING THE MACHINE….7222
BATTERY….7223
BATTERY HAZARD PREVENTION….7223
STARTING ENGINE WITH BOOSTER CABLES….7224
TOWING….7224
SAFETY RULES FOR TOWING….7224
LIFTING OBJECTS WITH BUCKET….7225
SAFETY RULES FOR LIFTING OBJECTS….7225
SAFETY MAINTENANCE INFORMATION….7226
WARNING TAG….7226
KEEP WORK PLACE CLEAN AND TIDY….7226
APPOINT LEADER WHEN WORKING WITH OTHERS….7226
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….7227
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….7227
PROPER TOOLS….7228
ACCUMULATOR….7228
PERSONNEL….7228
ATTACHMENTS….7229
WORK UNDER THE MACHINE….7229
NOISE….7229
WHEN USING HAMMER….7229
WELDING WORKS….7229
REMOVING BATTERY TERMINALS….7230
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….7230
DO NOT DISASSEMBLE RECOIL SPRINGS….7230
SAFETY RULES FOR HIGH-PRESSURE OIL….7230
PRECAUTION FOR HIGH FUEL PRESSURE….7231
SAFETY HANDLING HIGH-PRESSURE HOSES….7231
PRECAUTION FOR HIGH VOLTAGE….7231
WASTE MATERIALS….7232
AIR CONDITIONER MAINTENANCE….7232
COMPRESSED AIR….7232
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….7232
MACHINE VIEW ILLUSTRATIONS….7234
OVERALL MACHINE VIEW….7234
CONTROLS AND GAUGES….7235
DETAILED CONTROLS AND GAUGES….7237
MONITORING SYSTEM….7237
Basic Operation of Machine Monitor….7238
If There Is Abnormality When Starting Engine….7238
If Any Abnormality Occurs During Operation….7239
Emergency Monitors….7241
Engine Coolant Temperature Monitor….7241
Hydraulic Oil Temperature Monitor….7242
Engine Oil Pressure Monitor….7242
Caution Monitors….7243
Charge Level Monitor….7243
Fuel Level Monitor….7244
Air Cleaner Clogging Monitor….7244
Engine Coolant Temperature Monitor….7244
Hydraulic Oil Temperature Monitor….7244
Basic Check Monitors….7245
Radiator Coolant Level Monitor….7245
Engine Oil Level Monitor….7246
Maintenance Interval Monitor….7246
Meter Display Portion….7247
Pilot Display….7247
Engine Pre-heating Monitor….7247
Swing Lock Monitor….7248
Wiper Monitor….7248
Auto-deceleration Monitor….7248
Working Mode Monitor….7248
Travel Speed Monitor….7249
One-Touch Power Max. Monitor….7249
Gauges and Meter….7250
Engine Coolant Temperature Gauge….7250
Fuel Gauge….7250
Hydraulic Oil Temperature Gauge….7251
Service Meter….7251
Monitor Switches Portion….7252
Working Mode Selector Switch (Basic Switch)….7252
Auto-deceleration Switch (Selection Switch)….7253
Travel Speed Selector Switch (Selection Switch)….7254
Wiper Switch….7255
Window Washer Switch….7256
Maintenance Switch….7256
User Mode Adjustment Switch….7258
Fan Reverse Rotation….7258
Adjusting Set Value of Economy Mode….7261
Back Switch….7262
Up Switch, Down Switch….7262
Input Confirmation Switch….7263
Liquid Crystal Monitor Adjustment Switch….7263
Adjusting Brightness….7263
Adjusting Contrast….7264
Alarm Buzzer Stop Switch….7265
SWITCHES….7266
Starting Switch….7266
Fuel Control Dial….7267
Cigarette Lighter….7267
Machine Push-up Switch….7267
Lamp Switch….7268
Swing Lock Switch….7268
Boom Shockless Control Switch….7269
Horn Switch….7269
Room Lamp Switch….7269
Emergency Pump Drive Switch….7270
Swing Brake Cancel Switch….7270
Revolving Warning Lamp Switch….7270
Lower Wiper Switch….7271
Step Light Switch….7271
One-Touch Power Max. Switch….7271
Large Capacity Airflow Air Conditioner Blower Switch….7272
CONTROL LEVERS AND PEDALS….7273
Lock Lever….7273
Travel Levers (with Pedals and Auto-deceleration Device)….7274
Work Equipment Control Lever….7274
SUN ROOF….7276
Opening….7276
Closing….7276
WINDSHIELD….7277
Opening….7277
Closing….7280
Removing Lower Windshield….7281
EMERGENCY EXIT FROM OPERATOR'S CAB….7282
DOOR LOCK….7282
CAP WITH LOCK….7283
Opening and Closing Caps with Lock….7283
Opening the Cap….7283
Locking the Cap….7283
Opening and Closing Cover with Lock….7283
Opening the Cover (Locked Cover)….7283
Locking the Cover….7283
HOT AND COOL BOX….7284
MAGAZINE BOX….7284
ASHTRAY….7284
AIR CONDITIONER CONTROLS….7285
Air Conditioner Control Panel….7285
OFF Switch….7285
Fan Switch….7285
Temperature Control Switch….7286
Vent Selector Switch….7286
Auto Switch….7287
FRESH/RECIRC Selector Switch….7288
Display Monitor….7288
Air Conditioner Switch….7288
Sunlight Sensor….7289
Method of Operation….7289
Automatic Operation….7289
Stopping Automatic Operation….7290
Manual Operation….7290
Stopping Manual Operation….7292
Operation with Cold Air to Face and Warm Air to Feet….7292
Defroster Operation….7293
Use Air Conditioner with Care….7295
Ventilation….7295
Temperature Control….7295
Inspection and maintenance of Air Conditioner Equipped Machine….7295
Other Functions….7296
Self-diagnostic Function….7296
Function to Switch Set Temperature Display Between Fahrenheit and Celsius….7297
CAB RADIO….7297
Antenna….7297
Use Radio With Care….7297
AUXILIARY ELECTRIC POWER….7298
24V power source….7298
12V power source….7298
FUSE….7299
Fuse Capacities and Circuit Names….7299
CIRCUIT BREAKER….7300
CONTROLLER….7301
TOOL BOX….7301
GREASE PUMP….7302
Method of Use….7302
Precautions when Using….7303
Supplying Grease….7303
ACCUMULATOR….7305
Releasing Hydraulic Pressure With Accumulator….7305
MACHINE OPERATIONS AND CONTROLS….7306
BEFORE STARTING ENGINE….7306
Walk-around Checks….7306
Checks Before Starting….7307
Check Coolant Level, Add Coolant….7307
Check Oil Level in Engine Oil Pan, Add Oil….7308
Check Fuel Level, Add Fuel….7309
Check for Water and Sediment in Water Separator, Drain Water….7310
Drain Water And Sediment from Fuel Tank….7311
Check Oil Level in Hydraulic Tank, Add Oil….7311
Check Oil Level in Swing Machinery Case, Add Oil….7312
Check Oil Level in P.T.O Case, Add Oil….7313
Check Working Lamp Switch….7314
Check Electric Wiring….7315
Check Function of Horn….7315
Adjustment….7316
Seat Adjustment….7316
Rearview Mirrors….7318
Seat Belt….7319
Fastening and Removing….7319
Fastening Seat Belt….7319
Removing Belt….7319
Operations Before Starting Engine….7320
STARTING ENGINE….7323
AFTER STARTING ENGINE….7326
Warming Up Engine….7326
Warming Up Hydraulic Equipment….7328
Operation After Completion Of Warming-Up Operation….7332
STOPPING THE ENGINE….7333
MACHINE OPERATION….7334
Preparations for Moving the Machine….7334
Moving Machine Forward….7335
Moving Machine Backward….7336
Stopping Machine….7337
STEERING THE MACHINE….7338
Steering….7338
Steering the Machine when Stopped….7338
Changing Direction of the Machine….7339
Counter-rotation Turn (Spin Turn)….7339
SWINGING….7340
WORK EQUIPMENT CONTROLS AND OPERATIONS….7341
WORKING MODE….7342
Working Mode….7342
Setting Economy Mode….7343
PROHIBITED OPERATIONS….7344
Operations Using Swing Force….7344
Operations Using Travel Force….7344
Prohibition of Operations Using Hydraulic Cylinders to Stroke Ends….7344
Operations Using Bucket Dropping Force….7345
Operations Using Machine Dropping Force….7345
Digging Hard Rocky Ground….7345
Sudden Lever Shifting High Speed Travel….7345
GENERAL OPERATION INFORMATION….7346
Traveling….7346
High Speed Travel….7346
Precautions when Carrying Out Operations Continually with the Work Equipment in the Same Posture….7346
Permissible Water Depth….7347
TRAVELING ON SLOPES….7348
Traveling Downhill….7349
Engine Stopped on Slope….7349
Cab Doors on Slope….7349
ESCAPE FROM MUD….7350
Track on One Side Stuck….7350
Tracks on Both Sides Stuck….7350
RECOMMENDED APPLICATIONS….7351
Backhoe Work….7351
Ditching Work….7351
Loading Work….7351
BUCKET REPLACEMENT….7352
Replacement….7352
PARKING MACHINE….7354
MACHINE INSPECTION AFTER DAILY WORK….7355
LOCKING….7356
OVERLOAD WARNING DEVICE (option)….7356
TRANSPORTATION….7357
PRECAUTIONS FOR TRANSPORTATION….7357
LIFTING MACHINE….7357
SHIPPING MACHINE INFORMATION….7359
TRANSPORTATION POSTURE….7360
Three units for transportation….7360
Posture for Each Unit….7361
Upper Structure + Undercarriage….7361
Upper Structure….7361
Undercarriage….7361
Work Equipment….7362
Others….7363
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE….7365
Reducing Track Gauge….7365
Increasing Track Gauge….7366
COLD WEATHER OPERATION….7367
COLD WEATHER OPERATION INFORMATION….7367
Fuel and Lubricants….7367
Cooling System Coolant….7367
Battery….7368
Monitor….7369
AFTER DAILY WORK COMPLETION….7370
AFTER COLD WEATHER SEASON….7370
LONG TERM STORAGE….7371
BEFORE STORAGE….7371
DURING STORAGE….7371
AFTER STORAGE….7372
STARTING MACHINE AFTER LONG-TERM STORAGE….7372
TROUBLES AND ACTIONS….7373
RUNNING OUT OF FUEL….7373
Procedure for Bleeding Air….7373
PHENOMENA THAT ARE NOT FAILURES….7374
TOWING THE MACHINE….7375
SEVERE JOB CONDITION….7375
DISCHARGED BATTERY….7376
Battery Removal and Installation….7376
Battery Charges….7377
Starting Engine with Booster Cables….7378
Connecting and Disconnecting Booster Cables….7378
Booster Cable Connection….7379
Starting the Engine….7379
Booster Cable Disconnection….7379
OTHER TROUBLE….7380
Electrical System….7380
Chassis….7381
Engine….7382
Electronic Control System….7384
Machine Monitoring System….7384
Point of Contact to Telephone when Error Occurs….7385
MAINTENANCE INFORMATION….7388
Service Meter Reading….7388
Komatsu Genuine Replacement Parts….7388
Komatsu Genuine Lubricants….7388
Windshield Washer Fluid….7388
Fresh and Clean Lubricants….7388
Check Drained Oil and Used Filter….7388
Fuel Strainer….7388
Welding Instructions….7388
Do not Drop Things Inside Machine….7388
Dusty Jobsite….7389
Avoid Mixing Lubricants….7389
Locking the Inspection Covers….7389
Hydraulic System – Air Bleeding….7389
Hydraulic Hose Installation….7389
Checks After Inspection and Maintenance Works….7389
OUTLINE OF SERVICE….7390
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….7390
Oil….7390
Fuel….7390
Cooling System Coolant….7391
Grease….7391
Carrying Out KOWA (Komatsu Oil Wear Analysis)….7392
KOWA Analysis Items….7392
Oil Sampling….7392
Oil and Fuel Storage….7393
Filters….7393
ELECTRIC SYSTEM MAINTENANCE….7394
WEAR PARTS….7395
WEAR PARTS LIST….7395
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….7396
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….7397
TIGHTENING TORQUE SPECIFICATIONS….7398
TIGHTENING TORQUE LIST….7398
SAFETY CRITICAL PARTS….7399
SAFETY CRITICAL PARTS LIST….7400
MAINTENANCE SCHEDULE….7401
MAINTENANCE SCHEDULE CHART….7401
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)….7401
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….7401
WHEN REQUIRED….7401
CHECKS BEFORE STARTING….7401
EVERY 10 HOURS MAINTENANCE….7401
EVERY 100 HOURS MAINTENANCE….7401
EVERY 250 HOURS MAINTENANCE….7401
EVERY 500 HOURS MAINTENANCE….7402
EVERY 1000 HOURS MAINTENANCE….7402
EVERY 2000 HOURS MAINTENANCE….7402
EVERY 4000 HOURS MAINTENANCE….7402
EVERY 5000 HOURS MAINTENANCE….7402
EVERY 8000 HOURS MAINTENANCE….7402
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….7403
REPLACE HYDRAULIC OIL FILTER ELEMENT….7403
CHANGE OIL IN HYDRAULIC TANK….7403
REPLACE ADDITIONAL FILTER ELEMENT FOR BREAKER….7403
MAINTENANCE PROCEDURE….7404
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)….7404
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….7404
WHEN REQUIRED….7405
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….7405
Checking….7405
Cleaning or Replacing Outer Element….7406
Install Air Cleaner Element….7408
CLEAN INSIDE OF COOLING SYSTEM….7410
CHECK AND TIGHTEN TRACK SHOE BOLTS….7413
Tightening….7413
Order for Tightening….7413
CHECK AND ADJUST TRACK TENSION….7414
Checking….7414
Adjustment….7414
Increasing Track Tension….7414
Loosening Track Tension….7415
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….7416
ADJUST BUCKET CLEARANCE….7417
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….7418
Mixture Ratio of Pure Washer Fluid and Water….7418
CHECK AND MAINTENANCE AIR CONDITIONER….7419
Check Level of Refrigerant (gas)….7419
Inspection During Off Season….7419
Inspection and Maintenance Items….7419
CLEAN LINE FILTER, REMOVE DIRT….7420
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT….7421
CLEAN PILOT LINE FILTER, REMOVE DIRT….7422
BLEEDING AIR FROM HYDRAULIC SYSTEM….7423
Operation….7425
CHECK BEFORE STARTING….7426
EVERY 10 HOURS MAINTENANCE….7427
LUBRICATING….7427
EVERY 100 HOURS MAINTENANCE….7430
LUBRICATING SWING CIRCLE….7430
EVERY 250 HOURS MAINTENANCE….7431
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….7431
CHECK LEVEL OF BATTERY ELECTROLYTE….7432
When Checking Electrolyte Level from Side of Battery….7433
When it is Impossible to Check Electrolyte Level from Side of Battery….7433
When it is Possible to Use Indicator to Check Electrolyte Level….7433
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS….7434
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST….7435
Checking….7435
Adjustment….7435
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….7436
Checking….7436
Adjustment….7436
EVERY 500 HOURS MAINTENANCE….7437
REPLACE FUEL PRE-FILTER CARTRIDGE….7437
CHECK SWING PINION GREASE LEVEL, ADD GREASE….7440
CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS,FUEL COOLER FINS,AFTERCOOLER FINS,CONDENSER FINS (machines equipped with air conditioner),PTO OIL COOLER FINS….7441
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)….7443
CLEAN RECIRC AIR FILTER….7443
CLEAN FRESH AIR FILTER….7443
CLEAN STRAINER OF P.T.O LUBRICATING OIL FILTER….7444
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….7445
EVERY 1000 HOURS MAINTENANCE….7447
REPLACE FUEL MAIN FILTER CARTRIDGE….7447
REPLACE HYDRAULIC OIL FILTER ELEMENT….7450
CHANGE OIL IN SWING MACHINERY CASE….7451
CHANGE OIL IN P.T.O CASE….7452
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS….7453
REPLACE CORROSION RESISTOR CARTRIDGE….7453
CHECK WELDED STRUCTURE….7454
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT….7457
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)….7457
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….7458
EVERY 2000 HOURS MAINTENANCE….7459
CHANGE OIL IN FINAL DRIVE CASE….7459
CLEAN HYDRAULIC TANK STRAINER….7460
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)….7461
FUNCTION OF ACCUMULATOR….7461
CHECKING FUNCTION OF ACCUMULATOR….7462
METHOD OF RELEASING PRESSURE IN HYDRAULIC CIRCUIT….7464
CHECK ALTERNATOR, STARTING MOTOR….7464
EVERY 4000 HOURS MAINTENANCE….7465
CHECK WATER PUMP….7465
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)….7465
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER….7465
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER….7467
CHECK OPERATING CONDITION OF COMPRESSOR….7467
EVERY 5000 HOURS MAINTENANCE….7468
CHANGE OIL IN HYDRAULIC TANK….7468
EVERY 8000 HOURS MAINTENANCE….7469
REPLACE HIGH-PRESSURE PIPING CLAMP….7469
REPLACE FUEL SPRAY PREVENTION CAP….7469
SPECIFICATIONS….7472
GENERAL PRECAUTIONS FOR SAFETY….7476
PRECAUTIONS WHEN SELECTING….7476
READ THE INSTRUCTION MANUAL THOROUGHLY….7476
PRECAUTIONS WHEN REMOVING OR INSTALLING….7476
PRECAUTIONS WHEN USING….7477
ATTACHMENT GUIDE….7478
COMBINATIONS OF WORK EQUIPMENT….7478
Working Range Diagram….7479
TRACK SHOES SELECTION….7480
Selection….7480
HANDLING MACHINES EQUIPPED WITH KOMTRAX….7481
BASIC PRECAUTIONS….7481

Komatsu Hydraulic Excavators PC600-6, PC600LC-6, PC600-7, PC600LC-7, PC600-8, PC600LC-8 Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 9, 2025 by admin

Komatsu Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 1,993 pages
File Format: PDF
Language: English

TEN00405-03 – Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Operation & Maintenance Manual.pdf
SEN05377-03 – Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Shop Manual.pdf
GEN00101-02 – Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Field Assembly Instruction.pdf

TABLE OF CONTENTS
GEN00101-02 – Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Field Assembly Instruction…2
COVER…2
FOREWORD…3
CONTENTS…4
SPECIFICATIONS…7
PRECAUTIONS FOR FIELD ASSEMBLY…9
DISPOSAL OF REMOVED PARTS…10
ASSEMBLING PROCEDURES, APPLICABLE EQUIPMENT AND SCHEDULE…11
KIT LAYOUT DIAGRAM…12
TRANSPORTATION…13
LIST OF TOOLS FOR FIELD ASSEMBLING…18
TIGHTENING TORQUE…19
COATING MATERIALS…24
SELECTION OF WIRE ROPES USED FOR ASSEMBLY…26
A. ASSEMBLY OF CHASSIS…27
A- 1. Installation of Left and Right Track Frames…28
A- 2. Installation of Travel Pipe…33
A- 3. Installation of Operator Cab’s Left Handrail…38
A- 4. Installation of Operator Cab’s Door Stopper and Striker…39
A- 5. Installation of Rearview Mirror…41
A- 6. Installation of Handrail…46
A- 7-1 Installation of Step…49
A- 7-2 Installation of Step…50
A- 8. Installation of Left Side Step…51
A- 9. Sticking Sheet to Counterweight…52
A-10. Installation of Rear View Camera…53
A-11. Installation of Counterweight…58
A-12. Installation of Step Light…60
A-13. Bleeding of Air from Travel Motor…62
A-14-1 Installation of Travel Piping Cover…63
A-14-2 Installation of Travel Piping Cover…67
A-15. Installation of Travel Motor Guard…70
A-16. Testing Track Shoe Tension…71
A-17. Check Fuel, Coolant and Oil Levels…74
B. ASSEMBLING OF WORK EQUIPMENT…77
B- 1. Assembly of Arm Cylinder…78
B- 2. Connection of Arm Cylinder Hoses…79
B- 3. Installation of Boom Cylinder…80
B- 4. Installation of Boom Cylinder Hoses…81
B- 5. Installation of Boom Foot Dust Seal…82
B- 6. Assembly of Boom Assembly…83
B- 7. Installation of Hoses from Chassis Along Top of Boom…84
B- 8. Connection of Boom Cylinder Head…86
B- 9. Installation of Arm Assembly…87
B-10. Installation of Bucket Cylinder Hoses between Boom and Bucket Cylinder…89
B-11. Installation of Bucket…90
B-12. Connection of Work Equipment Grease Piping…93
B-13. Connection of Work Equipment Wiring…94
B-14. Greasing after Assembling Work Equipment…96
B-15. Bleeding Air from Work Equipment Circuit…97
B-16. Parts to be Touched up After Field Assembly…98
C. Assembling of Work Equipment of Loading Shovel…99
C- 1. Releasing residual pressure in hydraulic circuit…100
C- 2. Pulling out boom foot pin and boom cylinder foot pin…101
C- 3. Installation of boom cylinder foot…102
C- 4. Installation of boom and arm assembly…103
C- 5. Installation of boom cylinder hoses…104
C- 6. Installation of boom cylinder rod pin…105
C- 7. Installation of boom cylinder…106
C- 8. Installation of arm cylinder hoses…107
C- 9. Installation of bucket cylinder…108
C-10. Installation of bucket cylinder hoses…109
C-11. Installation of connecting hoses between chassis and boom top…110
C-12. Installation of bottom dump cylinder hoses…111
C-13. Installation of bucket assembly…112
C-14. Installation of working lamps…114
C-15. Installation of work equipment grease piping…116
C-16. Greasing after assembling of work equipment…117
C-17. Bleeding air from work equipment circuit…118
C-18. Checking oil level in hydraulic tank and adding oil…119
D. ASSEMBLING OF COUNTERWEIGHT REMOVER…121
D- 1. Sticking Sheet to Counterweight…122
D- 2. Adjustment of Shims for Counterweight…123
D- 3. Greasing…128
D- 4. Installation of Counterweight Remover…129
D- 5. Installation of Covers…130
D- 6. Installation of Clamps…131
D- 7. Installation of Hoses…134
D- 8. Bleeding Air from Counterweight Remover Circuit…135
D- 9. Installation of Counterweight…136
D-10. Installation of Accessories…138
D-11. Check of Operation…139
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY…141
M- 1. Inspection of Oil Level in Hydraulic Tank and Refill…142
M- 2. Replacement of Return Filter (Standard Filter to Flushing Filter)…144
M- 3. Flushing of Hydraulic Circuit…147
M- 4. Failure code…149
M- 5. Operating Method of …154
Field Assembly Inspection Report (Backhoe)…161
Field Assembly Inspection Report (Loading Shovel)…187
SEN05377-03 – Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Shop Manual…213
COVER…213
00 Index and foreword…223
Table of Contents…224
Table of Contents…224
Foreword and general information…234
Safety notice…234
How to read the shop manual…239
Explanation of terms for maintenance standard…241
Handling of hydraulic components…243
Method of disconnecting and connecting push-pull type coupler…245
Handling of electric equipment…248
How to read electric wire code…258
Precautions when performing work…261
Standard tightening torque table…264
List of abbreviation…268
Conversion table…272
01 Specification…277
Specifications…280
Specifications drawing…280
Working range drawings…282
Specifications…284
Table of weight…294
Table of fuel, coolant and lubricants…302
10 Structure and function…305
Engine and cooling system…307
Engine related parts…307
PTO…308
Cooling system…309
Power train system…310
Power train…310
Swing circle…312
Swing machinery…314
Final drive…316
Undercarriage and frame…318
Track frame and idler cushion…318
Hydraulic system…320
Hydraulic component layout…320
Valve control…322
Hydraulic tank and filter…324
Hydraulic pump (piston pump)…326
Cooling fan pump…354
Cooling fan motor…362
Control valve…368
Swing motor…384
Travel motor…392
PPC valve…413
Solenoid valve…421
PPC shuttle valve…428
Boom drift prevention valve…429
Boom LOWER regeneration valve…433
Arm regeneration valve…436
Quick return valve…439
Line oil filter…442
Center swivel joint…443
Accumulator…444
Electrical system…445
Engine control…445
Electrical control system…455
Monitor system…485
KOMTRAX system…511
Sensors…513
20 Standard value table…517
Standard value table…519
Standard value table for engine…519
Standard value table for machine…520
30 Testing and adjusting…543
Tool for testing, adjusting and troubleshooting…545
Tools for testing, adjusting, and troubleshooting…545
Engine and cooling system…549
Testing engine speed…549
Testing intake air pressure (boost pressure)…551
Testing exhaust gas temperature…552
Testing exhaust gas color…553
Testing and adjusting valve clearance…554
Testing compression pressure…555
Testing blowby pressure…557
Testing engine oil pressure…558
Testing EGR valve and bypass valve drive pressure…559
Handling fuel system parts…560
Releasing remaining pressure from fuel system…561
Testing fuel pressure…562
Cylinder cut-out test mode…563
No-injection cranking…564
Testing fuel return rate and leakage…565
Bleeding air from fuel circuit…568
Testing fuel circuit for leakage…570
Testing and adjusting alternator belt tension…571
Testing and adjusting air conditioner compressor belt tension…572
Undercarriage and frame…573
Testing swing circle bearing clearance…573
Checking and adjusting track tension…574
Hydraulic system…575
Testing and adjusting oil pressure in work equipment, swing and travel circuits…575
Testing and adjusting control circuit oil pressure…580
Testing and adjusting control oil pressure of piston pump…582
Testing servo piston movement…588
Testing PPC valve output pressure…590
Testing output pressure of solenoid valve and PPC shuttle valve…594
Adjusting play of work equipment and swing PPC vavles…600
Isolating the parts causing hydraulic drift in work equipment…601
Testing and adjusting travel deviation…603
Testing fan speed…605
Testing fan circuit oil pressure…606
Releasing remaining pressure from hydraulic circuit…607
Testing oil leakage…608
Bleeding air from each part…612
Electrical system…615
Special functions of machine monitor…615
Handling of voltage circuit of engine controller…659
Preparatory work for troubleshooting of electrical system…660
Inspection procedure of diode…665
Pm clinic…666
Pm Clinic service…666
UNDERCARRIAGE INSPECTION REPORT…678
40 Troubleshooting…681
General information on troubleshooting…688
Points to remember when troubleshooting…688
Sequence of events in troubleshooting…689
Checks before troubleshooting…690
Classification and procedures for troubleshooting…714
Failure codes table…717
Symptom and troubleshooting numbers…721
Information in troubleshooting table…724
Troubleshooting method for open circuit in wiring harness of pressure sensor system…726
Connector list and layout…728
Connection table for connector pin numbers…738
T- branch box and T- branch adapter table…774
Fuse locations…777
Troubleshooting by failure code…780
Failure code [989L00] Engine Controller Lock Caution 1…780
Failure code [989M00] Engine Controller Lock Caution 2…781
Failure code [989N00] Engine Controller Lock Caution 3…782
Failure code [AA10NX] Air Cleaner Clogging…783
Failure code [AB00KE] Charge Voltage Low…784
Failure code [B@BAZG] Eng Oil Press Low…786
Failure code [B@BAZK] Eng Oil Level Low…787
Failure code [B@BCNS] Eng Water Overheat…788
Failure code [B@BCZK] Eng Water Level Low…790
Failure code [B@HANS] Hyd Oil Overheat…792
Failure code [CA111] ECM Critical Internal Failure…794
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…796
Failure code [CA122] Chg Air Press Sensor High Error…798
Failure code [CA123] Chg Air Press Sensor Low Error…800
Failure code [CA131] Throttle Sensor High Error…802
Failure code [CA132] Throttle Sensor Low Error…804
Failure code [CA135] Eng Oil Press Sensor High Error…806
Failure code [CA141] Eng Oil Press Sensor Low Error…808
Failure code [CA144] Coolant Temp Sens High Error…810
Failure code [CA145] Coolant Temp Sens Low Error…812
Failure code [CA153] Chg Air Temp Sensor High Error…814
Failure code [CA154] Chg Air Temp Sensor Low Error…816
Failure code [CA187] Sens Supply 2 Volt Low Error…818
Failure code [CA221] Ambient Press Sens High Error…820
Failure code [CA222] Ambient Press Sens Low Error…822
Failure code [CA227] Sens Supply 2 Volt High Error…824
Failure code [CA234] Eng Overspeed…825
Failure code [CA238] Ne Speed Sens Supply Volt Error…826
Failure code [CA263] Fuel Temp Sensor High Error…828
Failure code [CA265] Fuel Temp Sensor Low Error…830
Failure code [CA271] IMV/PCV1 Short Error…832
Failure code [CA272] IMV/PCV1 Open Error…833
Failure code [CA273] PCV2 Short Error…834
Failure code [CA274] PCV2 Open Error…835
Failure code [CA322] Inj #1(L#1) Open/Short Error…836
Failure code [CA323] Inj #5 (L#5) Open/Short Error…838
Failure code [CA324] Inj #3(L#3) Open/Short Error…840
Failure code [CA325] Inj #6 (L#6) Open/Short Error…842
Failure code [CA331] Inj #2(L#2) Open/Short Error…844
Failure code [CA332] Inj #4 (L#4) Open/Short Error…846
Failure code [CA342] Calibration Code Incompatibility…848
Failure code [CA351] Injectors Drive Circuit Error…849
Failure code [CA352] Sens Supply 1 Volt Low Error…850
Failure code [CA386] Sens Supply 1 Volt High Error…852
Failure code [CA441] Battery Voltage Low Error…852
Failure code [CA442] Battery Voltage High Error…853
Failure code [CA449] Rail Press Very High Error…853
Failure code [CA451] Rail Press Sensor High Error…854
Failure code [CA452] Rail Press Sensor Low Error…856
Failure code [CA553] Rail Press High Error…858
Failure code [CA554] Rail Press Sensor In Range Error…858
Failure code [CA559] Supply Pump Press Low Error 1…859
Failure code [CA689] Eng Ne Speed Sensor Error…862
Failure code [CA731] Eng Bkup Speed Sens Phase Error…864
Failure code [CA757] All Continuous Data Lost Error…865
Failure code [CA778] Eng Bkup Speed Sensor Error…866
Failure code [CA1228] EGR Valve Servo Error 1…868
Failure code [CA1625] EGR Valve Servo Error 2…869
Failure code [CA1626] BP Valve Sol Current High Error…870
Failure code [CA1627] BP Valve Sol Current Low Error…872
Failure code [CA1628] Bypass Valve Servo Error 1…874
Failure code [CA1629] Bypass Valve Servo Error 2…875
Failure code [CA1631] BP Valve Pos Sens High Error…876
Failure code [CA1632] BP Valve Pos Sens Low Error…878
Failure code [CA1633] KOMNET Datalink Timeout Error…880
Failure code [CA2185] Throt Sens Sup Volt High Error…882
Failure code [CA2186] Throt Sens Sup Volt Low Error…884
Failure code [CA2249] Rail Press Very Low Error…885
Failure code [CA2271] EGR Valve Pos Sens High Error…886
Failure code [CA2272] EGR Valve Pos Sens Low Error…888
Failure code [CA2351] EGR Valve Sol Current High Error…890
Failure code [CA2352] EGR Valve Sol Current Low Error…892
Failure code [CA2555] Grid Htr Relay Open Circuit Error…894
Failure code [CA2556] Grid Htr Relay Short Circuit Error…896
Failure code [D110KB] Battery Relay Drive Short Circuit…898
Failure code [D163KB] Flash Light Relay Short Circuit…900
Failure code [D195KA] Step Light Relay Open Circuit…902
Failure code [D195KB] Step Light Relay Short Circuit…904
Failure code [D19JKZ] Personal code relay abnormality…906
Failure code [D862KA] GPS Antenna Open Circuit…908
Failure code [DA22KK] Pump Solenoid Power Low Error…910
Failure code [DA25KP] 5V Sensor1 Power Abnormality…912
Failure code [DA29KQ] Model Selection Abnormality…914
Failure code [DA2RMC] CAN Discon (Pump Con Detected)…916
Failure code [DA80MA] Auto. Lub. Abnormal…920
Failure code [DAF8KB] Camera Power Supply Short Circuit…922
Failure code [DAFGMC] GPS Module Error…924
Failure code [DAFRMC] CAN Discon (Monitor Detected)…925
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit…930
Failure code [DGH2KB] Hyd Oil Sensor Short…932
Failure code [DHPAMA] F Pump Press Sensor Abnormality…934
Failure code [DHPBMA] R Pump Press Sensor Abnormality…936
Failure code [DV20KB] Travel alarm short circuit…938
Failure code [DW43KA] Travel Speed Sol Open Circuit…940
Failure code [DW43KB] Travel Speed Sol Short Circuit…942
Failure code [DW45KA] Swing Brake Sol Open Circuit…944
Failure code [DW45KB] Swing Brake Sol Short Circuit…946
Failure code [DW48KA] CO Cancel Sol Open Circuit…948
Failure code [DW48KB] CO Cancel Sol Short Circuit…950
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit…952
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit…954
Failure code [DW7BKA] Fan Reverse Sol Open Circuit…956
Failure code [DW7BKB] Fan Reverse Sol Short Circuit…958
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit…960
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit…962
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit…964
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit…965
Failure code [DXA0KA] TVC Sol Open Circuit…966
Failure code [DXA0KB] TVC Sol Short Circuit…968
Failure code [DY20KA] Wiper Working Abnormality…970
Failure code [DY20MA] Wiper Parking Abnormality…974
Failure code [DY2CKA] Washer Drive Open Circuit…976
Failure code [DY2CKB] Washer Drive Short Circuit…978
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit…980
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit…984
Failure code [DY2FMA] Upper Wiper Working Abnormality…988
Failure code [DY2GKM] Wiper Select Abnormality…990
Troubleshooting of electrical system (E-mode)…994
E-1 Engine does not start (Engine does not crank)…994
E-2 Preheater does not operate…999
E-3 When starting switch is turned to ON position, machine monitor displays nothing…1003
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up…1006
E-5 Precaution item lights up while engine is running…1008
E-6 Emergency stop item lights up while engine is running…1010
E-7 Engine coolant temperature gauge does not indicate properly…1011
E-8 Fuel gauge does not indicate properly…1012
E-9 Hydraulic oil temperature gauge does not indicate properly…1014
E-10 Content of display on machine monitor is different from that of actual machine…1016
E-11 Some areas of machine monitor screen are not displayed…1016
E-12 Function switch does not operate…1016
E-13 Automatic warm-up system does not operate (in cold season)…1017
E-14 Auto-decelerator does not operate properly…1018
E-15 Working mode does not change…1019
E-16 Travel speed does not change…1020
E-17 Alarm buzzer cannot be canceled…1021
E-18 When starting switch is turned OFF, service meter is not displayed…1021
E-19 Service mode cannot be selected…1021
E-20 Any of work equipment, swing and travel does not work or cannot be locked…1022
E-21 Machine push-up function does not work or cannot be canceled…1024
E-22 Boom shockless function does not operate normally…1026
E-23 Swing brake does not operate normally…1028
E-24 Windshield wiper and window washer do not operate…1030
E-25 Travel alarm does not sound or does not stop sounding…1033
E-26 BOOM RAISE indicator is not displayed properly with monitoring function…1034
E-27 BOOM LOWER indicator is not displayed properly with monitoring function…1036
E-28 ARM IN indicator is not displayed properly with monitoring function…1038
E-29 ARM DUMP indicator is not displayed properly with monitoring function…1040
E-30 BUCKET CURL indicator is not displayed properly with monitoring function…1042
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function…1044
E-32 Swing indicator is not displayed properly with monitoring function…1046
E-33 Travel indicator is not displayed properly with monitoring function…1048
E-34 "Service" is not displayed normally by monitoring function…1050
E-35 Electric grease gun does not operate…1052
E-36 KOMTRAX system does not operate normally…1053
E-37 Bottom dump does not operate properly…1054
E-38 Horn does not sound or does not stop sounding…1057
E-39 Step light does not light up or go off…1060
Troubleshooting of hydraulic and mechanical system (H-mode)…1064
Before troubleshooting for hydraulic and mechanical systems…1064
Information in troubleshooting table (H-mode)…1069
H-1 All of work equipment, travel and swing work slow or lack power…1070
H-2 Engine speed lowers significantly or engine stalls…1072
H-3 Any of work equipment, swing and travel does not work…1074
H-4 Unusual noise is heard from around hydraulic pump…1076
H-5 Auto-decelerator is not canceled…1077
H-6 Speed or power of boom is low…1078
H-7 Speed or power of arm is low…1080
H-8 Speed or power of bucket is low…1081
H-9 Boom does not move…1082
H-10 Arm does not move…1082
H-11 Bucket does not move…1083
H-12 Bottom dump does not move…1083
H-13 Hydraulic drift of work equipment is large…1084
H-14 Time lag of work equipment is large…1085
H-15 One-touch power maximizing function does not work or is not canceled…1086
H-16 Machine push-up function does not work or is not canceled…1086
H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket…1086
H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm, swing and travel…1087
H-19 Swing speed is low at combined operation of arm and swing…1087
H-20 Machine deviates during travel…1088
H-21 Machine deviates significantly at start…1091
H-22 Machine deviates significantly during combined operation…1092
H-23 Travel speed or travel power is low…1093
H-24 One of tracks does not run (on one side alone)…1094
H-25 Travel speed does not change…1095
H-26 Upper structure does not swing…1096
H-27 Swing speed is low or acceleration is poor…1097
H-28 Upper structure overruns excessively when it stops swinging…1098
H-29 Shock is large when upper structure stops swinging…1099
H-30 Large unusual noise is heard when upper structure stops swinging40…1100
H-31 Hydraulic drift of swing is large…1101
Troubleshooting of engine (S-mode)…1102
Method of using troubleshooting chart…1102
S-1 Startability is poor…1106
S-2 Engine does not start…1108
S-3 Engine does not pick up smoothly…1112
S-4 Engine stops during operation…1113
S-5 Engine runs rough or is unstable…1114
S-6 Engine lacks power…1116
S-7 Exhaust smoke is black (incomplete combustion)…1118
S-8 Oil consumption is excessive (or exhaust smoke is blue)…1120
S-9 Oil becomes contaminated early…1121
S-10 Fuel consumption is excessive…1122
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)…1123
S-12 Oil pressure drops…1124
S-13 Oil level rises (coolant or fuel in oil)…1126
S-14 Coolant temperature rises too high (overheating)…1128
S-15 Unusual noise is made…1129
S-16 Vibration is excessive…1130
50 Disassembly and assembly…1131
General information on disassembly and assembly…1134
How to read Disassembly and Assembly…1134
Coating materials list…1136
Special tools list…1139
Sketches of special tools…1146
Engine and cooling system…1154
Removal and installation of fuel supply pump assembly…1154
Removal and installation of fuel injector assembly…1160
Removal and installation of cylinder head assembly…1163
Removal and installation of radiator assembly…1180
Removal and installation of hydraulic oil cooler assembly…1182
Removal and installation of aftercooler assembly…1184
Removal and installation of engine front seal…1186
Removal and installation of engine rear seal…1190
Removal and installation of engine, PTO and hydraulic pump assembly…1195
Removal and installation of cooling fan motor assembly…1203
Removal and installation of fuel tank assembly…1207
Power train…1208
Removal and installation of PTO assembly…1208
Disassembly and assembly of PTO assembly…1210
Disassembly and assembly of final drive assembly…1213
Removal and installation of swing motor and swing machinery assembly50…1236
Disassembly and assembly of swing machinery assembly…1238
Removal and installation of swing circle assembly…1253
Undercarriage and frame…1254
Separation and connection of track shoe assembly…1254
Disassembly and assembly of one link in field…1258
Removal and installation of idler assembly…1262
Disassembly and assembly of idler assembly…1264
Removal and installation of idler cushion assembly…1271
Disassembly and assembly of idler cushion assembly…1274
Removal and installation of track roller assembly…1278
Disassembly and assembly of track roller assembly…1280
Removal and installation of carrier roller assembly…1286
Disassembly and assembly of carrier roller assembly…1288
Removal and installation of revolving frame assembly…1294
Removal and installation of counterweight assembly…1296
Removal and installation of counterweight remover assembly…1299
Hydraulic system…1301
Removal and installation of center swivel joint assembly…1301
Disassembly and assembly of center swivel joint assembly…1302
Removal and installation of hydraulic tank assembly…1304
Removal and installation of hydraulic pump assembly…1306
Removal and installation of control valve assembly…1309
Disassembly and assembly of control valve assembly…1311
Removal and installation of swing motor assembly…1313
Disassembly and assembly of work equipment PPC valve assembly…1314
Disassembly and assembly of travel PPC valve assembly…1316
Disassembly and assembly of grease gun assembly…1318
Work equipment…1319
Removal and installation of bucket cylinder assembly…1319
Removal and installation of arm cylinder assembly…1323
Removal and installation of boom cylinder assembly…1327
Removal and installation of bottom dump cylinder assembly…1331
Removal and installation of bucket assembly…1333
Removal and installation of arm assembly…1337
Removal and installation of boom assembly…1340
Removal and installation of work equipment assembly…1344
Disassembly and assembly of work equipment cylinder assembly…1348
Cab and its attachments…1354
Removal and installation of operator's cab assembly…1354
Removal and installation of operator's cab glass (adhered window glass)…1358
Removal and installation of front window assembly…1368
Removal and installation of air conditioner unit assembly…1375
Electrical system…1379
Removal and installation of air conditioner compressor assembly…1379
Removal and installation of air conditioner condenser assembly…1382
Removal and installation of engine controller assembly…1384
Removal and installation of pump controller assembly…1386
Removal and installation of KOMTRAX terminal assembly…1388
Removal and installation of machine monitor assembly…1389
60 Maintenance standard…1391
Engine and cooling system…1393
Engine mount…1393
PTO…1395
Cooling system…1396
Power train…1397
Swing circle…1397
Swing machinery…1398
Final drive…1400
Sprocket…1402
Undercarriage and frame…1406
Track frame and idler cushion…1406
Idler…1408
Track roller…1412
Carrier roller…1415
Track shoe…1418
Hydraulic system…1428
Hydraulic pump…1428
Control valve…1438
Swing motor…1444
Travel motor…1445
PPC valve…1448
Boom drift prevention valve…1455
Regeneration valve (boom, arm)…1456
Center swivel joint…1457
Work equipment…1458
Work equipment…1458
Work equipment dimension…1462
Work equipment cylinder…1468
80 Appendix…1473
Air conditioner…1475
Precautions for refrigerant…1475
Air conditioner component…1476
Configuration and function of refrigeration cycle…1478
Outline of refrigeration cycle…1479
Air conditioner unit…1482
Air conditioner controller…1487
Compressor…1488
Condenser…1489
Receiver drier…1490
Procedure for testing and troubleshooting…1492
Circuit diagram and arrangement of connector pins…1494
System diagram…1496
Detail of air conditioner unit…1498
Parts and connectors layout…1500
Testing air leakage (duct)…1503
Testing with self-diagnosis function…1504
Testing temperature control…1507
Testing vent (mode) changeover…1509
Testing FRESH/RECIRC air changeover…1512
Testing inner sensor…1514
Testing evaporator temperature sensor…1515
Testing sunlight sensor…1517
Testing (dual) pressure switch for refrigerant…1518
Testing relays…1519
Troubleshooting chart 1…1520
Troubleshooting chart 2…1522
Information in troubleshooting table…1524
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)…1526
Troubleshooting for compressor and refrigerant system (Air is not cooled)…1531
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)…1535
Troubleshooting for temperature control…1539
Troubleshooting for vent (mode) changeover…1542
Troubleshooting for FRESH/RECIRC air changeover…1544
Troubleshooting for temperature sensor system…1546
Troubleshooting with gauge pressure…1547
Connection of service tool…1550
Precautions for disconnecting and connecting air conditioner piping…1552
Handling of compressor oil…1554
90 Diagrams and drawings…1557
Hydraulic circuit diagram…1559
Symbols used in hydraulic circuit diagrams…1559
Hydraulic circuit diagram…1563
Electrical circuit diagram…1567
Symbols used in electric circuit diagrams…1567
Electrical circuit diagram…1571
Air conditioner electrical circuit diagram…1583
TEN00405-03 – Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Operation & Maintenance Manual…1592
COVER…1592
FOREWORD…1593
BEFORE READING THIS MANUAL…1594
SAFETY INFORMATION…1595
INTRODUCTION…1596
USE OF MACHINE…1596
DIRECTIONS OF MACHINE…1596
VISIBILITY FROM OPERATOR'S SEAT…1597
PRODUCT INFORMATION…1599
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1599
EPA REGULATIONS, ENGINE NUMBER PLATE…1599
SERVICE METER LOCATION…1600
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1600
CONTENTS…1601
SAFETY…1605
SAFETY…1606
SAFETY LABELS…1609
LOCATION OF SAFETY LABELS…1610
SAFETY LABELS…1611
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…1617
PRECAUTIONS BEFORE STARTING OPERATION…1617
PREPARATIONS FOR SAFE OPERATION…1617
FIRE PREVENTION…1619
DO NOT GET CAUGHT IN WORK EQUIPMENT…1622
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…1622
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…1623
UNAUTHORIZED MODIFICATION…1623
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1624
PRECAUTIONS RELATED TO CAB GLASS…1624
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…1624
PRECAUTIONS FOR OPERATION…1625
PRECAUTIONS FOR JOBSITE…1625
STARTING ENGINE…1627
OPERATION…1629
TRANSPORTATION…1636
TOWING…1637
LIFTING OBJECTS WITH BUCKET…1638
PRECAUTIONS FOR MAINTENANCE…1639
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…1639
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1643
OPERATION…1649
MACHINE VIEW ILLUSTRATIONS…1650
OVERALL MACHINE VIEW…1650
CONTROLS AND GAUGES…1651
DETAILED CONTROLS AND GAUGES…1653
MONITORING SYSTEM…1653
SWITCHES…1721
CONTROL LEVERS AND PEDALS…1728
SUN ROOF…1731
WINDSHIELD…1732
EMERGENCY ESCAPE HAMMER…1738
DOOR LOCK…1738
CAP WITH LOCK…1739
HOT AND COOL BOX…1741
MAGAZINE BOX…1741
ASHTRAY…1741
AIR CONDITIONER CONTROLS…1742
RADIO…1755
FUSE…1760
CIRCUIT BREAKER…1761
CONTROLLER…1762
TOOL BOX…1762
GREASE PUMP…1763
FIRE EXTINGUISHER…1766
MACHINE OPERATIONS AND CONTROLS…1767
BEFORE STARTING ENGINE…1767
STARTING ENGINE…1787
AFTER STARTING ENGINE…1790
STOPPING THE ENGINE…1800
MACHINE OPERATION…1801
STEERING THE MACHINE…1805
SWINGING…1807
WORK EQUIPMENT CONTROLS AND OPERATIONS…1808
WORKING MODE…1810
PROHIBITED OPERATIONS…1813
GENERAL OPERATION INFORMATION…1818
TRAVELING ON SLOPES…1820
ESCAPE FROM MUD…1822
RECOMMENDED APPLICATIONS…1823
BUCKET REPLACEMENT…1824
PARKING MACHINE…1826
MACHINE INSPECTION AFTER DAILY WORK…1827
LOCKING…1828
TRANSPORTATION…1829
TRANSPORTATION PROCEDURE…1829
LIFTING MACHINE…1829
SHIPPING MACHINE INFORMATION…1830
TRANSPORTATION POSTURE…1831
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE…1837
COLD WEATHER OPERATION…1839
COLD WEATHER OPERATION INFORMATION…1839
AFTER DAILY WORK COMPLETION…1841
AFTER COLD WEATHER SEASON…1841
LONG TERM STORAGE…1842
BEFORE STORAGE…1842
DURING STORAGE…1842
AFTER STORAGE…1843
STARTING MACHINE AFTER LONG-TERM STORAGE…1843
TROUBLES AND ACTIONS…1844
RUNNING OUT OF FUEL…1844
PHENOMENA THAT ARE NOT FAILURES…1845
TOWING THE MACHINE…1846
SEVERE JOB CONDITION…1847
DISCHARGED BATTERY…1847
OTHER TROUBLE…1851
MAINTENANCE…1857
MAINTENANCE INFORMATION…1858
OUTLINE OF SERVICE…1860
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1860
ELECTRIC SYSTEM MAINTENANCE…1863
WEAR PARTS…1864
WEAR PARTS LIST…1864
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1865
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1867
TIGHTENING TORQUE SPECIFICATIONS…1868
TIGHTENING TORQUE LIST…1868
SAFETY CRITICAL PARTS…1869
SAFETY CRITICAL PARTS LIST…1870
MAINTENANCE SCHEDULE…1871
MAINTENANCE SCHEDULE CHART…1871
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1873
MAINTENANCE PROCEDURE…1874
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)…1874
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…1874
WHEN REQUIRED…1875
CHECK BEFORE STARTING…1899
EVERY 10 HOURS MAINTENANCE…1900
EVERY 100 HOURS MAINTENANCE…1903
EVERY 250 HOURS MAINTENANCE…1904
EVERY 500 HOURS MAINTENANCE…1910
EVERY 1000 HOURS MAINTENANCE…1921
EVERY 2000 HOURS MAINTENANCE…1932
EVERY 4000 HOURS MAINTENANCE…1939
EVERY 5000 HOURS MAINTENANCE…1942
EVERY 8000 HOURS MAINTENANCE…1943
SPECIFICATIONS…1945
SPECIFICATIONS…1946
ATTACHMENTS AND OPTIONS…1951
GENERAL PRECAUTIONS FOR SAFETY…1952
PRECAUTIONS WHEN SELECTING…1952
READ THE INSTRUCTION MANUAL THOROUGHLY…1952
PRECAUTIONS WHEN REMOVING OR INSTALLING…1952
PRECAUTIONS WHEN USING…1952
ATTACHMENT GUIDE…1953
COMBINATIONS OF WORK EQUIPMENT…1954
TRACK SHOES SELECTION…1957
HANDLING COUNTERWEIGHT REMOVER…1958
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1967
BASIC PRECAUTIONS…1967
LOADING SHOVEL…1969
EXPLANATION OF COMPONENTS…1970
SWITCHES…1970
FUSE…1973
OPERATIONS…1974
OPERATION OF WORK EQUIPMENT…1974
PRECAUTIONS DURING OPERATION…1976
PRECAUTIONS FOR OPERATION…1979
LOADING SHOVEL WORK…1981
TRANSPORTATION…1982
MACHINE CONFIGURATION FOR TRANSPORT…1982
WEAR PARTS…1983
WEAR PARTS LIST…1983
MAINTENANCE…1984
CHECK BEFORE STARTING…1984
EVERY 10 HOURS MAINTENANCE…1986
EVERY 5000 HOURS MAINTENANCE…1987
SPECIFICATION…1988
COMBINATION OF WORK EQUIPMENT…1989
COMBINATION OF WORK EQUIPMENT…1989
INDEX…1991

Komatsu Hydraulic Excavator PC600-8E0, PC600LC-8E0, PC650-8E0, PC650LC-8E0, PC700LC-8E0 Repair Service Manuals

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