Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC75UU, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC75UU 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.
SEBM000401 – Hydraulic Excavator PC75UU-1 Shop Manual.pdf
SEBM001302 – Hydraulic Excavator PC75UU-2 Shop Manual.pdf
SEBM016404 – Hydraulic Excavator PC75UU-3 Shop Manual.pdf
SEAM021W0100 – Hydraulic Excavator PC75UU-1 Operation & Maintenance Manual.pdf
SEAM005600 – Hydraulic Excavator PC75UU-2 Operation & Maintenance Manual.pdf
SEAM023201T – Hydraulic Excavator PC75UU-3 Operation & Maintenance Manual.pdf
Total Pages: 1,755 pages
File Format: PDF
Language: English
SEAM005600 – Hydraulic Excavator PC75UU-2 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…17
7.1 BEFORE STARTING ENGINE…17
7.2 OPERATING MACHINE…19
7.3 TRANSPORTATION…24
7.4 BATTERY…25
7.5 TOWING…26
7.6 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…41
10. GENERAL VIEW…42
10.1 GENERAL VIEW OF MACHINE…42
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…43
11. EXPLANATION OF COMPONENTS…44
11.1 MACHINE MONITOR…45
11.2 SWITCHES…51
11.3 CONTROL LEVERS AND PEDALS…54
11.4 ENGINE HOOD …57
11.5 FRONT WINDOW…58
11.6 SLIDING DOOR…60
11.7 FUSE BOX…61
11.8 FUSIBLE LINK…61
11.9 CAP WITH LOCK, COVER…62
11.10 TOOL BOX…62
11.11 GREASE GUN HOLDER…62
12. OPERATION…63
12.1 CHECK BEFORE STARTING ENGINE…63
12.2 STARTING ENGINE…70
12.3 OPERATION AND CHECK AFTER STARTING ENGINE…72
12.4 MOVING MACHINE OFF…75
12.5 STEERING MACHINE…77
12.6 STOPPING MACHINE…79
12.7 SWINGING…80
12.8 PROHIBITIONS FOR OPERATION…81
12.9 PRECAUTIONS FOR OPERATION…83
12.10 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…84
12.11 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…86
12.12 PARKING MACHINE…88
12.13 CHECKS AFTER FINISHING WORK…89
12.14 STOPPING ENGINE…89
12.15 CHECKS AFTER STOPPING ENGINE…90
12.16 LOCKING…90
12.17 HOW TO ESCAPE FROM MUD…91
12.18 REPLACEMENT OF BUCKET…92
12.19 HANDLING 4-SYSTEM…93
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…103
13. TRANSPORTATION…108
13.1 LOADING,UNLOADING WORK…108
13.2 METHOD FOR LIFTING CHASSIS…110
13.3 PRECAUTIONS FOR LOADING…112
13.4 PRECAUTIONS FOR TRANSPORTATION…112
14. COLD WEATHER OPERATION…113
14.1 PRECAUTIONS FOR LOW TEMPERATURE…113
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…115
14.3 PREPARING THE CAB HEATER…115
14.4 AFTER COLD WEATHER…115
15. LONG-TERM STORAGE…116
15.1 BEFORE STORAGE…116
15.2 DURING STORAGE…116
15.3 AFTER STORAGE…116
16. TROUBLESHOOTING…117
16.1 PHENOMENA THAT ARE NOT FAILURES…117
16.2 METHOD OF TOWING MACHINE…119
16.3 PRECAUTIONS ON PARTICULAR JOBSITES…119
16.4 IF BATTERY IS DISCHARGED…120
16.5 OTHER TROUBLE…123
MAINTENANCE…128
17. GUIDES TO MAINTENANCE…129
18. OUTLINES OF SERVICE…132
18.1 OUTLINE OF OIL,FUEL, COOLANT…132
18.2 RELATING TO ELECTRIC SYSTEM…135
19. WEAR PARTS LIST…136
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…137
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…141
21.1 INTRODUCTION OF NECESSARY TOOLS…141
21.2 TORQUE LIST…142
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…143
23. MAINTENANCE SCHEDULE CHART…145
23.1 MAINTENANCE SCHEDULE CHART…145
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…147
24. SERVICE PROCEDURE…148
24.1 INITIAL 250 HOURS SERVICE…148
24.2 WHEN REQUIRED…149
24.3 CHECK BEFORE STARTING…173
24.4 EVERY 50 HOURS SERVICE…177
24.5 EVERY 100 HOURS SERVICE…178
24.6 EVERY 250 HOURS SERVICE…180
24.7 EVERY 500 HOURS SERVICE…183
24.8 EVERY 1000 HOURS SERVICE…188
24.9 EVERY 2000 HOURS SERVICE…190
24.10 EVERY 4000 HOURS SERVICE…193
SPECIFICATIONS…194
25. SPECIFICATIONS…195
OPTIONS,ATTACHMENTS…198
26. USING CAR RADIO…199
26.1 EXPLANATION OF PARTS…199
26.2 METHOD OF USE…201
26.3 PRECAUTIONS FOR USE…202
26.4 SPECIFICATIONS…203
27. USING CAR COOLER…204
27.1 CONTROL PANEL…204
27.2 PRECAUTIONS WHEN USING…204
27.3 INSPECTION AND MAINTENANCE OF CAR COOLER…205
28. HANDLING WINDOW WASHER…207
28.1 OPERATION OF WINDOW WASHER…207
28.2 CHECK WINDOW WASHER FLUID, ADD FLUID…207
29. HANDLING BUCKET WITH HOOK…208
29.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…208
29.2 PROHIBITED OPERATIONS…208
29.3 PRECAUTIONS DURING OPERATIONS…208
30. GENERAL PRECAUTIONS…209
30.1 PRECAUTIONS RELATED TO SAFETY…209
31. INTRODUCTION OF ATTACHMENTS…210
31.1 SPECIFICATION, USE…210
31.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…211
31.3 PRECAUTIONS WHEN USING HYDRAULIC BREAKER…212
32. MACHINES ABLE TO INSTALL ATTACHMENTS…215
32.1 EXPLANATION OF EQUIPMENT…215
32.2 HYDRAULIC CIRCUIT…217
32.3 OPERATION…218
32.4 LONG-TERM STORAGE…219
32.5 SPECIFICATIONS…219
SEAM021W0100 – Hydraulic Excavator PC75UU-1 Operation & Maintenance Manual…220
COVER…220
FOREWORD…221
BREAKING IN YOUR NEW MACHINE…222
CONTENTS…223
GENERAL LOCATIONS AND SPECIFICATIONS…224
INSTRUMENTS AND CONTROLS…225
CHECK BEFORE STARTING…239
OPERATING YOUR MACHINE…244
REPLACEMENT OF BUCKET…256
COLD WEATHER OPERATION…257
PERIODIC MAINTENANCE…261
MAINTENANCE TABLE…262
OIL FILLER AND GAUGE POSITIONS…265
EVERY 50 HOURS SERVICE…266
EVERY 100 HOURS SERVICE…267
EVERY 250 HOURS SERVICE…271
EVERY 500 HOURS SERVICE…274
EVERY 1000 HOURS SERVICE…278
EVERY 2000 HOURS SERVICE…280
WHEN REQUIRED…284
ADJUSTMENT…296
HANDLING RUBBER SHOES…297
TROUBLE SHOOTING GUIDE…310
SERVICE METER…313
MACHINE AND ENGINE SERIAL NUMBERS…314
FUEL,COOLANT AND LUBRICANTS…315
SAFETY AND OPERATION…317
CONTENTS…318
SAFETY HINTS…319
RADIO…328
OPERATING THE CAR COOLER…330
EXCAVATOR'S WORK…332
HANDLING OF BATTERY…333
TRANSPORTATION…336
PRECAUTIONS FOR MAINTENANCE…338
STORAGE…343
COOLANT AND LUBRICANTS…345
SEAM023201T – Hydraulic Excavator PC75UU-3 Operation & Maintenance Manual…348
COVER…348
1.FOREWORD…349
2.SAFETY INFORMATION…350
3.INTRODUCTION…351
4.LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR…352
5.CONTENTS…353
SAFETY…357
6.GENERAL PRECAUTIONS…358
7.PRECAUTIONS DURING OPERATION…363
7.1 BEFORE STARTING ENGINE…363
7.2 OPERATING MACHINE…365
7.3 TRANSPORTATION…372
7.4 BATTERY…373
7.5 TOWING…375
7.6 BUCKET WITH HOOK…376
7.7 WINDOW WASHER FLUID…376
8.PRECAUTIONS FOR MAINTENANCE…377
8.1 BEFORE CARRYING OUT MAINTENANCE…377
8.2 DURING MAINTENANCE…381
9.POSITION FOR ATTACHING SAFETY LABELS…386
9.1 POSITION FOR ATTACHING SAFETY LABELS…386
OPERATION…391
10.GENERAL VIEW…392
10.1 GENERAL VIEW OF MACHINE…392
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…393
11.EXPLANATION OF COMPONENTS…394
11.1 MACHINE MONITOR…395
11.2 SWITCHES…401
11.3 CONTROL LEVERS AND PEDALS…405
11.4 ENGINE HOOD …408
11.5 FRONT WINDOW…409
11.6 SLIDING DOOR…411
11.7 REAR WINDOW…411
11.8 HAMMER FOR EMERGENCY ESCAPE …412
11.9 FUSE BOX…412
11.10 FUSIBLE LINK…413
11.11 CAP WITH LOCK,COVER…413
11.12 TOOL BOX…414
11.13 GREASE GUN HOLDER…414
11.14 OPERATION AND MAINTENANCE MANUAL POCKET…414
12.OPERATION…415
12.1 CHECK BEFORE STARTING ENGINE…415
12.2 STARTING ENGINE…423
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…425
12.4 MOVING MACHINE OFF…428
12.5 STEERING MACHINE…430
12.6 STOPPING MACHINE…432
12.7 SWINGING…433
12.8 PROHIBITIONS FOR OPERATION…434
12.9 PRECAUTIONS FOR OPERATION…436
12.10 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…437
12.11 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…439
12.12 PARKING MACHINE…441
12.13 CHECK AFTER FINISHING WORK…442
12.14 STOPPING ENGINE…442
12.15 CHECK AFTER STOPPING ENGINE…443
12.16 LOCKING…443
12.17 HOW TO ESCAPE FROM MUD…444
12.18 REPLACEMENT OF BUCKET…445
12.19 HANDLING 4-SYSTEM…446
12.20 HANDLING RUBBER SHOES (RUBBER SHOES ONLY)…456
13.TRANSPORTATION…461
13.1 LOADING,UNLOADING WORK…461
13.2 METHOD FOR LIFTING CHASSIS…463
13.3 PRECAUTIONS FOR LOADING…465
13.4 PRECAUTIONS FOR TRANSPORTATION…465
14.COLD WEATHER OPERATION…466
14.1 PRECAUTIONS FOR LOW TEMPERATURE…466
14.2 CAUTIONS AFTER COMPLETION OF WORK…468
14.3 PREPARING THE CAB HEATER…468
14.4 AFTER COLD WEATHER…468
15.LONG-TERM STORAGE…469
15.1 BEFORE STORAGE…469
15.2 DURING STORAGE…469
15.3 AFTER STORAGE…469
16.TROUBLESHOOTING…470
16.1 PHENOMENA THAT ARE NOT FAILURES…470
16.2 METHOD OF TOWING MACHINE…472
16.3 PRECAUTIONS ON PARTICULAR JOBSITES…472
16.4 IF BATTERY IS DISCHARGED…473
16.5 OTHER TROUBLE…476
MAINTENANCE …481
17.GUIDES TO MAINTENANCE…482
18.OUTLINES OF SERVICE…485
18.1 OUTLINE OF OIL,FUEL,COOLANT…485
18.2 RELATING TO ELECTRIC SYSTEM…488
19.WEAR PARTS LIST…489
20.USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…490
21.STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…494
21.1 TORQUE LIST…494
22.PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…495
23.MAINTENANCE SCHEDULE CHART…497
23.1 MAINTENANCE SCHEDULE CHART…497
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…499
24.SERVICE PROCEDURE…500
24.1 INITIAL 250 HOURS SERVICE…500
24.2 WHEN REQUIRED…501
24.3 CHECK BEFORE STARTING…529
24.4 EVERY 50 HOURS SERVICE…533
24.5 EVERY 100 HOURS SERVICE…534
24.6 EVERY 250 HOURS SERVICE…536
24.7 EVERY 500 HOURS SERVICE…541
24.8 EVERY 1000 HOURS SERVICE…547
24.9 EVERY 2000 HOURS SERVICE…549
24.10 EVERY 4000 HOURS SERVICE…549
24.11 EVERY 5000 HOURS SERVICE…550
SPECIFICATIONS…552
25.SPECIFICATIONS…553
OPTIONS,ATTACHMENTS…557
26.USING CAR RADIO…558
26.1 EXPLANATION OF PARTS…558
26.2 METHOD OF USE…560
26.3 PRECAUTIONS FOR USE…561
27.USING CAR COOLER…562
27.1 OPERATION OF CONTROL PANEL…562
27.2 PRECAUTIONS WHEN USING…562
27.3 INSPECTION AND MAINTENANCE OF CAR COOLER…563
28.HANDLING WINDOW WASHER…564
28.1 OPERATION OF WINDOW WASHER…564
28.2 CHECK WINDOW WASHER FLUID,ADD FLUID…564
29.HANDLING BUCKET WITH HOOK…565
29.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…565
29.2 PROHIBITED OPERATIONS…565
29.3 PRECAUTIONS DURING OPERATIONS…565
30.GENERAL PRECAUTIONS…566
30.1 PRECAUTIONS RELATED TO SAFETY…566
31.INTRODUCTION OF ATTACHMENTS…567
31.1 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…567
31.2 PRECAUTIONS WHEN USING HYDRAULIC BREAKER…568
SEBM000401 – Hydraulic Excavator PC75UU-1 Shop Manual…572
SEBM001302 – Hydraulic Excavator PC75UU-2 Shop Manual…784
COVER…784
CONTENTS…785
01 GENERAL…808
GENERAL ASSEMBLY DRAWING…809
SPECIFICATIONS…813
WEIGHT TABLE…817
LIST OF LUBRICANT AND WATER…819
10 STRUCTURE AND FUNCTION…821
HYDRAULIC PIPING DIAGRAM…822
HYDRULIC CIRCUIT DIAGRAM…823
ELECTRIC WIRING DIAGRAM…824
ELECTRIC CIRCUIT DIAGRAM…826
20 TESTING AND ADJUSTING…828
TABLE OF JUDGEMENT STANDARD VALUE…829
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…837
TOOLS FOR TESTING ,ADJUSTING,AND TROUBLESHOOTING…842
MEASURING ENGINE SPEED…843
MEASURING ENGINE OIL PRESSURE…843
MEASURING COMPRESSION PRESSURE…844
MEASURING BLOW-BY…845
ADJUSTING VALVE CLEARANCE…846
TESTING AND ADJUSTING FUEL INJECTION TIMING…847
TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION…848
ADJUSTING FUEL CONTROL LEVER…849
TESTING AND ADJUSTING TRACK SHOE TENSION…851
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…852
TESTING CONTROL CIRCUIT PRESSURE…855
MEASURING OUTPUT PRESSURE OF PPC VALVE…857
ADJUSTING PPC VALVE …858
MEASURING OUTLET PORT PRESSURE OF SOLENOID VALVE,EPC VALVE…859
MEASURING OIL LEAKAGE INSIDE CYLINDER…860
MEASURING OIL LEAKAGE FROM SWING,TRAVEL MOTOR…861
BLEEDING AIR FROM HYDRAULIC CIRCUIT…862
RELEASING REMAINING FROM HYDRAULIC CIRCUIT…864
ADJUSTING BLADE CONTROL LEVER…865
ADJUSTING TRAVEL CONTROL LEVER…866
PROCEDURE FOR RESETTING ELECTRICAL SYSTEM INPUT/OUTPUT SIGNALS AND CHECKING OPERATION…867
PROCEDURE FOR REPLACING POTENTIOMETER …878
PROCDURE FOR CHECKING DIODE…879
TROUBLESHOOTING…880
POINTS TO REMEMBER WHEN TROUBLESHOOTING…881
SEQUENCE OF EVENTS IN TROUBLESHOOTING…882
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…883
CHECKS BEFORE TROUBLESHOOTING…890
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM…891
CONNECTOR ARRANGEMENT DRAWING…895
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…899
HANDING CONNECTORS…906
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…907
DISPLAY METHOD FOR MONITOR PANEL,CONTROLLER…911
ACTION TAKEN BY SELF DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE…916
METHOD OF USING JUDGEMENT TABLE…917
METHOD OF USING TROUBLESHOOTING CHARTS…918
TROUBLESHOOTING OF CONTROLLER,ELECTRICAL SYSTEM (E MODE)…920
JUDGEMENT TABLE FOR CONTROLLER,ELECTRICAL,HYDRAULIC AND MECHANICAL SYSTEMS…921
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM…922
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS …925
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) …926
a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM…926
b) ABNORMALITY IN COMMUNICATIONS SYSTEM…927
E-2 ERROR CODE [21] (ABNORMALITY IN MODEL SELECTION SYSTEM)…928
E-3 ERROR CODE [22] (ABNORMALITY IN WORK EQUIPMENT SELECTION SYSTEM)…929
E-4 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTIOMETER SYSTEM)…930
E-5 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM)…931
E-6 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM)…932
E-7 ERROR CODE [41] (ABNORMALITY IN PPC LOCK SOLENOID SYSTEM)…933
E-8 ERROR CODE [42] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM)…934
E-9 ERROR CODE [44] (ABNORMALITY IN BOOM LOWER STOP SOLENIOD SYSTEM)…935
E-10 ERROR CODE [51] (ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM)…936
E-11 ERROR CODE [52] (ABNORMALITY IN ARM IN STOP SOLENOID SYSTEM)…937
E-12 WORK EQUIPMENT DOES NOT WORK EVEN WHEN EQUIPMENT LOCK LEVER IS RELEASED…938
E-13 DEPTH MODE,HEIGHT MODE,OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHING SET POSITION)…939
E-14 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE,DEPTH MODE,HEIGHT MODE,OFFSET MODE…940
E-15 CANCLE SWITCH IS NOT TURNED ON,BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRIC SYSTEM CAUTION LAMP FLASHES…941
E-16 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE,ARM IN,LEFT OFFSET (WHEN ERROR CODE [61] IS NOT DISPLAYED)…942
E-17 WORK EQUIPMENT LOCK LEVER IS AT LOCK POSITION BUT WORK EQUIPMENT MOVES…943
E-18 ENGINE DOES NOT START WHEN STARTING SWITCH IS TURNED TO START…944
E-19 EVEN WHEN STARTING SWITCH IS TURNED OFF,ENGINE DOES NOT STOP…946
E-20 UPPER STRUCTURE DOES NOT SWING (WHEN SWING LEVER IS OPERATED,AND NO ELECTRICITY FLOWS TO SWING BRAKE SOLENOID)…947
E-21 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN ELECTRIC CURRENT FLOWS TO SWING BRAKE SOLENIOD BOTH WHEN SWING LEVER IS OPERATED AND AT NEUTRAL)…949
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)…951
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW…952
a) SPEEDS OF ALL WORK EQUIPMENT AND SWING ARE SLOW (WHEN BLADE AND TRAVEL SPEEDS ARE NORMAL)…952
b) SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE ALL SLOW…954
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS…955
H-3 NO WORK EQUIPMENT,SWING,TRAVEL MOVE…956
a) NONE OF WORK EQUIPMENT AND SWING MOVE…956
b) NONE OF WORK EQUIPMENT, SWING, TRAVEL MOVE…956
H-4 ALL WORK EQUIPMENT,SWING,TRAVEL LACK POWER…957
H-5 ABNORMAL NOISE GENERATED FROM AROUND PUMP…957
H-6 WORK EQUIPMENT SPEED IS SLOW (ONE OF BOOM,ARM,BUCKET,OFFSET IS SLOW)…958
H-7 WORK EQUIPMENT LACKS POWER (ONE OF BOOM,ARM,BUCKET,OFFSET LACKS POWER)…959
H-8 WORK EQUIPMENT DOES NOT MOVE (ONE OF BOOM,ARM,BUCKET,OFFSET DOES NOT MOVE)…959
H-9 EXCESSIVE HYDRAULIC DRIFT…960
H-10 EXCESSIVE TIME LAG…960
H-11 WHEN MACHINE IS TRAVELING,IT DEVIATES NATURALLY TO ONE SIDE…961
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE…961
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE…963
H-12 EXCESSIVE DEVIATION WHEN STARTING…964
H-13 TRAVEL LACKS POWER (OR SPEED IS SLOW)…964
H-14 TRACK DOES NOT MOVE (ONE SIDE ONLY)…965
H-15 TRAVEL LEVER IS HEAVY…965
H-16 DOES NOT SWING…966
H-17 SWING SPEED IS SLOW OR ACCELERATION IS POOR…966
H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING…967
H-19 EXCESSIVE SHOCK WHEN STOPPING SWING…968
H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING …968
H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING…969
H-22 ERROR CODE [61] IS DISPLAYED ON MONITOR PANEL,AND JUST BEFORE INTERFERENCE,BOOM RAISE,ARM IN,AND LEFT OFFSET ALL STOP…970
H-23 BOOM RAISE,ARM IN,AND LEFT OFFSET DO NOT AUTOMATICALLY STOP AND THERE IS INTERFERENCE…971
TABLE OF FAILURE MODES AND CAUSES…972
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…973
M-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)…974
M-2 WHEN STARTING SWITCH IS TURNED ON,LAMPS LIGHT UP FOR 3 SECONDS,BUT THEN DO NOT GO OUT…974
M-3 WHEN STARTING SWITCH IS TURNED ON,SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS…975
a) NO GAUGE LAMPS LIGHT UP PREHEATING PILOT DOES NOT LIGHT UP…975
b) BATTERY ELECTROLYTE LEVEL CAUTION LAMP DOES NOT LIGHT UP ,ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP…975
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP…975
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…975
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED),CHARGE CAUTION LAMP DOES NOT LIGHT UP…976
M-5 WHEN STARTING SWITCH IS ON(ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…976
M-6 DURING PREHEATING,PREHEATING PILOT LAMP DOES NOT LIGHT UP …977
M-7 WHEN STARTING SWITCH IS ON (ENGINE STOPPED),BATTERY ELECTROLYTE LEVEL CAUTION LAMP LIGHTS UP (BATTERY ELECTROLYTE IS AT SPECIFIED LEVEL)…977
M-8 WHEN ENGINE IS RUNNNG,ENGINE OIL PESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)…978
M-9 WHEN ENGINE IS RNNING,CHARGE CAUTION LAMP LIGHTS UP…978
M-10 ABNORMALITY DISPLAY ON COOLANT TEMPERATURE GAUGE …979
a) AFTER ENGINE IS STARTED,LEVEL STAYS AT BOTTOM AND DOES NOT MOVE …979
b) AFTER ENGINE IS STARTED,LEVEL IMMEDIATELY RISES, ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE…979
M-11 ABNORMALITY DISPLAY ON FUEL GAUGE…980
a) ALL FUEL GAUGE SEGMENTS GO OUT…980
b) EVEN WHEN FUEL LEVEL GOES DOWN,FUEL GAUGE CONTINUES TO SHOW FULL…980
c) EVEN WHEN TANK IS FILLED,FUEL GAUGE DOES NOT SHOW FULL…981
M-12 DEFECTIVE OPERATION OF ALARM BUZZER…982
a) BUZZER DOES NOT SOUND…982
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP…982
M-13 WHEN ENGINE IS RUNNING,SERVICE METER DOES NOT ADVANCE…983
a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP…983
b) WHEN CHARGE CAUTION LAMP LIGHTS UP…983
M-14 NIGHT LINGHTING DOES NOT LIGHT UP…984
a) LIGHTING OF COOLANT TEMPERATURE GAUGE,FUEL GAUGE,DEPTH DISPLAY DOES NOT LIGHT UP…984
b) LIGHTING OF SERVICE METER DOES NOT LIGHT UP …984
M-15 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP,AND DOES NOT GO OUT (NO ABNORMALITY DISPLAY ON CONTROLLER,OPERATION IS NORMAL)…985
30 DISASSEMBLY AND ASSEMBLY…986
METHOD OF USING MANUAL…988
PRECAUTIONS WHEN CARRYING OUT OPERATION…989
SPECIAL TOOLS LIST…991
SCHEMATIC DRAWING OF SPECIAL TOOL…995
STARTING MOTOR…1001
REMOVAL AND INSTALLATION …1001
ALTERNATOR …1003
REMOVAL AND INSTALLATION…1003
FUEL INJECTION PUMP…1004
REMOVAL AND INSTALLATION …1004
WATER PUMP …1007
REMOVAL…1007
INSTALLATION…1008
NOZZLE HOLDER…1009
REMOVAL AND INSTALLTION…1009
THERMOSTAT…1010
REMOVAL AND INSTALLATION…1010
ENGINE FRONT SEAL…1011
REMOVAL AND INSTALLATION…1011
ENGINE REAR SEAL…1012
REMOVAL AND INSTALLATION…1012
CYLINDER HEAD…1013
REMOVAL…1013
INSTALLATION…1017
HYDRAULIC OIL COOLER…1019
REMOVAL AND INSTALLATION…1019
RADIATOR…1020
REMOVAL AND INSTALLATION…1020
ENGINE AND MAIN PUMP…1021
REMOVAL…1021
INSTALLATION…1024
DAMPER…1028
REMOVAL AND INSTALLATION…1028
CENTER SWIVEL JOINT…1029
REMOVAL AND INSTALLATION…1029
DISASSEMBLY AND ASSEMBLY…1031
TRAVEL MOTOR…1032
REMOVAL AND INSTALLATION…1032
SPROCKET…1033
REMOVAL AND INSTALLATION…1033
SWING MOTOR AND SWING MACHINERY…1034
REMOVAL AND INSTALLATION…1034
SWING MOTOR …1035
DISASSEMBLY…1035
ASSEMBLY…1039
SWING MACHINERY…1045
DISASSEMBLY…1045
ASSEMBLY…1052
REVOLVING FRAME…1059
REMOVAL …1059
INSTALLATION…1060
SWING CIRCLE…1061
REMOVAL AND INSTALLATION…1061
IDLER AND RECOIL SPRING…1062
REMOVAL AND INSTALLATION…1062
IDLER…1063
DISASSEMBLY…1063
ASSEMBLY…1064
RECOIL SPRING…1066
DISASSEMBLY …1066
ASSEMBLY…1067
TRACK ROLLER …1068
REMOVAL AND INSTALLATION…1068
DISASSEMBLY…1069
ASSEMBLY…1072
RUBBER SHOE…1079
REMOVAL AND INSTALLATION…1079
STEEL SHOE AND ROAD LINER …1080
EXPANSION AND INSTALLATION…1080
PPC PUMP…1081
REMOVAL AND INSTALLATION…1081
MAIN PUMP…1082
REMOVAL AND INSTALLATION…1082
DISASSEMBLY…1083
ASSEMBLY…1090
3-SPOOL CONTROL VALVE…1098
REMOVAL…1098
INSTALLATION…1099
DISASSEMBLY…1102
ASSEMBLY…1104
4-SPOOL CONTROL VALVE…1106
REMOVAL …1106
INSTALLATION…1107
MAIN RELIEF VALVE…1108
REMOVAL AND INSTALLATION…1108
DISASSEMBLY AND ASSEMBLY…1109
PPC VALVE ASSEMBLY ON LEFT SIDE OF WORK EQUIPMENT…1110
REMOVAL AND INSTALLATION…1110
PPC VALVE ON RIGHT SIDE OF WORK EQUIPMENT…1111
REMOVAL AND INSTALLATION…1111
WORK EQUIPMENT PPC VALVE…1112
DISASSEMBLY …1112
ASSEMBLY…1114
PPC VALVE FOR OFFSET OPERATION…1117
REMOVAL AND INSTALLATION…1117
ARM CYLINDER…1118
REMOVAL…1118
INSTALLATION…1119
BUCKERT CYLINDER…1120
REMOVAL…1120
INSTALLATION…1121
BOOM CYLINDER…1122
REMOVAL …1122
INSTALLATION…1123
OFFSET CYLINDER…1124
REMOVAL…1124
INSTALLATION…1125
BLADE CYLINDER…1126
REMOVAL …1126
INSTALLATION…1127
HYDRAULIC CYLINDER…1128
DISASSSEMBLY…1128
ASSEMBLY…1130
WORK EQUIPMENT…1132
REMOVAL…1132
INSTALLATION…1133
BUCKET…1134
REMOVAL AND INSTALLATION…1134
ARM…1135
REMOVAL …1135
INSTALLATION…1136
2ND BOOM…1137
REMOVAL …1137
INSTALLATION…1139
BUCKET AND ARM…1140
REMOVAL …1140
INSTALLATION…1141
1ST BOOM…1142
REMOVAL …1142
INSTALLATION…1143
BLADE…1144
REMOVAL AND INSTALLATION…1144
OPERATOR'S CAB…1145
REMOVAL AND INSTALLATION…1145
FLOOR FRAME…1146
REMOVAL …1146
INSTALLATION…1147
FUEL TANK…1148
REMOVAL AND INSTALLATION…1148
CONTROLLER…1149
REMOVAL AND INSTALLATION…1149
MONITOR…1150
REMOVAL AND INSTALLATION…1150
COUNTERWEIGHT…1151
REMOVAL AND INSTALLATION…1151
40 MAINTENANCE STANDARD…1152
SWING MACHINERY…1153
SWING CIRCLE…1154
TRACK FRAME,RECOIL SPRING…1155
IDLER…1156
TRACK ROLLER…1157
CARRIER ROLLER…1158
SPROCKET…1160
TRACK SHOE…1161
HYDRAULIC PUMP…1162
3-SPOOL CONTROL VALVE(FOR FRONT PUMP)…1163
3-SPOOL CONTROL VALVE(FOR CENTER PUMP)…1165
4-SPOOL CONTROL VALVE…1167
SWING MOTOR…1168
CENTER SWIVEL JOINT…1169
PPC VALVE…1170
HYDRAULIC CYLINDER…1172
WORK EQUIPMENT…1173
SEBM016404 – Hydraulic Excavator PC75UU-3 Shop Manual…1175
COVER…1175
CONTENTS…1176
01 GENERAL…1200
GENERAL ASSEMBLY DRAWING…1201
WORK EQUIPMENT RANGE DRAWING…1206
SPECIFICATIONS…1209
WEIGHT TABLE …1215
LIST OF LUBRICANT AND WATER…1219
10 STRUCTURE AND FUNCTION…1222
RADIATOR,OIL COOER…1223
PTO (COUPLING)…1225
POWER TRAIN…1227
SWING MACHINERY…1228
SWING CIRCLE…1229
TRACK FRAME…1230
HYDRAULIC EQUIPMENT LAYOUT…1231
HYDRAULIC TANK…1233
HYDRAULIC PUMP…1234
CONTROL VALVE…1260
SELF-PRESSURE REDUCING VALVE…1271
CLSS…1275
SWING MOTOR…1293
CENTER SWIVEL JOINT…1304
TRAVEL MOTOR…1308
VALVE CONTROL…1314
PPC VALVE…1315
SOLENOID VALVE…1326
SOLENOID VALVE,EPC VALVE…1328
WORK EQUIPMENT…1332
AIR CONDITIONER PIPING…1333
ELECTRIC WIRING DIAGRAM…1334
ENGINE CONTROL…1337
FOUR SYSTEM (4 SYSTEM)…1345
ELECTRICAL CONTROL SYSTEM…1363
MONITOR SYSTEM…1370
20 TESTING AND ADJUSTING…1376
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…1377
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…1378
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS…1385
TESTING AND ADJUSTING…1393
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…1394
MEASURING ENGINE SPEED…1395
MEASURING EXHAUST COLOR…1396
ADJUSTING VALVE CLEARANCE…1397
MEASURING COMPRESSION PRESSURE…1398
MEASURING BLOW-BY PRESSURE…1399
TESTING AND ADJUSTING FUEL INJECTION TIMING…1400
MEASURING ENGINE OIL PRESSURE…1401
ADJUSTING ENGINE STOP SOLENOID LINKAGE TESTING…1402
ADTUSTING FUEL CONTROL LINKAGE…1403
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…1404
MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE…1406
ADJUSTING PC VALVE…1407
MEASURING CONTROL CIRCUIT OIL PRESSURE (REDUCED PUMP DISCHARGE SELF-PRESSURE)…1408
MEASURING PPC VALVE OUTPUT PRESSURE…1409
TESTING SOLENOID VALVE OUTPUT PRESSURE…1410
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…1412
TESTING TRAVEL DEVIATION…1413
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…1414
MEASURING SWING, TRAVEL MOTOR OIL LEAKAGE…1415
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…1415
TESTING CLEARANCE OF SWING CIRCLE BEARING…1416
TESTING WEAR OF SPROCKET…1417
TESTING AND ADJUSTING TRACK SHOE TENSION…1418
BLEEDING AIR…1419
PROCEDURE FOR RESETTING ELECTRICAL SYSTEM INPUT/ OUTPUT SIGNALS AND CHECKING OPERATION…1421
PROCEDURE FOR ADJUSTMENT WHEN INSTALLING LONG ARM, SLIDE ARM (TELESCOPIC ARM)…1433
PROCEDURE FOR REPLACING POTENTIOMETER…1434
PROCEDURE FOR CHECKING DIODE…1435
TROUBLESHOOTING…1436
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1437
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1438
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…1439
CHECKS BEFORE TROUBLESHOOTING…1447
CONNECTOR TYPES AND MOUNTING LOCATIONS…1448
CONNECTOR ARRANGEMENT DIAGRAM…1450
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1453
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…1463
DISPLAY METHOD FOR MONITOR PANEL,CONTROLLER…1467
METHOD OF USING JUDGEMENT TABLE…1471
METHOD OF USING TROUBLESHOOTING CHARTS…1472
TROUBLESHOOTING OF ENGINE (S MODE)…1474
METHOD OF USING TROUBLESHOOTING CHART…1475
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…1479
S-2 ENGINE DOSE NOT START…1481
(1) ENGINE DOSE NOT TURN…1481
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…1482
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOSE NOT START(FUEL IS BEING INJECTED)…1483
S-3 ENGINE DOSE NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…1484
S-4 ENGINE STOPS DURING OPERATIONS…1485
S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)…1486
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…1487
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…1488
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…1489
S-9 OIL BECOMES CONTAMINATED QUICKLY…1490
S-10 FUEL CONSUMPTION IS EXCESSIVE…1491
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN…1492
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…1493
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)…1494
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…1495
S-15 ABNORMAL NOISE IS MADE…1496
S-16 VIBRATION IS EXCESSIVE…1497
TROUBLESHOOTING OF CONTROLLER,ELECTRICAL SYSTEM(E MODE)…1498
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE…1500
JUDGEMENT TABLE FOR 4 SYSTEM…1506
JUDGEMENT TABLE FOR CHASSIS RELATED PARTS…1508
ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM…1510
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM…1515
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS…1518
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM)…1519
a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM…1519
b) ABNORMALITY IN COMMUNICATIONS SYSTEM…1520
E-2 ERROR CODE [21] (ABNORMALITY IN MODEL SELECTION SYSTEM)…1521
E-3 ERROR CODE [22] (ABNORMALITY IN WORK EQUIPMENT SELECTION SYSTEM)…1522
E-4 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTLOMETER SYSTEM)…1523
E-5 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM)…1524
E-6 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM)…1525
E-7 ERROR CODE [37] (ABNORMALITY IN POTENTIOMETER POWER SOURCE SYSTEM) IS DISPLAYED…1526
E-8 ERROR CODE [38] (ABNORMALITY IN SLIDE ARM LENGTH SENSOR SYSTEM) IS DISPLAYED…1527
E-9 ERROR CODE [41] (ABNORMALITY IN PPC LOCK SOLENOID SYSTEM)…1528
E-10 ERROR CODE [42] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID STSTEM)…1529
E-11 ERROR CODE [44] (ABNORMALITY IN BOOM LOWER STOP SOLENOID SYSTEM)…1530
E-12 ERROR CODE [51] (ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM)…1531
E-13 ERROR CODE [52] (ABNORMALITY IN ARM IN STOP EPC SOLENOID SYSTEM) IS DISPLAYED…1532
E-14 ERROR CODE [61] (VALVE OPEN) IS DISPLAYED…1532
E-15 DEPTH MODE, HEIGHT MODE,OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHING SET POSITION)…1533
E-16 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE,DEPTH MODE,HEIGHTMODE,OFFSET MODE…1535
E-17 CANCEL SWITCH IS NOT TURNED ON,BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRIC SYSTEM CAUTION LAMP FLASHES…1536
E-18 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE,ARM IN,LEFT OFFSET(WHEN ERROR CODE [61] IS NOT DISPLAYED)…1537
a) ALL OPERATIONS STOP IMMEDIATELY BOFORE INTERFERENCE…1537
b) THERE IS INTERFERENCE…1537
E-19 WHEN TELESCOPIC ARM IS EXTENDED (MORE THAN 200 MM) AUTOMATIC STOP DISTANCE IS NEAR…1538
E-20 WHEN SLIDE ARM IS RETRACTED (LESS THAN 200 MM) AUTOMATIC STOP DISTANCE IS FAR …1539
E-21 WORK EQUIPMENT DOSE MOVE WHEN WORK EQUIPMENT LOCK LEVER IS SET TO FREE POSITION…1540
E-22 WORK EQUIPMENT DOSE MOVE WHEN WORK EQUIPMENT LOCK LEVER IS SET TO FREE POSITION…1541
E-23 DOSE NOT SWING…1542
E-24 EXCESSIVE HYDRAULIC DRIFT OF SWING (SWING BRAKE HAS NO EFFECT)…1545
E-25 EVEN WHEN TRAVEL BOOST PEDAL IS OPERATED (DEPRESSED),SPEED DOSE NOT INCREASE…1548
E-26 TRAVEL BOOST PEDAL IS NOT BEING OPERATED (NOT DEPRESSED) BUT SPEED REMAINS BOOSTED…1549
E-27 POWER MODE DOSE NOT SWITCH…1550
a) WHEN ENGINE SPEED IS AT MID-RANGE SPEED OR ABOVE (LIMIT SWITCH ON) BUT WORK EQUIPMENT SPEED SLOW…1550
b) EXCESSIVE DROP IN ENGINE SPEED WHEN ENGINE SPEED IS BELOW MID-RANGE SPEED (LIMIT SWITCH ON)…1551
E-28 WIPER DOSE NOT WORK…1552
E-29 ENGINE DOSE NOT START …1553
a) STARTING MOTOR DOSE NOT TURN…1553
b) ENGINE STOP SOLENOID DOSE NOT WORK (STARTING MOTOR TURNS)…1556
E-30 ENGINE DOSE NOT STOP…1557
E-31 DEFECTIVE ENGINE CONTROL…1558
a) DOSE NOT WORK,OR WORKS AND THEN STOPS WORKING…1558
b) WORKS,BUT DOSE NOT WORKS SMOOTHLY (CABLE WORK ABNORMAL OR INSUFFICIENT STROKE)…1560
c) SWIFT SLOW-DOWN DOSE NOT WORK…1562
d) WORKS AT NEAR IDLING BUT DOSE NOT WORK UP TO FULL (LOAD BECOMES LARGER)…1563
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)…1564
TABLE OF FAILURE MODES AND CAUSES…1565
H-1 SPEEDS OF ALL WORK EQUIPMENT,TRAVEL,AND SWING ARE SLOW OR LACK POWER…1567
a) SPEEDS OF ALL WORK EQUIPMENT,TRAVEL,AND SWING ARE ALL SLOW OR LACK POWER…1567
b) SPEEDS OF SWING AND BLADE ARE ALL SLOW OR LACK POWER (BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE NORMAL)…1567
c) SPEEDS OF BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE ALL SLOW OR LACK POWER (SWING AND BLADE ARE NORMAL)…1568
d) SPEEDS OF ALL WORK EQUIPMENT (BOOM,ARM,BUCKET,OFFSET) ARE ALL SLOW OR LACK POWER (TRAVEL AND AWING ARE NORMAL)…1570
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS…1571
H-3 NONE OF WORK EQUIPMENT,TRAVEL,OR SWING MOVE…1572
a) NONE OF WORK EQUIPMENT,TRAVEL,OR SWING MOVE…1572
b) NONE OF BOOM,ARM,BUCKET,OFFSET,OR TRAVEL MOVE (SWING AND BLADE ARE NORMAL)…1572
c) SWING AND BLADE DO NOT MOVE (BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE NORMAL)…1572
H-4 ABNORMAL NOISE GENERATED FROM AROUND PUMP…1573
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR (BOOM,ARM,BUCKET,OFFSET)…1573
H-6 BOOM IS SLOW OR LACKS POWER…1574
H-7 ARM IS SLOW OR LACKS POWER …1576
H-8 BUCKET IS SLOW OR LACKS POWER…1578
H-9 BLADE IS SLOW OR LACKS POWER…1578
H-10 WORK EQUIPMENT DOSE NOT MOVE (ONE OF BOOM,ARM,BUCKET,OFFSET,BLADE DOSE NOT MOVE)…1579
H-11 EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT…1580
a) EXCESSIVE HYDRAULIC DRIFT OF BOOM,ARM,BUCKET…1580
b) EXCESSIVE HYDRAULIC DRIFT OF BLADE…1580
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…1581
H-13 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS SLOW…1581
H-14 IN SWING + BOOM RAISE,BOOM RAISE IS SLOW…1582
H-15 IN TRAVEL + BOOM RAISE,TRAVEL SPEED DROPS EXCESSIVELY…1582
H-16 WHEN MACHINE IS TRAVELING,IT DEVIATES NATURALLY TO ONE SIDE (DEVIATION IS EXCESSIVE WHEN TRAVELING)…1583
a) DEVIATES IN SAME DIRECTION IN BOTH FORWARD AND REVERSE…1583
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE…1584
H-17 EXCESSIVE DEVIATION WHEN STARTING…1585
H-18 TRAVEL SPEED IS SLOW OR LACKS POWER …1585
H-19 STEERING IS DIFFICULT TO TURN…1586
H-20 TRAVEL SPEED DOSE NOT SWITCH…1587
H-21 TRACK DOSE NOT MOVE (ONE SIDE ONLY)…1587
H-22 UPPER STRUCTURE DOSE NOT SWING…1588
a) DOSE NOT SWING TO EITHER LEFT OR RIGHT…1588
b) DOSE NOT SWING IN ONE DIRECTION (EITHER LEFT OR RIGHT)…1588
H-23 SWING ACCELERATION IS POOR OR SPEED IS SLOW…1589
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING…1591
a) OVERRUN IN ONE DIRECTION ONLY…1591
b) OVERRUN IN BOTH DIRECTIONS…1591
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY0…1592
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…1592
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING…1593
a) WHEN SWING HOLDING BRAKE IS RELEASED…1593
b) WHEN SWING HOLDING BRAKE IS APPLIED…1593
TROUBLESHOOTING 0F MACHINE MONITOR SYSTEM (M MODE)…1594
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM…1595
M-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)…1596
M-2 WHEN STARTING SWITCH IS TURNED ON,LAMPS LIGHT UP FOR 3 SECONDS,BUT THEN DO NOT GO OUT…1596
M-3 WHEN STARTING SWITCH IS TURNED ON,SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS…1597
a) NO GAUGE LIGHT UP PREHEATING PILOT DOSE NOT LIGHT UP…1597
b) BATTERY ELECTROLYTE LEVEL CAUTION LAMP DOSE NOT LIGHT UP ELECTRIC SYSTEM CAUTION LAMP DOSE NOT LIGHT UP…1597
c) CHARGE CAUTION DOSE NOT LIGHT UP…1597
d) ENGINE OIL PRESSURE CAUTION LAMP DOSE NOT LIGHT UP…1597
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHARGE CAUTION LAMP DOSE NOT LIGHT UP…1598
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOSE NOT LIGHT UP …1598
M-6 DURING PREHEATING ,PREHEATING PILOT DOSE NOT LIGHT UP …1599
M-7 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)…1599
M-8 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP…1600
M-9 ABNORMALITY DISPLAY ON COOLANT TEMPERATURE GAUGE…1600
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM AND DOSE NOT MOVE…1600
b) AFTER ENGINE IS ATARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE …1601
c) WATER TEMPERATURE GAUGE GOSE OUT…1601
M-10 ABNORMALITY DISPTAY ON FUEL GAUGE…1602
a) ALL FUEL GAUGE SEGMENTS GO OUT…1602
b) EVEN WHEN FUEL LEVEL GOSE DOWN, FUEL GAUGE CONTINUES TO SHOW FULL…1602
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOSE NOT SHOW FULL…1603
M-11 DEFECTIVE OPERATION OF ALARM BUZZER…1604
a) BUZZER DOSE NOT SOUND…1604
b) BUZZER CONTINUES TO SOUND AND DOSE NOT STOP…1604
M-12 WHEN ENGINE IS RUNING, SERVISE METER DOSE NOT ADVANCE…1605
a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP…1605
b) WHEN CHARGE CAUTION LAMP LIGHTS UP…1605
M-13 NIGHT LIGHTING DOSE NOT LIGHT UP…1606
a) LIGHTING OF COOLANT TEMPERATURE GAUGE, FUEL GAUGE, DEPTH DISPLAY DOSE NOT LIGHT UP…1606
b) LIGHTING OF SERVICE METER DOSE NOT LIGHT UP …1606
M-14 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP, AND DOSE NOT GO OUT (ON ABNORMALITY DISPLAY ON CONTROLLER, OPERATION IS NORMAL)…1607
M-15 HEATER DOSE NOT WORK…1608
a) DOSE NOT WORK AT EITHER LO OR HI…1608
b) DOSE NOT WORK AT LO ONLY…1608
c) DOSE NOT WORK AT HI ONLY…1608
30 DISASSEMBLY AND ASSEMBLY…1610
SERIAL NO.:15001-19000 (MOUNT THE 4D95LE-2ENGINE)…1611
METHOD OF USING MANUAL…1613
PRECAUTIONS WHEN CARRYING OUT OPERATION…1614
SPECIAL TOOL LIST…1616
SCHEMATIC DRAWING OF SPECIAL TOOL…1620
STARTING MOTOR…1621
REMOVAL AND INSTALLATION…1621
ALTERNATOR …1622
REMOVAL AND INSTALLATION…1622
FUEL INJECTION PUMP…1623
REMOVAL …1623
INSTALLATION…1625
WATER PUMP…1628
REMOVAL AND INSTALLATION…1628
NOZZLE HOLDER …1629
REMOVAL AND INSTALLATION…1629
THERMOSTAT…1630
REMOVAL AND INSTALLATION…1630
ENGINE OIL COOLER CORE…1631
REMOVAL AND INSTALLATION…1631
CYLINDER HEAD…1632
REMOVAL…1632
INSTALLATION…1636
RADIATOR AND HYDRAULIC OIL COOLER …1639
REMOVAL …1639
INSTALLATION…1640
ENGINE AND MAIN PUMP…1641
REMOVAL…1641
INSTALLATION…1645
CENTER SWIVEL JOINT…1646
REMOVAL …1646
INSTALLATION…1647
DISASSEMBLY AND ASSEMBLY…1648
TRAVEL MOTOR…1649
REMOVAL AND INSTALLATION…1649
SPROCKET…1650
REMOVAL AND INSTALLATION…1650
SWING MOTOR AND SWING MACHINERY…1651
REMOVAL…1651
INSTALLATION…1652
SWING MACHINERY…1653
DISASSEMBLY…1653
ASSEMBLY…1656
REVOLVING FRAME…1659
REMOVAL…1659
INSTALLATION…1660
SWING CIRCLE…1661
REMOVAL AND INSTALLATION…1661
IDLER AND RECOIL SPRING…1662
REMOVAL AND INSTALLATION…1662
IDLER …1663
DISASSEMBLY…1663
ASSEMBLY…1664
RECOIL SPRING…1666
DISASSEMBLY…1666
ASSEMBLY …1667
TRACK ROLLER…1668
REMOVAL AND INSTALLATION…1668
DISASSEMBLY …1669
ASSEMBLY…1671
CARRIER ROLLER …1673
REMOVAL AND INSTALLATION…1673
DISASSEMBLY AND ASSEMBLY…1674
RUBBER SHOE…1675
REMOVAL AND INSTALLATION…1675
STEEL SHOE AND ROAD LINER …1676
REMOVAL AND INSTALLATION…1676
MAIN PUMP…1677
REMOVAL…1677
INSTALLATION…1678
MAIN PUMP INPUT SHAFT OIL SEAL …1679
REMOVAL AND INSTALLATION…1679
SELF PRESSURE REDUCING VALVE…1680
REMOVAL AND INSTALLATION…1680
CONTROL VALVE…1681
REMOVAL…1681
INSTALLATION…1682
DISASSEMBLY…1683
ASSEMBLY …1688
MAIN RELIEF VALVE…1694
DISASSEMBLY AND ASSEMBLY…1694
SOLENOID VALVE…1695
REMOVAL AND INSTALLATION…1695
WORK EQUIPMENT L. H. PPC VALVE…1697
REMOVAL AND INSTALLATION…1697
WORK EQUIPMENT R. H. PPC VALVE…1698
REMOVAL AND INSTALLATION…1698
WORK EQUIPMENT AND SWING PPC VALVE…1699
DISASSEMBLY…1699
ASSEMBLY …1700
TRAVEL PPC VALVE …1701
REMOVAL AND INSTALLATION…1701
DISASSEMBLY …1702
ASSEMBLY…1703
BLAND PPC VALVE…1704
REMOVAL AND INSTALLATION…1704
OFFSET PPC VALVE …1705
REMOVAL AND INSTALLATION…1705
DISASSEMBLY…1706
ASSEMBLY…1707
ARM CYLINDER…1708
REMOVAL…1708
INSTALLATION…1709
BUCKET CYLINDER …1710
REMOVAL…1710
INSTALLATION…1711
BOOM CYLINDER…1712
REMOVAL …1712
INSTALLATION…1713
OFFSET CYLINDER…1714
REMOVAL…1714
INSTALLATION…1715
BLADE CYLINDER…1716
REMOVAL…1716
MOUNT…1717
HYDRAULIC CYLINDER…1718
DISASSEMBLY…1718
ASSEMBLY…1720
WORK EQUIPMENT …1723
REMOVAL…1723
INSTALLATION…1724
BUCKET …1725
REMOVAL AND INSTALLATION…1725
ARM …1726
REMOVAL…1726
INSTALLATION…1727
SECOND BOOM…1728
REMOVAL…1728
INSTALLATION…1731
BUCKET AND ARM …1732
REMOVAL…1732
INSTALLATION…1733
FIRST BOOM…1734
REMOVAL …1734
INSTALLATION…1736
BLADE…1737
REMOVAL AND INSTALLATION…1737
OPERATOR'S CAB …1738
REMOVAL AND INSTALLATION…1738
FLOOR FRAME…1739
REMOVAL…1739
INSTALLATION…1742
FUEL TANK …1743
REMOVAL AND INSTALLATION…1743
CONTROLLER …1744
REMOVAL AND INSTALLATION…1744
MONITOR…1745
REMOVAL AND INSTALLATION…1745
COUNTERWEIGHT…1746
REMOVAL AND INSTALLATION…1746
SERIAL NO.: 19001 AND UP (MOUNT THE 4D95LE-2ENGINE…1747
RADIATOR AND HYD RAULIC OIL COOLER …1748
REMOVAL AND INSTALLATION…1748
ENGINE MAIN PUMP …1749
REMOVAL…1749
INSTALLATION…1753
REVOLVING FRAME …1754
REMOVAL…1754
INSTALLATION…1755
MAIN PUMP …1756
REMOVAL …1756
INSTALLATION…1757
FLOOR FRAME…1758
REMOVAL…1758
INSTALLATION…1760
COUNTERWEIGHT…1761
REMOVAL AND INSTALLATION…1761
40 MAINTENANCE STANDARD…1762
SWING MACHINERY…1763
SWING CIRCLE…1764
TRACK FRAME, RECOIL SPRING…1765
IDLER…1766
TRACK ROLLER…1767
CARRIER ROLLER…1768
SPROCKET…1769
TRACK SHOE…1770
HYDRAULIC PUMP…1773
CONTROL VALVE…1775
SELF PRESSURE REDUCING VALVE…1782
SWING MOTOR…1784
CENTER SWIVEL JOINT…1785
WORK EQUIPMENT, SWING PPC VALVE…1786
TRAVEL PPC VALVE…1787
BLADE, OFFSET PPC VALVE…1788
HYDRAULIC CYLINDER…1789
WORK EQUIPMENT…1791
DIMENSION OF WORK EQUIPMENT…1795
90 OTHERS…1799
HYDRAULIC CIRCUIT DIAGRAM…1800
STANDERD SPEC…1800
SERVICE VALVE SPEC…1801
SLIDE ARM SPEC…1802
MONO BOOM SPEC…1803
ELECTRICAL CIRCUIT DIAGRAM…1804
STANDERD SPEC. …1804
LONG ARM SPEC…1805
Komatsu Hydraulic Excavator PC75UU Repair Service Manuals